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NASA NTRS1994

Large-displacement structural durability analyses of simple bend specimen emulating rocket nozzle liners

Large-displacement elastic and elastic-plastic, finite-element stress-strain analyses of an oxygen-tree high-conductivity (OFHC) copper plate specimen were performed using an updated Lagrangian formulation. The plate specimen is intended for low-cost experiments that emulate the most important thermomechanical loading and failure modes of a more complex rocket nozzle. The plate, which is loaded in bending at 593 C, contains a centrally located and internally pressurized channel. The cyclic crack initiation lives were estimated using the results from the analyses and isothermal strain-controlled low-cycle fatigue data for OFHC copper. A comparison of the predicted and experimental cyclic lives showed that an elastic analysis predicts a longer cyclic life than that observed in experiments by a factor greater than 4. The results from elastic-plastic analysis for the plate bend specimen, however, predicted a cyclic life in close agreement with experiment, thus justifying the need for the more rigorous stress-strain analysis.

Arya, Vinod K.↗

NASA NTRS1994

Computational Simulation of the Formation and Material Behavior of Ice

Computational methods are described for simulating the formation and the material behavior of ice in prevailing transient environments. The methodology developed at the NASA Lewis Research Center was adopted. A three dimensional finite-element heat transfer analyzer was used to predict the thickness of ice formed under prevailing environmental conditions. A multi-factor interaction model for simulating the material behavior of time-variant ice layers is presented. The model, used in conjunction with laminated composite mechanics, updates the material properties of an ice block as its thickness increases with time. A sample case of ice formation in a body of water was used to demonstrate the methodology. The results showed that the formation and the material behavior of ice can be computationally simulated using the available composites technology.

Tong, Michael T.↗

NASA NTRS1994

Wing design for a civil tiltrotor transport aircraft

The goal of this research is the proper tailoring of the civil tiltrotor's composite wing-box structure leading to a minimum-weight wing design. With focus on the structural design, the wing's aerodynamic shape and the rotor-pylon system are held fixed. The initial design requirement on drag reduction set the airfoil maximum thickness-to-chord ratio to 18 percent. The airfoil section is the scaled down version of the 23 percent-thick airfoil used in V-22's wing. With the project goal in mind, the research activities began with an investigation of the structural dynamic and aeroelastic characteristics of the tiltrotor configuration, and the identification of proper procedures to analyze and account for these characteristics in the wing design. This investigation led to a collection of more than thirty technical papers on the subject, some of which have been referenced here. The review of literature on the tiltrotor revealed the complexity of the system in terms of wing-rotor-pylon interactions. The aeroelastic instability or whirl flutter stemming from wing-rotor-pylon interactions is found to be the most critical mode of instability demanding careful consideration in the preliminary wing design. The placement of wing fundamental natural frequencies in bending and torsion relative to each other and relative to the rotor 1/rev frequencies is found to have a strong influence on the whirl flutter. The frequency placement guide based on a Bell Helicopter Textron study is used in the formulation of frequency constraints. The analysis and design studies are based on two different finite-element computer codes: (1) MSC/NASATRAN and (2) WIDOWAC. These programs are used in parallel with the motivation to eventually, upon necessary modifications and validation, use the simpler WIDOWAC code in the structural tailoring of the tiltrotor wing. Several test cases were studied for the preliminary comparison of the two codes. The results obtained so far indicate a good overall agreement between the two codes.

Rais-Rohani, Masoud↗

NASA NTRS1994

Steady and unsteady blade stresses within the SSME ATD/HPOTP inducer

There were two main goals of the ATD HPOTP (alternate turbopump development)(high pressure oxygen turbopump). First, determine the steady and unsteady inducer blade surface strains produced by hydrodynamic sources as a function of flow capacity (Q/N), suction specific speed (Nss), and Reynolds number (Re). Second, to identify the hydrodynamic source(s) of the unsteady blade strains. The reason the aforementioned goals are expressed in terms of blade strains as opposed to blade hydrodynamic pressures is because of the interest regarding the high cycle life of the inducer blades. This report focuses on the first goal of the test program which involves the determination of the steady and unsteady strain (stress) values at various points within the inducer blades. Strain gages were selected as the strain measuring devices. Concurrent with the experimental program, an analytical study was undertaken to produce a complete NASTRAN finite-element model of the inducer. Computational fluid dynamics analyses were utilized to provide the estimated steady-state blade surface pressure loading needed as load input to the NASTRAN inducer model.

Gross, R. Steven↗

NASA NTRS1994

An assessment of the adaptive unstructured tetrahedral grid, Euler Flow Solver Code FELISA

A three-dimensional solution-adaptive Euler flow solver for unstructured tetrahedral meshes is assessed, and the accuracy and efficiency of the method for predicting sonic boom pressure signatures about simple generic models are demonstrated. Comparison of computational and wind tunnel data and enhancement of numerical solutions by means of grid adaptivity are discussed. The mesh generation is based on the advancing front technique. The FELISA code consists of two solvers, the Taylor-Galerkin and the Runge-Kutta-Galerkin schemes, both of which are spacially discretized by the usual Galerkin weighted residual finite-element methods but with different explicit time-marching schemes to steady state. The solution-adaptive grid procedure is based on either remeshing or mesh refinement techniques. An alternative geometry adaptive procedure is also incorporated.

Djomehri, M. Jahed↗

NASA NTRS1995

Simulation of rotor blade element turbulence

A piloted, motion-based simulation of Sikorsky's Black Hawk helicopter was used as a platform for the investigation of rotorcraft responses to vertical turbulence. By using an innovative temporal and geometrical distribution algorithm that preserved the statistical characteristics of the turbulence over the rotor disc, stochastic velocity components were applied at each of twenty blade-element stations. This model was implemented on NASA Ames' Vertical Motion Simulator (VMS), and ten test pilots were used to establish that the model created realistic cues. The objectives of this research included the establishment of a simulation-technology basis for future investigation into real-time turbulence modeling. This goal was achieved; our extensive additions to the rotor model added less than a 10 percent computational overhead. Using a VAX 9000 computer the entire simulation required a cycle time of less than 12 msec. Pilot opinion during this simulation was generally quite favorable. For low speed flight the consensus was that SORBET (acronym for title) was better than the conventional body-fixed model, which was used for comparison purposes, and was determined to be too violent (like a washboard). For high speed flight the pilots could not identify differences between these models. These opinions were something of a surprise because only the vertical turbulence component on the rotor system was implemented in SORBET. Because of the finite-element distribution of the inputs, induced outputs were observed in all translational and rotational axes. Extensive post-simulation spectral analyses of the SORBET model suggest that proper rotorcraft turbulence modeling requires that vertical atmospheric disturbances not be superimposed at the vehicle center of gravity but, rather, be input into the rotor system, where the rotor-to-body transfer function severely attenuates high frequency rotorcraft responses.

Mcfarland, R. E.↗

NASA NTRS1994

Thin tailored composite wing for civil tiltrotor

The tiltrotor aircraft is a flight vehicle which combines the efficient low speed (i.e., take-off, landing, and hover) characteristics of a helicopter with the efficient cruise speed of a turboprop airplane. A well-known example of such vehicle is the Bell-Boeing V-22 Osprey. The high cruise speed and range constraints placed on the civil tiltrotor require a relatively thin wing to increase the drag-divergence Mach number which translates into lower compressibility drag. It is required to reduce the wing maximum thickness-to-chord ratio t/c from 23% (i.e., V-22 wing) to 18%. While a reduction in wing thickness results in improved aerodynamic efficiency, it has an adverse effect on the wing structure and it tends to reduce structural stiffness. If ignored, the reduction in wing stiffness leads to susceptibility to aeroelastic and dynamic instabilities which may consequently cause a catastrophic failure. By taking advantage of the directional stiffness characteristics of composite materials the wing structure may be tailored to have the necessary stiffness, at a lower thickness, while keeping the weight low. The goal of this study is to design a wing structure for minimum weight subject to structural, dynamic and aeroelastic constraints. The structural constraints are in terms of strength and buckling allowables. The dynamic constraints are in terms of wing natural frequencies in vertical and horizontal bending and torsion. The aeroelastic constraints are in terms of frequency placement of the wing structure relative to those of the rotor system. The wing-rotor-pylon aeroelastic and dynamic interactions are limited in this design study by holding the cruise speed, rotor-pylon system, and wing geometric attributes fixed. To assure that the wing-rotor stability margins are maintained a more rigorous analysis based on a detailed model of the rotor system will need to ensue following the design study. The skin-stringer-rib type architecture is used for the wing-box structure. The design variables include upper and lower skin ply thicknesses and orientation angles, spar and rib web thicknesses and cap areas, and stringer cross-sectional areas. These design variables will allow the maximum tailoring of the structure to meet the design requirements most efficiently. Initial dynamic analysis has been conducted using MSC/NASTRAN to determine the baseline wing's frequencies and mode shapes. For the design study we intend to use the finite-element based code called WIDOWAC (Wing Design Optimization With Aeroeastic Constraints) that was developed at NASA Langley in early 1970's for airplane wing structural analysis and preliminary design. Currently, the focus is on modification and validation of this code which will be used for the civil tiltrotor design efforts.

Rais-Rohani, Masoud↗

NASA NTRS1993

Time-Accurate Unsteady Flow Simulations Supporting the SRM T+68-Second Pressure Spike Anomaly Investigation (STS-54B)

Time-accurate unsteady flow simulations are being performed supporting the SRM T+68sec pressure 'spike' anomaly investigation. The anomaly occurred in the RH SRM during the STS-54 flight (STS-54B) but not in the LH SRM (STS-54A) causing a momentary thrust mismatch approaching the allowable limit at that time into the flight. Full-motor internal flow simulations using the USA-2D axisymmetric code are in progress for the nominal propellant burn-back geometry and flow conditions at T+68-sec--Pc = 630 psi, gamma = 1.1381, T(sub c) = 6200 R, perfect gas without aluminum particulate. In a cooperative effort with other investigation team members, CFD-derived pressure loading on the NBR and castable inhibitors was used iteratively to obtain nominal deformed geometry of each inhibitor, and the deformed (bent back) inhibitor geometry was entered into this model. Deformed geometry was computed using structural finite-element models. A solution for the unsteady flow has been obtained for the nominal flow conditions (existing prior to the occurrence of the anomaly) showing sustained standing pressure oscillations at nominally 14.5 Hz in the motor IL acoustic mode that flight and static test data confirm to be normally present at this time. Average mass flow discharged from the nozzle was confirmed to be the nominal expected (9550 lbm/sec). The local inlet boundary condition is being perturbed at the location of the presumed reconstructed anomaly as identified by interior ballistics performance specialist team members. A time variation in local mass flow is used to simulate sudden increase in burning area due to localized propellant grain cracks. The solution will proceed to develop a pressure rise (proportional to total mass flow rate change squared). The volume-filling time constant (equivalent to 0.5 Hz) comes into play in shaping the rise rate of the developing pressure 'spike' as it propagates at the speed of sound in both directions to the motor head end and nozzle. The objectives of the present analysis are to: (1) capture the dynamic responses of the motor combustion gas flow to correlate with available low-frequency (less than 12.5 sample/sec) data and (2) observe the high-frequency (up to 50 Hz) characteristics of the response to determine any potentials for dynamic coupling.

Dougherty, N. S.↗

NASA NTRS1995

Robust integration schemes for generalized viscoplasticity with internal-state variables. Part 2: Algorithmic developments and implementation

This two-part report is concerned with the development of a general framework for the implicit time-stepping integrators for the flow and evolution equations in generalized viscoplastic models. The primary goal is to present a complete theoretical formulation, and to address in detail the algorithmic and numerical analysis aspects involved in its finite element implementation, as well as to critically assess the numerical performance of the developed schemes in a comprehensive set of test cases. On the theoretical side, the general framework is developed on the basis of the unconditionally-stable, backward-Euler difference scheme as a starting point. Its mathematical structure is of sufficient generality to allow a unified treatment of different classes of viscoplastic models with internal variables. In particular, two specific models of this type, which are representative of the present start-of-art in metal viscoplasticity, are considered in applications reported here; i.e., fully associative (GVIPS) and non-associative (NAV) models. The matrix forms developed for both these models are directly applicable for both initially isotropic and anisotropic materials, in general (three-dimensional) situations as well as subspace applications (i.e., plane stress/strain, axisymmetric, generalized plane stress in shells). On the computational side, issues related to efficiency and robustness are emphasized in developing the (local) interative algorithm. In particular, closed-form expressions for residual vectors and (consistent) material tangent stiffness arrays are given explicitly for both GVIPS and NAV models, with their maximum sizes 'optimized' to depend only on the number of independent stress components (but independent of the number of viscoplastic internal state parameters). Significant robustness of the local iterative solution is provided by complementing the basic Newton-Raphson scheme with a line-search strategy for convergence. In the present second part of the report, we focus on the specific details of the numerical schemes, and associated computer algorithms, for the finite-element implementation of GVIPS and NAV models.

Li, Wei↗

NASA NTRS1992

Effect of low-speed impact damage and damage location on behavior of composite panels

An investigation of the effects of low-speed impact damage on the compression and tension strength of thin (less than .05 inches thick) and moderately thick (between .12 and .17 inches thick) composite specimens was conducted. Impact speeds ranged from 50 to 550 ft/sec (impact energies from .25 to 30.7 ft-lb) and impact locations were near or away from a lateral unloaded edge. In this study, thin tension-loaded or compression-loaded specimens with only 90 deg and +/- 40 deg plies which were impacted away from the unloaded edge suffered less reduction in maximum load-carrying capability due to impact damage than the same specimens impacted near the unloaded edge. Unlike the thin laminates, failure loads of thicker compression-loaded specimens with a similar stacking sequence were independent of impact location. Failure loads of thin tension-loaded specimens with 0 deg plies were independent of impact location while failure loads of thicker compression-loaded specimens with 0 deg plies were dependent upon impact location. A finite-element analysis of strain distributions across the panel width indicated that high axial strains occur near the unloaded edges of postbuckled panels, indicating that impacts near the unloaded edge would significantly effect the behavior of postbuckled panels.

Jegley, Dawn↗

NASA NTRS1993

Test results from large wing and fuselage panels

This paper presents the first results in an assessment of the strength, stiffness, and damage tolerance of stiffened wing and fuselage subcomponents. Under this NASA funded program, 10 large wing and fuselage panels, variously fabricated by automated tow placement and dry-stitched preform/resin transfer molding, are to be tested. The first test of an automated tow placement six-longeron fuselage panel under shear load was completed successfully. Using NASTRAN finite-element analysis the stiffness of the panel in the linear range prior to buckling was predicted within 3.5 percent. A nonlinear analysis predicted the buckling load within 10 percent and final failure load within 6 percent. The first test of a resin transfer molding six-stringer wing panel under compression was also completed. The panel failed unexpectedly in buckling because of inadequate supporting structure. The average strain was 0.43 percent with a line load of 20.3 kips per inch of width. This strain still exceeds the design allowable strains. Also, the stringers did not debond before failure, which is in contrast to the general behavior of unstitched panels.

Madan, Ram C.↗

NASA NTRS1995

FPCAS3D User's guide: A three dimensional full potential aeroelastic program, version 1

The FPCAS3D computer code has been developed for aeroelastic stability analysis of bladed disks such as those in fans, compressors, turbines, propellers, or propfans. The aerodynamic analysis used in this code is based on the unsteady three-dimensional full potential equation which is solved for a blade row. The structural analysis is based on a finite-element model for each blade. Detailed explanations of the aerodynamic analysis, the numerical algorithms, and the aeroelastic analysis are not given in this report. This guide can be used to assist in the preparation of the input data required by the FPCAS3D code. A complete description of the input data is provided in this report. In addition, six examples, including inputs and outputs, are provided.

Bakhle, Milind A.↗

NASA NTRS1994

Buckling and vibration analysis of laminated panels using VICONOPT

The analysis aspects of the 23,000-line FORTRAN program VIPASA with constraints and optimization (VICONOPT) are described. Overall stiffness matrices assembled from the earlier exact vibration and instability of plate assemblies including shear and anisotropy (VIPASA) flat plate stiffnesses are optionally coupled by Langrangian multipliers to find critical buckling loads, or natural frequencies of undamped vibration, of prismatic assemblies of anisotropic flat plates with arbitrarily located point supports or simple transverse supporting frames. The longitudunal continuity of typical wing and fuselage panels is closely approximated because the solutions are for the infinitely long structure obtained by repeating a bay and its supports longitudinally. Any longitudinally invariant in-plane plate stresses are permitted, and very rapid solutions are guaranteed by numerous refinements, including multilevel substructuring and a method for repetitive cross sections that is exact for regular polygons used to represent cylinders. Modal displacements and stresses in or between plies of laminated plates are calculated and plotted, with values being recovered at all nodes of substructures. Comparison with usual approximate finite-element methods confirms that, for comparably converged solutions, VICONOPT is typically between 100 and 10(exp 4) times faster.

Kennedy, David↗

NASA NTRS1993

Space station static and dynamic analyses using parallel methods

Algorithms for high-performance parallel computers are applied to perform static analyses of large-scale Space Station finite-element models (FEMs). Several parallel-vector algorithms under development at NASA Langley are assessed. Sparse matrix solvers were found to be more efficient than banded symmetric or iterative solvers for the static analysis of large-scale applications. In addition, new sparse and 'out-of-core' solvers were found superior to substructure (superelement) techniques which require significant additional cost and time to perform static condensation during global FEM matrix generation as well as the subsequent recovery and expansion. A method to extend the fast parallel static solution techniques to reduce the computation time for dynamic analysis is also described. The resulting static and dynamic algorithms offer design economy for preliminary multidisciplinary design optimization and FEM validation against test modes. The algorithms are being optimized for parallel computers to solve one-million degrees-of-freedom (DOF) FEMs. The high-performance computers at NASA afforded effective software development, testing, efficient and accurate solution with timely system response and graphical interpretation of results rarely found in industry. Based on the author's experience, similar cooperation between industry and government should be encouraged for similar large-scale projects in the future.

Gupta, V.↗

NASA NTRS1994

Buckling of imperfect, anisotropic, ring-stiffened cylinders under combined loads

The objective of this study is to develop an anlysis to predict buckling loads of ring-stiffened anisotropic cylinders subject to axial compression, torsion, and internal pressure. This structure is modeled as a branched shell. A nonlinear axisymmetric prebuckling equilibrium state is assumed which is amenable to an exact solution within each branch. Axisymmetric geometric imperfections are included. Buckling displacements are represented by a Fourier series in the circumferential coordination and the finite-element method in the axial coordinate. Application of the Trefftz criterion to the second variation of the total potential energy leads to a nonlinear eigenvalue problem for the buckling load and mode. Results are presented for both unstiffened and ring-stiffened cylinders in the form of buckling interaction diagrams. Imperfections can cause an unexpected buckling mode in the ring web which would not occur for the perfect structure, and pressurization diminishes the benefit of adding rings to the unstiffened shell to increase the buckling load. The implementation of the analysis methodology into a structural sizing algorithm is discussed.

Ley, Robert P.↗

NASA NTRS1995

Calculations of Diffuser Flows with an Anisotropic K-Epsilon Model

A newly developed anisotropic K-epsilon model is applied to calculate three axisymmetric diffuser flows with or without separation. The new model uses a quadratic stress-strain relation and satisfies the realizability conditions, i.e., it ensures both the positivity of the turbulent normal stresses and the Schwarz' inequality between any fluctuating velocities. Calculations are carried out with a finite-element method. A second-order accurate, bounded convection scheme and sufficiently fine grids are used to ensure numerical credibility of the solutions. The standard K-epsilon model is also used in order to highlight the performance of the new model. Comparison with the experimental data shows that the anisotropic K-epsilon model performs consistently better than does the standard K-epsilon model in all of the three test cases.

Zhu, J.↗

NASA NTRS1995

Buckling Analysis of Debonded Sandwich Panel Under Compression

A sandwich panel with initial through-the-width debonds is analyzed to study the buckling of its faceskin when subject to an in-plane compressive load. The debonded faceskin is modeled as a beam on a Winkler elastic foundation in which the springs of the elastic foundation represent the sandwich foam. The Rayleigh-Ritz and finite-difference methods are used to predict the critical buckling load for various debond lengths and stiffnesses of the sandwich foam. The accuracy of the methods is assessed with a plane-strain finite-element analysis. Results indicate that the elastic foundation approach underpredicts buckling loads for sandwich panels with isotropic foam cores.

Sleight, David W.↗

NASA NTRS1976

The Effects of Variable Mass and Geometry, Pretwist, Shear Deformation and Rotatory Inertia on the Resonant Frequencies of Intact Long Bones: A Finite Element Model Analysis

The influence of pretwist, nonuniformities in mass and flexural stiffness, rotatory inertia and shear deformation on the natural frequencies of intact bones is evaluated by means of a linear elastic, finite-element model which has been programmed for solution on the digital computer. Theoretical results are compared to the results on the forced vibration of intact canine radii obtained experimentally by Thompson. Surprisingly, inclusion of fairly large pretwist angles (from -14 to 12 deg for one specimen) had little affect on the first three frequencies of transverse vibration in either the cranial or lateral directions. Inclusion of shear deformation reduced the third-mode frequency in the stiffest (lateral) direction by about six percent, otherwise shear deformation played a minor role in determining natural frequencies. Similarly. rotatory inertia had negligible influence up to the third natural frequency. The predominant influence on the first three natural frequencies of transverse vibration could be attributed to the variations in mass and flexural stiffness along the length of the test specimens. Different effective moduli of elasticity are required to yield correct absolute values for the frequencies which correspond to experimental findings. thus implying the presence of some inhomogeneities in material properties around the bone cross-section and/or along its length.

Young, Donald R.↗