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At least 1,099 records · Page 61

Dynamic Capacity and Surface Fatigue Life for Spur and Helical Gears

A mathematical model for surface fatigue life of gear, pinion, or entire meshing gear train is given. The theory is based on a previous statistical approach for rolling-element bearings. Equations are presented which give the dynamic capacity of the gear set. The dynamic capacity is the transmitted tangential load which gives a 90 percent probability of survival of the gear set for one million pinion revolutions. The analytical results are compared with test data for a set of AISI 9310 spur gears operating at a maximum Hertz stress of 1.71 billion N/sq m and 10,000 rpm. The theoretical life predictions are shown to be good when material constants obtained from rolling-element bearing tests were used in the gear life model.

Coy, J. J.↗

Time Accurate Unsteady Pressure Loads Simulated for the Space Launch System at a Wind Tunnel Condition

Using the Fully Unstructured Three-Dimensional (FUN3D) computational fluid dynamics code, an unsteady, time-accurate flow field about a Space Launch System configuration was simulated at a transonic wind tunnel condition (Mach = 0.9). Delayed detached eddy simulation combined with Reynolds Averaged Naiver-Stokes and a Spallart-Almaras turbulence model were employed for the simulation. Second order accurate time evolution scheme was used to simulate the flow field, with a minimum of 0.2 seconds of simulated time to as much as 1.4 seconds. Data was collected at 480 pressure taps at locations, 139 of which matched a 3% wind tunnel model, tested in the Transonic Dynamic Tunnel (TDT) facility at NASA Langley Research Center. Comparisons between computation and experiment showed agreement within 5% in terms of location for peak RMS levels, and 20% for frequency and magnitude of power spectral densities. Grid resolution and time step sensitivity studies were performed to identify methods for improved accuracy comparisons to wind tunnel data. With limited computational resources, accurate trends for reduced vibratory loads on the vehicle were observed. Exploratory methods such as determining minimized computed errors based on CFL number and sub-iterations, as well as evaluating frequency content of the unsteady pressures and evaluation of oscillatory shock structures were used in this study to enhance computational efficiency and solution accuracy. These techniques enabled development of a set of best practices, for the evaluation of future flight vehicle designs in terms of vibratory loads.

Alter, Stephen J.↗

Extraction of Vibration Data with Imaging

To date, the primary sensing technology used to measure the vibration response has been accelerometers and strain gages mounted directly to the structure and using either wired or, more recently, wireless telemetry. Cost issues with these sensors and the associated data acquisition systems typically limit the numbers that are deployed on in situ structures. Although there are a few structures with larger sensing counts that in some cases exceed over 1000 sensors, more typical numbers range from ten to one hundred sensors resulting in low spatial resolution when they are applied to physically large systems. When one considers that nuclear power plant structures usually have complex geometries, material properties, connectivity and boundary conditions, it is clear these current approaches to vibration measurements can only provide limited information about a system’s dynamics response characteristics. As an alternative, many non-contact measurement technologies have emerged, including point wise measurement methods such as Global Positioning System (GPS), microwave interferometry, and laser Doppler vibrometry (LDV), as well as simultaneous full-field measurement methods such as electronic speckle pattern interferometry, holography interferometry, and muon tomography, some of which can provide high spatial resolution measurements. Among these methods, digital video imaging techniques have emerged as a feasible solution for full-field vibration measurements that provide significantly more detailed dynamic response information because every pixel becomes a measurement point. Furthermore, recent advances in image processing and computer vision algorithms have been successfully used to process video data for experimental and operational modal analysis. Such full-field measurements have the potential to significantly improve many current structural assessment procedures including system identification (modal parameter estimation), structural health monitoring, load reconstruction, model validation, and model updating. Furthermore, more recent full-field imaging techniques can be accomplished with relatively low-cost, commercially-available off-the-shelf cameras. However, these measurement procedures have other limitations that must be considered such as the ability to only measure visibly accessible points on a structure and a more limited dynamic range and bandwidth than can be achieved with accelerometers or strain gages.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

Current Capabilities of AFRL’s Spacecraft Simulation Tool

Assessment of spacecraft integration issues is typically accomplished with a combination of numerical tools developed to simulate different regions with different key physics. For instance, a detailed study of spacecraft with an electric propulsion device requires a device model, a plume model, and a spacecraft charging model. AFRL’s in-house spacecraft simulation tool, TURF, is now capable of performing all of these calculations in one simulation. In addition, the plume simulation capability has been expanded significantly to improve speed and accuracy. Other upgrades in TURF include adaptive mesh refinement (AMR) and dynamic load balancing. All of these upgrades are covered in this paper by providing detailed descriptions or pointing to relevant references. This paper also presents three example simulations demonstrating its multi-physics multi-scale capability.

spacecraft simulation↗

Nonlinear modeling and performance analysis of cracked beam microgyroscopes

Cracks constitute a common structural defect in microelectromechanical systems that may arise during manufacturing, mechanical fatigue, or shock loading. Areas weakened by cracks increase the flexibility of the microstructure. Furthermore, depending on the crack severity, the increased flexibility can cause dramatic changes in the static and dynamic behaviors of electrically actuated MEMS. In this study, a numerical investigation of the depth and location of multiple edge cracks on the performance of beam microgyroscopes is conducted. Applying the Griffith strain energy release theorem for an edge crack, the vibrational characteristics of microgyroscopes with multiple cracks including the static deflection, natural frequencies, and mode shapes are studied analytically. Then, the differential quadrature method is employed to model the nonlinear dynamic behaviors of the cracked gyroscope system. Cracks initiated along the driving or sensing directions of the microgyroscope are found to have differing effects on its nonlinear dynamic response. This numerical study reveals that the onset of severe single cracks or a series of multiple cracks can significantly affect the sensitivity of the microgyroscope to base rotations and therefore leads to a degradation in the performance of the damaged MEMS sensor. This study also shows that a potential design approach for broadband microgyroscope systems manufactured with cracks can be proposed.

42 ENGINEERING↗

OC7 phase I: CFD investigation of viscous forces on rectangular members of semisubmersibles

In Phase I of the Offshore Code Comparison Collaboration 7 (OC7) project, we aim to address key questions related to the modeling of viscous hydrodynamic loads on floating platforms. Here, this paper presents results from a collaborative effort within Phase I of the OC7 project. We investigate viscous forces acting on the rectangular members of semisubmersible platforms using high-fidelity computational fluid dynamics (CFD) simulations. The parametric CFD analyses include two-and-a-half-dimensional (2.5D) simulations of pontoon sections of two different semisubmersible platform designs (the VolturnUS-S and the INO WINDMOOR) and full three-dimensional (3D) structure simulations of the VolturnUS-S platform. We extract both the added mass and drag coefficients that are typically used in engineering-level hydrodynamic models from the 2.5D forced oscillation simulations with various Keulegan-Carpenter numbers and compare them to the coefficients from the 3D forced oscillation simulations. We observe consistent variation of the coefficients along the pontoon legs due to 3D platform and free-surface effects. With the breadth of the simulations and component-level detailed analyses, this work establishes a useful database and several empirical formulas for selecting hydrodynamic coefficients when modeling semisubmersible platforms in engineering tools.

13 HYDRO ENERGY↗

Lubricant Rheology in Concentrated Contacts

A revue of experimental investigations of lubricant behaviour in highly stressed situations shows that a Newtonian model for lubricant rheology is insufficient for explanation of traction behaviour. The oil film build-up, on the other hand, is fairly well predicted using a Newtonian lubricant model except at high slide to roll ratios and at very high loads, where the non-Newtonian behaviour starts to be important already outside the Hertzian contact area. Two main types of experiments are reported: static and dynamic. In static experiments the pressure is typically applied to the lubricant more than a million times longer than in an EHD contact. Depending on the pressure-temperature history of the experiment the lubricant will become a crystallized or amorphous solid at high pressures. In dynamic experiments, where the pressure is applied as short time as in real EHD contacts, the oil is in an amorphous solid state. Depending on the viscosity, time-scale, elasticity of the oil and the bearing surfaces, the oil film pressure, shear strain rate and the type of lubricant, different properties of the oil are important for prediction of shear stresses in the oil. This can be seen from the different proposed models for the lubricant, where it is described as being for instance a Newtonian liquid, an elastic liquid, a plastic liquid and an elastic-plastic solid.

Bo O Jacobson↗

Rocket Engine Oscillation Diagnostics

Rocket engine oscillating data can reveal many physical phenomena ranging from unsteady flow and acoustics to rotordynamics and structural dynamics. Because of this, engine diagnostics based on oscillation data should employ both signal analysis and physical modeling. This paper describes an approach to rocket engine oscillation diagnostics, types of problems encountered, and example problems solved. Determination of design guidelines and environments (or loads) from oscillating phenomena is required during initial stages of rocket engine design, while the additional tasks of health monitoring, incipient failure detection, and anomaly diagnostics occur during engine development and operation. Oscillations in rocket engines are typically related to flow driven acoustics, flow excited structures, or rotational forces. Additional sources of oscillatory energy are combustion and cavitation. Included in the example problems is a sampling of signal analysis tools employed in diagnostics. The rocket engine hardware includes combustion devices, valves, turbopumps, and ducts. Simple models of an oscillating fluid system or structure can be constructed to estimate pertinent dynamic parameters governing the unsteady behavior of engine systems or components. In the example problems it is shown that simple physical modeling when combined with signal analysis can be successfully employed to diagnose complex rocket engine oscillatory phenomena.

Nesman, Tom↗

Vibratory Loads Reduction Testing of the NASA/Army/MIT Active Twist Rotor

Recent studies have indicated that controlled strain-induced blade twisting can be attained using piezoelectric active fiber composite technology, and that such advancement may provide a mechanism for reduced rotorcraft vibrations and increased rotor performance. In order to validate these findings experimentally, a cooperative effort between the NASA Langley Research Center, the Army Research Laboratory, and the MIT Active Materials and Structures Laboratory has been developed. As a result of this collaboration a four-bladed, aeroelastically-scaled, active-twist model rotor has been designed and fabricated for testing in the heavy gas test medium of the NASA Langley Transonic Dynamics Tunnel. Initial wind tunnel testing has been conducted to assess the impact of active blade twist on both fixed- and rotating-system vibratory loads in forward flight. The active twist control was found to have a pronounced effect on all system loads and was shown to generally offer reductions in fixed-system loads of 60% to 95%, depending upon flight condition, with 1.1 to 1.4 of dynamic blade twist observed. A summary of the systems developed and the vibratory loads reduction results obtained are presented in this paper.

Wilbur, Matthew↗

Numerical Study of Flow Augmented Thermal Management for Entry and Re-Entry Environments

The use of a flow augmented thermal management system for entry and re-entr environments is one method for reducing heat and drag loads. This concept relies on jet penetration from supersonic and hypersonic counterflowing jets that could significantly weaken and disperse the shock-wave system of the spacecraft flow field. The objective of this research effort is to conduct parametric studies of the supersonic flow over a 2.6% scale model of the Apollo capsule, with and without the counterflowing jet, using time-accurate and steady-state computational fluid dynamics simulations. The numerical studies, including different freestream Mach number angle of attack counterflowing jet mass flow rate, and nozzle configurations, were performed to examine their effect on the drag and beat loads and to explore the counternowing jet condition. The numerical results were compared with the test data obtained from transonic blow-down wind-tunnel experiments conducted independently at NASA MSFC.

Cheng, Gary C.↗

Dynamic stress analysis of smooth and notched fiber composite flexural specimens

A detailed analysis of the dynamic stress field in smooth and notched fiber composite (Charpy-type) specimens is reported in this paper. The analysis is performed with the aid of the direct transient response analysis solution sequence of MSC/NASTRAN. Three unidirectional composites were chosen for the study. They are S-Glass/Epoxy, Kevlar/Epoxy and T-300/Epoxy composite systems. The specimens are subjected to an impact load which is modeled as a triangular impulse with a maximum of 2000 lb and a duration of 1 ms. The results are compared with those of static analysis of the specimens subjected to a peak load of 2000 lb. For the geometry and type of materials studied, the static analysis results gave close conservative estimates for the dynamic stresses. Another interesting inference from the study is that the impact induced effects are felt by S-Glass/Epoxy specimens sooner than Kevlar/Epoxy or T-300/Epoxy specimens.

Murthy, P. L. N.↗

Dynamic stress analysis of smooth and notched fiber composite flexural specimens

A detailed analysis of the dynamic stress field in smooth and notched fiber composite (Charpy-type) specimens is reported in this paper. The analysis is performed with the aid of the direct transient response analysis solution sequence of MSC/NASTRAN. Three unidirectional composites were chosen for the study. They are S-Glass/Epoxy, Kevlar/Epoxy and T-300/Epoxy composite systems. The specimens are subjected to an impact load which is modeled as a triangular impulse with a maximum of 2000 lb and a duration of 1 ms. The results are compared with those of static analysis of the specimens subjected to a peak load of 2000 lb. For the geometry and type of materials studied, the static analysis results gave close conservative estimates for the dynamic stresses. Another interesting inference from the study is that the impact induced effects are felt by S-Glass/Epoxy specimens sooner than Kevlar/Epoxy or T-300/Epoxy specimens.

Murthy, P. L. N.↗

Current research in cavitating fluid films

A review of the current research of cavitation in fluid films is presented. Phenomena and experimental observations include gaseous cavitation, vapor cavitation, and gas entrainment. Cavitation in flooded, starved, and dynamically loaded journal bearings, as well as squeeze films are reviewed. Observations of cavitation damage in bearings and the possibility of cavitation between parallel plates with microasperities were discussed. The transcavity fluid transport process, meniscus motion and geometry or form of the film during rupture, and reformation were summarized. Performance effects were related to heat transfer models in the cavitated region and hysteresis influence on rotor dynamics coefficients. A number of cavitation algorithms was presented together with solution procedures using the finite difference and finite element methods. Although Newtonian fluids were assumed in most of the discussions, the effect of non-Newtonian fluids on cavitation was also discussed.

Brewe, D. E.↗

Enhanced Contact Graph Routing (ECGR) MACHETE Simulation Model

Contact Graph Routing (CGR) for Delay/Disruption Tolerant Networking (DTN) space-based networks makes use of the predictable nature of node contacts to make real-time routing decisions given unpredictable traffic patterns. The contact graph will have been disseminated to all nodes before the start of route computation. CGR was designed for space-based networking environments where future contact plans are known or are independently computable (e.g., using known orbital dynamics). For each data item (known as a bundle in DTN), a node independently performs route selection by examining possible paths to the destination. Route computation could conceivably run thousands of times a second, so computational load is important. This work refers to the simulation software model of Enhanced Contact Graph Routing (ECGR) for DTN Bundle Protocol in JPL's MACHETE simulation tool. The simulation model was used for performance analysis of CGR and led to several performance enhancements. The simulation model was used to demonstrate the improvements of ECGR over CGR as well as other routing methods in space network scenarios. ECGR moved to using earliest arrival time because it is a global monotonically increasing metric that guarantees the safety properties needed for the solution's correctness since route re-computation occurs at each node to accommodate unpredicted changes (e.g., traffic pattern, link quality). Furthermore, using earliest arrival time enabled the use of the standard Dijkstra algorithm for path selection. The Dijkstra algorithm for path selection has a well-known inexpensive computational cost. These enhancements have been integrated into the open source CGR implementation. The ECGR model is also useful for route metric experimentation and comparisons with other DTN routing protocols particularly when combined with MACHETE's space networking models and Delay Tolerant Link State Routing (DTLSR) model.

Segui, John S.↗

Numerical simulation of aerothermal loads in hypersonic engine inlets due to shock impingement

The effect of shock impingement on an axial corner simulating the inlet of a hypersonic vehicle engine is modeled using a finite-difference procedure. A three-dimensional dynamic grid adaptation procedure is utilized to move the grids to regions with strong flow gradients. The adaptation procedure uses a grid relocation stencil that is valid at both the interior and boundary points of the finite-difference grid. A linear combination of spatial derivatives of specific flow variables, calculated with finite-element interpolation functions, are used as adaptation measures. This computational procedure is used to study laminar and turbulent Mach 6 flows in the axial corner. The description of flow physics and qualitative measures of heat transfer distributions on cowl and strut surfaces obtained from the analysis are compared with experimental observations. Conclusions are drawn regarding the capability of the numerical scheme for enhanced modeling of high-speed compressible flows.

Ramakrishnan, R.↗

Enhanced Correlation of SMART Active Flap Rotor Loads

This is a follow-on study to a 2010 correlation effort. Measured data from the SMART rotor test in the NASA Ames 40- by 80- Foot Wind Tunnel are compared with CAMRAD II calculations. As background, during the wind tunnel test, unexpectedly high inboard loads were encountered, and it was hypothesized at that time that due to changes in the flexbeams over the years, the flexbeam properties used in the analysis needed updating. Boeing Mesa, recently updated these properties. This correlation study uses the updated flexbeam properties. Compared to earlier studies, the following two enhancements are implemented: i) the inboard loads (pitchcase and flexbeam loads) correlation is included for the first time (reliable prediction of the inboard loads is a prerequisite for any future anticipated flight-testing); ii) the number of blade modes is increased to better capture the flap dynamics and the pitchcase-flexbeam dynamics. Also, aerodynamically, both the rolled-up wake model and the more complex, multiple trailer wake model are used, with the latter slightly improving the blade chordwise moment correlation. This sensitivity to the wake model indicates that CFD is needed. Three high-speed experimental cases, one uncontrolled free flap case and two commanded flap cases, are considered. The two commanded flap cases include a 2o flap deflection at 5P case and a 0o flap deflection case. For the free flap case, selected modifications to the HH-06 section flap airfoil pitching moment table are implemented. For the commanded 2o flap case, the experimental flap variation is approximately matched by increasing the analytical flap hinge stiffness. This increased flap hinge stiffness is retained for the commanded 0o flap case also, which is treated as a free flap case, but with larger flap hinge stiffness. The change in the mid-span and outboard loads correlation due to the updating of the flexbeam properties is not significant. Increasing the number of blade modes results in an effective, commanded flap hinge stiffness of 4X baseline, not 3X as reported earlier. The inboard loads correlation is reasonable, but needs further study. Overall, the free flap case correlation is reasonable, thus confirming the basic correctness of the current semi-empirical modifications; the correlation for the commanded 2o flap at 5P case and the 0o flap case is also reasonable.

Kottapalli, Sesi↗

An active homopolar magnetic bearing with high temperature superconductor (HTS) coils and ferromagnetic cores

A proof-of-feasibility demonstration showed that high temperature superconductor (HTS) coils can be used in a high-load, active magnetic bearing in liquid nitrogen. A homopolar radial bearing with commercially wound HTS (Bi 2223) bias and control coils produced over 200 lb (890 N) radial load capacity (measured non-rotating) and supported a shaft to 14000 rpm. The goal was to show that HTS coils can operate stably with ferromagnetic cores in a feedback controlled system at a current density similar to that in Cu in liquid nitrogen. Design compromises permitted use of circular coils with rectangular cross section. Conductor improvements will eventually permit coil shape optimization, higher current density and higher bearing load capacity. The bias coil, wound with non-twisted, multifilament HTS conductor, required negligible power to carry its direct current. The control coils were wound with monofilament HTS sheathed in Ag. These dissipated negligible power for direct current (i.e. for steady radial load components). When an alternating current (AC) was added, the AC component dissipated power which increased rapidly with frequency and quadratically with AC amplitude. In fact at frequencies above about 2 hz, the effective resistance of the control coil conductor actually exceeds that of the silver which is in electrical parallel with the oxide superconductor. This is at least qualitatively understandable in the context of a Bean-type model of flux and current penetration into a Type II superconductor. Fortunately the dynamic currents required for bearing stability are of small amplitude. These results show that while twisted multifilament conductor is not needed for stable levitation, twisted multifilaments will be required to reduce control power for sizable dynamic loads, such as those due to unbalance.

Brown, G. V.↗

Thermo-hydraulic steam pipe models for district heating simulations: Simplifications to balance accuracy and simulation speed

Steam piping networks are essential for optimizing performance in industrial processes and district heating systems. However, dynamic models that balance thermo-hydraulic accuracy with computational efficiency remain limited. In response, this paper presents a new discretized steam pipe model based on the plug flow approach, capturing key thermo-hydraulic behaviors while simplifying steam phase change processes. Implemented in Modelica, the model accurately calculates temperature and pressure distributions along steam pipelines. To improve computational efficiency for district-scale simulations, five model simplifications are introduced: lumped thermo-hydraulic functions, empirical correlations, fluid state approximations, steady-state dynamics and inclusion of flow derivatives. These simplified models achieve 85%-98% accuracy in predicting pressure drop and condensation losses, including dynamic condensate behavior during pipe warm-up—a factor often overlooked in existing models. The models support diverse network configurations, scaling effectively to systems with multiple distribution pipes and connected building loads. Discrete models provide detailed insights but exhibit a cubic increase in simulation time as the network scales by N connected building O(N 2.42 ). In contrast, lumped models simulate 10–28 times faster than discrete, offering quadratic scaling of simulation time O(N 1.73 ). However, they still require 6 times more computation time than a lossless network, highlighting the inherent computational challenges of modeling compressible fluid flow. In conclusion, the steady-state lumped variant, with its near-linear scalability in computational time O(N 1.01 ), emerges as an efficient solution for preliminary design evaluations and extensive parametric studies.

15 GEOTHERMAL ENERGY↗