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At least 1,153 records · Page 64

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DOE OSTI2023

Thermal Analysis of Thermal Shield for PIP-II SSR1 Cryomodule

Fermilab's PIP-II project plans to enhance the onsite accelerator into the world's most intense neutrino beam, bringing Fermilab into the next generation of particle accelerators. The five different types of cryomodules are vital parts of the PIP-II project and each requires numerous engineering analyses to prove operation. For example, the thermal shield of the Single Spoke Resonator-1 (SSR1) cryomodule required a thermal analysis to ensure the design was operating as intended before fabrication commenced. The thermal shield is cooled by the supercritical helium inside of the extrusion and must remain between 45 and 80 Kelvin. The main purpose of the thermal shield is to intercept different high heat loads and thermal radiation and prevent them from reaching the more sensitive internal components. Finite Element Analysis (FEM) was used to determine temperature estimates of the thermal shield based on the location of a variety of heat sources. Results determined temperatures exceeding the design limit around the crucial component of the current leads. Due to superconducting properties, the areas around the current leads cannot surpass 68 Kelvin. Different solutions to the critical high-temperature areas will be proposed. These solutions range from changing the properties of the helium flow to designing an attachment for the thermal shield. Each proposition works as a viable solution, however, each proposition also has its own set of advantages and disadvantages that are described for further design consideration.

43 PARTICLE ACCELERATORS↗

NASA NTRS1991

An Evaluation of the Iosipescu Specimen for Composite Materials Shear Property Measurement

A detailed evaluation of the suitability of the Iosipescu specimen tested in the modified Wyoming fixture is presented. An experimental investigation using conventional strain gage instrumentation and moire interferometry is performed. A finite element analysis of the Iosipescu shear test for unidirectional and cross-ply composites is used to assess the uniformity of the shear stress field in the vicinity of the notch, and demonstrate the effect of the nonuniform stress field upon the strain gage measurements used for the determination of composite shear moduli. From the test results for graphite-epoxy laminates, it is shown that the proximity of the load introduction point to the test section greatly influences the individual gage readings for certain fiber orientations but the effect upon shear modulus measurement is relatively unimportant. A numerical study of the load contact effect shows the sensitivity of some fiber configurations to the specimen/fixture contact mechanism and may account for the variations in the measured shear moduli. A comparison of the strain gage readings from one surface of a specimen with corresponding data from moire interferometry on the opposite face documented an extreme sensitivity of some fiber orientations to eccentric loading which induced twisting and yielded spurious shear stress-strain curves. In the numerical analysis, it is shown that the Iosipescu specimens for different fiber orientations have to be modeled differently in order to closely approximate the true loading conditions. Correction factors are needed to allow for the nonuniformity of the strain field and the use of the average shear stress in the shear modulus evaluation. The correction factors, which are determined for the region occupied by the strain gage rosette, are found to be dependent upon the material orthotropic ratio and the finite element models. Based upon the experimental and numerical results, recommendations for improving the reliability and accuracy of the shear modulus values are made, and the implications for shear strength measurement discussed. Further application of the Iosipescu shear test to woven fabric composites is presented. The limitations of the traditional strain gage instrumentation on the satin weave and high tow plain weave fabrics is discussed. Test results of a epoxy based aluminum particulate composite is also presented. A modification of the Iosipescu specimen is proposed and investigated experimentally and numerically. It is shown that the proposed new specimen design provides a more uniform shear stress field in the test section and greatly reduces the normal and shear stress concentrations in the vicinity of the notches. While the fabrication and the material cost of the proposed specimen is tremendously reduced, it is shown the accuracy of the shear modulus measurement is not sacrificed.

Ho, Henjen↗

NASA NTRS2010

The Application of Ultrasonic Inspection to Crimped Electrical Connections

The development of a new ultrasonic measurement technique to quantitatively assess wire crimp terminations is discussed. The development of a prototype instrument, based on a modified, commercially available, crimp tool, is demonstrated for applying this technique when wire crimps are installed. The crimp tool has three separate crimping locations that accommodate the three different ferrule diameters. The crimp tool in this study is capable of crimping wire diameters ranging from 12 to 26 American Wire Gauge (AWG). A transducer design is presented that allows for interrogation of each of the three crimp locations on the crimp tool without reconfiguring the device. An analysis methodology, based on transmitted ultrasonic energy and timing of the first received pulse is shown to correlate to both crimp location in the tool and the AWG of the crimp/ferrule combination. The detectability of a number of the crimp failure pathologies, such as missing strands, partially inserted wires and incomplete crimp compression, is discussed. A wave propagation model, solved by finite element analysis, describes the compressional ultrasonic wave propagation through the junction during the crimping process.

Cramer, K. Elliott↗

DOE OSTI2021

Design Optimization of A-Type Heat Exchangers based on High Performance, Non-Round Tubes

Air-to-refrigerant heat exchangers (HXs) have been the topic of considerable research as they are the fundamental heat transfer components of HVAC&R systems. For residential and commercial applications, indoor heat exchangers are often in A-type configurations to reduce air-conditioner system footprint while still delivering the required cooling or heating. Classical HX design practices typically assume a uniform frontal air velocity profile to facilitate the use of conventional tube-fin airside heat transfer and pressure drop correlations for performance prediction. However, it is well-reported throughout the literature that A-type HXs experience significant airflow maldistribution which can severely degrade HX performance. Additionally, recent advancements in simulation software such as Computational Fluid Dynamics (CFD), Finite Element Analysis (FEA) and optimization algorithms have led researchers to consider primary heat transfer surface optimization to achieve highly compact HXs which do not require fins. In this paper, an A-type HX which utilizes shape-optimized non-round tubes is optimized for minimum duct size and airside pressure drop. This is achieved through coupling of an experimentally validated finite volume HX model with automated 2D CFD simulations of airflow through the HX for airside thermal-hydraulic performance evaluation. Preliminary results show that the optimal designs deliver similar capacity while achieving 20% reductions in airside pressure drop and duct cross-section area. Additionally, the optimal design apex angles in this study were similar to those from previous A-Type HX optimization studies for conventional tube-fin HX geometries, suggesting that the apex angle for optimal A-Type configuration performance may be independent of tube geometry.

42 ENGINEERING↗

NASA NTRS2013

Longitudinally Jointed Edge-Wise Compression HoneyComb Composite Sandwich Coupon Testing And Fe Analysis: Three Methods of Strain Measurement, And Comparison

Three distinct strain measurement methods (i.e., foil resistance strain gages, fiber optic strain sensors, and a three-dimensional digital image photogrammetry that gives full field strain and displacement measurements) were implemented to measure strains on the back and front surfaces of a longitudinally jointed curved test article subjected to edge-wise compression testing, at NASA Goddard Space Flight Center, according to ASTM C364. The pre-test finite element analysis (FEA) was conducted to assess ultimate failure load and predict strain distribution pattern throughout the test coupon. The predicted strain pattern contours were then utilized as guidelines for installing the strain measurement instrumentations. The foil resistance strain gages and fiber optic strain sensors were bonded on the specimen at locations with nearly the same analytically predicted strain values, and as close as possible to each other, so that, comparisons between the measured strains by strain gages and fiber optic sensors, as well as the three-dimensional digital image photogrammetric system are relevant. The test article was loaded to failure (at ~167 kN), at the compressive strain value of ~10,000 micro epsilon. As a part of this study, the validity of the measured strains by fiber optic sensors is examined against the foil resistance strain gages and the three-dimensional digital image photogrammetric data, and comprehensive comparisons are made with FEA predictions.

Farrokh, Babak↗

NASA NTRS1983

Propagating plane harmonic waves through finite length plates of variable thickness using finite element techniques

An analysis is given using finite element techniques which addresses the propagaton of a uniform incident pressure wave through a finite diameter axisymmetric tapered plate immersed in a fluid. The approach utilized in developing a finite element solution to this problem is based upon a technique for axisymmetric fluid structure interaction problems. The problem addressed is that of a 10 inch diameter axisymmetric fixed plate totally immersed in a fluid. The plate increases in thickness from approximately 0.01 inches thick at the center to 0.421 inches thick at a radius of 5 inches. Against each face of the tapered plate a cylindrical fluid volume was represented extending five wavelengths off the plate in the axial direction. The outer boundary of the fluid and plate regions were represented as a rigid encasement cylinder as was nearly the case in the physical problem. The primary objective of the analysis is to determine the form of the transmitted pressure distribution on the downstream side of the plate.

Clark, J. H.↗

NASA NTRS1992

Thermal residual stresses in silicon-carbide/titanium (0/90) laminate

The current work formulated a micromechanical analysis of a cross-ply laminate and calculated the thermal residual stress in a very thick (0/90)(sub 2n) silicon-carbide/titanium laminate. Results were also shown for a unidirectional laminate of the same material. Discrete fiber-matrix models assuming a rectangular array of fibers with a fiber volume fraction of 32.5 percent and a three-dimensional, finite-element analysis were used. Significant differences in the trends and magnitudes for the fiber, matrix, and interface stresses were calculated for unidirectional and (0/90) models. Larger hoop stresses calculated for the (0/90) model indicate that it may be more susceptible to radial cracking when subjected to mechanical loading than the unidirectional model. The axial stresses in the matrix were calculated to be slightly larger for the (0/90) model. The compressive axial stresses in the fiber were significantly larger in the (0/90) model. The presence of the cross-ply in the (0/90) model reduced the constraint on the fiber, producing radial interface stresses that were less compressive, which could lead to earlier failure of the fiber-matrix interface.

Bigelow, C. A.↗

NASA NTRS2015

Aerodynamic Load Analysis of a Variable Camber Continuous Trailing Edge Flap System on a Flexible Wing Aircraft

This paper presents an investigative aerodynamic analysis conducted on the novel control surface known as a Variable Camber Continuous Trailing Edge Flap (VCCTEF). The VCCTEF is modeled as a control effector on the NASA Generic Transport Model (GTM) where wing flexibility is considered. Aerodynamic modeling of the aircraft is conducted using vortex-lattice method (VLM), and an aeroelastic model of the aircraft that utilizes a coupled finite-element analysis (FEA) vortex-lattice solution is employed. VLM solutions are used to determine quasi-steady aerodynamic loading over the aeroelastic wing structures with VCCTEF. The load data is used to calculate aerodynamic sensitivities to control surface deployment and is also integrated to determine overall hinge moments. This analysis is conducted for different flight conditions, where control sensitivities compare the VCCTEF effectiveness against conventional control surfaces. Hinge moment results provide insight into aeroelastic wing loads, and worst case hinge moments for the VCCTEF can be estimated. Results show that the VCCTEF offers greater control authority than conventional ailerons at cruise, and nominal flap settings are determined for a low-speed take-off condition where the VCCTEF maintains comparable control effectiveness. Worst case hinge moment values are presented, where for a possible VCCTEF configuration, the stiff wing model demonstrates up to a 5.90 percent increase in flap hinge moment relative to a rigid model, and a reduced stiffness model demonstrates up to an 11.42 percent increase.

Aeroelasticity↗

NASA NTRS1973

Finite Element Method for Thermal Analysis

A two- and three-dimensional, finite-element thermal-analysis program which handles conduction with internal heat generation, convection, radiation, specified flux, and specified temperature boundary conditions is presented. Elements used in the program are the triangle and tetrahedron for two- and three-dimensional analysis, respectively. The theory used in the program is developed, and several sample problems demonstrating the capability and reliability of the program are presented. A guide to using the program, description of the input cards, and program listing are included.

Heuser, J.↗

NASA NTRS1975

Application of NASTRAN for stress analysis of left ventricle of the heart

Knowing the stress and strain distributions in the left ventricular wall of the heart is a prerequisite for the determination of the muscle elasticity and contractility in the process of assessing the functional status of the heart. NASTRAN was applied for the calculation of these stresses and strains and to help in verifying the results obtained by the computer program FEAMPS which was specifically designed for the plane-strain finite-element analysis of the left ventricular cross sections. Adopted for the analysis are the true shape and dimensions of the cross sections reconstructed from multiplanar X-ray views of a left ventricle which was surgically isolated from a dog's heart but metabolically supported to sustain its beating. A preprocessor was prepared to accommodate both FEAMPS and NASTRAN, and it has also facilitated the application of both the triangular element and isoparameteric quadrilateral element versions of NASTRAN. The stresses in several crucial regions of the left ventricular wall calculated by these two independently developed computer programs are found to be in good agreement. Such confirmation of the results is essential in the development of a method which assesses the heart performance.

Pao, Y. C.↗

DOE OSTI2024

Thermal Analysis of a Polypropylene Capacitor for Resonant Tuning Networks in WPT Applications

This study presents the thermal analysis of polypropylene capacitors operating at high frequencies and high currents used in the resonant tuning networks for electric vehicle (EV) wireless charging systems. The thermal analysis and performance results of the CELEM polypropylene capacitors are presented at different currents for a polyphase wireless power transfer (WPT) system while the study can be expanded to other capacitors by different manufacturers. Thermal equivalent circuit of the capacitor is derived and required cold plate size and design calculations are conducted by modeling the polypropene capacitor in MATLAB. The polypropene capacitor's finite element analysis (FEA) model is developed using COMSOL Multiphysics simulation software, and the thermal characteristics and analysis of the capacitor are presented in this paper.

Aktas, Ahmet↗

NASA NTRS2009

Design and Analysis of the International X-Ray Observatory Mirror Modules

The Soft X-Ray Telescope (SXT) modules are the fundamental focusing assemblies on NASA's next major X-ray telescope mission, the International X-Ray Observatory (IXO). The preliminary design and analysis of these assemblies has been completed, addressing the major engineering challenges and leading to an understanding of the factors effecting module performance. Each of the 60 modules in the Flight Mirror Assembly (FMA) supports 200-300 densely packed 0.4 mm thick glass mirror segments in order to meet the unprecedented effective area required to achieve the scientific objectives of the mission. Detailed Finite Element Analysis (FEA), materials testing, and environmental testing have been completed to ensure the modules can be successfully launched. Resulting stress margins are positive based on detailed FEA, a large factor of safety, and a design strength determined by robust characterization of the glass properties. FEA correlates well with the results of the successful modal, vibration, and acoustic environmental tests. Deformation of the module due to on-orbit thermal conditions is also a major design driver. A preliminary thermal control system has been designed and the sensitivity of module optical performance to various thermal loads has been determined using optomechanical analysis methods developed for this unique assembly. This design and analysis furthers the goal of building a module that demonstrates the ability to meet IXO requirements, which is the current focus of the IXO FMA technology development team.

McClelland, Ryan S.↗

NASA NTRS1991

An equivalent domain integral method for three-dimensional mixed-mode fracture problems

A general formulation of the equivalent domain integral (EDI) method for mixed mode fracture problems in cracked solids is presented. The method is discussed in the context of a 3-D finite element analysis. The J integral consists of two parts: the volume integral of the crack front potential over a torus enclosing the crack front and the crack surface integral due to the crack front potential plus the crack face loading. In mixed mode crack problems the total J integral is split into J sub I, J sub II, and J sub III representing the severity of the crack front in three modes of deformations. The direct and decomposition methods are used to separate the modes. These two methods were applied to several mixed mode fracture problems, were analyzed, and results were found to agree well with those available in the literature. The method lends itself to be used as a post-processing subroutine in a general purpose finite element program.

Shivakumar, K. N.↗

NASA NTRS1992

An equivalent domain integral method for three-dimensional mixed-mode fracture problems

Shivakumar, K. N.↗

DOE OSTI2021

Design of High Power Density 100 kW Surface Permanent Magnet Machine with No Heavy Rare Earth Material Using Current Source Inverter for Traction Application

Surface permanent magnet (SPM) machines are appealing candidates for traction applications because of high power density and high efficiency. Rare-earth magnets deliver high performance but raise concerns about material supply dependability, particularly if they use heavy rare-earth materials. This paper presents the design of a high-performance SPM machine without any heavy rare-earth material that is optimized specifically for a current-source inverter (CSI) traction drive. This machine is designed for a constant-power speed ratio (CPSR) of 3. A genetic algorithm has been performed to achieve a target of 50 kW/L active power density at speeds up to 20,000 rpm. Operation at a peak line-to-line voltage of 800 V can be achieved using 1200 V power devices with a safety margin. The predicted electromagnetic and rotor structural performance characteristics are presented using both analytical and finite element analysis (FEA) results.

(CPSR)↗

DOE OSTI2022

Transportation Analysis of the Fermilab High-Beta 650 MHz Cryomodule

The prototype High-Beta 650 MHz cryomodule for the PIP-II project will be the first of its kind to be transported internationally, and the round trip from FNAL to STFC UKRI will use a combination of road and air transit. Transportation of an assembled cryomodule poses a significant technical challenge, as excitation can generate high stresses and cyclic loading. To accurately assess the behavior of the cryomodule, Finite Element Analysis (FEA) was used to analyze all major components. First, all individual components were studied. For the critical/complex components, the analysis was in fine detail. Afterwards, all models were brought to a simplified state (necessary for computational expenses), verified to have the same behavior as their detailed counterparts, and combined to form larger sub-assemblies, with the ultimate analysis including the full cryomodule. We report the criteria for acceptance and methods of analysis, and results for selected components and sub-assemblies.

43 PARTICLE ACCELERATORS↗

NASA NTRS1978

NASTRAN analysis of a wheel-rail loading on its foundation

One type of azimuth bearing for a large ground antenna (100 m) will consist of steel wheels, mounted at four corners of the alidade, rolling on a circular flat rail which provides the vertical restraints; a radial constraining bearing at the center of the alidade provides the horizontal restraints. One important design feature is the compressive stresses in the grout or concrete foundation under the wheel-rail load. A finite element analysis check was made of a particular design that consists of a steel rail resting on a concrete foundation. Symmetry was assumed as much as possible in order to minimize the models, but meaningful element sizes were used. Recently developed isoparametric hexahedron elements available in the NASTRAN computing program, which minimizes the number of elements required while maintaining the accuracy of the computed stresses, were used with two versions of NASTRAN. Test cases to check with the analytical solutions were made. A side loading was also applied to calculate the increase in the concrete stresses.

Katow, M. S.↗

NASA NTRS1996

An Analysis of the Magneto-Optic Imaging System

The Magneto-Optic Imaging system is being used for the detection of defects in airframes and other aircraft structures. The system has been successfully applied to detecting surface cracks, but has difficulty in the detection of sub-surface defects such as corrosion. The intent of the grant was to understand the physics of the MOI better, in order to use it effectively for detecting corrosion and for classifying surface defects. Finite element analysis, image classification, and image processing are addressed.

Nath, Shridhar↗