Additive Manufacturing Design, Process and Quality Controls
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Doug Wells↗
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Additive Manufacturing Design, Process and Quality Controls
Explore the source record for details and available documents.
Doug Wells↗
Preliminary control law and hardware designs for a ride quality augmentation system for commuter aircraft. Phase 2
The continued investigation of the design of Ride Quality Augmentation Systems (RQAS) for commuter aircraft is described. The purpose of these RQAS is the reduction of the vertical and lateral acceleration response of the aircraft due to atmospheric turbulence by the application of active control. The current investigations include the refinement of the sample data feedback control laws based on the control-rate-weighting and output-weighting optimal control design techniqes. These control designs were evaluated using aircraft time simulations driven by Dryden spectra turbulence. Fixed gain controllers were tested throughout the aircrft operating envelope. The preliminary design of the hardware modifications necessary to implement and test the RQAS on a commuter aircraft is included. These include a separate surface elevator and the flap modifications to provide both direct lift and roll control. A preliminary failure mode investigation was made for the proposed configuration. The results indicate that vertical acceleration reductions of 45% and lateral reductions of more than 50% are possible. A fixed gain controller appears to be feasible with only minor response degradation.
Davis, D. J.↗
A design procedure and handling quality criteria for lateral directional flight control systems
A practical design procedure for aircraft augmentation systems is described based on quadratic optimal control technology and handling-quality-oriented cost functionals. The procedure is applied to the design of a lateral-directional control system for the F4C aircraft. The design criteria, design procedure, and final control system are validated with a program of formal pilot evaluation experiments.
Stein, G.↗
Initial Investigation of Reaction Control System Design on Spacecraft Handling Qualities for Earth Orbit Docking
A program of research, development, test, and evaluation is planned for the development of Spacecraft Handling Qualities guidelines. In this first experiment, the effects of Reaction Control System design characteristics and rotational control laws were evaluated during simulated proximity operations and docking. Also, the influence of piloting demands resulting from varying closure rates was assessed. The pilot-in-the-loop simulation results showed that significantly different spacecraft handling qualities result from the design of the Reaction Control System. In particular, cross-coupling between translational and rotational motions significantly affected handling qualities as reflected by Cooper-Harper pilot ratings and pilot workload, as reflected by Task-Load Index ratings. This influence is masked but only slightly by the rotational control system mode. While rotational control augmentation using Rate Command Attitude Hold can reduce the workload (principally, physical workload) created by cross-coupling, the handling qualities are not significantly improved. The attitude and rate deadbands of the RCAH introduced significant mental workload and control compensation to evaluate when deadband firings would occur, assess their impact on docking performance, and apply control inputs to mitigate that impact.
Bailey, Randall E.↗
A design procedure for the handling qualities optimization of the X-29A aircraft
A design technique for handling qualities improvement was developed for the X-29A aircraft. As with any new aircraft, the X-29A control law designers were presented with a relatively high degree of uncertainty in their mathematical models. The presence of uncertainties, and the high level of static instability of the X-29A caused the control law designers to stress stability and robustness over handling qualities. During flight test, the mathematical models of the vehicle were validated or corrected to match the vehicle dynamic behavior. The updated models were then used to fine tune the control system to provide fighter-like handling characteristics. A design methodology was developed which works within the existing control system architecture to provide improved handling qualities and acceptable stability with a minimum of cost in both implementation as well as software verification and validation.
Bosworth, John T.↗
Reliability Quantification of the Flexure: A Critical Stirling Convertor Component
Uncertainties in the manufacturing, fabrication process, material behavior, loads, and boundary conditions results in the variation of the stresses and strains induced in the flexures and its fatigue life. Past experience and the test data at material coupon levels revealed a significant amount of scatter of the fatigue life. Owing to these facts, the design of the flexure, using conventional approaches based on safety factor or traditional reliability based on similar equipment considerations does not provide a direct measure of reliability. Additionally, it may not be feasible to run actual long term fatigue tests due to cost and time constraints. Therefore it is difficult to ascertain material fatigue strength limit. The objective of the paper is to present a methodology and quantified results of numerical simulation for the reliability of flexures used in the Stirling convertor for their structural performance. The proposed approach is based on application of finite element analysis method in combination with the random fatigue limit model, which includes uncertainties in material fatigue life. Additionally, sensitivity of fatigue life reliability to the design variables is quantified and its use to develop guidelines to improve design, manufacturing, quality control and inspection design process is described.
Shah, Ashwin R.↗
High Quality Spotlight SAR Processing Algorithm Designed for LiteSAR Mission
A high quality spotlight SAR processing algorithm is presented. In this algorithm, subband images of the radar illuminated spot are pocessed using well known strip mode processing algorithms.
banwidth spotlight data Doppler analysis autofocus↗
Incorporating Handling Qualities Analysis into Rotorcraft Conceptual Design
This paper describes the initial development of a framework to incorporate handling qualities analyses into a rotorcraft conceptual design process. In particular, the paper describes how rotorcraft conceptual design level data can be used to generate flight dynamics models for handling qualities analyses. Also, methods are described that couple a basic stability augmentation system to the rotorcraft flight dynamics model to extend analysis to beyond that of the bare airframe. A methodology for calculating the handling qualities characteristics of the flight dynamics models and for comparing the results to ADS-33E criteria is described. Preliminary results from the application of the handling qualities analysis for variations in key rotorcraft design parameters of main rotor radius, blade chord, hub stiffness and flap moment of inertia are shown. Varying relationships, with counteracting trends for different handling qualities criteria and different flight speeds are exhibited, with the action of the control system playing a complex part in the outcomes. Overall, the paper demonstrates how a broad array of technical issues across flight dynamics stability and control, simulation and modeling, control law design and handling qualities testing and evaluation had to be confronted to implement even a moderately comprehensive handling qualities analysis of relatively low fidelity models. A key outstanding issue is to how to 'close the loop' with an overall design process, and options for the exploration of how to feedback handling qualities results to a conceptual design process are proposed for future work.
Analysis into Rotorcraft↗
Physics-informed graph neural networks for predicting cetane number with systematic data quality analysis
Designing alternative fuels for advanced compression ignition engines necessitates a predictive model for cetane number (CN). In this study, the physics-informed graph neural networks are introduced for a reliable CN prediction by considering molecular features pertinent to the physical properties of molecules that affect CN. The reliability of measured data is another key factor to consider for improving the predictive model. Various experimental instruments for measuring CN exist, including standard and non-standard methods. In this regard, a systematic data quality analysis was carried out for the total 630 CNs collected from literature and new measurements in this study using Advanced Fuel Ignition Delay Analyzer (AFIDA). The results from this data curation process were reflected in the model by imposing lower sample weights on the data coming from less reliable measurement techniques. This approach effectively maximized the prediction accuracy while incorporating data from all available sources. Using the sample weights decreased the mean absolute error (MAE) up to 0.8 CN units. The accuracy was also improved by introducing the CN-related physical properties (the number of hydrogen bond donors and acceptors); the test set MAE is 5.74 and 7.01 for the model with and without such properties, respectively. Investigating molecular structural effects on CN was also carried out to gain chemical insights into factors used to design new fuel candidates. The dimensionality reduction analysis of feature vectors showed a clear clustering in terms of functional groups and CN and the structural effect derived from the model was consistent with the physicochemical insights. Finally, this physics-informed model and data curation would be helpful for accurate CN prediction and inform rational fuel design.
97 MATHEMATICS AND COMPUTING↗
Flared landing approach flying qualities. Volume 1: Experiment design and analysis
An inflight research study was conducted utilizing the USAF Total Inflight Simulator (TIFS) to investigate longitudinal flying qualities for the flared landing approach phase of flight. The purpose of the experiment was to generate a consistent set of data for: (1) determining what kind of commanded response the pilot prefers in order to flare and land an airplane with precision, and (2) refining a time history criterion that took into account all the necessary variables and their characteristics that would accurately predict flying qualities. The result of the first part provides guidelines to the flight control system designer, using MIL-F-8785-(C) as a guide, that yield the dynamic behavior pilots perfer in flared landings. The results of the second part provides the flying qualities engineer with a newly derived flying qualities predictive tool which appears to be highly accurate. This time domain predictive flying qualities criterion was applied to the flight data as well as six previous flying qualities studies, and the results indicate that the criterion predicted the flying qualities level 81% of the time and the Cooper-Harper pilot rating, within + or - 1, 60% of the time.
Weingarten, Norman C.↗
Ride quality criteria and the design process
Conceptual designs for advanced ground transportation systems often hinge on obtaining acceptable vehicle ride quality while attempting to keep the total guideway cost (initial and subsequent maintenance) as low as possible. Two ride quality standards used extensively in work sponsored by the U.S. Department of Transportation (DOT) are the DOT-Urban Tracked Air Cushion Vehicle (UTACV) standard and the International Standards Organization (ISO) reduced ride comfort criteria. These standards are reviewed and some of the deficiencies, which become apparent when trying to apply them in practice, are noted. Through the use of a digital simulation, the impact of each of these standards on an example design process is examined. It is shown that meeting the ISO specification for the particular vehicle/guideway case investigated is easier than meeting the UTACV standard.
Ravera, R. J.↗
Potential of water quality wetlands to mitigate habitat losses from agricultural drainage modernization
Given widespread biodiversity declines, a growing global human population, and demands to improve water quality, there is an immediate need to explore land management solutions that support multiple ecosystem services. Agricultural water quality wetlands designed to provide both water quality benefits and wetland and grassland habitat are an emerging restoration solution that may reverse habitat declines in intensive agricultural areas. Installation of water quality wetlands in the Upper Midwest, USA, when considered alongside the repair and modification of aging agricultural tile drainage infrastructure, is a likely scenario that may mitigate nutrient pollution exported from agricultural systems and improve crop yields. The capacity of water quality wetlands to provide habitat within the wetland pool and the surrounding grassland is not well-studied, particularly with respect to potential habitat changes resulting from drainage infrastructure upgrades. For the current study, we produced spatially explicit models of 37 catchments distributed throughout an important region for agriculture and biodiversity, the Des Moines Lobe of Iowa. Four scenarios were considered - with and without improved drainage and with and without water quality wetlands - to estimate the net potential habitat implications of these scenarios for amphibians, grassland birds, and wild bees. Model results indicate that drainage modification alone will likely result in moderate direct losses of suitable amphibian habitat and large declines in overall habitat quality. However, inclusion of water quality wetlands at the catchment scale may mitigate these amphibian habitat losses while also increasing grassland bird and pollinator habitat. In conclusion, the impacts of water quality wetlands and drainage modernization on waterfowl in the region require additional study.
54 ENVIRONMENTAL SCIENCES↗
Flying qualities criteria and flight control design
Despite the application of sophisticated design methodology, newly introduced aircraft continue to suffer from basic flying qualities deficiencies. Two recent meetings, the DOD/NASA Workshop on Highly Augmented Aircraft Criteria and the NASA Dryden Flight Research Center/Air Force Flight Test Center/AIAA Pilot Induced Oscillation Workshop, addressed this problem. An overview of these meetings is provided from the point of view of the relationship between flying qualities criteria and flight control system design. Among the items discussed are flying qualities criteria development, the role of simulation, and communication between flying qualities specialists and control system designers.
Berry, D. T.↗
JSC Metal Finishing Waste Minimization Methods
THe paper discusses the following: Johnson Space Center (JSC) has achieved VPP Star status and is ISO 9001 compliant. The Structural Engineering Division in the Engineering Directorate is responsible for operating the metal finishing facility at JSC. The Engineering Directorate is responsible for $71.4 million of space flight hardware design, fabrication and testing. The JSC Metal Finishing Facility processes flight hardware to support the programs in particular schedule and mission critical flight hardware. The JSC Metal Finishing Facility is operated by Rothe Joint Venture. The Facility provides following processes: anodizing, alodining, passivation, and pickling. JSC Metal Finishing Facility completely rebuilt in 1998. Total cost of $366,000. All new tanks, electrical, plumbing, and ventilation installed. Designed to meet modern safety, environmental, and quality requirements. Designed to minimize contamination and provide the highest quality finishes.
Sullivan, Erica↗
The AMACStar ASIC for the HL-LHC ATLAS ITk Strip detector: design, verification, testing, and quality assurance
For the high-luminosity upgrade to the LHC (HL-LHC), the ATLAS detector at CERN requires an all-new inner detector, the Inner Tracker (ITk). The ITk Strip subdetector is made up of silicon modules, which include three types of radiation-hard ASICs. One of these is the Autonomous Monitor and Control (AMAC). The AMAC is manufactured by Global Foundries using 130 nm CMOS8RF DM technology and is approximately 3 by 5 mm in size. This ASIC autonomously monitors the temperatures, voltages, and currents in the module components while controlling critical values in order to prevent these quantities from reaching dangerous levels. The final design, AMACStar, was verified, tested, and ensured to perform all necessary functions. A quality control procedure using an in-house probe station set-up was developed in order to ensure that every individual chip on each wafer of AMACStars required by the ITk Strip project met performance requirements. The average per wafer yield of usable AMACStars is 92.33%, exceeding the design-specific 90% yield estimated for project costing. This estimate was based on actual yields for similar designs in this process.
Analogue electronic circuits↗
High angle of attack flying qualities criteria for longitudinal rate command systems
This study was designed to investigate flying qualities requirements of alternate pitch command systems for fighter aircraft at high angle of attack. Flying qualities design guidelines have already been developed for angle of attack command systems at 30, 45, and 60 degrees angle of attack, so this research fills a similar need for rate command systems. Flying qualities tasks that require post-stall maneuvering were tested during piloted simulations in the McDonnell Douglas Aerospace Manned Air Combat Simulation facility. A generic fighter aircraft model was used to test angle of attack rate and pitch rate command systems for longitudinal gross acquisition and tracking tasks at high angle of attack. A wide range of longitudinal dynamic variations were tested at 30, 45, and 60 degrees angle of attack. Pilot comments, Cooper-Harper ratings, and pilot induced oscillation ratings were taken from five pilots from NASA, USN, CAF, and McDonnell Douglas Aerospace. This data was used to form longitudinal design guidelines for rate command systems at high angle of attack. These criteria provide control law design guidance for fighter aircraft at high angle of attack, low speed flight conditions. Additional time history analyses were conducted using the longitudinal gross acquisition data to look at potential agility measures of merit and correlate agility usage to flying qualities boundaries. This paper presents an overview of this research.
Wilson, David J.↗
Quality Assurance Surveillance Tool Designed for SLS EM-1 Certificate of Flight Readiness
Exploration Mission-1 (EM-1) is an uncrewed mission that is launching on the Space Launch System (SLS) Block 1 vehicle. This is a critical flight test for the agency's human deep space exploration goals. Exploration Ground Systems (EGS) Quality (SA-F2) is responsible for providing Quality Assurance Surveillance Plans (QASPs) for NASA contracts and facilities. A QASP assures products and services are provided to EGS in accordance with the contract requirements. In order to encapsulate the multiple KSC Safety and Mission Assurance surveillance and audit activities that need to be accomplished specifically for EM-1 Certificate of Flight Reediness (CoFR), a QASP tool needed to be implemented. This tool would be able to intuitively track Work Authorization Documents (WADs) under development by Test Operations Support Contract (TOSC), reviewed and accepted WADs, Government Mandatory Inspection Points (GMIPs), Nonconformances (NCs), Material Review Board (MRB) Status, Corrective Actions, Alterations, Deviations, and Waivers for flight hardware and Ground Support Equipment (GSE). This would help ensure that all SLS EM-1 flight hardware and related GSE surveillances and requirements are being recognized and completed with zero constraints identified for the mission.
Morris, Patrick↗