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NASA NTRS2012

Deterministic Design Optimization of Structures in OpenMDAO Framework

Nonlinear programming algorithms play an important role in structural design optimization. Several such algorithms have been implemented in OpenMDAO framework developed at NASA Glenn Research Center (GRC). OpenMDAO is an open source engineering analysis framework, written in Python, for analyzing and solving Multi-Disciplinary Analysis and Optimization (MDAO) problems. It provides a number of solvers and optimizers, referred to as components and drivers, which users can leverage to build new tools and processes quickly and efficiently. Users may download, use, modify, and distribute the OpenMDAO software at no cost. This paper summarizes the process involved in analyzing and optimizing structural components by utilizing the framework s structural solvers and several gradient based optimizers along with a multi-objective genetic algorithm. For comparison purposes, the same structural components were analyzed and optimized using CometBoards, a NASA GRC developed code. The reliability and efficiency of the OpenMDAO framework was compared and reported in this report.

Coroneos, Rula M.↗

NASA NTRS2012

Deterministic Design Optimization of Structures in OpenMDAO Framework

Coroneos, Rula M.↗

NASA NTRS1974

Optimizing subsystem test programs

The goal of reduction of space system costs is pursued in the areas of standardization of subsystem test requirements as well as overall subsystem test program resource requirements. A number of standard components are being developed by NASA. The rationale for the various environmental tests applicable to future missions and launch vehicles is discussed. The need for and approach to developing standard component specifications is presented. In addition, a method for reduction of test expenditures utilizing indexes of mission effect and hardware history as indicators of test requirements is proposed.

Meyer, W. H.↗

NASA NTRS2007

Design for Reliability and Safety Approach for the NASA New Launch Vehicle

The United States National Aeronautics and Space Administration (NASA) is in the midst of a space exploration program intended for sending crew and cargo to the international Space Station (ISS), to the moon, and beyond. This program is called Constellation. As part of the Constellation program, NASA is developing new launch vehicles aimed at significantly increase safety and reliability, reduce the cost of accessing space, and provide a growth path for manned space exploration. Achieving these goals requires a rigorous process that addresses reliability, safety, and cost upfront and throughout all the phases of the life cycle of the program. This paper discusses the "Design for Reliability and Safety" approach for the NASA new crew launch vehicle called ARES I. The ARES I is being developed by NASA Marshall Space Flight Center (MSFC) in support of the Constellation program. The ARES I consists of three major Elements: A solid First Stage (FS), an Upper Stage (US), and liquid Upper Stage Engine (USE). Stacked on top of the ARES I is the Crew exploration vehicle (CEV). The CEV consists of a Launch Abort System (LAS), Crew Module (CM), Service Module (SM), and a Spacecraft Adapter (SA). The CEV development is being led by NASA Johnson Space Center (JSC). Designing for high reliability and safety require a good integrated working environment and a sound technical design approach. The "Design for Reliability and Safety" approach addressed in this paper discusses both the environment and the technical process put in place to support the ARES I design. To address the integrated working environment, the ARES I project office has established a risk based design group called "Operability Design and Analysis" (OD&A) group. This group is an integrated group intended to bring together the engineering, design, and safety organizations together to optimize the system design for safety, reliability, and cost. On the technical side, the ARES I project has, through the OD&A environment, implemented a probabilistic approach to analyze and evaluate design uncertainties and understand their impact on safety, reliability, and cost. This paper focuses on the use of the various probabilistic approaches that have been pursued by the ARES I project. Specifically, the paper discusses an integrated functional probabilistic analysis approach that addresses upffont some key areas to support the ARES I Design Analysis Cycle (DAC) pre Preliminary Design (PD) Phase. This functional approach is a probabilistic physics based approach that combines failure probabilities with system dynamics and engineering failure impact models to identify key system risk drivers and potential system design requirements. The paper also discusses other probabilistic risk assessment approaches planned by the ARES I project to support the PD phase and beyond.

Safie, Fayssal, M.↗

NASA NTRS2012

Systematic Sensor Selection Strategy (S4) User Guide

This paper describes a User Guide for the Systematic Sensor Selection Strategy (S4). S4 was developed to optimally select a sensor suite from a larger pool of candidate sensors based on their performance in a diagnostic system. For aerospace systems, selecting the proper sensors is important for ensuring adequate measurement coverage to satisfy operational, maintenance, performance, and system diagnostic criteria. S4 optimizes the selection of sensors based on the system fault diagnostic approach while taking conflicting objectives such as cost, weight and reliability into consideration. S4 can be described as a general architecture structured to accommodate application-specific components and requirements. It performs combinational optimization with a user defined merit or cost function to identify optimum or near-optimum sensor suite solutions. The S4 User Guide describes the sensor selection procedure and presents an example problem using an open source turbofan engine simulation to demonstrate its application.

Sowers, T. Shane↗

NASA NTRS2004

Flexible Approximation Model Approach for Bi-Level Integrated System Synthesis

Bi-Level Integrated System Synthesis (BLISS) is an approach that allows design problems to be naturally decomposed into a set of subsystem optimizations and a single system optimization. In the BLISS approach, approximate mathematical models are used to transfer information from the subsystem optimizations to the system optimization. Accurate approximation models are therefore critical to the success of the BLISS procedure. In this paper, new capabilities that are being developed to generate accurate approximation models for BLISS procedure will be described. The benefits of using flexible approximation models such as Kriging will be demonstrated in terms of convergence characteristics and computational cost. An approach of dealing with cases where subsystem optimization cannot find a feasible design will be investigated by using the new flexible approximation models for the violated local constraints.

Sobieszczanski-Sobieski, Jaroslaw↗

NASA NTRS1988

Optimal cooperative time-fixed impulsive rendezvous

A method has been developed for determining optimal, i.e., minimum fuel, trajectories for the fixed-time cooperative rendezvous of two spacecraft. The method presently assumes that the vehicles perform a total of three impulsive maneuvers with each vehicle being active, that is, making at least one maneuver. The cost of a feasible 'reference' trajectory is improved by an optimizer which uses an analytical gradient developed using primer vector theory and a new solution for the optimal terminal (rendezvous) maneuver. Results are presented for a large number of cases in which the initial orbits of both vehicles are circular but in which the initial positions of the vehicles and the allotted time for rendezvous are varied. In general, the cost of the cooperative rendezvous is less than that of rendezvous with one vehicle passive. Further improvement in cost may be obtained in the future when additional, i.e., midcourse, impulses are allowed and inserted as indicated for some cases by the primer vector histories which are generated by the program.

Mirfakhraie, Koorosh↗

NASA NTRS2019

Dynamic Replanning of Low Noise Rotorcraft Operations

A new method for rapidly planning and dynamically replanning low noise rotorcraft flight operations is developed. A large database of rotorcraft maneuver segments is generated, and an acoustic cost is assigned to each segment by using a computationally efficient semiempirical rotorcraft noise modeling method that accurately models the changes in rotor noise caused by maneuvering flight. Combinatoric optimization techniques are then employed to combine these maneuver segments into a low noise optimal flight path. A simple heuristic for estimating the total acoustic cost required to reach the target location is developed and incorporated into the search algorithm, allowing the computation of low noise paths in seconds. A procedure for implementing an “anytime” version of the method is described, enabling feasible solutions to be dynamically replanned “on the fly”—i.e., in fractions of a second—and refined over time to a low noise optimal solution.

Greenwood, Eric↗

NASA NTRS2004

The Need for Analogue Missions in Scientific Human and Robotic Planetary Exploration

With the increasing challenges of planetary missions, and especially with the prospect of human exploration of the moon and Mars, the need for earth-based mission simulations has never been greater. The current focus on science as a major driver for planetary exploration introduces new constraints in mission design, planning, operations, and technology development. Analogue missions can be designed to address critical new integration issues arising from the new science-driven exploration paradigm. This next step builds on existing field studies and technology development at analogue sites, providing engineering, programmatic, and scientific lessons-learned in relatively low-cost and low-risk environments. One of the most important outstanding questions in planetary exploration is how to optimize the human and robotic interaction to achieve maximum science return with minimum cost and risk. To answer this question, researchers are faced with the task of defining scientific return and devising ways of measuring the benefit of scientific planetary exploration to humanity. Earth-based and spacebased analogue missions are uniquely suited to answer this question. Moreover, they represent the only means for integrating science operations, mission operations, crew training, technology development, psychology and human factors, and all other mission elements prior to final mission design and launch. Eventually, success in future planetary exploration will depend on our ability to prepare adequately for missions, requiring improved quality and quantity of analogue activities. This effort demands more than simply developing new technologies needed for future missions and increasing our scientific understanding of our destinations. It requires a systematic approach to the identification and evaluation of the categories of analogue activities. This paper presents one possible approach to the classification and design of analogue missions based on their degree of fidelity in ten key areas. Various case studies are discussed to illustrate the approach.

Snook, K. J.↗

NASA NTRS1996

Mid-Infrared Optimized Resolution Spacecraft (MIRORS)

A concept study was performed in 1994 to develop a mission design for a telescope to achieve the highest possible spatial resolution in the 10-30 micron range within a $200 million mission cost cap. The selected approach for the resulting Mid-Infrared Optimized Resolution Spacecraft (MIRORS) concept design utilizes a partially filled five meter aperture.

infrared↗

NASA NTRS1997

Methods for Sensitivity Analysis in Gradient-Based Shape Optimization: A Review

CFD is now being widely used in the design of mechanical and aerospace systems and their components. Improving the accuracy and efficiency of this process can reduce its cost and increase its effectiveness. Other motivating factors that push and pull CFD into design optimization are; (1) the need for design methodologies (single- and multi-disciplinary) to reduce cost and time in developing new fluid and aero systems for fast response to market changes; (2) new design requirements outside existing database; (3) new CFD algorithms and growth in computing power; (4) need for increased product quality and reliability; (5) lack of test facilities; (6) limitations and cost of testing techniques; (7) limitations of existing design practices; and (8) prohibitive cost of and conflicting designs derived from isolated component analyses and design, which are repetitive in nature and omit mutual interference.

Baysal, Oktay↗

NASA NTRS1975

Conceptual design of reduced energy transports

This paper reports the results of a conceptual design study of new, near-term fuel-conservative aircraft. A parametric study was made to determine the effects of cruise Mach number and fuel cost on the 'optimum' configuration characteristics and on economic performance. Supercritical wing technology and advanced engine cycles were assumed. For each design, the wing geometry was optimized to give maximum return on investment at a particular fuel cost. Based on the results of the parametric study, a reduced energy configuration was selected. Compared with existing transport designs, the reduced energy design has a higher aspect ratio wing with lower sweep, and cruises at a lower Mach number. It yields about 30% more seat-miles/gal than current wide-body aircraft. At the higher fuel costs anticipated in the future, the reduced energy design has about the same economic performance as existing designs.

Ardema, M. D.↗

NASA NTRS1994

Optimal control theory determination of feasible return-to-launch-site aborts for the HL-20 Personnel Launch System vehicle

The personnel launch system (PLS) being studied by NASA is a system to complement the space shuttle and provide alternative access to space. The PLS consists of a manned spacecraft launched by an expendable launch vehicle (ELV). A candidate for the manned spacecraft is the HL-20 lifting body. In the event of an ELV malfunction during the initial portion of the ascent trajectory, the HL-20 will separate from the rocket and perform an unpowered return to launch site (RTLS) abort. This work details an investigation, using optimal control theory, of the RTLS abort scenario. The objective of the optimization was to maximize final altitude. With final altitude as the cost function, the feasibility of an RTLS abort at different times during the ascent was determined. The method of differential inclusions was used to determine the optimal state trajectories, and the optimal controls were then calculated from the optimal states and state rates.

Dutton, Kevin E.↗

NASA NTRSDate not supplied

Lightweight Thrust Chamber Assemblies using Multi-Alloy Additive Manufacturing and Composite Overwrap

Additive Manufacturing (AM) has brought significant design and fabrication opportunities for complex components with internal features such as liquid rocket engine thrust chambers not previously possible. This technology allows for significant cost savings and schedule reductions in addition to new performance optimization through weight reduction and increased margins. Specific to regeneratively-cooled combustion chambers and nozzles for liquid rocket engines, additive manufacturing offers the ability to form the complex internal coolant channels and the closeout of the channels to contain the high pressure liquid propellants with a single operation. Much of additive manufacturing development has focused on monolithic alloys using Laser Powder Bed Fusion (L-PBF), which do not allow for complete optimization of the structure. The National Aeronautics and Space Administration (NASA) completed feasibility of an AM bimetallic L-PBF GRCop-84 copper-alloy combustion chamber with an AM electron beam freeform Inconel 625 structural jacket under the Low Cost Upper Stage Propulsion (LCUSP) Project. A follow-on project called Rapid Analysis and Manufacturing Propulsion Technology (RAMPT) is under development to further expand large-scale multi-alloy thrust chambers while maturing composite overwrap technology for significant weight savings opportunities. The RAMPT project has three primary objectives: 1) Advancing blown powder Directed Energy Deposition (DED) to fabricate integral-channel large scale nozzles, 2) Develop composite overwrap technology to reduce weight and provide structural capability for thrust chamber assemblies, and 3) Develop bimetallic and multi-metallic additively manufactured radial and axial joints to optimize material performance. In addition to these primary manufacturing developments, analytical modeling efforts compliment the process development to simulate the AM processes to reduce build failures and distortions. The RAMPT project is also maturing the supply chain for various manufacturing processes described above in addition to L-PBF of GRCop-42. This paper will present an overview of the RAMPT project, the process development and hardware progress to date, material and hot-fire testing results, along with future developments.

Additive Manufacturing↗

NASA NTRS1994

Using parallel banded linear system solvers in generalized eigenvalue problems

Subspace iteration is a reliable and cost effective method for solving positive definite banded symmetric generalized eigenproblems, especially in the case of large scale problems. This paper discusses an algorithm that makes use of two parallel banded solvers in subspace iteration. A shift is introduced to decompose the banded linear systems into relatively independent subsystems and to accelerate the iterations. With this shift, an eigenproblem is mapped efficiently into the memories of a multiprocessor and a high speedup is obtained for parallel implementations. An optimal shift is a shift that balances total computation and communication costs. Under certain conditions, we show how to estimate an optimal shift analytically using the decay rate for the inverse of a banded matrix, and how to improve this estimate. Computational results on iPSC/2 and iPSC/860 multiprocessors are presented.

DISTRIBUTED MEMORY MULTIPROCES↗

NASA NTRS2015

Targeted Structural Optimization with Additive Manufacturing of Metals

The recent advances in additive manufacturing (AM) of metals have now improved the state-of-the-art such that traditionally non-producible parts can be readily produced in a cost-effective way. Because of these advances in manufacturing technology, structural optimization techniques are well positioned to supplement and advance this new technology. The goal of this project is to develop a structural design, analysis, and optimization framework combined with AM to significantly light-weight the interior of metallic structures while maintaining the selected structural properties of the original solid. This is a new state-of-the-art capability to significantly reduce mass, while maintaining the structural integrity of the original design, something that can only be done with AM. In addition, this framework will couple the design, analysis, and fabrication process, meaning that what has been designed directly represents the produced part, thus closing the loop on the design cycle and removing human iteration between design and fabrication. This fundamental concept has applications from light-weighting launch vehicle components to in situ resource fabrication.

Burt, Adam↗

NASA NTRS1993

Using parallel banded linear system solvers in generalized eigenvalue problems

Subspace iteration is a reliable and cost effective method for solving positive definite banded symmetric generalized eigenproblems, especially in the case of large scale problems. This paper discusses an algorithm that makes use of two parallel banded solvers in subspace iteration. A shift is introduced to decompose the banded linear systems into relatively independent subsystems and to accelerate the iterations. With this shift, an eigenproblem is mapped efficiently into the memories of a multiprocessor and a high speed-up is obtained for parallel implementations. An optimal shift is a shift that balances total computation and communication costs. Under certain conditions, we show how to estimate an optimal shift analytically using the decay rate for the inverse of a banded matrix, and how to improve this estimate. Computational results on iPSC/2 and iPSC/860 multiprocessors are presented.

Zhang, Hong↗

NASA NTRS2003

Airport Pricing Strategies

Conventional economic wisdom suggests that congestion pricing would be an appropriate response to cope with the growing congestion levels currently experienced at many airports. Several characteristics of aviation markets, however, may make naive congestion prices equal to the value of marginal travel delays a non-optimal response. This paper has developed a model of airport pricing that captures a number of these features. The model in particular reflects that airlines typically have market power and are engaged in oligopolistic competition at different sub-markets; that part of external travel delays that aircraft impose are internal to an operator and hence should not be accounted for in congestion tolls. We presented an analytical treatment for a simple bi-nodal symmetric network, which through the use of 'hyper-networks' would be readily applicable to dynamic problems (in discrete time) such as peak - off-peak differences, and some numerical exercises for the same symmetric network, which was only designed to illustrate the possible comparative static impacts of tolling, in addition to marginal equilibrium conditions as could be derived for the general model specification. Some main conclusions are that second-best optimal tolls are typically lower than what would be suggested by congestion costs alone and may even be negative, and that the toll as derived by Brueckner (2002) may not lead to an increase in total welfare. While Brueckner (2002) has made clear that congestion tolls on airports may be smaller than expected when congestion costs among aircraft are internal for a firm, our analysis adds to this that a further downward adjustment may be in order due to market power. The presence of market power (which causes prices to exceed marginal costs) may cause the pure congestion toll to be suboptimal, because the resulting decrease in demand is too high (the pure congestion tall does not take into account the decrease in consumer surplus). The various downward adjustments in welfare maximizing tolls may well cause the optimal values of these to be negative. Insofar as subsidization is considered unacceptable for whichever reason, our results warn that the most efficient among the non-negative tolls may actually be a zero toll; the pure congestion toll may actually decrease welfare compared to the base case. The model in this paper contains a few simplifying assumptions that may be relaxed in future work. Load factors and aircraft capacity are fixed in this model for simplicity. In a more advanced version of this model, load factors and aircraft capacity can be endogenized. This makes the derivation of the optimality conditions far more complicated, but it should be feasible in a numerical experiment. One can also add a fourth layer to the model, describing the airport's optimization problem. For example, the airport can maximize profits under a cost recovery constraint. The model then deals with interactions between four types of agents. No distinction is made between peak and off-peak traffic in this paper. Finally, the results of the numerical exercise in this paper need to be checked against an asymmetric equilibrium.

Pels, Eric↗