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At least 1,045 records · Page 58

Surface Vibration Measurement and Analysis for UAM/UAS Electric Motor Noise

Urban Air Mobility vehicles are an emerging class of vertical lift vehicles using electric motors to drive multiple rotors for lift. The outrunner electric motors that are commonly used, may be capable of generating noise that could contribute to the vehicle’s overall noise profile and could generate cabin noise. Understanding and predicting the noise requires more knowledge of the rotor vibrations and eventually a model to predict the frequencies of those vibrations. This work presents a measurement of the rotor vibrations of two different small-scale motors. Two techniques to measure the surface vibration were used. The displacement spectra are compared with acoustic measurements. A finite element analysis model is used to predict the rotor resonance frequencies. The predicted frequencies are in fair agreement with the experimentally observed vibration frequencies, but requires further work to understand discrepancies.

Electric Motor Noise↗

The use of an optical data acquisition system for bladed disk vibration analysis

A new concept in instrumentation was developed by engineers at NASA Lewis Research Center to collect vibration data from multi-bladed rotors. This new concept, known as the optical data acquisition system, uses optical transducers to measure bladed tip delections by reflection light beams off the tips of the blades as they pass in front of the optical transducer. By using an array of transducers around the perimeter of the rotor, detailed vibration signals can be obtained. In this study, resonant frequencies and mode shapes were determined for a 56 bladed rotor using the optical system. Frequency data from the optical system was also compared to data obtained from strain gauge measurements and finite element analysis and was found to be in good agreement.

Lawrence, C.↗

The use of an optical data acquisition system for bladed disk vibration analysis

A new concept in instrumentation was developed by engineers at NASA Lewis Research Center to collect vibration data from multi-bladed rotors. This new concept, known as the optical data acquisition system, uses optical transducers to measure bladed tip deflections by reflection of light beams off the tips of the blades as they pass in front of the optical transducer. By using an array of transducers around the perimeter of the rotor, detailed vibration signals can be obtained. In this study, resonant frequencies and mode shapes were determined for a 56 bladed rotor using the optical system. Frequency data from the optical system was also compared to data obtained from strain gauge measurements and finite element analysis and was found to be in good agreement.

Lawrence, C.↗

SSME structural dynamic model development, phase 2

A set of test correlated mathematical models of the SSME High Pressure Oxygen Turbopump (HPOTP) housing and rotor assembly was produced. New analysis methods within the EISI/EAL and SPAR systems were investigated and runstreams for future use were developed. The LOX pump models have undergone extensive modification since the first phase of this effort was completed. The rotor assembly from the original model was abandoned and a new, more detailed model constructed. A description of the new rotor math model is presented. Also, the pump housing model was continually modified as additional test data have become available. This model is documented along with measured test results. Many of the more advanced features of the EAL/SPAR finite element analysis system were exercised. These included the cyclic symmetry option, the macro-element procedures, and the fluid analysis capability. In addition, a new tool was developed that allows an automated analysis of a disjoint structure in terms of its component modes. A complete description of the implementation of the Craig-Bampton method is given along with two worked examples.

Foley, M. J.↗

Effects of stacking sequence on impact damage resistance and residual strength for quasi-isotropic laminates

Residual strength of an impacted composite laminate is dependent on details of the damage state. Stacking sequence was varied to judge its effect on damage caused by low-velocity impact. This was done for quasi-isotropic layups of a toughened composite material. Experimental observations on changes in the impact damage state and postimpact compressive performance were presented for seven different laminate stacking sequences. The applicability and limitations of analysis compared to experimental results were also discussed. Postimpact compressive behavior was found to be a strong function of the laminate stacking sequence. This relationship was found to depend on thickness, stacking sequence, size, and location of sublaminates that comprise the impact damage state. The postimpact strength for specimens with a relatively symmetric distribution of damage through the laminate thickness was accurately predicted by models that accounted for sublaminate stability and in-plane stress redistribution. An asymmetric distribution of damage in some laminate stacking sequences tended to alter specimen stability. Geometrically nonlinear finite element analysis was used to predict this behavior.

Dost, Ernest F.↗

ACT Payload Shroud Structural Concept Analysis and Optimization

Aerospace structural applications demand a weight efficient design to perform in a cost effective manner. This is particularly true for launch vehicle structures, where weight is the dominant design driver. The design process typically requires many iterations to ensure that a satisfactory minimum weight has been obtained. Although metallic structures can be weight efficient, composite structures can provide additional weight savings due to their lower density and additional design flexibility. This work presents structural analysis and weight optimization of a composite payload shroud for NASA s Ares V heavy lift vehicle. Two concepts, which were previously determined to be efficient for such a structure are evaluated: a hat stiffened/corrugated panel and a fiber reinforced foam sandwich panel. A composite structural optimization code, HyperSizer, is used to optimize the panel geometry, composite material ply orientations, and sandwich core material. HyperSizer enables an efficient evaluation of thousands of potential designs versus multiple strength and stability-based failure criteria across multiple load cases. HyperSizer sizing process uses a global finite element model to obtain element forces, which are statistically processed to arrive at panel-level design-to loads. These loads are then used to analyze each candidate panel design. A near optimum design is selected as the one with the lowest weight that also provides all positive margins of safety. The stiffness of each newly sized panel or beam component is taken into account in the subsequent finite element analysis. Iteration of analysis/optimization is performed to ensure a converged design. Sizing results for the hat stiffened panel concept and the fiber reinforced foam sandwich concept are presented.

Zalewski, Bart B.↗

Design oriented structural analysis

Desirable characteristics and benefits of design oriented analysis methods are described and illustrated by presenting a synoptic description of the development and uses of the Equivalent Laminated Plate Solution (ELAPS) computer code. ELAPS is a design oriented structural analysis method which is intended for use in the early design of aircraft wing structures. Model preparation is minimized by using a few large plate segments to model the wing box structure. Computational efficiency is achieved by using a limited number of global displacement functions that encompass all segments over the wing planform. Coupling with other codes is facilitated since the output quantities such as deflections and stresses are calculated as continuous functions over the plate segments. Various aspects of the ELAPS development are discussed including the analytical formulation, verification of results by comparison with finite element analysis results, coupling with other codes, and calculation of sensitivity derivatives. The effectiveness of ELAPS for multidisciplinary design application is illustrated by describing its use in design studies of high speed civil transport wing structures.

Giles, Gary L.↗

Effect of High-Speed Rotation on High-Temperature Superconducting Coils for High Efficiency Megawatt Motor

The use of a superconducting rotor in the High Efficiency Megawatt Motor (HEMM) comes with a number of challenges. The HEMM’s rotor must be designed so that the superconducting coil can tolerate the forces it will encounter during operation. These forces introduce considerable risk to the design of the HEMM. Because this risk cannot be adequately addressed through refined analysis, a set of experiments was deemed necessary to demonstrate that the HEMM’s superconducting coils can survive the stresses imparted by the centrifugal forces acting on the coil during full-speed operation of the machine. These experiments required spin testing a full-scale HEMM coil on a representative rotor structure at room temperature and sequentially higher rotation speeds and measuring the superconductivity response of the coil in liquid nitrogen (LN2) before and after each spin test. Tests were carried out to the full centripetal loading of a recent HEMM design. According to finite element analysis, this load produced stress components in the coil that exceed their design limit by a factor of 1 to 7.4. Although not yet confirmed, the current HEMM design is expected to produce even smaller stresses in the coil due to a 20 percent reduction in the coil’s mass and an increased volume of structural material. The only degradation of the coil that occurred during this testing resulted from a test rig failure and from the voltage taps, which are not part of the final coil design.

Electrified Aircraft Propulsion↗

Testing and Analysis of a Composite Non-Cylindrical Aircraft Fuselage Structure: Ultimate Design Loads - Part 1

The Environmentally Responsible Aviation Project aimed to develop aircraft technologies enabling significant fuel burn and community noise reductions. Small incremental changes to the conventional metallic alloy-based 'tube and wing' configuration were not sufficient to achieve the desired metrics. One airframe concept identified by the project as having the potential to dramatically improve aircraft performance was a composite-based hybrid wing body configuration. Such a concept, however, presented inherent challenges stemming from, among other factors, the necessity to transfer wing loads through the entire center fuselage section which accommodates a pressurized cabin confined by flat or nearly flat panels. This paper discusses finite element analysis and testing of a large-scale hybrid wing body center section structure developed and constructed to demonstrate that the Pultruded Rod Stitched Efficient Unitized Structure concept can meet these challenging demands of the next generation airframes. Part I of the paper considers the five most critical load conditions, which are internal pressure only and positive and negative g-loads with and without internal pressure. Analysis results are compared with measurements acquired during testing. Performance of the test article is found to be closely aligned with predictions and, consequently, able to support the hybrid wing body design loads in pristine and barely visible impact damage conditions.

Przekop, Adam↗

Aerothermal Performance Constraints for Small Radius Leading Edges Operating at Hypervelocity

Small radius leading edges and nosetips were used to minimize wave drag in early hypervelocity vehicle concepts until further analysis demonstrated that extreme aerothermodynamic heating blunted the available thermal protection system materials. Recent studies indicate that ultra-high temperature composite (UHTC) materials are shape stable at temperatures approaching 3033 K and will be available for use as sharp leading edge components in the near future. Steady-state aerothermal performance constraints for UHTC components are presented in this paper to identify their non-ablating operational capability at altitudes from sea level to 90 km. An integrated design tool was developed to estimate these constraints. The tool couples aerothermodynamic heating with material response using commercial finite element analysis software and is capable of both steady-state and transient analysis. Performance during entry is analyzed by transient thermal analysis along the trajectory. The thermal load condition from the transient thermal analysis is used to estimate thermal stress. Applying the tool to UHTC materials shows that steady-state, non-ablating operation of a HfB2/SiC(A-7) (A-7) component is possible at velocities approaching Earth's circular orbital velocity of 7.9 km/s at altitudes approaching 70 km.

Kolodziej, Paul↗

Accounting for Uncertainties in Strengths of SiC MEMS Parts

A methodology has been devised for accounting for uncertainties in the strengths of silicon carbide structural components of microelectromechanical systems (MEMS). The methodology enables prediction of the probabilistic strengths of complexly shaped MEMS parts using data from tests of simple specimens. This methodology is intended to serve as a part of a rational basis for designing SiC MEMS, supplementing methodologies that have been borrowed from the art of designing macroscopic brittle material structures. The need for this or a similar methodology arises as a consequence of the fundamental nature of MEMS and the brittle silicon-based materials of which they are typically fabricated. When tested to fracture, MEMS and structural components thereof show wide part-to-part scatter in strength. The methodology involves the use of the Ceramics Analysis and Reliability Evaluation of Structures Life (CARES/Life) software in conjunction with the ANSYS Probabilistic Design System (PDS) software to simulate or predict the strength responses of brittle material components while simultaneously accounting for the effects of variability of geometrical features on the strength responses. As such, the methodology involves the use of an extended version of the ANSYS/CARES/PDS software system described in Probabilistic Prediction of Lifetimes of Ceramic Parts (LEW-17682-1/4-1), Software Tech Briefs supplement to NASA Tech Briefs, Vol. 30, No. 9 (September 2006), page 10. The ANSYS PDS software enables the ANSYS finite-element-analysis program to account for uncertainty in the design-and analysis process. The ANSYS PDS software accounts for uncertainty in material properties, dimensions, and loading by assigning probabilistic distributions to user-specified model parameters and performing simulations using various sampling techniques.

Nemeth, Noel↗

Reversibly Assembled Microparticles for Sustained Applications on the Moon and Mars

A sustained presence in any extra-terrestrial environment will require the capability to generate materials, goods, and ultimately vehicles, construction supplies and habitats to be tenable. As an example, NASA, in collaboration with Made In Space, Inc., recently reported the results of extensive research toward enabling3D printing in space. The extensive characterization and comparison of 3D printed articles suggested that, overall, articles generated in the International Space Station microgravity environment were comparable to those generated on Earth. The benefit of in-space manufacturing can be increased through utilization of recyclable materials. A recent analysis of a hypothetical 1,100 day round trip mission to Mars determined that significant mass savings and increase in mission probability of success could be achieved through in-space manufacturing with recyclable materials. NASA’s project ESPUR (Enabling Sustained Presence Using Recyclables), through support from NASA Langley’s Innovative Research and Development Fund, is investigating novel, polymer-coated, epoxy microparticle systems as an enabling technology to realize in-space manufacturing using recyclable feedstocks. Building from previously reported results, further progress toward synthesis of the polymer coating containing click chemical functionalities will be described here. Finite elemental analysis (FEA) has been utilized, in light of scale-free/small world considerations in an effort to identify compositions most likely to yield robust macroscopic geometries. Initial results will be described here. Finally, potential mass savings and life cycle of this recyclable materials technology will be discussed.

Click Chemistry↗

Coupled multi-disciplinary composites behavior simulation

The capabilities of the computer code CSTEM (Coupled Structural/Thermal/Electro-Magnetic Analysis) are discussed and demonstrated. CSTEM computationally simulates the coupled response of layered multi-material composite structures subjected to simultaneous thermal, structural, vibration, acoustic, and electromagnetic loads and includes the effect of aggressive environments. The composite material behavior and structural response is determined at its various inherent scales: constituents (fiber/matrix), ply, laminate, and structural component. The thermal and mechanical properties of the constituents are considered to be nonlinearly dependent on various parameters such as temperature and moisture. The acoustic and electromagnetic properties also include dependence on vibration and electromagnetic wave frequencies, respectively. The simulation is based on a three dimensional finite element analysis in conjunction with composite mechanics and with structural tailoring codes, and with acoustic and electromagnetic analysis methods. An aircraft engine composite fan blade is selected as a typical structural component to demonstrate the CSTEM capabilities. Results of various coupled multi-disciplinary heat transfer, structural, vibration, acoustic, and electromagnetic analyses for temperature distribution, stress and displacement response, deformed shape, vibration frequencies, mode shapes, acoustic noise, and electromagnetic reflection from the fan blade are discussed for their coupled effects in hot and humid environments. Collectively, these results demonstrate the effectiveness of the CSTEM code in capturing the coupled effects on the various responses of composite structures subjected to simultaneous multiple real-life loads.

Singhal, Surendra N.↗

Influence of Material Distribution on Impact Resistance of Hybrid Composites

Impact events occur in a wide variety of circumstances. A typical example is a bullet impacting a target made of composite material. These impact events produce time-varying loads on a structure that can result in damage. As a first step to understanding the damage resistance issue in composite laminates, an accurate prediction of the transient response during an impact event is necessary. The analysis of dynamic loadings on laminated composite plates has undergone considerable development recently. Rayleigh-Ritz energy method was used to determine the impact response of laminated plates. The impact response of composite plates using shear deformation plate theory was analyzed. In recent work a closed-form solution was obtained for a rectangular plate with four edges simply supported subjected to a center impact load using classical plate theory. The problem was further investigated and the analysis results compared of both classical plate theory and shear deformation theory, and found that classical plate theory predicts very accurate results for the range of small deformations considered. In this study, the influence of cross sectional material distribution on the comparative impact responses of hybrid metal laminates subjected to low and medium velocity impacts is investigated. A simple linear model to evaluate the magnitude of the impact load is proposed first, and it establishes a relation between the impact velocity and the impact force. Then a closed-form solution for impact problem is presented. The results were compared with the finite element analysis results. For an 11 layer-hybrid laminate, the impact response as a function of material distribution in cross-section is presented. With equal areal weight, the effect of the number of laminate layers on the impact resistance is also investigated. Finally, the significance of the presented results is discussed.

Abatan, Ayu↗

Structural Reliability Using Probability Density Estimation Methods Within NESSUS

A reliability analysis studies a mathematical model of a physical system taking into account uncertainties of design variables and common results are estimations of a response density, which also implies estimations of its parameters. Some common density parameters include the mean value, the standard deviation, and specific percentile(s) of the response, which are measures of central tendency, variation, and probability regions, respectively. Reliability analyses are important since the results can lead to different designs by calculating the probability of observing safe responses in each of the proposed designs. All of this is done at the expense of added computational time as compared to a single deterministic analysis which will result in one value of the response out of many that make up the density of the response. Sampling methods, such as monte carlo (MC) and latin hypercube sampling (LHS), can be used to perform reliability analyses and can compute nonlinear response density parameters even if the response is dependent on many random variables. Hence, both methods are very robust; however, they are computationally expensive to use in the estimation of the response density parameters. Both methods are 2 of 13 stochastic methods that are contained within the Numerical Evaluation of Stochastic Structures Under Stress (NESSUS) program. NESSUS is a probabilistic finite element analysis (FEA) program that was developed through funding from NASA Glenn Research Center (GRC). It has the additional capability of being linked to other analysis programs; therefore, probabilistic fluid dynamics, fracture mechanics, and heat transfer are only a few of what is possible with this software. The LHS method is the newest addition to the stochastic methods within NESSUS. Part of this work was to enhance NESSUS with the LHS method. The new LHS module is complete, has been successfully integrated with NESSUS, and been used to study four different test cases that have been proposed by the Society of Automotive Engineers (SAE). The test cases compare different probabilistic methods within NESSUS because it is important that a user can have confidence that estimates of stochastic parameters of a response will be within an acceptable error limit. For each response, the mean, standard deviation, and 0.99 percentile, are repeatedly estimated which allows confidence statements to be made for each parameter estimated, and for each method. Thus, the ability of several stochastic methods to efficiently and accurately estimate density parameters is compared using four valid test cases. While all of the reliability methods used performed quite well, for the new LHS module within NESSUS it was found that it had a lower estimation error than MC when they were used to estimate the mean, standard deviation, and 0.99 percentile of the four different stochastic responses. Also, LHS required a smaller amount of calculations to obtain low error answers with a high amount of confidence than MC. It can therefore be stated that NESSUS is an important reliability tool that has a variety of sound probabilistic methods a user can employ and the newest LHS module is a valuable new enhancement of the program.

Chamis, Chrisos C.↗

Structural Design and Analysis of Un-pressurized Cargo Delivery Vehicle

As part of the Exploration Systems Architecture Study, NASA has defined a family of vehicles to support lunar exploration and International Space Station (ISS) re-supply missions after the Shuttle s retirement. The Un-pressurized Cargo Delivery Vehicle (UCDV) has been envisioned to be an expendable logistics delivery vehicle that would be used to deliver external cargo to the ISS. It would be launched on the Crew Launch Vehicle and would replace the Crew Exploration Vehicle. The estimated cargo would be the weight of external logistics to the ISS. Determining the minimum weight design of the UCDV during conceptual design is the major issue addressed in this paper. This task was accomplished using a procedure for rapid weight estimation that was based on Finite Element Analysis and sizing of the vehicle by the use of commercially available codes. Three design concepts were analyzed and their respective weights were compared. The analytical structural weight was increased by a factor to account for structural elements that were not modeled. Significant reduction in weight of a composite design over metallic was achieved for similar panel concepts.

Martinovic, Zoran N.↗

TURBO-AE: An Aeroelastic Code for Propulsion Applications

NASA's Advanced Subsonic Technology (AST) program is developing new technologies to increase the fuel efficiency of commercial aircraft engines, improve the safety of engine operation, and reduce engine emissions and noise. With the development of new designs for ducted fans, compressors, and turbines to achieve these goals, a basic aeroelastic requirement is that there should be no flutter or high resonant blade stresses in the operating regime. To verify the aeroelastic soundness of these designs, we need an accurate prediction and analysis code. Such a two-dimensional viscous propulsion aeroelastic code, named TURBO-AE, is being developed at the NASA Lewis Research Center. The TURBO-AE aeroelastic code is based on a three-dimensional unsteady aerodynamic Euler/Navier-Stokes turbomachinery code TURBO, developed under a grant from NASA Lewis. TURBO-AE can model viscous flow effects that play an important role in certain aeroelastic problems, such as flutter with flow separation (or stall flutter) and flutter in the presence of shock and boundary-layer interaction. The structural dynamics representation of the blade in the TURBO-AE code is based on a normal mode representation. A finite element analysis code, such as NASTRAN, is used to calculate in-vacuum vibration modes and the associated natural frequency. A work-per-cycle approach is used to determine aeroelastic (flutter) stability. With this approach, the motion of the blade is prescribed to be a harmonic vibration in a specified in vacuum normal mode. The aerodynamic forces acting on the vibrating blade and the work done by these forces on the vibrating blade during a cycle of vibration are calculated. If positive work is being done on the blade by the aerodynamic forces, the blade is dynamically unstable, since it will extract energy from the flow, leading to an increase in the amplitude of the blade's oscillation. Initial calculations have been done for a configuration representative of the Energy Efficient Engine fan rotor. The accompanying figure shows the work-per-cycle after each cycle of vibration. It can be seen that the work-per-cycle does not vary much after the fourth cycle. The negative sign of the converged work-per-cycle shows that the fan blade is dynamically stable and will not flutter. TURBO-AE will provide a useful aeroelastic prediction/analysis capability for engine manufacturers. It will reduce design cycle times by allowing new blade designs to be verified for aeroelastic soundness before blades are built and tested. With this prediction capability, it will be possible to build thinner, lighter, and faster rotating blades without encountering aeroelastic problems like stall flutter and high-cycle fatigue due to forced vibrations.

Bakhle, Milind A.↗

Design, Optimization, and Evaluation of A1-2139 Compression Panel with Integral T-Stiffeners

A T-stiffened panel was designed and optimized for minimum mass subjected to constraints on buckling load, yielding, and crippling or local stiffener failure using a new analysis and design tool named EBF3PanelOpt. The panel was designed for a compression loading configuration, a realistic load case for a typical aircraft skin-stiffened panel. The panel was integrally machined from 2139 aluminum alloy plate and was tested in compression. The panel was loaded beyond buckling and strains and out-of-plane displacements were extracted from 36 strain gages and one linear variable displacement transducer. A digital photogrammetric system was used to obtain full field displacements and strains on the smooth (unstiffened) side of the panel. The experimental data were compared with the strains and out-of-plane deflections from a high-fidelity nonlinear finite element analysis.

Mulani, Sameer B.↗