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NASA NTRS2017

Insights into the Behavior of Potential Structural Failures Originating from Localized High Stress Regions in Configurations Relevant to Solid Rocket Motor Nozzles

During the structural certification effort for the Space Launch System solid rocket booster nozzle, it was identified that no consistent method for addressing local negative margins of safety in non-metallic materials had been developed. Relevant areas included bond-line terminations and geometric features in the composite nozzle liners. In order to gain understanding, analog test specimens were designed that very closely mimic the conditions in the actual full scale hardware. Different locations in the nozzle were represented by different analog specimen designs. This paper describes those tests and corresponding results. Finite element analysis results for the tests are presented. Strain gage correlation of the analysis to the test results is addressed. Furthermore, finite fracture mechanics (a coupled stress and energy failure criterion) is utilized to predict the observed crack pop-in loads for the different configurations. The finite fracture mechanics predictions are found to be within a 10% error relative to the average measured pop-in load for each of four configurations. Initiation locations, arrest behaviors, and resistances to further post-arrest crack propagation are also discussed.

McCutcheon, David Matthew↗

NASA NTRSDate not supplied

Novel Test and Analysis Methodology for the Assessment of Joint under Re-entry Environment

Spacecraft thermal protection systems require unique approaches for design verification due to the extreme environments seen during space travel and atmospheric re-entry. In this work, unique considerations for design, analysis, and verification of a tiled heatshield design with material nonlinearity, material property temperature-dependency, material property rate-dependency, and geometric stress concentrations are presented. Such designs require a thorough application of the building block approach to derive appropriate material property datasets, and a novel application of analysis models to aid in the structural verification with testing. The custom application of material rate-dependency in finite element analysis software is presented as a means of leveraging the rate-dependent test data for the material property dataset. Because bonded tile heatshields contain so many design considerations and nonlinearities which often preclude the ability to easily achieve the requisite test factors in qualification testing, a novel sub-element test was developed that amplifies the stress singularity beyond flight conditions. The test achieves an over-test over flight stress conditions. The approach for sub-element coupon design can be extended to other bonded joint designs and can be used in aiding a qualification program.

Pavel Babuska↗

NASA NTRS1986

The 15 meter hoop-column antenna dynamics: Test and analysis

A 15 meter model of the hoop-column antenna concept has been vibration tested for model characterization and analytical model verification. Linear finite element analysis predicted the global vibration frequencies accurately. Good agreement between analysis and test data was obtained only after the analytical model was refined using static test data. As structures become more flexible, structural properties determined from static data become more accurate and should be used to update analytical models. Global vibration modes are not significantly affected by the surface mesh which permits simplified analytical models to be used for prediction of global behavior. These reduced models are believed sufficient for preliminary design and controls simulations where only global behavior is desired. The mesh modes were highly damped due to the knit mesh used for the reflector surface. These modes were also highly coupled and very difficult to measure in the laboratory. The inability to fully characterize the antenna mesh modes in the laboratory indicates robust methods for active surface vibration suppression will be needed. Fortunately, the surface mesh exhibits high passive damping which should be beneficial to active control systems.

Belvin, W. Keith↗

NASA NTRS1991

Analysis of delamination onset and growth in curved laminates

Delamination onset and growth from a matrix crack in a curved composite laminate are studied. Finite element analysis is used to determine values of G which can be compared to the interlaminar fracture toughness of the composite for delamination predictions. The delamination is assumed to grow from the matrix crack and to remain straight and perpendicular to the edge. G is larger at the free edge than in the center and increases with delamination growth. Thus, once delamination begins from the matrix crack it should continue around the curved section with no increase in applied load. In the local vicinity of the matrix crack the rate of change of G decreases initially and then begins to increase with a point of inflection in between. Measured failure loads and the interlaminar fracture toughness of the composite are used to show that the point of inflection corresponds to the critical value of G.

Martin, Roderick H.↗

NASA NTRS1996

A Thermostructural Analysis of a Diboride Composite Leading Edge

In an effort to support the design of zirconium diboride composite leading edges for hypersonic vehicles, a finite element model (FEM) of a prototype leading edge was created and finite element analysis (FEA) was employed to assess its thermal and structural response to aerothermal boundary conditions. Unidirectional material properties for the structural components of the leading edge, a continuous fiber reinforced diboride composite, were computed with COSTAR. These properties agree well with those experimentally measured. To verify the analytical approach taken with COSMOS/M, an independent FEA of one of the leading edge assembly components was also done with COSTAR. Good agreement was obtained between the two codes. Both showed that a unidirectional lay-up had the best margin of safety for a simple loading case. Both located the maximum stress in the same region and ply. The magnitudes agreed within 4 percent. Trajectory based aerothermal heating was then applied to the leading edge assembly FEM created with COSMOS/M to determine steady state temperature response, displacement, stresses, and contact forces due to thermal expansion and thermal strains. Results show that the leading edge stagnation line temperature reached 4700 F. The maximum computed failure index for the laminated composite components peaks at 4.2, and is located at the bolt flange in layer 2 of the side bracket. The temperature gradient in the tip causes a compressive stress of 279 ksi along its width and substantial tensile stresses within its depth.

Kowalski, Tom↗

NASA NTRS2008

Software Performs Complex Design Analysis

Designers use computational fluid dynamics (CFD) to gain greater understanding of the fluid flow phenomena involved in components being designed. They also use finite element analysis (FEA) as a tool to help gain greater understanding of the structural response of components to loads, stresses and strains, and the prediction of failure modes. Automated CFD and FEA engineering design has centered on shape optimization, which has been hindered by two major problems: 1) inadequate shape parameterization algorithms, and 2) inadequate algorithms for CFD and FEA grid modification. Working with software engineers at Stennis Space Center, a NASA commercial partner, Optimal Solutions Software LLC, was able to utilize its revolutionary, one-of-a-kind arbitrary shape deformation (ASD) capability-a major advancement in solving these two aforementioned problems-to optimize the shapes of complex pipe components that transport highly sensitive fluids. The ASD technology solves the problem of inadequate shape parameterization algorithms by allowing the CFD designers to freely create their own shape parameters, therefore eliminating the restriction of only being able to use the computer-aided design (CAD) parameters. The problem of inadequate algorithms for CFD grid modification is solved by the fact that the new software performs a smooth volumetric deformation. This eliminates the extremely costly process of having to remesh the grid for every shape change desired. The program can perform a design change in a markedly reduced amount of time, a process that would traditionally involve the designer returning to the CAD model to reshape and then remesh the shapes, something that has been known to take hours, days-even weeks or months-depending upon the size of the model.

Source record↗

NASA NTRS2004

Modeling and Evaluation of Canted Coil Springs as High Temperature Seal Preloading Devices

Future reusable launch vehicles will require advanced structural seals. This includes propulsion seals along edges and hinge lines in hypersonic engines, and control surface seals for movable flaps and elevons on proposed reentry vehicles. Seals must remain in sealing engagement with opposing surfaces, for multiple missions, even though the seal gap may be opening and closing due to thermal and structural loads. To meet this requirement either the seals themselves must be resilient or there must be a resilient structural element behind the seals. Case Western Reserve University is working with NASA s Glenn Research Center to develop more resilient high temperature seal components and preloading devices. Results are presented for a finite element analysis of a canted coil spring that is being considered as a high temperature seal preloading device. This type of spring is a leading candidate due to its ability to provide nearly constant force over a large deflection. The finite element analyses were verified by comparing them to experimental results of canted coil springs of three different stiffnesses, measured at Glenn Research Center. Once validated the parameterized model was combined with a scripting algorithm to assess the effects of key spring design variables (wire diameter, coils per inch, cant amplitude, eccentricity, and spring width) on spring stiffness and maximum Von Mises stress to aid in subsequent design.

Oswald, Jay J.↗

NASA NTRS2014

Hybrid-Wing-Body Vehicle Composite Fuselage Analysis and Case Study

Recent progress in the structural analysis of a Hybrid Wing-Body (HWB) fuselage concept is presented with the objective of structural weight reduction under a set of critical design loads. This pressurized efficient HWB fuselage design is presently being investigated by the NASA Environmentally Responsible Aviation (ERA) project in collaboration with the Boeing Company, Huntington Beach. The Pultruded Rod-Stiffened Efficient Unitized Structure (PRSEUS) composite concept, developed at the Boeing Company, is approximately modeled for an analytical study and finite element analysis. Stiffened plate linear theories are employed for a parametric case study. Maximum deflection and stress levels are obtained with appropriate assumptions for a set of feasible stiffened panel configurations. An analytical parametric case study is presented to examine the effects of discrete stiffener spacing and skin thickness on structural weight, deflection and stress. A finite-element model (FEM) of an integrated fuselage section with bulkhead is developed for an independent assessment. Stress analysis and scenario based case studies are conducted for design improvement. The FEM model specific weight of the improved fuselage concept is computed and compared to previous studies, in order to assess the relative weight/strength advantages of this advanced composite airframe technology

Mukhopadhyay, Vivek↗

NASA NTRS1978

Evaluation and expansion of an analytical model for fatigue of notched composite laminates

The analytical and experimental study performed to expand the existing static and fatigue failure analysis is described. The analytical effort extended the analysis to include interlaminar effects, while the experimental effort developed methods to obtain basic experimental data required as input to the analysis. The static failure analysis for notched laminates was modified to include interlaminar effects near the notch. Three dimensional elastic and two dimensional elasticplastic finite element analysis were performed for some notched laminates.

Ramkumar, R. L.↗

NASA NTRS1987

Manual for Program PSTRESS: Peel stress computation

Described is the use of the interactive FORTRAN computer program PSTRESS, which computes a closed form solution for two bonded plates subjected to applied moments, vertical shears, and in-plane forces. The program calculates in-plane stresses in the plates, deflections of the plates, and peel and shear stresses in the adhesive. The document briefly outlines the analytical method used by PSTRESS, describes the input and output of the program, and presents a sample analysis. The results of the latter are shown to be within a few percent of results obtained using a NASTRAN finite element analysis. An appendix containing a listing of PSTRESS is included.

Barkey, Derek A.↗

NASA NTRS2018

Parametric Analysis of Aircraft WingWeight Using Low-Order Physics-Based Analysis

In the conceptual aircraft design phase, prediction of the empty weight typically relies on empirically-based regression equations which execute quickly and require little detailed information about the internal structural layout. Since they are based on existing aircraft, however, empirical methods can lose their validity for newer technologies and unconventional configurations. Designers can transition to higher-order, physics-based analysis methods to improve the accuracy of the weight prediction, but at the cost of complex model setup and increased computational time. This paper describes a methodology for low-order aero-structural analysis of conceptual aircraft configurations that increases the use of physics-based analysis in conceptual design, but is less complex and time-consuming than higher-order methods such as finite-element analysis. The methodology uses Vehicle Sketch Pad (OpenVSP) to model the aircraft geometry, and ASWING to perform the aero-structural analysis. The internal forces and moments from the ASWING analysis are post-processed to calculate the resulting direct and shear stresses in the structure, and the thickness distributions of the aircraft components are varied to match the maximum von Mises stress at each cross section to the material allowable. To offset the increased computational time relative to empirical weight equations, a process is studied which uses parametric variation to develop a regression equation relating the weight of the aircraft wing to major design variables. This new weight equation is similar to existing empirical equations, but is built using the more physics-based methodology; the new equation could be used to augment or replace portions of the empirical database to improve the validity of the wing weight prediction for unconventional configurations and advanced technologies.

Olson, Erik D.↗

NASA NTRS2020

TURBOMAT-FR: Turbomachinery Aeroelastic Forced Response Analysis Automation Using MATLAB® Part 2

The primary aim of this effort is to develop a software tool named “Turbomachinery Aeroelastic Analysis Tool for Forced Response (TURBOMAT-FR)” using MATLAB® (The MathWorks, Inc.) scripts. The tool will aid in performing routine forced response analysis of turbomachinery fan blades with the aid of the modal summation method (MSUM). The MSUM approach requires a modal solution consisting of modal displacements, frequencies, and stresses. The MATLAB® scripts facilitate easy extraction of the required quantities from the computational fluid dynamics (CFD) and MSC Nastran (Hexagon AB) solution files. These quantities are subsequently utilized by the MSUM approach to perform a complete forced response analysis using the MATLAB® scripts. The MATLAB® scripts in TURBOMAT-FR are utilized in postprocessing of the MSC Nastran finite element analysis outputs in three types of solutions or steps, namely (1) stresses and displacements from static or steady response solution, (2) unsteady stresses and displacements from direct forced response solution, and (3) modal solution containing modal displacements and modal stresses. In step (4), separate MATLAB® scripts are also developed to read the processed outputs in step (3) and perform forced response analysis using MSUM. It should be noted that the direct forced response solution from step (2) will provide for a comparison with those obtained from the MSUM approach in steps (3) and (4). The TURBOMAT-FR MATLAB® scripts mentioned previously are presented in two reports designated Parts 1 and 2. Part 1 presents the scripts needed to accomplish steps (1) and (2). The current report, Part 2, presents the scripts needed to accomplish steps (3) and (4), noted previously. The TURBOMAT-FR MATLAB® scripts provided here in Part 2 facilitate the calculation of unsteady stresses using MSUM and provide an automated procedure associated with aeroelastic forced response analysis with different pressure files. The unsteady stresses calculated using MSUM can be compared with those presented in Part 1. A cantilevered blade-alone model subjected to a realistic pressure loading to a boundary was used for static and unsteady direct forced response analysis to demonstrate the effectiveness of the TURBOMATFR MATLAB® scripts.

T S R Reddy↗

NASA NTRS1981

Advanced superposition methods for high speed turbopump vibration analysis

The small, high pressure Mark 48 liquid hydrogen turbopump was analyzed and dynamically tested to determine the cause of high speed vibration at an operating speed of 92,400 rpm. This approaches the design point operating speed of 95,000 rpm. The initial dynamic analysis in the design stage and subsequent further analysis of the rotor only dynamics failed to predict the vibration characteristics found during testing. An advanced procedure for dynamics analysis was used in this investigation. The procedure involves developing accurate dynamic models of the rotor assembly and casing assembly by finite element analysis. The dynamically instrumented assemblies are independently rap tested to verify the analytical models. The verified models are then combined by modal superposition techniques to develop a completed turbopump model where dynamic characteristics are determined. The results of the dynamic testing and analysis obtained are presented and methods of moving the high speed vibration characteristics to speeds above the operating range are recommended. Recommendations for use of these advanced dynamic analysis procedures during initial design phases are given.

Nielson, C. E.↗

NASA NTRS1989

Sublaminate analysis of interlaminar fracture in composites. II - Applications

A validation of the sublaminate analysis method of Armanios and Rehfield (1989) is provided by comparison of the predictions with a quasi-three-dimensional finite-element analysis. A comparison of the total strain-energy release rate with a classical plate model is also provided. Closed-form expressions for the total strain-energy rate and the strain-energy release-rate components are developed. The sublaminate analysis developed is simple, and the results are generated using a desktop computer.

Armanios, Erian A.↗

NASA NTRS2002

Eigenvalues of Rectangular Waveguide Using FEM With Hybrid Elements

A finite element analysis using hybrid triangular-rectangular elements is developed to estimate eigenvalues of a rectangular waveguide. Use of rectangular vector-edge finite elements in the vicinity of the PEC boundary and triangular elements in the interior region more accurately models the physical nature of the electromagnetic field, and consequently quicken the convergence.

Deshpande, Manohar D.↗

NASA NTRS2003

Predicting the Reliability of Ceramics Under Transient Loads and Temperatures With CARES/Life

A methodology is shown for predicting the time-dependent reliability of ceramic components against catastrophic rupture when subjected to transient thermomechanical loads (including cyclic loads). The methodology takes into account the changes in material response that can occur with temperature or time (i.e., changing fatigue and Weibull parameters with temperature or time). This capability has been added to the NASA CARES/Life (Ceramic Analysis and Reliability Evaluation of Structures/Life) code. The code has been modified to have the ability to interface with commercially available finite element analysis (FEA) codes executed for transient load histories. Examples are provided to demonstrate the features of the methodology as implemented in the CARES/Life program.

Nemeth, Noel N.↗

NASA NTRS2005

Structural Analysis of an Inflation-Deployed Solar Sail With Experimental Validation

Under the direction of the NASA In-Space Propulsion Technology Office, the team of L Garde, NASA Jet Propulsion Laboratory, Ball Aerospace, and NASA Langley Research Center has been developing a scalable solar sail configuration to address NASA s future space propulsion needs. Prior to a flight experiment of a full-scale solar sail, a comprehensive phased test plan is currently being implemented to advance the technology readiness level of the solar sail design. These tests consist of solar sail component, subsystem, and sub-scale system ground tests that simulate the vacuum and thermal conditions of the space environment. Recently, two solar sail test articles, a 7.4-m beam assembly subsystem test article and a 10-m four-quadrant solar sail system test article, were tested in vacuum conditions with a gravity-offload system to mitigate the effects of gravity. This paper presents the structural analyses simulating the ground tests and the correlation of the analyses with the test results. For programmatic risk reduction, a two-prong analysis approach was undertaken in which two separate teams independently developed computational models of the solar sail test articles using the finite element analysis software packages: NEiNastran and ABAQUS. This paper compares the pre-test and post-test analysis predictions from both software packages with the test data including load-deflection curves from static load tests, and vibration frequencies and mode shapes from structural dynamics tests. The analysis predictions were in reasonable agreement with the test data. Factors that precluded better correlation of the analyses and the tests were uncertainties in the material properties, test conditions, and modeling assumptions used in the analyses.

Sleight, David W.↗

NASA NTRS1989

Ground Shake Test of the Boeing Model 360 Helicopter Airframe

Boeing Helicopters, together with other U.S. Helicopter manufacturers, is engaged in a finite element applications program designed to emplace in the U.S. a superior capability to utilize finite element analysis models in support of helicopter airframe structurel design. This program was given the acronym DAMVIBS (Design Analysis Methods for VIBrationS). The test plan is reviewed and results are presented for a shake test of the Boeing Model 360 helicopter. Results of the test will serve as the basis for validation of a finite element vibration model of the helicopter.

Reed, D. A.↗