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Three dimensional stress analysis of spiral bevel gears in mesh using the finite element method is presented. A finite element model is generated by solving equations that identify tooth surface coordinates. Contact is simulated by the automatic generation of nonpenetration constraints. This method is compared to a finite element contact analysis conducted with gap elements.
The basic theory of solid mechanics was deemed complete circa 1860 when St. Venant provided the strain formulation or the field compatibility condition. The strain formulation was incomplete. The missing portion has been formulated and identified as the boundary compatibility condition (BCC). The BCC, derived through a variational formulation, has been verified through integral theorem and solution of problems. The BCC, unlike the field counterpart, do not trivialize when expressed in displacements. Navier s method and the stiffness formulation have to account for the extra conditions especially at the inter-element boundaries in a finite element model. Completion of the strain formulation has led to the revival of the direct force calculation methods: the Integrated Force Method (IFM) and its dual (IFMD) for finite element analysis, and the completed Beltrami-Michell formulation (CBMF) in elasticity. The benefits from the new methods in elasticity, in finite element analysis, and in design optimization are discussed. Existing solutions and computer codes may have to be adjusted for the compliance of the new conditions. Complacency because the discipline is over a century old and computer codes have been developed for half a century can lead to stagnation of the discipline.
Dynamic characterization of a thin film inflatable elliptical structure is described in detail. A two-step finite element modeling approach in MSC/NASTRAN is utilized, consisting of (1) a nonlinear static pressurization procedure used to obtain the updated stiffness matrix, and (2) a modal "restart" eigen solution that uses the modified stiffness matrix. Unique problems encountered in modeling of this large Hexameter lightweight inflatable arc identified, including considerable difficulty in obtaining convergence in the nonlinear finite element pressurization solution. It was found that the extremely thin polyimide film material (.001 in or 1 mil) presents tremendous problems in obtaining a converged solution when internal pressure loading is applied. Approaches utilized to overcome these difficulties are described. Comparison of finite element predictions for frequency and mode shapes of the inflated structure with closed-form solutions for a flat pre-tensioned membrane indicate reasonable agreement.
Developments in design sensitivity analysis (DSA) method have been made using two fundamentally different approaches as shown. In the first approach, a discretized structural finite element model is used to carry out DSA. There are three different methods in the discrete DSA approach: finite difference, semi-analytical, and analytical methods. The finite difference method is a popular one due to its simplicity, but a serious shortcoming of the method is the uncertainty in the choice of a perturbation step size of design variables. In the semi-analytical method, the derivatives of stiffness matrix is computed by finite differences, whereas in the analytical method, the derivatives are obtained analytically. For the shape design variable, computation of analytical derivative of stiffness matrix is quite costly. Because of this, the semi-analytical method is a popular choice in discrete shape DSA approach. However, recently, Barthelemy and Haftka presented that the semi-analytical method can have serious accuracy problems for shape design variables in structures modeled by beam, plate, truss, frame, and solid elements. They found that accuracy problems occur even for a simple cantilever beam. In the second approach, a continuum model of the structure is used to carry out DSA.
The functional, structural adequacy of a 20 meter long generic space truss (Mini-Mast), subjected to fatigue loading, was examined with respect to the failure modes which are most likely to occur during services. The space truss is made of thin-walled tubes having unidirectional, zero degree layups of Celanese G50 graphite fibers/Narmco 5217 epoxy composites. The approach used to investigate the most probable failure mode of the truss under fatigue loading is to determine the stress level, including the types of stress, in the member first, then followed by failure mode analysis based on the stress level just determined. To begin, an approximate beam-parameter truss (BPT) model is analyzed first, followed by a detailed analysis of the truss using a finite element model (FEM) run with NASTRAN code. The response results of the BPT model are used to compare FEM results and to check any major deviation of trend derived from the FEM. The purpose of the work was to search available fatigue data of the tube material, to conduct approximate dynamical stress analysis of the BPT model, to run detailed dynamical stress analysis of the FEM model using NASTRAN code, and to predict the fatigue life of the truss member based on limited fatigue data.
A NASA Langley-sponsored rotorcraft structural dynamics program, known as Design Analysis Methods for VIBrationS (DAMVIBS), has been under development since 1984. The objective of this program was to establish the technology base needed by the industry to develop an advanced finite-element-based dynamics design analysis capability for vibrations. Under the program, teams from the four major helicopter manufacturers have formed finite-element models, conducted ground vibration tests, made test/analysis comparisons of both metal and composite airframes, performed 'difficult components' studies on airframes to identify components which need more complete finite-element representation for improved correlation, and evaluated industry codes for computing coupled rotor-airframe vibrations. Studies aimed at establishing the role that structural optimization can play in airframe vibrations design work have also been initiated. Five government/industry meetings were held in connection with these activities during the course of the program. Because the DAMVIBS Program is coming to an end, the fifth meeting included a brief assessment of the program and its benefits to the industry.
A NASA Langley-sponsored rotorcraft structural dynamics program, known as Design Analysis Methods for VIBrationS (DAMVIBS), has been under development since 1984. The objective of this program was to establish the technology base needed by the industry to develop an advanced finite-element-based dynamics design analysis capability for vibrations. Under the program, teams from the four major helicopter manufacturers have formed finite-element models, conducted ground vibration tests, made test/analysis comparisons of both metal and composite airframes, performed 'difficult components' studies on airframes to identify components which need more complete finite-element representation for improved correlation, and evaluated industry codes for computing coupled rotor-airframe vibrations. Studies aimed at establishing the role that structural optimization can play in airframe vibrations design work have also been initiated. Five government/industry meetings were held in connection with these activities during the course of the program. Because the DAMVIBS Program is coming to an end, the fifth meeting included a brief assessment of the program and its benefits to the industry.
Modeling and simulation of structural impacts into soil continue to challenge analysts to develop accurate material models and detailed analytical simulations to predict the soil penetration event. This paper discusses finite element modeling of a series of penetrometer drop tests into soft clay. Parametric studies are performed with penetrometers of varying diameters, masses, and impact speeds to a maximum of 45 m/s. Parameters influencing the simulation such as the contact penalty factor and the material model representing the soil are also studied. An empirical relationship between key parameters is developed and is shown to correlate experimental and analytical results quite well. The results provide preliminary design guidelines for Earth impact that may be useful for future space exploration sample return missions.
This paper presents high fidelity Navier-Stokes simulations of the Boeing Subsonic Ultra Green Aircraft Research truss-braced wing wind-tunnel model and compares the results to linear MSC. Nastran flutter analysis and preliminary data from a recent wind-tunnel test of that model at the NASA Langley Research Center Transonic Dynamics Tunnel. The simulated conditions under consideration are zero angle of attack, so that structural nonlinearity can be neglected. It is found that, for Mach number greater than 0.78, the linear flutter analysis predicts flutter onset dynamic pressure below the wind-tunnel test and that predicted by the Navier-Stokes analysis. Furthermore, the wind-tunnel test revealed that the majority of the high structural dynamics cases were wing limit cycle oscillation (LCO) rather than flutter. Most Navier-Stokes simulated cases were also LCO rather than hard flutter. There is dip in the wind-tunnel test flutter/LCO onset in the Mach 0.76-0.80 range. Conditions tested above that Mach number exhibited no aeroelastic instability at the dynamic pressures reached in the tunnel. The linear flutter analyses do not show a flutter/LCO dip. The Navier-Stokes simulations also do not reveal a dip; however, the flutter/LCO onset is at a significantly higher dynamic pressure at Mach 0.90 than at lower Mach numbers. The Navier-Stokes simulations indicate a mild LCO onset at Mach 0.82, then a more rapidly growing instability at Mach 0.86 and 0.90. Finally, the modeling issues and their solution related to the use of a beam and pod finite element model to generate the Navier-Stokes structure mode shapes are discussed.
The fatigue damage of a space propulsion system component is computed using probabilistic structural analysis methods. The analysis takes into account the variations in static and dynamic loads, the uncertainty in structural damping, and the scatter in material fatigue resistance. The key elements of the probabilistic approach include: (1) a numerical engine model for describing the global component interface loads consistent with engine balance, (2) models for computing the local mode boundary conditions on the component, (3) a static structural analysis model that captures the strains at a damage critical location as a function of engine performance variables, (4) a finite element model for assessment of the random amplitude stress response due to random base and pressure excitations with uncertain power and correlation length, and (5) advanced first order reliability methods for computing the probabilities associated with the fatigue damage.
A time-domain study of the random response of a laminated plate subjected to combined acoustic and thermal loads is carried out. The features of this problem also include given uniform static inplane forces. The formulation takes into consideration a possible initial imperfection in the flatness of the plate. High decibel sound pressure levels along with high thermal gradients across thickness drive the plate response into nonlinear regimes. This calls for the analysis to use von Karman large deflection strain-displacement relationships. A finite element model that combines the von Karman strains with the first-order shear deformation plate theory is developed. The development of the analytical model can accommodate an anisotropic composite laminate built up of uniformly thick layers of orthotropic, linearly elastic laminae. The global system of finite element equations is then reduced to a modal system of equations. Numerical simulation using a single-step algorithm in the time-domain is then carried out to solve for the modal coordinates. Nonlinear algebraic equations within each time-step are solved by the Newton-Raphson method. The random gaussian filtered white noise load is generated using Monte Carlo simulation. The acoustic pressure distribution over the plate is capable of accounting for a grazing incidence wavefront. Numerical results are presented to study a variety of cases.
Two major efforts were begun concerning the Space Telescope focal plane structure joint. The 3-D solid finite element modeling of the bipod flexure plate was carried out. Conceptual models were developed for the load transfer through the three major bolts to the flexure plate. The flexure plate drawings were reconstructed using DADAM for the purpose of developing a file from which the coordinates of any point on the flexure plate could be determined and also to locate the attachment points of the various components which connect with the flexure plate. For modeling convenience the CADAM drawing of the flexure plate has been divided into several regions which will be subdivided into finite elements using MSGMESH, which is a finite element mesh generator available with MSC/NASTRAN. In addition to the CADAM work on the flexure plate, an effort was also begun to develop computer aided drawings of the peripheral beam which will be used to assist in modeling the connection between it and the flexure plate.
Analytical and experimental techniques for the prediction and ground verification of the damped structural dynamics of space structures are developed. The options available for similarity-scaled model testing, including replica and multiple scale approaches, are reviewed. For the case when the distortion of potentially dissipative or nonlinear joints, which would be required in multiple-scale modeling, is impractical, a new type of modeling is introduced, which uses a hybrid of joints at replica scale and connecting elements at a modified multiple scale. The model design requirements for replica, multiple-scale, and hybrid models are developed, and the expected scaling of nonlinear dissipation in joints is derived. A damping prediction scheme is developed that relies on a finite element model of the undamped structure and measurements of the individual joint properties to predict the modal damping of the truss attributable to the joints. A hybrid-scaled model of a segment of the Space Station was built and dynamically tested. The predicted and measured truss damping compared favorably.
A comparison study is described which has indicated that the finite element and lumped parameter methods are comparable for steady-state conduction/convection analyses. The finite element model was advantageous because of the ease of model verification with computer graphics. Some problems encountered in constructing compatible thermal and structural models have indicated the need for further methodology developments to automate the transition between thermal and structural analyses. The need for more efficient finite element nonlinear transient algorithms has been cited. With further development in the thermal analysis area, the finite element method offers high potential for an integrated thermal/structural analysis capability.
The natural frequencies and mode shapes of a 1/15 scale space shuttle dynamics model are analytically determined. The model, a parallel beam type structure with delta wings, is dynamically representative of the stiffness and mass properties of an early space shuttle design. Important characteristics of the model are elastic interfaces with adjustable spring rates. Normal mode computations are made using the finite element modeling technique as implemented in the NASTRAN (NASA Structural Analysis) computer program. The feasibility of neglecting elastic deformations in the lower modes was investigated using a rigid body model. Using NASTRAN, natural frequencies and mode shapes were first calculated for the booster fuselage, orbiter fuselage, and both delta wings in a free-free condition. Next, the fuselages were connected for various spring rates. Then the wings were attached to each fuselage, and the booster and orbiter were analyzed as separate airplanes. Finally, the two airplanes were elastically joined, and the complete model was analyzed.
Previously developed dynamic models for the calculation of lift-off dynamic response of the space shuttle vehicle can handle only response of the vehicle with eight holddown arms attached or with all holddown arms detached. The new model developed in the referenced report takes into account the transition period between holddown and lift-off by giving the model the ability to vary holddown point separation as a function of vehicle flexible body and rigid body motion. This report documents a study made to verify the new model's capability to simulate vehicle response at lift-off. To do this, a finite element model of the skirt is made and coupled to the free-free modes of the vehicle and cantilevered modes calculated and compared with the previously developed model. Results indicate that the new model will be able to predict accurate vehicle loads.
The objective of the paper is to propose a generic model on the shape and attitude control of a representative space structure. Reduction of the finite element model is based on modal identities and modal cost analysis. The model may help to: (a) suggest improved methods for designing reduced order controllers for large elastic spacecraft, (b) enhance coherence between the frequency-response and time-response multivariable applications, (c) examine computational efficiency of the multivariable control algorithms, and (d) suggest other desirable theoretical and numerical research areas.
The paper presents a finite element analysis of the end-notched flexure (ENF) test specimen for Mode II interlaminar fracture testing of composite materials. Virtual crack closure and compliance techniques employed to calculate strain energy release rates from linear elastic two-dimensional analysis indicate that the ENF specimen is a pure Mode II fracture test within the constraints of small deflection theory. Furthermore, the ENF fracture specimen is shown to be relatively insensitive to process-induced cracks, offset from the laminate midplane. Frictional effects are investigated by including the contact problem in the finite element model. A parametric study investigating the influence of delamination length, span, thickness, and material properties assessed the accuracy of beam theory expressions for compliance and strain energy release rate, GII. Finite element results indicate that data reduction schemes based upon beam theory underestimate GII by approximately 20-40 percent for typical unidirectional graphite fiber composite test specimen geometries. Consequently, an improved data reduction scheme is proposed.