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NASA NTRS2011

Unsteady Aerodynamic Model Tuning for Precise Flutter Prediction

A simple method for an unsteady aerodynamic model tuning is proposed in this study. This method is based on the direct modification of the aerodynamic influence coefficient matrices. The aerostructures test wing 2 flight-test data is used to demonstrate the proposed model tuning method. The flutter speed margin computed using only the test validated structural dynamic model can be improved using the additional unsteady aerodynamic model tuning, and then the flutter speed margin requirement of 15 % in military specifications can apply towards the test validated aeroelastic model. In this study, unsteady aerodynamic model tunings are performed at two time invariant flight conditions, at Mach numbers of 0.390 and 0.456. When the Mach number for the unsteady model tuning approaches to the measured fluttering Mach number, 0.502, at the flight altitude of 9,837 ft, the estimated flutter speed is approached to the measured flutter speed at this altitude. The minimum flutter speed difference between the estimated and measured flutter speed is -.14 %.

Pak, Chan-Gi↗
NASA NTRS2011

Mars Science Laboratory Entry Guidance Improvements for Mars 2018 (DRAFT)

In 2011, the Mars Science Laboratory (MSL) will be launched in a mission to deliver the largest and most capable rover to date to the surface of Mars. A follow on MSL-derived mission, referred to as Mars 2018, is planned for 2018. Mars 2018 goals include performance enhancements of the Entry, Descent and Landing over that of its predecessor MSL mission of 2011. This paper will discuss the main elements of the modified 2018 EDL preliminary design that will increase performance on the entry phase of the mission. In particular, these elements will increase the parachute deploy altitude to allow for more time margin during the subsequent descent and landing phases and reduce the delivery ellipse size at parachute deploy through modifications in the entry reference trajectory design, guidance trigger logic design, and the effect of additional navigation hardware.

Garcia-Llama, Eduardo↗
NASA NTRS2013

Development of the Orion Crew-Service Module Umbilical Retention and Release Mechanism

The Orion CSM umbilical retention and release mechanism supports and protects all of the cross-module commodities between the spacecrafts crew and service modules. These commodities include explosive transfer lines, wiring for power and data, and flexible hoses for ground purge and life support systems. The mechanism employs a single separation interface which is retained with pyrotechnically actuated separation bolts and supports roughly two dozen electrical and fluid connectors. When module separation is commanded, either for nominal on-orbit CONOPS or in the event of an abort, the mechanism must release the separation interface and sever all commodity connections within milliseconds of command receipt. There are a number of unique and novel aspects of the design solution developed by the Orion mechanisms team. The design is highly modular and can easily be adapted to other vehiclesmodules and alternate commodity sets. It will be flight tested during Orions Exploration Flight Test 1 (EFT-1) in 2014, and the Orion team anticipates reuse of the design for all future missions. The design packages fluid, electrical, and ordnance disconnects in a single separation interface. It supports abort separations even in cases where aerodynamic loading prevents the deployment of the umbilical arm. Unlike the Apollo CSM umbilical which was a destructive separation device, the Orion design is resettable and flight units can be tested for separation performance prior to flight.Initial development testing of the mechanisms separation interface resulted in binding failures due to connector misalignments. The separation interface was redesigned with a robust linear guide system, and the connector separation and boom deployment were separated into two discretely sequenced events. These changes addressed the root cause of the binding failure by providing better control of connector alignment. The new design was tuned and validated analytically via Monte Carlo simulation. The analytical validation was followed by a repeat of the initial test suite plus test cases at thermal extremes and test cases with imposed mechanical failures demonstrating fault tolerance. The mechanism was then exposed to the qualification vibration environment. Finally, separation testing was performed at full speed with live ordnance.All tests of the redesigned mechanism resulted in successful separation of the umbilical interface with adequate force margins and timing. The test data showed good agreement with the predictions of the Monte Carlo simulation. The simulation proved invaluable due to the number of variables affecting the separation and the uncertainty associated with each. The simulation allowed for rapid assessment of numerous trades and contingency scenarios, and can be easily reconfigured for varying commodity sets and connector layouts.

Separation↗
NASA NTRS2015

Integrated Assessment of Climate Change Impacts on Maize Farms and Farm Household Incomes in South India: A Case Study from Tamil Nadu: Chapter - 9

South India is characterized by a wide variety of landscapes, soils and climatic zones. It is comprised of tropical, semi-arid, humid-moist, and high-altitude environments, which support a diversity of agricultural systems. Our study focused on the state of Tamil Nadu, which is characterized by a generally tropical climate, and receive rainfall during both the southwest monsoon season (SWM, June to September) and the northeast monsoon (NEM, September to December). Agriculture continues to be an important sector in the state economy, as more than 56 of the people depend on agriculture and allied sectors for their livelihood. Analysis of land-use patterns in Tamil Nadu reveals that in the past decade there has been a reduction in net sown area and current fallow, while the share of cultivable wastelands has increased. The area under cereals, pulses, and oilseeds had marginally declined, although area under commercial crops like turmeric, sugar-cane, banana, fruits, and vegetables has shown an increasing trend. The production performance of major crops like cereals, pulses, and oilseeds has not shown any significant increase. Demand and supply gap of important crops in Tamil Nadu for the year 2010 indicates that the state is lagging far behind in the production of various crops.

agriculture↗
NASA NTRS2016

Application of Deterministic and Probabilistic System Design Methods and Enhancements of Conceptual Design Tools for ERA Project

This report documents work done by the Aerospace Systems Design Lab (ASDL) at the Georgia Institute of Technology, Daniel Guggenheim School of Aerospace Engineering for the National Aeronautics and Space Administration, Aeronautics Research Mission Directorate, Integrated System Research Program, Environmentally Responsible Aviation (ERA) Project. This report was prepared under contract NNL12AA12C, "Application of Deterministic and Probabilistic System Design Methods and Enhancement of Conceptual Design Tools for ERA Project". The research within this report addressed the Environmentally Responsible Aviation (ERA) project goal stated in the NRA solicitation "to advance vehicle concepts and technologies that can simultaneously reduce fuel burn, noise, and emissions." To identify technology and vehicle solutions that simultaneously meet these three metrics requires the use of system-level analysis with the appropriate level of fidelity to quantify feasibility, benefits and degradations, and associated risk. In order to perform the system level analysis, the Environmental Design Space (EDS) [Kirby 2008, Schutte 2012a] environment developed by ASDL was used to model both conventional and unconventional configurations as well as to assess technologies from the ERA and N+2 timeframe portfolios. A well-established system design approach was used to perform aircraft conceptual design studies, including technology trade studies to identify technology portfolios capable of accomplishing the ERA project goal and to obtain accurate tradeoffs between performance, noise, and emissions. The ERA goal, shown in Figure 1, is to simultaneously achieve the N+2 benefits of a cumulative noise margin of 42 EPNdB relative to stage 4, a 75 percent reduction in LTO NOx emissions relative to CAEP 6 and a 50 percent reduction in fuel burn relative to the 2005 best in class aircraft. There were 5 research task associated with this research: 1) identify technology collectors, 2) model technology collectors in EDS, 3) model and assess ERA technologies, 4) LTO and cruise emission prediction, and 5) probabilistic analysis of technology collectors and portfolios.

Mavris, Dimitri N.↗
NASA NTRS2016

Predictive Evaluations of Oxygen-Rich Hydrocarbon Combustion Gas-Centered Swirl Coaxial Injectors using a Flamelet-Based 3-D CFD Simulation Approach

NASA Marshall Space Flight Center (MSFC) has embarked upon a joint project with the Air Force to improve the state-of-the-art of space application combustion device design and operational understanding. One goal of the project is to design, build and hot-fire test a 40,000 pound-thrust Oxygen/Rocket Propellant-2 (RP-2) Oxygen-Rich staged engine at MSFC. The overall project goals afford the opportunity to test multiple different injector designs and experimentally evaluate the any effect on the engine performance and combustion dynamics. To maximize the available test resources and benefits, pre-test, combusting flow, Computational Fluid Dynamics (CFD) analysis was performed on the individual injectors to guide the design. The results of the CFD analysis were used to design the injectors for specific, targeted fluid dynamic features and the analysis results also provided some predictive input for acoustic and thermal analysis of the main Thrust Chamber Assembly (TCA). MSFC has developed and demonstrated the ability to utilize a computationally efficient, flamelet-based combustion model to guide the pre-test design of single-element Gas Centered Swirl Coaxial (GCSC) injectors. Previous, Oxygen/RP-2 simulation models utilizing the Loci-STREAM flow solver, were validated using single injector test data from the EC-1 Air Force test facility. The simulation effort herein is an extension of the validated, CFD driven, single-injector design approach applied to single injectors which will be part of a larger engine array. Time-accurate, Three-Dimensional, CFD simulations were performed for five different classes of injector geometries. Simulations were performed to guide the design of the injector to achieve a variety of intended performance goals. For example, two GCSC injectors were designed to achieve stable hydrodynamic behavior of the propellant circuits while providing the largest thermal margin possible within the design envelope. While another injector was designed to purposefully create a hydrodynamic instability in the fuel supply circuit as predicted by the CFD analysis. Future multi-injector analysis and testing will indicate what if any changes occur in the predicted behavior for the single-element injector when the same injector geometry is placed in a multi-element array.

Richardson, Brian R.↗
NASA NTRS2016

Creating Systems Engineering Products with Executable Models in a Model-Based Engineering Environment

Applying systems engineering across the life-cycle results in a number of products built from interdependent sources of information using different kinds of system level analysis. This paper focuses on leveraging the Executable System Engineering Method (ESEM) which automates requirements verification (e.g. power and mass budget margins and duration analysis of operational modes) using executable SysML models. The particular value proposition is to integrate requirements, and executable behavior and performance models for certain types of system level analysis. The models are created with modeling patterns that involve structural, behavioral and parametric diagrams, and are managed by an open source Model Based Engineering Environment (named OpenMBEE). This paper demonstrates how the ESEM is applied in conjunction with OpenMBEE to create key engineering products (e.g. operational concept document) for the Alignment and Phasing System (APS) within the Thirty Meter Telescope (TMT) project, which is under development by the TMT International Observatory (TIO).

MBSE↗
NASA NTRS2023

Wheat Crop Traits Conferring High Yield Potential May Also Improve Yield Stability Under Climate Change

Increasing genetic wheat yield potential is considered by many as critical to increasing global wheat yields and production, baring major changes in consumption patterns. Climate change challenges breeding by making target environments less predictable, altering regional productivity and potentially increasing yield variability. Here we used a crop simulation model solution in the SIMPLACE framework to explore yield sensitivity to select trait characteristics (radiation use efficiency [RUE], fruiting efficiency and light extinction coefficient) across 34 locations representing the world’s wheat-producing environments, determining their relationship to increasing yields, yield variability and cultivar performance. The magnitude of the yield increase was trait-dependent and differed between irrigated and rainfed environments. RUE had the most prominent marginal effect on yield, which increased by about 45 % and 33 % in irrigated and rainfed sites, respectively, between the minimum and maximum value of the trait. Altered values of light extinction coefficient had the least effect on yield levels. Higher yields from improved traits were generally associated with increased inter-annual yield variability (measured by standard deviation), but the relative yield variability (as coefficient of variation) remained largely unchanged between base and improved genotypes. This was true under both current and future climate scenarios. In this context, our study suggests higher wheat yields from these traits would not increase climate risk for farmers and the adoption of cultivars with these traits would not be associated with increased yield variability.

Climate change↗
NASA NTRS2026

An Investigation Regarding the Effects of Volume Dynamics on Gas Turbine Engine Performance and Operability

This work explores the impact of adding volume dynamics to an electrified turbofan engine model. The zero-dimensional single-input single-output volume elements capture the physics of fluid compressibility of flow in the engine core gas path turbomachinery during transient operation with greater fidelity. Some background regarding the motivation for this effort is provided. A model of the volume element is developed from first principles. The baseline engine model is described and an explanation is given of the modifications made to incorporate the volume elements into the new model. Details of the simulated inputs, designed to elicit exaggerated dynamic responses and to facilitate comparison between the baseline and modified engine models, are explicated. The results of these simulations are presented and discussed, demonstrating that the transient performance and operability of the modified engine model, measured by parameters such as shaft speeds, thrust, and high-pressure compressor (HPC) stall margin, are impacted by the additional dynamics. Commentary is provided regarding potential explanations for the differences in behavior exhibited by the two models. Finally, suggestions are offered for future work that might improve the volume models developed in this effort and leverage the improved fidelity enabled by the modeling of turbomachinery volume dynamics.

Volume dynamics↗
NASA NTRS2014

Adaptive Augmenting Control Flight Characterization Experiment on an F/A-18

This paper summarizes the Adaptive Augmenting Control (AAC) flight characterization experiments performed using an F/A-18 (TN 853). AAC was designed and developed specifically for launch vehicles, and is currently part of the baseline autopilot design for NASA's Space Launch System (SLS). The scope covered here includes a brief overview of the algorithm (covered in more detail elsewhere), motivation and benefits of flight testing, top-level SLS flight test objectives, applicability of the F/A-18 as a platform for testing a launch vehicle control design, test cases designed to fully vet the AAC algorithm, flight test results, and conclusions regarding the functionality of AAC. The AAC algorithm developed at Marshall Space Flight Center is a forward loop gain multiplicative adaptive algorithm that modifies the total attitude control system gain in response to sensed model errors or undesirable parasitic mode resonances. The AAC algorithm provides the capability to improve or decrease performance by balancing attitude tracking with the mitigation of parasitic dynamics, such as control-structure interaction or servo-actuator limit cycles. In the case of the latter, if unmodeled or mismodeled parasitic dynamics are present that would otherwise result in a closed-loop instability or near instability, the adaptive controller decreases the total loop gain to reduce the interaction between these dynamics and the controller. This is in contrast to traditional adaptive control logic, which focuses on improving performance by increasing gain. The computationally simple AAC attitude control algorithm has stability properties that are reconcilable in the context of classical frequency-domain criteria (i.e., gain and phase margin). The algorithm assumes that the baseline attitude control design is well-tuned for a nominal trajectory and is designed to adapt only when necessary. Furthermore, the adaptation is attracted to the nominal design and adapts only on an as-needed basis (see Figure 1). The MSFC algorithm design was formulated during the Constellation Program and reached a high maturity level during SLS through simulation-based development and internal and external analytical review. The AAC algorithm design has three summary-level objectives: (1) "Do no harm;" return to baseline control design when not needed, (2) Increase performance; respond to error in ability of vehicle to track command, and (3) Regain stability; respond to undesirable control-structure interaction or other parasitic dynamics. AAC has been successfully implemented as part of the Space Launch System baseline design, including extensive testing in high-fidelity 6-DOF simulations the details of which are described in [1]. The Dryden Flight Research Center's F/A-18 Full-Scale Advanced Systems Testbed (FAST) platform is used to conduct an algorithm flight characterization experiment intended to fully vet the aforementioned design objectives. FAST was specifically designed with this type of test program in mind. The onboard flight control system has full-authority experiment control of ten aerodynamic effectors and two throttles. It has production and research sensor inputs and pilot engage/disengage and real-time configuration of up to eight different experiments on a single flight. It has failure detection and automatic reversion to fail-safe mode. The F/A-18 aircraft has an experiment envelope cleared for full-authority control and maneuvering and exhibits characteristics for robust recovery from unusual attitudes and configurations aided by the presence of a qualified test pilot. The F/A-18 aircraft has relatively high mass and inertia with exceptional performance; the F/A-18 also has a large thrust-to-weight ratio, owing to its military heritage. This enables the simulation of a portion of the ascent trajectory with a high degree of dynamic similarity to a launch vehicle, and the research flight control system can simulate unstable longitudinal dynamics. Parasitic dynamics such as slosh and bending modes, as well as atmospheric disturbances, are being produced by the airframe via modification of bending filters and the use of secondary control surfaces, including leading and trailing edge flaps, symmetric ailerons, and symmetric rudders. The platform also has the ability to inject signals in flight to simulate structural mode resonances or other challenging dynamics. This platform also offers more test maneuvers and longer maneuver times than a single rocket or missile test, which provides ample opportunity to fully and repeatedly exercise all aspects of the algorithm. Prior to testing on an F/A-18, AAC was the only component of the SLS autopilot design that had not been flight tested. The testing described in this paper raises the Technology Readiness Level (TRL) early in the SLS Program and is able to demonstrate its capabilities and robustness in a flight environment.

VanZwieten, Tannen S.↗
NASA NTRS2015

Terra and Aqua MODIS Thermal Emissive Bands On-Orbit Calibration and Performance

Since launch, the Moderate Resolution Imaging Spectroradiometer (MODIS) instruments on the Terra and Aqua spacecraft have operated successfully for more than 14 and 12 years, respectively. A key instrument for National Aeronautics and Space Administration Earth Observing System missions, MODIS was designed to make continuous observations for studies of Earth's land, ocean, and atmospheric properties and to extend existing data records from heritage Earth observing sensors. The 16 thermal emissive bands (TEBs) (3.75-14.24 micrometers) are calibrated on orbit using a temperature controlled blackbody (BB). Both Terra and Aqua MODIS BBs have displayed minimal drift over the mission lifetime, and the seasonal variations of the BB temperature are extremely small in Aqua MODIS. The long-term gain and noise equivalent difference in temperature performance of the 160 TEB detectors on both MODIS instruments have been well behaved and generally very stable. Small but noticeable variations of Aqua MODIS bands 33-36 (13.34-14.24 micrometer) response in recent years are primarily due to loss of temperature control margin of its passive cryoradiative cooler. As a result, fixed calibration coefficients, previously used by bands when the BB temperature is above their saturation temperatures, are replaced by the focal-plane-temperature-dependent calibration coefficients. This paper presents an overview of the MODIS TEB calibration, the on-orbit performance, and the challenging issues likely to impact the instruments as they continue operating well past their designed lifetime of six years.

TEBs↗
NASA NTRS1993

Initial Galileo propulsion system in-flight characterization

The Galilee RetroPropulsion Module (RPM) has performed excellently throughout the first three years of mission operations. The RPM is a state-of-the-art, pressure-fed, bipropellant propulsion system, provided to NASA by Germany. Due to efficient navigation, propellant margin has substantially increased since launch, enabling extensive contingency maneuvering and the second asteroid flyby while maintaining the confidence level for successfully completing the orbital tour of the planet Jupiter, beginning in 1995. The RPM has responded very well to the challenges brought about by the attempts to deploy the Galileo High Gain Antenna. No thruster thermal instabilities have been observed during maneuvers through the end of 1992; however, lateral thruster performance shifts have been nonnegligible and remain unexplained. Nearly all Galileo thrusters are exceeding ground performance test levels by 1-7 percent.

Barber, T. J.↗
NASA NTRS2004

Performance Benefits for a Turboshaft Engine Using Nonlinear Engine Control Technology Investigated

The potential benefits of nonlinear engine control technology applied to a General Electric T700 helicopter engine were investigated. This technology is being developed by the U.S. Navy SPAWAR Systems Center for a variety of applications. When used as a means of active stability control, nonlinear engine control technology uses sensors and small amounts of injected air to allow compressors to operate with reduced stall margin, which can improve engine pressure ratio. The focus of this study was to determine the best achievable reduction in fuel consumption for the T700 turboshaft engine. A customer deck (computer code) was provided by General Electric to calculate the T700 engine performance, and the NASA Glenn Research Center used this code to perform the analysis. The results showed a 2- to 5-percent reduction in brake specific fuel consumption (BSFC) at the three Sikorsky H-60 helicopter operating points of cruise, loiter, and hover.

Jones, Scott M.↗
NASA NTRS1994

Design and performance of the telescope and detector covers on the Extreme Ultraviolet Explorer satellite

Two cover mechanisms were designed and developed for the Extreme Ultraviolet Explorer (EUVE) science payload to keep the EUVE telescope mirrors and detectors sealed from the atmospheric environment until the spacecraft was placed into orbit. There were four telescope front covers and seven motorized detector covers on the EUVE science payload. The EUVE satellite was launched into orbit in June 1992 and all the covers operated successfully after launch. This success can be attributed to high design margins and extensive testing at each level of assembly. This paper described the design of the telescope front covers and the motorized detector covers. This paper also discusses some of the many design considerations and modifications made as performance and reliability problems became apparent from each phase of testing.

Tom, James L.↗
NASA NTRS2009

Modeling Unsteady Cavitation and Dynamic Loads in Turbopumps

A computational fluid dynamics (CFD) model that includes representations of effects of unsteady cavitation and associated dynamic loads has been developed to increase the accuracy of simulations of the performances of turbopumps. Although the model was originally intended to serve as a means of analyzing preliminary designs of turbopumps that supply cryogenic propellant liquids to rocket engines, the model could also be applied to turbopumping of other liquids: this can be considered to have been already demonstrated, in that the validation of the model was performed by comparing results of simulations performed by use of the model with results of sub-scale experiments in water. The need for this or a similar model arises as follows: Cavitation instabilities in a turbopump are generated as inlet pressure drops and vapor cavities grow on inducer blades, eventually becoming unsteady. The unsteady vapor cavities lead to rotation cavitation, in which the cavities detach from the blades and become part of a fluid mass that rotates relative to the inducer, thereby generating a fluctuating load. Other instabilities (e.g., surge instabilities) can couple with cavitation instabilities, thereby compounding the deleterious effects of unsteadiness on other components of the fluid-handling system of which the turbopump is a part and thereby, further, adversely affecting the mechanical integrity and safety of the system. Therefore, an ability to predict cavitation- instability-induced dynamic pressure loads on the blades, the shaft, and other pump parts would be valuable in helping to quantify safe margins of inducer operation and in contributing to understanding of design compromises. Prior CFD models do not afford this ability. Heretofore, the primary parameter used in quantifying cavitation performance of a turbopump inducer has been the critical suction specific speed at which head breakdown occurs. This parameter is a mean quantity calculated on the basis of assumed steady-state operation of the inducer; it does not account for dynamic pressure loads associated with unsteady flow caused by instabilities. Because cavitation instabilities occur well before mean breakdown in inducers, engineers have, until now, found it necessary to use conservative factors of safety when analyzing the results of numerical simulations of flows in turbopumps.

Hosangadi, Ashvin↗
NASA NTRS2017

Optimal Control Allocation with Load Sensor Feedback for Active Load Suppression, Flight-Test Performance

The problem of control command and maneuver induced structural loads is an important aspect of any control system design. The aircraft structure and the control architecture must be designed to achieve desired piloted control responses while limiting the imparted structural loads. The classical approach is to utilize high structural margins, restrict control surface commands to a limited set of analyzed combinations, and train pilots to follow procedural maneuvering limitations. With recent advances in structural sensing and the continued desire to improve safety and vehicle fuel efficiency, it is both possible and desirable to develop control architectures that enable lighter vehicle weights while maintaining and improving protection against structural damage. An optimal control technique has been explored and shown to achieve desirable vehicle control performance while limiting sensed structural loads to specified values. This technique has been implemented and flown on the National Aeronautics and Space Administration Full-scale Advanced Systems Testbed aircraft. The flight tests illustrate that the approach achieves the desired performance and show promising potential benefits. The flights also uncovered some important issues that will need to be addressed for production application.

cFOSS↗
NASA NTRS2017

Entry, Descent, and Landing technological barriers and crewed MARSvehicle performance analysis

Mars has been explored historically only by robotic crafts, but a crewed mission encompasses several new engineering challenges – high ballistic coefficient entry, hypersonic decelerators, guided entry for reaching intended destinations within acceptable margins for error in the landing ellipse, and payload mass are all critical factors for evaluation. A comprehensive EDL parametric analysis has been conducted in support of a high mass landing architecture by evaluating three types of vehicles −70° Sphere Cone, Ellipsled and SpaceX hybrid architecture called Red Dragon as potential candidate options for crewed entry vehicles. Aerocapture at the Martian orbit of about 400 km and subsequent Entry-from-orbit scenarios were investigated at velocities of 6.75 km/s and 4 km/s respectively. A study on aerocapture corridor over a range of entry velocities (6–9 km/s) suggests that a hypersonic L/D of 0.3 is sufficient for a Martian aerocapture. Parametric studies conducted by varying aeroshell diameters from 10 m to 15 m for several entry masses up to 150 mt are summarized and results reveal that vehicles with entry masses in the range of about 40–80 mt are capable of delivering cargo with a mass on the order of 5–20 mt. For vehicles with an entry mass of 20 mt to 80 mt, probabilistic Monte Carlo analysis of 5000 cases for each vehicle were run to determine the final landing ellipse and to quantify the statistical uncertainties associated with the trajectory and attitude conditions during atmospheric entry. Strategies and current technological challenges for a human rated Entry, Descent, and Landing to the Martian surface are presented in this study.

Prabhakar Subrahmanyam↗
NASA NTRS2010

ACT Payload Shroud Structural Concept Analysis and Optimization

Aerospace structural applications demand a weight efficient design to perform in a cost effective manner. This is particularly true for launch vehicle structures, where weight is the dominant design driver. The design process typically requires many iterations to ensure that a satisfactory minimum weight has been obtained. Although metallic structures can be weight efficient, composite structures can provide additional weight savings due to their lower density and additional design flexibility. This work presents structural analysis and weight optimization of a composite payload shroud for NASA s Ares V heavy lift vehicle. Two concepts, which were previously determined to be efficient for such a structure are evaluated: a hat stiffened/corrugated panel and a fiber reinforced foam sandwich panel. A composite structural optimization code, HyperSizer, is used to optimize the panel geometry, composite material ply orientations, and sandwich core material. HyperSizer enables an efficient evaluation of thousands of potential designs versus multiple strength and stability-based failure criteria across multiple load cases. HyperSizer sizing process uses a global finite element model to obtain element forces, which are statistically processed to arrive at panel-level design-to loads. These loads are then used to analyze each candidate panel design. A near optimum design is selected as the one with the lowest weight that also provides all positive margins of safety. The stiffness of each newly sized panel or beam component is taken into account in the subsequent finite element analysis. Iteration of analysis/optimization is performed to ensure a converged design. Sizing results for the hat stiffened panel concept and the fiber reinforced foam sandwich concept are presented.

Zalewski, Bart B.↗