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At least 1,153 records · Page 64

A study of facilities and fixtures for testing of a high speed civil transport wing component

A study was performed to determine the feasibility of testing a large-scale High Speed Civil Transport wing component in the Structures and Materials Testing Laboratory in Building 1148 at NASA Langley Research Center. The report includes a survey of the electrical and hydraulic resources and identifies the backing structure and floor hard points which would be available for reacting the test loads. The backing structure analysis uses a new finite element model of the floor and backstop support system in the Structures Laboratory. Information on the data acquisition system and the thermal power requirements is also presented. The study identified the hardware that would be required to test a typical component, including the number and arrangement of hydraulic actuators required to simulate expected flight loads. Load introduction and reaction structure concepts were analyzed to investigate the effects of experimentally induced boundary conditions.

Cerro, J. A.↗

Hypersonic engine component experiments in high heat flux, supersonic flow environment

A major concern in advancing the state-of-the-art technologies for hypersonic vehicles is the development of an aeropropulsion system capable of withstanding the sustained high thermal loads expected during hypersonic flight. Even though progress has been made in the computational understanding of fluid dynamics and the physics/chemistry of high speed flight, there is also a need for experimental facilities capable of providing a high heat flux environment for testing component concepts and verifying/calibrating these analyses. A hydrogen/oxygen rocket engine heat source was developed at the NASA Lewis Research Center as one element in a series of facilities at national laboratories designed to fulfill this need. This 'Hot Gas Facility' is capable of providing heat fluxes up to 450 w/sq cm on flat surfaces and up to 5,000 w/sq cm at the leading edge stagnation point of a strut in a supersonic flow stream. Gas temperatures up to 3050 K can also be attained. Two recent experimental programs conducted in this facility are discussed. The objective of the first experiment is to evaluate the erosion and oxidation characteristics of a coating on a cowl leading edge (or strut leading edge) in a supersonic, high heat flux environment. Macrophotographic data from a coated leading edge model show progressive degradation over several thermal cycles at aerothermal conditions representative of high Mach number flight. The objective of the second experiment is to assess the capability of cooling a porous surface exposed to a high temperature, high velocity flow environment and to provide a heat transfer data base for a design procedure. Experimental results from transpiration cooled surfaces in a supersonic flow environment are presented.

Gladden, Herbert J.↗

Development of an Aeroelastic Modeling Capability for Transient Nozzle Side Load Analysis

Lateral nozzle forces are known to cause severe structural damage to any new rocket engine in development. Currently there is no fully coupled computational tool to analyze this fluid/structure interaction process. The objective of this study was to develop a fully coupled aeroelastic modeling capability to describe the fluid/structure interaction process during the transient nozzle operations. The aeroelastic model composes of three components: the computational fluid dynamics component based on an unstructured-grid, pressure-based computational fluid dynamics formulation, the computational structural dynamics component developed in the framework of modal analysis, and the fluid-structural interface component. The developed aeroelastic model was applied to the transient nozzle startup process of the Space Shuttle Main Engine at sea level. The computed nozzle side loads and the axial nozzle wall pressure profiles from the aeroelastic nozzle are compared with those of the published rigid nozzle results, and the impact of the fluid/structure interaction on nozzle side loads is interrogated and presented.

Wang, Ten-See↗

Acoustics Research of Propulsion Systems

The liftoff phase induces high acoustic loading over a broad frequency range for a launch vehicle. These external acoustic environments are used in the prediction of the internal vibration responses of the vehicle and components. Present liftoff vehicle acoustic environment prediction methods utilize stationary data from previously conducted hold-down tests to generate 1/3 octave band Sound Pressure Level (SPL) spectra. In an effort to update the accuracy and quality of liftoff acoustic loading predictions, non-stationary flight data from the Ares I-X were processed in PC-Signal in two flight phases: simulated hold-down and liftoff. In conjunction, the Prediction of Acoustic Vehicle Environments (PAVE) program was developed in MATLAB to allow for efficient predictions of sound pressure levels (SPLs) as a function of station number along the vehicle using semi-empirical methods. This consisted of generating the Dimensionless Spectrum Function (DSF) and Dimensionless Source Location (DSL) curves from the Ares I-X flight data. These are then used in the MATLAB program to generate the 1/3 octave band SPL spectra. Concluding results show major differences in SPLs between the hold-down test data and the processed Ares I-X flight data making the Ares I-X flight data more practical for future vehicle acoustic environment predictions.

Gao, Ximing↗

Application of fracture mechanics and half-cycle theory to the prediction of fatigue life of aerospace structural components

The service life of aircraft structural components undergoing random stress cycling was analyzed by the application of fracture mechanics. The initial crack sizes at the critical stress points for the fatigue crack growth analysis were established through proof load tests. The fatigue crack growth rates for random stress cycles were calculated using the half-cycle method. A new equation was developed for calculating the number of remaining flights for the structural components. The number of remaining flights predicted by the new equation is much lower than that predicted by the conventional equation. This report describes the application of fracture mechanics and the half-cycle method to calculate the number of remaining flights for aircraft structural components.

Ko, William L.↗

Face Sheet/Core Disbond Growth in Honeycomb Sandwich Panels Subjected to Ground-Air-Ground Pressurization and In-Plane Loading

Typical damage modes in light honeycomb sandwich structures include face sheet/core disbonding and core fracture, both of which can pose a threat to the structural integrity of a component. These damage modes are of particular interest to aviation certification authorities since several in-service occurrences, such as rudder structural failure and other control surface malfunctions, have been attributed to face sheet/core disbonding. Extensive studies have shown that face sheet/core disbonding and core fracture can lead to damage propagation caused by internal pressure changes in the core. The increasing use of composite sandwich construction in aircraft applications makes it vitally important to understand the effect of ground-air-ground (GAG) cycles and conditions such as maneuver and gust loads on face sheet/core disbonding. The objective of the present study was to use a fracture mechanics based approach developed earlier to evaluate the loading at the disbond front caused by ground-air-ground pressurization and in-plane loading. A honeycomb sandwich panel containing a circular disbond at one face sheet/core interface was modeled with three-dimensional (3D) solid finite elements. The disbond was modeled as a discrete discontinuity and the strain energy release rate along the disbond front was computed using the Virtual Crack Closure Technique (VCCT). Special attention was paid to the pressure-deformation coupling which can decrease the pressure load within the disbonded sandwich section significantly when the structure is highly deformed. The commercial finite element analysis software, Abaqus/Standard, was used for the analyses. The recursive pressure-deformation coupling problem was solved by representing the entrapped air in the honeycomb cells as filled cavities in Abaqus/Standard. The results show that disbond size, face sheet thickness and core thickness are important parameters that determine crack tip loading at the disbond front. Further, the pressure-deformation coupling was found to have an important load decreasing effect [6]. In this paper, a detailed problem description is provided first. Second, the analysis methodology is presented. The fracture mechanics approach used is described and the specifics of the finite element model, including the fluid-filled cavities, are introduced. Third, the initial model verification and validation are discussed. Fourth, the findings from a closely related earlier study [6] are summarized. These findings provided the basis for the current investigation. Fifth, an aircraft ascent scenario from 0 to 12192 m (0 to 40000 ft) is considered and the resulting crack tip loading at the disbond front is determined. In-plane loading to simulate maneuvers and gust conditions are also considered. Sixth, the results are shown for a curved panel, which was used to simulate potential fuselage applications. Finally, a brief summary of observations is presented and recommendations for improvement are provided.

Chen, Zhi M.↗

Deflection-Compensating Beam for use inside a Cylinder

A design concept for a beam for a specific application permits variations and options for satisfying competing requirements to minimize certain deflections under load and to minimize the weight of the beam. In the specific application, the beam is required to serve as a motion-controlled structure for supporting a mirror for optical testing in the lower third portion of a horizontal, cylindrical vacuum chamber. The cylindrical shape of the chamber is fortuitous in that it can be (and is) utilized as an essential element of the deflection-minimizing design concept. The beam is, more precisely, a table-like structure comprising a nominally flat, horizontal portion with vertical legs at its ends. The weights of the beam and whatever components it supports are reacted by the contact forces between the lower ends of the legs and the inner cylindrical chamber wall. Whereas the bending moments arising from the weights contribute to a beam deflection that is concave with its lowest point at midlength, the bending moments generated by the contact forces acting on the legs contribute to a beam deflection that is convex with its highest point at midlength. In addition, the bending of the legs in response to the weights causes the lower ends of the legs to slide downward on the cylindrical wall. By taking the standard beam-deflection equations, combining them with the geometric relationships among the legs and the horizontal portion of the beam, and treating the sliding as a component of deflection, it is possible to write an equation for the net vertical deflection as a function of the load and of position along the beam. A summary of major conclusions drawn from the equation characterization is included.

Goodman, Dwight↗

Solar wind mass-loading at Comet Halley - A lesson from Venus?

Recent observations at Comet Halley show that the region within which cometary ions become the dominant component lies outside of the magnetic field-free cavity. This behavior resembles that found at Venus under conditions where the incident solar wind dynamic pressure exceeds the ionospheric pressure. On these occasions the magnetosheath magnetic field is found well inside of the region where planetary ions are observed. Although scaling and the details of formation of the inner boundary of the magnetic field are different for these two objects, the processes by which the interplanetary magnetic field penetrates into the ionospheres at Venus and at Comet Halley are in many ways analogous.

Breus, T. K.↗

Uncertainty Models for the Hybrid Parametric Variation Method of Uncertainty Quantification; Analysis

There is some level of uncertainty in every finite element model (FEM), which flows to a level of uncertainty in predicted results. The purpose of uncertainty quantification (UQ) is to provide statistical bounds on prediction accuracy based on model uncertainty. This is distinct from model updating, which attempts to modify models to improve their accuracy. UQ does not improve the accuracy of models, but accepts that the models are inherently inaccurate and attempts to quantify the impact of that inaccuracy on predicted results. Previously, an alternate method for UQ, called the Hybrid Parametric Variation (HPV) method, was applied to Space Launch System (SLS) Hurty/Craig-Bampton (HCB) components to predict system-level statistics for launch vehicle attitude control transfer functions and core stage section loads due to buffet. The HPV method combines a parametric variation of the HCB fixed-interface (FI) modal frequencies with a nonparametric variation (NPV) method that randomly varies the HCB mass and stiffness matrices as Wishart random matrix distributions using random matrix theory (RMT). Alternatively, the most common method for modeling uncertainty in the structural dynamics community is a parametric approach, which varies physical parameters in the model. However, there are several disadvantages associated with the parametric method. Determining a reduced set of parameters that have a significant impact on the system response can be time consuming, and the selected parameter probability distributions are rarely reliably known. Therefore, in practice, the parameters are surrogates for the actual errors, and the link to parameter uncertainty is unknown. Another major drawback is that the uncertainty that can be represented is limited to the form of the nominal FEM. It is the experience of the authors that based on numerous aerospace programs, almost all FEM errors are in form rather than parameter values. This hypothesis is supported by the observation of the authors that it is almost never possible to ‘tune’ a FEM to match modal test results by only modifying model parameters. Model-form uncertainty cannot be directly represented by FEM input parameters nor included in a parametric approach. However, model-form uncertainty can be modeled using RMT, where a probability distribution is developed for the matrix ensemble of interest. The major advantage of the NPV method is that it covers errors in model form. The HPV method anchors uncertainty at the HCB component level to component modal test results by matching the HCB and test modes based on mode descriptions or other methods, and then applying differing levels of frequency variation. The specific variations depend on the confidence to which a component FEM has been validated through modal testing. The NPV method is layered on the frequency variation to match modal test self-orthogonality and cross-orthogonality (XO) results. Once the component uncertainty models are identified, they are assembled, and the uncertainty is propagated to the system level using a Monte Carlo (MC) analysis approach that generates statistics for system-level predictions This provides a UQ method that can be traced to test data, which can be updated as additional data and improved correlated models become available. The purpose of this paper is to collect and present all of the theory for HPV that has been previously published in reports and papers and to present examples of its application. Specifically, component uncertainty models based on the dispersion of corresponding mass and stiffness matrices using proposed test/analysis correlation metrics are investigated. The first example is purely academic so that the true answers are known, and the validity of the HPV method and the corresponding uncertainty models can be determined. The purpose of this paper is to collect and present all of the theory for HPV that has been previously published in reports and papers and to present examples of its application. Specifically, component uncertainty models based on the dispersion of corresponding mass and stiffness matrices using proposed test/analysis correlation metrics are investigated. The first example is purely academic so that the true answers are known, and the validity of the HPV method and the corresponding uncertainty models can be determined. The second example is an application to a component that is design specific to the SLS. Based on this work and other assessments, the HPV method provides another tool to the toolset used for complex system UQ analysis. From experience gathered to date using the HPV method, additional design specific applications must be investigated to provide further confidence in the validity of the HPV method of UQ analysis.

Uncertainty quantification↗

A fundamental study of drag and an assessment of conventional drag-due-to-lift reduction devices

The integral conservation laws of fluid mechanics are used to assess the drag efficiency of lifting wings, both CTOL and various out-of-plane configurations. The drag-due-to-lift is separated into two major components: (1) the induced drag-due-to-lift that depends on aspect ratio but is relatively independent of Reynolds number; (2) the form drag-due-to-lift that is independent of aspect ratio but dependent on the details of the wing section design, planform and Reynolds number. For each lifting configuration there is an optimal load distribution that yields the minimum value of drag-due-to-lift. For well designed high aspect ratio CTOL wings the two drag components are independent. With modern design technology CTOL wings can be (and usually are) designed with a drag-due-to-lift efficiency close to unity. Wing tip-devices (winglets, feathers, sails, etc.) can improve drag-due-to-lift efficiency by 10 to 15% if they are designed as an integral part of the wing. As add-on devices they can be detrimental. It is estimated that 25% improvements of wing drag-due-to-lift efficiency can be obtained with joined tip configurations and vertically separated lifting elements without considering additional benefits that might be realized by improved structural efficiency. It is strongly recommended that an integrated aerodynamic/structural approach be taken in the design of (or research on) future out-of-plane configurations.

Yates, J. E.↗

Preload Loss in a Spacecraft Fastener via Vibration-Induced Unwinding

Sound engineering practice requires that fasteners and bolted joints maintain preload in service. NASA recently concluded a series of vibration tests of a multicomponent structure intended to simulate an upper stage section of a launch vehicle. The stacked components were joined through six circumferentially placed bolted cup-cone-style pyrotechnic joint mechanisms designed to share spacecraft structural loads and then enable separation during ascent. Over the course of the vibration test campaign, all six bolted cup-cone mechanisms experienced some degree of preload loss with two mechanisms losing half of their original bolt preload. A subsequent forensic anomaly investigation concluded that vibration-induced unwinding of the preload nut-and-bolt assemblies occurred despite the use of safety wire and high levels of thread friction. A series of experiments were done to better understand how large, heavily preloaded fasteners could unwind. Additionally, thread friction torque was measured and the fastener locking capability of safety wire was evaluated. The friction coefficient between the clamped cup-cone components was characterized and finally a highly instrumented mechanism-level vibration test was done to reproduce the unwinding phenomenon to better understand the mechanism's behavior. The conclusion drawn was that vibration and structural forces led to relative motion (sliding) of the clamped components, resulting in self-loosening and unwinding effects on the nut-and-bolt assembly. To counter this phenomenon, more effective fastener locking methodologies were recommended and a follow-on effort was initiated to quantify the relationship between preload, component motion, and resulting unwinding forces. It is hoped that elucidation of these effects can be used to design more effective fastener locking features.

fasteners↗

Energy Efficient Engine: High-pressure compressor test hardware detailed design report

The objective of the NASA Energy Efficient Engine program is to identify and verify the technology required to achieve significant reductions in fuel consumption and operating cost for future commercial gas turbine engines. The design and analysis is documented of the high pressure compressor which was tested as part of the Pratt and Whitney effort under the Energy Efficient Engine program. This compressor was designed to produce a 14:1 pressure ratio in ten stages with an adiabatic efficiency of 88.2 percent in the flight propulsion system. The corresponding expected efficiency for the compressor component test rig is 86.5 percent. Other performance goals are a surge margin of 20 percent, a corrected flow rate of 35.2 kg/sec (77.5 lb/sec), and a life of 20,000 missions and 30,000 hours. Low loss, highly loaded airfoils are used to increase efficiency while reducing the parts count. Active clearance control and case trenches in abradable strips over the blade tips are included in the compressor component design to further increase the efficiency potential. The test rig incorporates variable geometry stator vanes in all stages to permit maximum flexibility in developing stage-to-stage matching. This provision precluded active clearance control on the rear case of the test rig. Both the component and rig designs meet or exceed design requirements with the exception of life goals, which will be achievable with planned advances in materials technology.

Howe, David C.↗

Signal conditioner test set

A system was developed for testing components contained in a signal conditioning module with a transistor and capacitor included in a circuit. The system includes a housing with a socket into which the module to be tested is plugged. A test switch is provided for selectively connecting a variable load to either a transistor or capacitor in the circuit for testing the operation. A signal generating circuit is provided for generating signals for use in testing the components of the module.

Houck, W. H.↗

Prediction of service life of aircraft structural components using the half-cycle method

The service life of aircraft structural components undergoing random stress cycling was analyzed by the application of fracture mechanics. The initial crack sizes at the critical stress points for the fatigue-crack growth analysis were established through proof load tests. The fatigue-crack growth rates for random stress cycles were calculated using the half-cycle method. A new equation was developed for calculating the number of remaining flights for the structural components. The number of remaining flights predicted by the new equation is much lower than that predicted by the conventional equation.

Ko, William L.↗

Lateral ring metal elastic wheel absorbs shock loading

Lateral ring metal elastic wheel absorbs practically all shock loading when operated over extremely rough terrain and delivers only a negligible shock residue to associated suspension components. The wheel consists of a rigid aluminum assembly to which lateral titanium ring flexible elements with treads are attached.

Galan, L.↗

A magnifying scratch-gage force transducer

Single-component scratch-gage transducer incorporates a unique motion magnification scheme to increase the magnitude of the load measuring scratch approximately 15 times over that of conventional models. It is small, load carrying and high in natural frequency.

Scott, C. E.↗

The use of statistical characteristics of reducer vibrations as diagnostic symptoms

The results of a statistical analysis of the vibrations of the experimental RS-1 reducer stand, with a spiral-gear transmission, operating on a closed circuit, are presented. The analysis was carried out on the Minsk-2 and Minsk-32 digital computers, with two-channel analog-digital converter, built in the Institute of the Science of Mechanics. Two-dimensional distribution patterns, conditional dispersions and dispersion ratios were calculated. The octave-band-filtered first harmonics of the tooth frequency f sub z of the vibrations at two different measurement points were considered as the components of the vibration process to be analyzed. The regression lines, corresponding to different values of the loading torque, are presented. Since it was not the gear drive parameters which were determined by diagnostic methods, but the characteristics most sensitive to change in state of the object of the investigation, the loading torque, which is the simplest and most accessible for measurement, was chosen as the condition parameter.

Balitskiy, F. Y.↗

The biological effect of prolonged radiation and ways of selecting new anti-radiation drugs effective in this kind of radiation injury

The basic characteristics of prolonged radiation - increased tolerance of radiation injury - are attributed to cellular kinetics; as dose rate is reduced, the population rate is not disturbed, particularly that of stem cells which makes it possible for the organism to tolerate higher radiation loads. It is concluded that this effect makes approved radio protectors, whose effect contains an established cytostatic component, unsuitable for prolonged radiation. It is better to correct the stem pool formation process by either accelerating the proliferation of cells or limiting the effect of stimuli causing cells to lose colony forming properties.

Rogozkin, V. D.↗