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DOE OSTI2020

Opportunities and Challenges in Metal Forming for Lightweighting: Review and Future Work

Abstract The purposes of this review are to summarize the historical progress in the last 60 years of lightweight metal forming, to analyze the state-of-the-art, and to identify future directions in the context of Cyber-physically enabled circular economy. In honoring the 100th anniversary of the establishment of the Manufacturing Engineering Division of ASME, this review paper first provides the impact of the metal forming sector on the economy and historical perspectives of metal forming research work published by the ASME Journal of Manufacturing Science and Engineering, followed by the motivations and trends in lightweighting. To achieve lightweighting, one needs to systematically consider: (1) materials and material characterization; (2) innovative forming processes; and (3) simulation tools for integrated part design and process design. A new approach for process innovation, i.e., the Performance-Constraints-Mechanism-Innovation (PCMI) framework, is proposed to systematically seek new processes. Finally, trends and challenges for the further development in circular economy are presented for future exploration.

Engineering↗

NASA NTRS2012

Theory of a Traveling Wave Feed for a Planar Slot Array Antenna

Planar arrays of waveguide-fed slots have been employed in many radar and remote sensing applications. Such arrays are designed in the standing wave configuration because of high efficiency. Traveling wave arrays can produce greater bandwidth at the expense of efficiency due to power loss in the load or loads. Traveling wave planar slot arrays may be designed with a long feed waveguide consisting of centered-inclined coupling slots. The feed waveguide is terminated in a matched load, and the element spacing in the feed waveguide is chosen to produce a beam squinted from the broadside. The traveling wave planar slot array consists of a long feed waveguide containing resonant-centered inclined coupling slots in the broad wall, coupling power into an array of stacked radiating waveguides orthogonal to it. The radiating waveguides consist of longitudinal offset radiating slots in a standing wave configuration. For the traveling wave feed of a planar slot array, one has to design the tilt angle and length of each coupling slot such that the amplitude and phase of excitation of each radiating waveguide are close to the desired values. The coupling slot spacing is chosen for an appropriate beam squint. Scattering matrix parameters of resonant coupling slots are used in the design process to produce appropriate excitations of radiating waveguides with constraints placed only on amplitudes. Since the radiating slots in each radiating waveguide are designed to produce a certain total admittance, the scattering (S) matrix of each coupling slot is reduced to a 2x2 matrix. Elements of each 2x2 S-matrix and the amount of coupling into the corresponding radiating waveguide are expressed in terms of the element S11. S matrices are converted into transmission (T) matrices, and the T matrices are multiplied to cascade the coupling slots and waveguide sections, starting from the load end and proceeding towards the source. While the use of non-resonant coupling slots may provide an additional degree of freedom in the design, resonant coupling slots simplify the design process. The amplitude of the wave going to the load is set at unity. The S11 parameter, r of the coupling slot closest to the load, is assigned an arbitrary value. A larger value of r will reduce the power dissipated in the load while increasing the reflection coefficient at the input port. It is now possible to obtain the excitation of the radiating waveguide closest to the load and the coefficients of the wave incident and reflected at the input port of this coupling slot. The next coupling slot parameter, r , is chosen to realize the excitation of that radiating waveguide. One continues this process moving towards the source, until all the coupling slot parameters r and hence the S11 parameter of the 4-port coupler, r, are known for each coupling slot. The goal is to produce the desired array aperture distribution in the feed direction. From an interpolation of the computed moment method data for the slot parameters, all the coupling slot tilt angles and lengths are obtained. From the excitations of the radiating waveguides computed from the coupling values, radiating slot parameters may be obtained so as to attain the desired total normalized slot admittances. This process yields the radiating slot parameters, offsets, and lengths. The design is repeated by choosing different values of r for the last coupling slot until the percentage of power dissipated in the load and the input reflection coefficient values are satisfactory. Numerical results computed for the radiation pattern, the tilt angles and lengths of coupling slots, and excitation phases of the radiating waveguides, are presented for an array with uniform amplitude excitation. The design process has been validated using computer simulations. This design procedure is valid for non-uniform amplitude excitations as well.

Rengarajan, Sembiam↗

NASA NTRS2004

A Multiagent Modeling Environment for Simulating Work Practice in Organizations

In this paper we position Brahms as a tool for simulating organizational processes. Brahms is a modeling and simulation environment for analyzing human work practice, and for using such models to develop intelligent software agents to support the work practice in organizations. Brahms is the result of more than ten years of research at the Institute for Research on Learning (IRL), NYNEX Science & Technology (the former R&D institute of the Baby Bell telephone company in New York, now Verizon), and for the last six years at NASA Ames Research Center, in the Work Systems Design and Evaluation group, part of the Computational Sciences Division (Code IC). Brahms has been used on more than ten modeling and simulation research projects, and recently has been used as a distributed multiagent development environment for developing work practice support tools for human in-situ science exploration on planetary surfaces, in particular a human mission to Mars. Brahms was originally conceived of as a business process modeling and simulation tool that incorporates the social systems of work, by illuminating how formal process flow descriptions relate to people s actual located activities in the workplace. Our research started in the early nineties as a reaction to experiences with work process modeling and simulation . Although an effective tool for convincing management of the potential cost-savings of the newly designed work processes, the modeling and simulation environment was only able to describe work as a normative workflow. However, the social systems, uncovered in work practices studied by the design team played a significant role in how work actually got done-actual lived work. Multi- tasking, informal assistance and circumstantial work interactions could not easily be represented in a tool with a strict workflow modeling paradigm. In response, we began to develop a tool that would have the benefits of work process modeling and simulation, but be distinctively able to represent the relations of people, locations, systems, artifacts, communication and information content.

Sierhuis, Maarten↗

NASA NTRS2002

Error Estimation and Uncertainty Propagation in Computational Fluid Mechanics

Numerical simulation has now become an integral part of engineering design process. Critical design decisions are routinely made based on the simulation results and conclusions. Verification and validation of the reliability of the numerical simulation is therefore vitally important in the engineering design processes. We propose to develop theories and methodologies that can automatically provide quantitative information about the reliability of the numerical simulation by estimating numerical approximation error, computational model induced errors and the uncertainties contained in the mathematical models so that the reliability of the numerical simulation can be verified and validated. We also propose to develop and implement methodologies and techniques that can control the error and uncertainty during the numerical simulation so that the reliability of the numerical simulation can be improved.

Zhu, J. Z.↗

NASA NTRS2000

Numerical Propulsion System Simulation: An Overview

The cost of implementing new technology in aerospace propulsion systems is becoming prohibitively expensive and time consuming. One of the main contributors to the high cost and lengthy time is the need to perform many large-scale hardware tests and the inability to integrate all appropriate subsystems early in the design process. The NASA Glenn Research Center is developing the technologies required to enable simulations of full aerospace propulsion systems in sufficient detail to resolve critical design issues early in the design process before hardware is built. This concept, called the Numerical Propulsion System Simulation (NPSS), is focused on the integration of multiple disciplines such as aerodynamics, structures and heat transfer with computing and communication technologies to capture complex physical processes in a timely and cost-effective manner. The vision for NPSS, as illustrated, is to be a "numerical test cell" that enables full engine simulation overnight on cost-effective computing platforms. There are several key elements within NPSS that are required to achieve this capability: 1) clear data interfaces through the development and/or use of data exchange standards, 2) modular and flexible program construction through the use of object-oriented programming, 3) integrated multiple fidelity analysis (zooming) techniques that capture the appropriate physics at the appropriate fidelity for the engine systems, 4) multidisciplinary coupling techniques and finally 5) high performance parallel and distributed computing. The current state of development in these five area focuses on air breathing gas turbine engines and is reported in this paper. However, many of the technologies are generic and can be readily applied to rocket based systems and combined cycles currently being considered for low-cost access-to-space applications. Recent accomplishments include: (1) the development of an industry-standard engine cycle analysis program and plug 'n play architecture, called NPSS Version 1, (2) A full engine simulation that combines a 3D low-pressure subsystem with a 0D high pressure core simulation. This demonstrates the ability to integrate analyses at different levels of detail and to aerodynamically couple components, the fan/booster and low-pressure turbine, through a 3D computational fluid dynamics simulation. (3) Simulation of all of the turbomachinery in a modern turbofan engine on parallel computing platform for rapid and cost-effective execution. This capability can also be used to generate full compressor map, requiring both design and off-design simulation. (4) Three levels of coupling characterize the multidisciplinary analysis under NPSS: loosely coupled, process coupled and tightly coupled. The loosely coupled and process coupled approaches require a common geometry definition to link CAD to analysis tools. The tightly coupled approach is currently validating the use of arbitrary Lagrangian/Eulerian formulation for rotating turbomachinery. The validation includes both centrifugal and axial compression systems. The results of the validation will be reported in the paper. (5) The demonstration of significant computing cost/performance reduction for turbine engine applications using PC clusters. The NPSS Project is supported under the NASA High Performance Computing and Communications Program.

Lytle, John K.↗

DOE OSTI2019

Essential Signal Simulation Enabled by Netlist Transforms (ESSENT) v1.0

Hardware simulation is an indispensable tool for designing chips as well as researching future architectures. Unfortunately, the slow rate of simulation can often bottleneck the design process, as designers must wait to see the results of a simulation before changing the design and starting a new simulation. The Essential Signal Simulation Enabled by Netlist Transforms (ESSENT) is a tool designed to accelerate hardware simulations. ESSENT takes in a design, uses graph algorithms to identify opportunities for conditional execution, and generates a simulator that leverages these opportunities. The generated simulator produces the exact same simulation results that would be returned by an unoptimized simulator, but in substantially less time. For input, ESSENT takes in designs formatted in FIRRTL (an open format).

Beamer, Scott↗

DOE OSTI2019

Wind Energy Modeling and Simulation, Volume 1: Atmosphere and Plant

In order to optimise the yield of wind power from existing and future wind plants, the entire breadth of the system of a plant, from the wind field to the turbine components, needs to be modelled in the design process. The modelling and simulation approaches used in each subsystem as well as the system-wide solution methods to optimize across subsystem boundaries are described in this reference. Chapters are written by technical experts in each field, describing the current state of the art in modelling and simulation for wind plant design. This comprehensive, two-volume research reference will provide long-lasting insight into the methods that will need to be developed for the technology to advance into its next generation. Volume 1 covers the computing challenges in full turbine modelling, then discusses bridging scales in the atmosphere and turbulence modelling, wind forecasting, wind plant flow, and plant level controller design.

17 WIND ENERGY↗

DOE OSTI2019

Wind Energy Modeling and Simulation, Volume 2: Turbine and System

In order to optimise the yield of wind power from existing and future wind plants, the entire breadth of the system of a plant, from the wind field to the turbine components, needs to be modelled in the design process. The modelling and simulation approaches used in each subsystem as well as the system-wide solution methods to optimize across subsystem boundaries are described in this reference. Chapters are written by technical experts in each field, describing the current state of the art in modelling and simulation for wind plant design. This comprehensive, two-volume research reference will provide long-lasting insight into the methods that will need to be developed for the technology to advance into its next generation. Volume 2 covers turbine level aerodynamics, aeroelasticity, rotors drivetrains and electrical systems, wind turbine control, offshore foundations, system optimization, and grid modelling.

17 WIND ENERGY↗

NASA NTRS1990

Applications of formal simulation languages in the control and monitoring subsystems of Space Station Freedom

The notions, benefits, and drawbacks of numeric simulation are introduced. Two formal simulation languages, Simpscript and Modsim are introduced. The capabilities of each are discussed briefly, and then the two programs are compared. The use of simulation in the process of design engineering for the Control and Monitoring System (CMS) for Space Station Freedom is discussed. The application of the formal simulation language to the CMS design is presented, and recommendations are made as to their use.

Lacovara, R. C.↗

NASA NTRS2004

Simulation of Wind Profile Perturbations for Launch Vehicle Design

Ideally, a statistically representative sample of measured high-resolution wind profiles with wavelengths as small as tens of meters is required in design studies to establish aerodynamic load indicator dispersions and vehicle control system capability. At most potential launch sites, high- resolution wind profiles may not exist. Representative samples of Rawinsonde wind profiles to altitudes of 30 km are more likely to be available from the extensive network of measurement sites established for routine sampling in support of weather observing and forecasting activity. Such a sample, large enough to be statistically representative of relatively large wavelength perturbations, would be inadequate for launch vehicle design assessments because the Rawinsonde system accurately measures wind perturbations with wavelengths no smaller than 2000 m (1000 m altitude increment). The Kennedy Space Center (KSC) Jimsphere wind profiles (150/month and seasonal 2 and 3.5-hr pairs) are the only adequate samples of high resolution profiles approx. 150 to 300 m effective resolution, but over-sampled at 25 m intervals) that have been used extensively for launch vehicle design assessments. Therefore, a simulation process has been developed for enhancement of measured low-resolution Rawinsonde profiles that would be applicable in preliminary launch vehicle design studies at launch sites other than KSC.

Adelfang, S. I.↗

DOE OSTI2016

Component-based workflows for parallel thermomechanical analysis of arrayed geometries

Component-based simulation workflows can increase the agility of the design process by streamlining adaptation of new simulation methods. Here, we present one such workflow for parallel unstructured mesh-based simulations and demonstrate its usefulness in the thermomechanical analysis of an array of solder joints used in microelectronics fabrication. We automate the simulation process from problem specification to the solution of the underlying PDEs, including problem setup, domain definition, and mesh generation. We establish the utility of the proposed approach by demonstrating that qualitatively different stress concentrations are seen in solder joints near the center of such an array and a solder joint seen at the edge of the same array.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗

NASA NTRS2004

Reducing the Time and Cost of Testing Engines

Producing a new aircraft engine currently costs approximately $1 billion, with 3 years of development time for a commercial engine and 10 years for a military engine. The high development time and cost make it extremely difficult to transition advanced technologies for cleaner, quieter, and more efficient new engines. To reduce this time and cost, NASA created a vision for the future where designers would use high-fidelity computer simulations early in the design process in order to resolve critical design issues before building the expensive engine hardware. To accomplish this vision, NASA's Glenn Research Center initiated a collaborative effort with the aerospace industry and academia to develop its Numerical Propulsion System Simulation (NPSS), an advanced engineering environment for the analysis and design of aerospace propulsion systems and components. Partners estimate that using NPSS has the potential to dramatically reduce the time, effort, and expense necessary to design and test jet engines by generating sophisticated computer simulations of an aerospace object or system. These simulations will permit an engineer to test various design options without having to conduct costly and time-consuming real-life tests. By accelerating and streamlining the engine system design analysis and test phases, NPSS facilitates bringing the final product to market faster. NASA's NPSS Version (V)1.X effort was a task within the Agency s Computational Aerospace Sciences project of the High Performance Computing and Communication program, which had a mission to accelerate the availability of high-performance computing hardware and software to the U.S. aerospace community for its use in design processes. The technology brings value back to NASA by improving methods of analyzing and testing space transportation components.

Source record↗

NASA NTRSDate not supplied

Human Systems Intergration & Engineering: HSI & E Design Influence

The design of space systems is a long and complicated process where changes to the design increase cost and schedule as the design progresses into implementation. Human Systems Integration uses tools such as mockups, Virtual Reality, Augmented Reality and human simulations early in the design process to evaluate designs for usability, operability, and maintainability. This early design influence provides cost and schedule savings during manufacturing and operations. Examples of how MSFC EV74 Human Systems Integration Team have used these tools to evaluate hardware designs will be discussed.

Tanya Andrews↗

DOE OSTI2023

Design of a Geothermal Power Plant With Solar Thermal Topping Cycle

Geothermal power plants are a reliable source of low-carbon power generation. However, modern electricity markets comprise relatively large proportions of variable renewable energy generation that may require power plants to flexibly dispatch energy. The power output, efficiency, and dispatch flexibility of a geothermal plant can be enhanced by integrating solar thermal energy into the system, as well as possibly compensating against ambient temperature variations. Concentrating solar thermal (CST) can generate temperatures much higher than conventional geothermal systems. Using a solar topping cycle is one way to efficiently convert high-temperature solar heat to electricity while also cascading lower-temperature heat to the geothermal power cycle, thereby increasing its power output and possibly its efficiency. A hybrid power cycle design is proposed and simulated using SimTech IPSEpro process modeling software. The design configuration depends on the expected temperature of the geothermal resource and the quantity of solar heat added at the design point. These design considerations are described and expected performance is calculated. The solar heat addition varies throughout the day and year; therefore, off-design models are necessary to assess the impact of solar availability (and ambient temperature) on the power plant performance. Off-design models are developed and combined with hourly weather data to facilitate an evaluation of annual system performance.

concentrating solar power↗

DOE OSTI2018

High-Temperature Sapphire Pressure Sensors for Harsh Environments

The project aimed to develop and characterize an optical pressure sensor capable of withstanding high temperatures, up to 1000 °C. Survivability in harsh environments was enabled using sapphire for both the substrate and the optical fibers, therefore mitigating thermal expansion mismatch. Such material cannot be machined through conventional microfabrication techniques, and unique additive and subtractive methods had to be studied and implemented. Subtractive methods included laser-machining the sapphire substrate using a picosecond laser machining tool. At first, the parameters of importance were theoretically and experimentally evaluated such that the fluence, the pulse spacing, and the number of passes were found to strongly influence the laser ablation process. A simulation tool was designed to predict the final pattern when inputting a set of parameters and a profile. This model was complemented with laser ablation material physics models and Bayesian uncertainty analysis for one dimensional and three dimensional ablation processes. An additive process called thermocompression bonding was studied in order to seal the diaphragm substrate to the back cavity. At first, bonding strength using this technique was examined using the chevron-notch method that allow to determine the fracture toughness of this bond. This parameter is independent of the geometry used and therefore can be extended to other geometries used in actual sensor bonding. A theoretical and experimental study of internal damage caused by the laser micromachining of the sapphire material was carried out. The research identified enhanced strength and fracture toughness along laser ablated surfaces. This was determined using bend bar specimens and Vicker’s microindentations. Softening of the plasticity behavior (as indicated by nanoindentation experiments) was also investigated using finite deformation plasticity modeling via a contact mechanics finite element simulation. Good correlations between experiments and the model were achieved to determine material parameters that can be used in future MEMS based sensor design and modeling to minimize sensor failure loads. The enhanced strength and fracture toughness was determined to be due to compressive residual stress near laser ablated surfaces. This was confirmed through x-ray spectra taken along different crystal structure planes in combination and Bayesian uncertainty analysis. The Bayesian analysis inferred the entire residual strain tensor (six components) and the residual stress tensor. The results illustrated compressive in-plane stress was the most likely cause of enhanced strength and toughness after laser machining. Due to major equipment failures, a parallel route for fabricating the sensor was taken, using commercially available sapphire removal method (subtractive) and ceramic adhesive bonding (additive). The fully-packaged sensor utilized laser micromachining for the sapphire substrate fabrication and was comprised only of high-temperature-compatible materials. Calibration tests of the sensor in both room-temperature and high-temperature plane-wave tubes showed good linearity and consistent frequency response, in the tested frequency range. The sensor also showed good thermal stability in tests up to 300 °C, proving the fiber-optic lever and its packaging process to be a promising approach for high-temperature measurements. The calibration from 23 °C to 300 °C gave a raw sensitivity of 3.9 × 10 -7 V/Pa and a normalized sensitivity of 9.8 × 10 -8 Pa -1 which were consistent within the temperature range. The sensor had a resonance at 16.3 kHz and a flat band (±3 dB) up to 10.3 kHz. The noise floor of the sensor at 1 kHz was 316 nV/Hz 1/2 , resulting in a MDP of 0.8 Pa. Previously, diaphragm delamination due to CTE mismatch was found at 500 °C, causing packaging failure. Unfortunately high temperature validation in hot jet environment could not be made in time. In the future, it is suggested that the two sapphire substrates be bonded by thermal compression bonding with an intermediate platinum layer instead of using an alumina-based adhesive, and therefore achieve higher temperature capacity up to 1000 °C.

77 NANOSCIENCE AND NANOTECHNOLOGY↗

NASA NTRS2011

Three-Dimensional Finite Element Ablative Thermal Response and Thermostructural Design of Thermal Protection Systems

A finite element ablation and thermal response program is presented for simulation of three-dimensional transient thermostructural analysis. The three-dimensional governing differential equations and finite element formulation are summarized. A novel probabilistic design methodology for thermal protection systems is presented. The design methodology is an eight step process beginning with a parameter sensitivity study and is followed by a deterministic analysis whereby an optimum design can determined. The design process concludes with a Monte Carlo simulation where the probabilities of exceeding design specifications are estimated. The design methodology is demonstrated by applying the methodology to the carbon phenolic compression pads of the Crew Exploration Vehicle. The maximum allowed values of bondline temperature and tensile stress are used as the design specifications in this study.

Dec, John A.↗

NASA NTRS1993

Improvements in hover display dynamics for a combat helicopter

This paper describes a piloted simulation conducted on the NASA Ames Vertical Motion Simulator. The objective of the experiment was to investigate the handling qualities benefits attainable using new display law design methods for hover displays. The new display laws provide improved methods to specify the behavior of the display symbol that predicts the vehicle's ground velocity in the horizontal plane; it is the primary symbol that the pilot uses to control aircraft horizontal position. The display law design was applied to the Apache helmet-mounted display format, using the Apache vehicle dynamics to tailor the dynamics of the velocity predictor symbol. The representations of the Apache vehicle used in the display design process and in the simulation were derived from flight data. During the simulation, the new symbol dynamics were seen to improve the pilots' ability to maneuver about hover in poor visual cuing environments. The improvements were manifested in pilot handling qualities ratings and in measured task performance. The paper details the display design techniques, the experiment design and conduct, and the results.

Eshow, Michelle M.↗

NASA NTRS1993

Improvements in hover display dynamics for a combat helicopter

Eshow, Michelle M.↗