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All sourcesNASA NTRSDOE OSTI
NASA NTRS2019

Integrated Design and Manufacturing Analysis for Automated Fiber Placement Structures

Automated fiber placement provides many advancements beyond traditional hand layups in terms of efficiency and reliability. However, there are also a variety of unique challenges that arise with automated fiber placement technology. In particular, steering of tows over doubly-curved tool surfaces can result in material overlaps and gaps due to path convergence/divergence, fiber angle deviation, as well defects in the tows themselves such as puckers and wrinkles. Minimization of these defects is traditionally considered a task for the manufacturing discipline. Manufacturing specifications are often created for these defects based on laminate testing and can be inflexible to avoid more tests. Recent efforts have been made under the National Aeronautics and Space Administration (NASA) Advanced Composites Project (ACP) to develop software tools and processes that provide automated coupling between design and manufacturing disciplines. The objective of this coupling is to provide information to the design discipline on the manufacturability of a laminate while the laminate is being designed. A variety of software tools, both existing commercial tools and research tools under development, will be used to achieve this objective: HyperSizer for laminate optimization, the Computer Aided Process Planning module for selection of manufacturing process parameters, Vericut Composite Programming for tow path simulation, and COMPRO for deposition and cure defects. The newly developed “Central Optimizer” tool will be used to tie the modules together and drive the design for manufacturing process.

Noevere, August↗
NASA NTRS2006

Accuracy Quantification of the Loci-CHEM Code for Chamber Wall Heat Transfer in a GO2/GH2 Single Element Injector Model Problem

A robust rocket engine combustor design and development process must include tools which can accurately predict the multi-dimensional thermal environments imposed on solid surfaces by the hot combustion products. Currently, empirical methods used in the design process are typically one dimensional and do not adequately account for the heat flux rise rate in the near-injector region of the chamber. Computational Fluid Dynamics holds promise to meet the design tool requirement, but requires accuracy quantification, or validation, before it can be confidently applied in the design process. This effort presents the beginning of such a validation process for the Loci-CHEM CFD code. The model problem examined here is a gaseous oxygen (GO2)/gaseous hydrogen (GH2) shear coaxial single element injector operating at a chamber pressure of 5.42 MPa. The GO2/GH2 propellant combination in this geometry represents one the simplest rocket model problems and is thus foundational to subsequent validation efforts for more complex injectors. Multiple steady state solutions have been produced with Loci-CHEM employing different hybrid grids and two-equation turbulence models. Iterative convergence for each solution is demonstrated via mass conservation, flow variable monitoring at discrete flow field locations as a function of solution iteration and overall residual performance. A baseline hybrid was used and then locally refined to demonstrate grid convergence. Solutions were obtained with three variations of the k-omega turbulence model.

West, Jeff↗
NASA NTRS2006

Accuracy Quantification of the Loci-CHEM Code for Chamber Wall Heat Fluxes in a G02/GH2 Single Element Injector Model Problem

A robust rocket engine combustor design and development process must include tools which can accurately predict the multi-dimensional thermal environments imposed on solid surfaces by the hot combustion products. Currently, empirical methods used in the design process are typically one dimensional and do not adequately account for the heat flux rise rate in the near-injector region of the chamber. Computational Fluid Dynamics holds promise to meet the design tool requirement, but requires accuracy quantification, or validation, before it can be confidently applied in the design process. This effort presents the beginning of such a validation process for the Loci- CHEM CPD code. The model problem examined here is a gaseous oxygen (GO2)/gaseous hydrogen (GH2) shear coaxial single element injector operating at a chamber pressure of 5.42 MPa. The GO2/GH2 propellant combination in this geometry represents one the simplest rocket model problems and is thus foundational to subsequent validation efforts for more complex injectors. Multiple steady state solutions have been produced with Loci-CHEM employing different hybrid grids and two-equation turbulence models. Iterative convergence for each solution is demonstrated via mass conservation, flow variable monitoring at discrete flow field locations as a function of solution iteration and overall residual performance. A baseline hybrid grid was used and then locally refined to demonstrate grid convergence. Solutions were also obtained with three variations of the k-omega turbulence model.

West, Jeff↗
NASA NTRS2012

Hydrocarbon Rocket Technology Impact Forecasting

Ever since the Apollo program ended, the development of launch propulsion systems in the US has fallen drastically, with only two new booster engine developments, the SSME and the RS-68, occurring in the past few decades.1 In recent years, however, there has been an increased interest in pursuing more effective launch propulsion technologies in the U.S., exemplified by the NASA Office of the Chief Technologist s inclusion of Launch Propulsion Systems as the first technological area in the Space Technology Roadmaps2. One area of particular interest to both government agencies and commercial entities has been the development of hydrocarbon engines; NASA and the Air Force Research Lab3 have expressed interest in the use of hydrocarbon fuels for their respective SLS Booster and Reusable Booster System concepts, and two major commercially-developed launch vehicles SpaceX s Falcon 9 and Orbital Sciences Antares feature engines that use RP-1 kerosene fuel. Compared to engines powered by liquid hydrogen, hydrocarbon-fueled engines have a greater propellant density (usually resulting in a lighter overall engine), produce greater propulsive force, possess easier fuel handling and loading, and for reusable vehicle concepts can provide a shorter turnaround time between launches. These benefits suggest that a hydrocarbon-fueled launch vehicle would allow for a cheap and frequent means of access to space.1 However, the time and money required for the development of a new engine still presents a major challenge. Long and costly design, development, testing and evaluation (DDT&E) programs underscore the importance of identifying critical technologies and prioritizing investment efforts. Trade studies must be performed on engine concepts examining the affordability, operability, and reliability of each concept, and quantifying the impacts of proposed technologies. These studies can be performed through use of the Technology Impact Forecasting (TIF) method. The Technology Impact Forecasting method is a normative forecasting technique that allows the designer to quantify the effects of adding new technologies on a given design. This method can be used to assess and identify the necessary technological improvements needed to close the gap that exists between the current design and one that satisfies all constraints imposed on the design. The TIF methodology allows for more design knowledge to be brought to the earlier phases of the design process, making use of tools such as Quality Function Deployments, Morphological Matrices, Response Surface Methodology, and Monte Carlo Simulations.2 This increased knowledge allows for more informed decisions to be made earlier in the design process, resulting in shortened design cycle time. This paper will investigate applying the TIF method, which has been widely used in aircraft applications, to the conceptual design of a hydrocarbon rocket engine. In order to reinstate a manned presence in space, the U.S. must develop an affordable and sustainable launch capability. Hydrocarbon-fueled rockets have drawn interest from numerous major government and commercial entities because they offer a low-cost heavy-lift option that would allow for frequent launches1. However, the development of effective new hydrocarbon rockets would likely require new technologies in order to overcome certain design constraints. The use of advanced design methods, such as the TIF method, enables the designer to identify key areas in need of improvement, allowing one to dial in a proposed technology and assess its impact on the system. Through analyses such as this one, a conceptual design for a hydrocarbon-fueled vehicle that meets all imposed requirements can be achieved.

Stuber, Eric↗
NASA NTRS2019

Design and Analysis of a Tool for Automated Fiber Placement of Composite Wind Tunnel Blades

For decades, composite wind tunnel blades have been constructed using labor-intensive hand layup processes. Automated Fiber Placement (AFP) is a relatively new technology that has not seen widespread use in manufacturing composite wind tunnel blades. AFP offers the potential for reduced manufacturing time, reduced cost, and improved consistency compared to traditional hand layup procedures. These manufacturing qualities are becoming increasingly important as existing wind tunnel blades are replaced due to impact damage or wear and tear from decades of use. Researchers at the NASA Langley Research Center are currently using the Integrated Structural Assembly of Advanced Composites (ISAAC) facility to investigate the feasibility of AFP for manufacturing composite wind tunnel blades. ISAAC uses manufacturing tools as surfaces on which to place fiber tows. A manufacturing tool was developed for using AFP to build a wind tunnel blade shape. This paper presents the structural design and analysis of this tool, for use with AFP, constructed from high temperature thermoplastics. The tool fabricated by this design process was successfully used for AFP and oven cure of two representative airfoil shaped composite structures.

Brian Mason↗
NASA NTRS1994

The Role of Computers in Research and Development at Langley Research Center

This document is a compilation of presentations given at a workshop on the role cf computers in research and development at the Langley Research Center. The objectives of the workshop were to inform the Langley Research Center community of the current software systems and software practices in use at Langley. The workshop was organized in 10 sessions: Software Engineering; Software Engineering Standards, methods, and CASE tools; Solutions of Equations; Automatic Differentiation; Mosaic and the World Wide Web; Graphics and Image Processing; System Design Integration; CAE Tools; Languages; and Advanced Topics.

Wieseman, Carol D.↗
NASA NTRS2018

SLS Navigation Model-Based Design Approach

The SLS Program chose to implement a Model-based Design and Model-based Requirements approach for managing component design information and system requirements. This approach differs from previous large-scale design efforts at Marshall Space Flight Center where design documentation alone conveyed information required for vehicle design and analysis and where extensive requirements sets were used to scope and constrain the design. The SLS Navigation Team has been responsible for the Program-controlled Design Math Models (DMMs) which describe and represent the performance of the Inertial Navigation System (INS) and the Rate Gyro Assemblies (RGAs) used by Guidance, Navigation, and Controls (GN&C). The SLS Navigation Team is also responsible for the navigation algorithms. The navigation algorithms are delivered for implementation on the flight hardware as a DMM. For the SLS Block 1-B design, the additional GPS Receiver hardware is managed as a DMM at the vehicle design level. This paper provides a discussion of the processes and methods used to engineer, design, and coordinate engineering trades and performance assessments using SLS practices as applied to the GN&C system, with a particular focus on the Navigation components. These include composing system requirements, requirements verification, model development, model verification and validation, and modeling and analysis approaches. The Model-based Design and Requirements approach does not reduce the effort associated with the design process versus previous processes used at Marshall Space Flight Center. Instead, the approach takes advantage of overlap between the requirements development and management process, and the design and analysis process by efficiently combining the control (i.e. the requirement) and the design mechanisms. The design mechanism is the representation of the component behavior and performance in design and analysis tools. The focus in the early design process shifts from the development and management of design requirements to the development of usable models, model requirements, and model verification and validation efforts. The models themselves are represented in C/C++ code and accompanying data files. Under the idealized process, potential ambiguity in specification is reduced because the model must be implementable versus a requirement which is not necessarily subject to this constraint. Further, the models are shown to emulate the hardware during validation. For models developed by the Navigation Team, a common interface/standalone environment was developed. The common environment allows for easy implementation in design and analysis tools. Mechanisms such as unit test cases ensure implementation as the developer intended. The model verification and validation process provides a very high level of component design insight. The origin and implementation of the SLS variant of Model-based Design is described from the perspective of the SLS Navigation Team. The format of the models and the requirements are described. The Model-based Design approach has many benefits but is not without potential complications. Key lessons learned associated with the implementation of the Model Based Design approach and process from infancy to verification and certification are discussed

Oliver, T. Emerson↗
NASA NTRS1981

System data communication structures for active-control transport aircraft, volume 1

Candidate data communication techniques are identified, including dedicated links, local buses, broadcast buses, multiplex buses, and mesh networks. The design methodology for mesh networks is then discussed, including network topology and node architecture. Several concepts of power distribution are reviewed, including current limiting and mesh networks for power. The technology issues of packaging, transmission media, and lightning are addressed, and, finally, the analysis tools developed to aid in the communication design process are described. There are special tools to analyze the reliability and connectivity of networks and more general reliability analysis tools for all types of systems.

Hopkins, A. L.↗
NASA NTRS1990

Discrete event simulation tool for analysis of qualitative models of continuous processing systems

An artificial intelligence design and qualitative modeling tool is disclosed for creating computer models and simulating continuous activities, functions, and/or behavior using developed discrete event techniques. Conveniently, the tool is organized in four modules: library design module, model construction module, simulation module, and experimentation and analysis. The library design module supports the building of library knowledge including component classes and elements pertinent to a particular domain of continuous activities, functions, and behavior being modeled. The continuous behavior is defined discretely with respect to invocation statements, effect statements, and time delays. The functionality of the components is defined in terms of variable cluster instances, independent processes, and modes, further defined in terms of mode transition processes and mode dependent processes. Model construction utilizes the hierarchy of libraries and connects them with appropriate relations. The simulation executes a specialized initialization routine and executes events in a manner that includes selective inherency of characteristics through a time and event schema until the event queue in the simulator is emptied. The experimentation and analysis module supports analysis through the generation of appropriate log files and graphics developments and includes the ability of log file comparisons.

Malin, Jane T.↗
NASA NTRS1994

Image tools for UNIX

This talk features two simple and useful tools for digital image processing in the UNIX environment. They are xv and pbmplus. The xv image viewer which runs under the X window system reads images in a number of different file formats and writes them out in different formats. The view area supports a pop-up control panel. The 'algorithms' menu lets you blur an image. The xv control panel also activates the color editor which displays the image's color map (if one exists). The xv image viewer is available through the internet. The pbmplus package is a set of tools designed to perform image processing from within a UNIX shell. The acronym 'pbm' stands for portable bit map. Like xv, the pbm plus tool can convert images from and to many different file formats. The source code and manual pages for pbmplus are also available through the internet. This software is in the public domain.

Banks, David C.↗
NASA NTRS2005

CFD Code Validation of Wall Heat Fluxes for a G02/GH2 Single Element Combustor

This paper puts forth the case for the need for improved injector design tools to meet NASA s Vision for Space Exploration goals. Requirements for this improved tool are outlined and discussed. The potential for Computational Fluid Dynamics (CFD) to meet these requirements is noted along with its current shortcomings, especially relative to demonstrated solution accuracy. The concept of verification and validation is introduced as the primary process for building and quantifying the confidence necessary for CFD to be useful as an injector design tool. The verification and validation process is considered in the context of the Marshall Space Flight Center (MSFC) Combustion Devices CFD Simulation Capability Roadmap via the Simulation Readiness Level (SRL) concept. The portion of the validation process which demonstrates the ability of a CFD code to simulate heat fluxes to a rocket engine combustor wall is the focus of the current effort. The FDNS and Loci-CHEM codes are used to simulate a shear coaxial single element G02/GH2 injector experiment. The experiment was conducted a t a chamber pressure of 750 psia using hot propellants from preburners. A measured wall temperature profile is used as a boundary condition to facilitate the calculations. Converged solutions, obtained from both codes by using wall functions with the K-E turbulence model and integrating to the wall using Mentor s baseline turbulence model, are compared to the experimental data. The initial solutions from both codes revealed significant issues with the wall function implementation associated with the recirculation zone between the shear coaxial jet and the chamber wall. The FDNS solution with a corrected implementation shows marked improvement in overall character and level of comparison to the data. With the FDNS code, integrating to the wall with Mentor s baseline turbulence model actually produce a degraded solution when compared to the wall function solution with the K--E model. The Loci-CHEM solution, produced by integrating to the wall with Mentor s baseline turbulence model, matches both the heat flux rise rate in the near injector region and the peak heat flux level very well. However, it moderately over predicts the heat fluxes downstream of the reattachment point. The Loci-CHEM solution achieved by integrating to the wall with Mentor s baseline turbulence model was clearly superior to the other solutions produced in this effort.

Lin, Jeff↗
NASA NTRS2003

Analysis and Test Correlation of Proof of Concept Box for Blended Wing Body-Low Speed Vehicle

The Low Speed Vehicle (LSV) is a 14.2% scale remotely piloted vehicle of the revolutionary Blended Wing Body concept. The design of the LSV includes an all composite airframe. Due to internal manufacturing capability restrictions, room temperature layups were necessary. An extensive materials testing and manufacturing process development effort was underwent to establish a process that would achieve the high modulus/low weight properties required to meet the design requirements. The analysis process involved a loads development effort that incorporated aero loads to determine internal forces that could be applied to a traditional FEM of the vehicle and to conduct detailed component analyses. A new tool, Hypersizer, was added to the design process to address various composite failure modes and to optimize the skin panel thickness of the upper and lower skins for the vehicle. The analysis required an iterative approach as material properties were continually changing. As a part of the material characterization effort, test articles, including a proof of concept wing box and a full-scale wing, were fabricated. The proof of concept box was fabricated based on very preliminary material studies and tested in bending, torsion, and shear. The box was then tested to failure under shear. The proof of concept box was also analyzed using Nastran and Hypersizer. The results of both analyses were scaled to determine the predicted failure load. The test results were compared to both the Nastran and Hypersizer analytical predictions. The actual failure occurred at 899 lbs. The failure was predicted at 1167 lbs based on the Nastran analysis. The Hypersizer analysis predicted a lower failure load of 960 lbs. The Nastran analysis alone was not sufficient to predict the failure load because it does not identify local composite failure modes. This analysis has traditionally been done using closed form solutions. Although Hypersizer is typically used as an optimizer for the design process, the failure prediction was used to help gain acceptance and confidence in this new tool. The correlated models and process were to be used to analyze the full BWB-LSV airframe design. The analysis and correlation with test results of the proof of concept box is presented here, including the comparison of the Nastran and Hypersizer results.

Spellman, Regina L.↗
NASA NTRS1996

Parallelization of a Parabolized Navier-Stokes Solver with a Design Optimizer

The design of future supersonic aircraft, such as the High Speed Civil Transport (HSCT), will rely heavily on computational methods for aircraft design and the prediction of the complex aerodynamics encountered in flight. Parabolized Navier-Stokes (PNS) equation flow solvers are recognized as efficient and accurate computational tools for the solution of supersonic and hypersonic flow-fields, while design optimizers have the potential to be valuable tools within the overall design process. Presently, however, the execution of the flow solver in conjunction with a design optimizer presents a computationally intensive and formidable problem. To meet the challenges and increasing demand for multidisciplinary numerical tools which are faster, more robust and provide greater functionality, alternative strategies are explored to increase computational throughput by coupling a design optimizer and flow solver in a parallel processing environment. To address this problem the parallel processing of a PNS flow solver with a nonlinear constraint design optimizer is investigated as an alternative computational method.

Pallis, J. M.↗
NASA NTRS2001

Extensional Rheology Experiment Developed to Investigate the Rheology of Dilute Polymer Solutions in Microgravity

A fundamental characteristic of fluid is viscosity; that is, the fluid resists forces that cause it to flow. This characteristic, or parameter, is used by manufacturers and end-users to describe the physical properties of a specific material so that they know what to expect when a material, such as a polymer, is processed through an extruder, a film blower, or a fiber-spinning apparatus. Normally, researchers will report a shear viscosity that depends on the rate of an imposed shearing flow. Although this type of characterization is sufficient for some processes, simple shearing experiments do not provide a complete picture of what a processor may expect for all materials. Extensional stretching flows are common in many polymer-processing operations such as extrusion, blow molding, and fiber spinning. Therefore, knowledge of the complete rheological (ability to flow and be deformed) properties of the polymeric fluid being processed is required to accurately predict and account for the flow behavior. In addition, if numerical simulations are ever able to serve as a priori design tools for optimizing polymer processing operations such as those described above, an accurate knowledge of the extensional viscosity of a polymer system and its variation with temperature, concentration, molecular weight, and strain rate is critical.

Logsdon, Kirk A.↗
NASA NTRS2010

Parametric Geometry, Structured Grid Generation, and Initial Design Study for REST-Class Hypersonic Inlets

Computational design and analysis of three-dimensional hypersonic inlets with shape transition has been a significant challenge due to the complex geometry and grid required for three-dimensional viscous flow calculations. Currently, the design process utilizes an inviscid design tool to produce initial inlet shapes by streamline tracing through an axisymmetric compression field. However, the shape is defined by a large number of points rather than a continuous surface and lacks important features such as blunt leading edges. Therefore, a design system has been developed to parametrically construct true CAD geometry and link the topology of a structured grid to the geometry. The Adaptive Modeling Language (AML) constitutes the underlying framework that is used to build the geometry and grid topology. Parameterization of the CAD geometry allows the inlet shapes produced by the inviscid design tool to be generated, but also allows a great deal of flexibility to modify the shape to account for three-dimensional viscous effects. By linking the grid topology to the parametric geometry, the GridPro grid generation software can be used efficiently to produce a smooth hexahedral multiblock grid. To demonstrate the new capability, a matrix of inlets were designed by varying four geometry parameters in the inviscid design tool. The goals of the initial design study were to explore inviscid design tool geometry variations with a three-dimensional analysis approach, demonstrate a solution rate which would enable the use of high-fidelity viscous three-dimensional CFD in future design efforts, process the results for important performance parameters, and perform a sample optimization.

Ferlemann, Paul G.↗
NASA NTRS2008

Verifying and Validating Proposed Models for FSW Process Optimization

This slide presentation reviews Friction Stir Welding (FSW) and the attempts to model the process in order to optimize and improve the process. The studies are ongoing to validate and refine the model of metal flow in the FSW process. There are slides showing the conventional FSW process, a couple of weld tool designs and how the design interacts with the metal flow path. The two basic components of the weld tool are shown, along with geometries of the shoulder design. Modeling of the FSW process is reviewed. Other topics include (1) Microstructure features, (2) Flow Streamlines, (3) Steady-state Nature, and (4) Grain Refinement Mechanisms

Schneider, Judith↗
NASA NTRS2009

Framework for Multidisciplinary Analysis, Design, and Optimization with High-Fidelity Analysis Tools

A plan is presented for the development of a high fidelity multidisciplinary optimization process for rotorcraft. The plan formulates individual disciplinary design problems, identifies practical high-fidelity tools and processes that can be incorporated in an automated optimization environment, and establishes statements of the multidisciplinary design problem including objectives, constraints, design variables, and cross-disciplinary dependencies. Five key disciplinary areas are selected in the development plan. These are rotor aerodynamics, rotor structures and dynamics, fuselage aerodynamics, fuselage structures, and propulsion / drive system. Flying qualities and noise are included as ancillary areas. Consistency across engineering disciplines is maintained with a central geometry engine that supports all multidisciplinary analysis. The multidisciplinary optimization process targets the preliminary design cycle where gross elements of the helicopter have been defined. These might include number of rotors and rotor configuration (tandem, coaxial, etc.). It is at this stage that sufficient configuration information is defined to perform high-fidelity analysis. At the same time there is enough design freedom to influence a design. The rotorcraft multidisciplinary optimization tool is built and substantiated throughout its development cycle in a staged approach by incorporating disciplines sequentially.

Orr, Stanley A.↗
NASA NTRS2020

Design for Manufacturing Tool for Automated Fiber Placement Structures - Verification and Validation

A tool has been developed to address the growing Design for Manufacturing needs for composite structures, specifically those manufactured with automated fiber placement. This manufacturing approach presents unique challenges associated with puckers and wrinkling, tow overlaps and gaps, fiber deviation, and laminate strength. Achieving a satisfactory laminate design usually requires finding compromises between those four areas. The developed tool, dubbed the Central Optimizer, assists with the process of balancing competing design metrics in automated fiber placement. This tool was developed under the NASA Advanced Composites Consortium with input from industry partners. Under this program, the Central Optimizer has been exercised on three different structures to verify its functionality and validate ability to improve the design process for automated fiber placement structures.

August T Noevere↗