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Results for “Optimized Structural Design”

Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 1,225 records · Page 68
All sourcesNASA NTRSDOE OSTI
NASA NTRS1975

Experiment definition phase shuttle laboratory LDRL-10.6 experiment

The acquisition and tracking links of shuttle to molniya satellite and shuttle to ground are established. Link parameters and tolerance are analyzed. A 10-micromillimeter optomechanical subsystem brassboard model was designed and measured for optical properties and weight optimization. The design incorporates an afocal rotating Gregorian telescope in a two-gimbal berylium structure with beam steering control mechanisms. Parameters for both the optomechanical subsystem and spaceborne terminals are included.

Source record↗
NASA NTRS1989

STRUTEX: A prototype knowledge-based system for initially configuring a structure to support point loads in two dimensions

Only recently have engineers begun making use of Artificial Intelligence (AI) tools in the area of conceptual design. To continue filling this void in the design process, a prototype knowledge-based system, called STRUTEX has been developed to initially configure a structure to support point loads in two dimensions. This prototype was developed for testing the application of AI tools to conceptual design as opposed to being a testbed for new methods for improving structural analysis and optimization. This system combines numerical and symbolic processing by the computer with interactive problem solving aided by the vision of the user. How the system is constructed to interact with the user is described. Of special interest is the information flow between the knowledge base and the data base under control of the algorithmic main program. Examples of computed and refined structures are presented during the explanation of the system.

Robers, James L.↗
NASA NTRS1990

Advances and trends in computational structures technology

The major goals of computational structures technology (CST) are outlined, and recent advances in CST are examined. These include computational material modeling, stochastic-based modeling, computational methods for articulated structural dynamics, strategies and numerical algorithms for new computing systems, multidisciplinary analysis and optimization. The role of CST in the future development of structures technology and the multidisciplinary design of future flight vehicles is addressed, and the future directions of CST research in the prediction of failures of structural components, the solution of large-scale structural problems, and quality assessment and control of numerical simulations are discussed.

Noor, A. K.↗
NASA NTRS2008

Electron Beam Freeform Fabrication: A Fabrication Process that Revolutionizes Aircraft Structural Designs and Spacecraft Supportability

The technological inception and challenges, as well as current applications of the electron beam freeform fabrication (EBF3) process are outlined. The process was motivated by the need for a new metals technology that would be cost-effective, enable the production of new alloys and that would could be used for efficient, lightweight structures. EBF3 is a rapid metal fabrication, layer-additive process that uses no molds or tools and which yields properties equivalent to wrought. The benefits of EBF3 include it near-net shape which minimizes scrap and reduces part count; efficiency in design which allows for lighter weight and enhanced performance; and, its "green" manufacturing process which yields minimal waste products. EBF3 also has a high tensile strength, while a structural test comparison found that EBF3 panels performed 5% lower than machined panels. Technical challenges in the EBF3 process include a need for process control monitoring and an improvement in localized heat response. Currently, the EBF3 process can be used to add details onto forgings and to construct and form complex shapes. However, it has potential uses in a variety of industries including aerospace, automotive, sporting goods and medical implant devices. The novel structural design capabilities of EBF3 have the ability to yield curved stiffeners which may be optimized for performance, low weight, low noise and damage tolerance applications. EBF3 has also demonstrated its usefulness in 0-gravity environments for supportability in space applications.

Taminger, Karen M.↗
NASA NTRS2022

Optimization Approach for Wind Tunnel Fan Blade Strain Gage Correlation with Test Fixture Unknowns

NASA has a significant maintenance challenge with the aging wind tunnel infrastructure across the Agency. Some wind tunnel fan blades, such as those in the National Transonic Facility at NASA Langley Research Center, have been in use for far longer than their planned 10-year lifetime. No detailed analytical models of the fan blades from their initial fabrication were created. To support the fabrication of either new, nominally identical fan blades or newly designed fan blades, accurate analytical models of the existing fan blades are necessary to demonstrate an understanding of the capabilities of the existing fan blades. Additionally, the existing documentation of the testing of the existing fan blades has gaps. In this report, a process for improving test-analysis correlation for these wind tunnel fan blades is discussed. This process involved a detailed study of unknown parameters in test fixture parameters from the old and incomplete test documentation. To improve correlation, these unknown parameters were used as design variables in an optimization study to minimize the error between test data and computed structural responses. Legacy strain gage data from tests conducted in 1981 were compared with results from a finite element model created in 2019. The use of test data from 1981 was necessary because none of the existing fan blades could be spared for use in destructive structural testing. While this process was demonstrated for wind tunnel fan blades, this process could be utilized for evaluating unknowns in test fixtures for other structural test configurations.

wind tunnel↗
DOE OSTI2022

Rapid approach for structural design of the tower and monopile for a series of 25 MW offshore turbines

The goal of further reducing the Levelized Cost of Energy (LCOE) has driven the investigation of large-scale wind turbines. This work presents a simple, rapid and detailed approach for the structural design of the tower and monopile without a controller, but with frequency and high fidelity structural verification. The approach uses an optimization to reduce the mass of the structures while meeting strength, buckling and geometric constraints by using analytical equations. A verification of frequency constraints is performed with BModes, and ANSYS Mechanical APDL is used for high fidelity verification of stress and buckling. The approach is applied to study the design space of three 25 MW offshore wind turbines with different rotor diameters and cone angles, and to evaluate the nacelle center of mass fore-aft location effect. Results obtained show that the tower and monopile are more susceptible to changes in the rotor thrust than the overturning moment even for designs with high pre-cone angle and large distance of the nacelle center of mass from the tower axis. But it is possible to obtain structurally feasible tower and monopile designs for the three 25 MW turbines studied while not exceeding diameter and wall thickness limits. However, mass penalties can be decreased by 0.8-14%, to further reduce the cost of energy, by increasing the diameter limit which may require manufacturing technology development. The approach applied and studies serve to understand the design space of the tower and monopile for a 25 MW turbine, and provide baseline designs that can be used in the development of a controller and evaluation of a full suite of design load cases.

17 WIND ENERGY↗
NASA NTRS2001

Simultaneous Aerodynamic Analysis and Design Optimization (SAADO) for a 3-D Flexible Wing

The formulation and implementation of an optimization method called Simultaneous Aerodynamic Analysis and Design Optimization (SAADO) are extended from single discipline analysis (aerodynamics only) to multidisciplinary analysis - in this case, static aero-structural analysis - and applied to a simple 3-D wing problem. The method aims to reduce the computational expense incurred in performing shape optimization using state-of-the-art Computational Fluid Dynamics (CFD) flow analysis, Finite Element Method (FEM) structural analysis and sensitivity analysis tools. Results for this small problem show that the method reaches the same local optimum as conventional optimization. However, unlike its application to the win,, (single discipline analysis), the method. as I implemented here, may not show significant reduction in the computational cost. Similar reductions were seen in the two-design-variable (DV) problem results but not in the 8-DV results given here.

Gumbert, Clyde R.↗
NASA NTRS2001

Simultaneous Aerodynamic Analysis and Design Optimization (SAADO) for a 3-D Flexible Wing

The formulation and implementation of an optimization method called Simultaneous Aerodynamic Analysis and Design Optimization (SAADO) are extended from single discipline analysis (aerodynamics only) to multidisciplinary analysis - in this case, static aero-structural analysis and applied to a simple 3-D wing problem. The method aims to reduce the computational expense incurred in performing shape optimization using state-of-the-art Computational Fluid Dynamics (CFD) flow analysis, Finite Element Method (FEM) structural analysis and sensitivity analysis tools. Results for this small problem show that the method reaches the same local optimum as conventional optimization. However, unlike its application to the rigid wing (single discipline analysis), the method, as implemented here, may not show significant reduction in the computational cost. Similar reductions were seen in the two-design-variable (DV) problem results but not in the 8-DV results given here.

Gumbert, Clyde R.↗
DOE OSTI2024

Optimization of Triply Periodic Minimal Surface Heat Exchanger to Achieve Compactness, High Efficiency, and Low-Pressure Drop

With advancements in additive manufacturing (AM) techniques, high-quality triply periodic minimal surface (TPMS) structures can now be produced. TPMS walled heat exchangers (HX) hold significant potential for industrial applications and are receiving increasing attention. This paper explores the impact of various TPMS design variables on flow and thermal performance to optimize TPMS heat exchangers for compactness, high efficiency, and low pressure drop. The design variables examined include the type of TPMS lattice, unit cell size, wall thickness, aspect ratio, TPMS orientation, and equivalent thickness. The study reveals that the flow and heat transfer performance of TPMS structures are significantly affected by these design variables. For the Gyroid, Diamond, and SplitP lattices, performance is nearly identical when the surface-to-volume ratio is kept constant. The average velocity of the fluid in the TPMS HX should be 0.3 m/s. The corresponding Re is between 300~800. Thin wall thickness, small equivalent thickness, and flat lattice configurations can significantly reduce pressure drop while maintaining the overall heat transfer coefficient. Additionally, the angle between the flow direction and TPMS orientation can increase pressure drop. Three aluminum heat exchangers were successfully printed using an AM machine, and testing results are comparable with theoretical prediction.

42 ENGINEERING↗
NASA NTRS2014

Additive Manufacturing of Low Cost Upper Stage Propulsion Components

NASA is currently developing Additive Manufacturing (AM) technologies and design tools aimed at reducing the costs and manufacturing time of regeneratively cooled rocket engine components. These Low Cost Upper Stage Propulsion (LCUSP) tasks are funded through NASA's Game Changing Development Program in the Space Technology Mission Directorate. The LCUSP project will develop a copper alloy additive manufacturing design process and develop and optimize the Electron Beam Freeform Fabrication (EBF3) manufacturing process to direct deposit a nickel alloy structural jacket and manifolds onto an SLM manufactured GRCop chamber and Ni-alloy nozzle. In order to develop these processes, the project will characterize both the microstructural and mechanical properties of the SLMproduced GRCop-84, and will explore and document novel design techniques specific to AM combustion devices components. These manufacturing technologies will be used to build a 25K-class regenerative chamber and nozzle (to be used with tested DMLS injectors) that will be tested individually and as a system in hot fire tests to demonstrate the applicability of the technologies. These tasks are expected to bring costs and manufacturing time down as spacecraft propulsion systems typically comprise more than 70% of the total vehicle cost and account for a significant portion of the development schedule. Additionally, high pressure/high temperature combustion chambers and nozzles must be regeneratively cooled to survive their operating environment, causing their design to be time consuming and costly to build. LCUSP presents an opportunity to develop and demonstrate a process that can infuse these technologies into industry, build competition, and drive down costs of future engines.

Protz, Christopher↗
NASA NTRS2024

Usage of ChatGPT for Engineering Design and Analysis Tool Development

ChatGPT, a generative AI large language model, has recently captured significant attention in both the computer science community and the broader public domain. It has demonstrated a wide range of capabilities, from answering simple questions to writing fully functional computer code. This study spotlights both the capabilities and limitations of ChatGPT when addressing engineering problems. The model's capacity to generate practical engineering tools is highlighted through an example of a prompt that leads to an interactive plotting tool, enabling the examination of the fluid boundary layer around a fan blade. Subsequently, the paper also uncovers potential pitfalls in ChatGPT’s application, shown through an unsuccessful attempt to use ChatGPT to automate a process in Ansys Workbench through scripting. The research further investigates ChatGPT's proficiency in addressing inquiries and providing explanations about the functionalities of OpenMDAO, an open-source, multidisciplinary design, analysis, and optimization tool developed at NASA Glenn Research Center. Finally, an optimization methodology, developed with ChatGPT’s help, is applied to the structural optimization of a fan blade. The developed optimization method utilizes T-Blade3 for geometry generation, Ansys Mechanical for meshing and finite element analysis, and sci-kit learn’s MLPRegressor method to generate a trained neural network model of the design space. OpenMDAO is then used to find the optimal point within the design space. The outcome is a significant reduction in stress in the optimized model—less than one-fifth of the stress value in the baseline model.

Design↗
NASA NTRSDate not supplied

Usage of ChatGPT for Engineering Design and Analysis Tool Development

ChatGPT, a generative AI large language model, has recently captured significant attention in both the computer science community and the broader public domain. It has demonstrated a wide range of capabilities, from answering simple questions to writing fully functional computer code. This study spotlights both the capabilities and limitations of ChatGPT when addressing engineering problems. The model's capacity to generate practical engineering tools is highlighted through an example of a prompt that leads to an interactive plotting tool, enabling the examination of the fluid boundary layer around a fan blade. Subsequently, the paper also uncovers potential pitfalls in ChatGPT’s application, shown through an unsuccessful attempt to use ChatGPT to automate a process in Ansys Workbench through scripting. The research further investigates ChatGPT's proficiency in addressing inquiries and providing explanations about the functionalities of OpenMDAO, an open-source, multidisciplinary design, analysis, and optimization tool developed at NASA Glenn Research Center. Finally, an optimization methodology, developed with ChatGPT’s help, is applied to the structural optimization of a fan blade. The developed optimization method utilizes T-Blade3 for geometry generation, Ansys Mechanical for meshing and finite element analysis, and sci-kit learn’s MLPRegressor method to generate a trained neural network model of the design space. OpenMDAO is then used to find the optimal point within the design space. The outcome is a significant reduction in stress in the optimized model—less than one-fifth of the stress value in the baseline model.

Design↗
NASA NTRS1972

Brayton cycle heat exchanger and duct assembly (HXDA, preliminary design and technology tests

A preliminary design of the heat exchanger and duct assembly (HXDA) for a 60 kwe, closed loop, Brayton cycle space power system is presented. This system is weight optimized within the constraints imposed by the defined structural and operational requirements. Also presented are the results of several small scale tests, directed to obtaining specific design data and/or the resolution of a design approach for long life Brayton cycle heat exchanger systems.

Coombs, M. G.↗
DOE OSTI2025

Effect of 3D-printed surface textures on wear mechanism in 3-body abrasion of soil

This study systematically investigates the enhancement of wear resistance in 3D printed surface textures through both experimental and theoretical approaches. Three distinct surface morphologies (Smooth Surface, Surface with uniformly distributed Pits, and Surface with uniformly distributed Bumps) were fabricated using High-Impact Polystyrene, where the meso-scale textures were precisely controlled through the 3D printing process. Wear behavior was evaluated using a 3-body wear tester in an abrasive particle environment, analyzing the influence of surface textures under various operating conditions. Systematic wear tests revealed that optimally designed surface textures achieved a remarkable 77 % reduction in wear compared to the worst-performing sample. The wear mechanisms were comprehensively characterized through weight loss measurements, Scanning Electron Microscopy (SEM), and Energy Dispersive Spectroscopy (EDS) analyses, elucidating the surface morphology changes and their interaction with wear particles. Notably, the study identified how the geometric characteristics of surface textures influence the movement of wear particles and the distribution of contact stresses. Discrete element method simulations corroborated the experimental findings, providing theoretical validation for the enhanced wear resistance of the optimal structure. The high correlation between simulated wear patterns and experimental results validates the reliability of the proposed design methodology. In conclusion, these results demonstrate that 3D printed surface texturing offers a cost-effective and scalable approach to significantly improve wear resistance in engineering applications, presenting a practical alternative to conventional, high-cost surface engineering methods.

3-body abrasion↗
DOE OSTI2020

Structural Optimization (Final Technical Report V.2.0)

The overall Project (Project) objective is to materially decrease the leveled cost of energy (LCOE) of the Columbia Power (CPwr) StingRAY utility-scale wave energy converter (WEC). This will be achieved by reducing structural material and manufacturing costs and increasing energy output. In this Project, improving the overall Power-to-Weight ratio (PWR) is accomplished through lowering design margins - allowing for weight reduction and more efficient, cost-effective WEC manufacturing and assembly - and by optimizing mass-related WEC performance parameters, such as center of gravity and system inertia. A mixed materials approach to further structural optimization was developed under this Project and validated with extensive laboratory structural testing. This approach substitutes fiber-reinforced plastic (FRP) for steel where appropriate. The benefits of steel are maintained where most useful, for instance at structural joints where the stiffness of steel is required, and the complex geometry is more readily fabricated with steel. However, there are structural spans whose simple shapes are readily fabricated with mandrel-wound FRP and where significant cost and weight savings can be found. An adhesive, double lap shear joint is used to join the FRP and steel subcomponents.

16 TIDAL AND WAVE POWER↗
NASA NTRS1973

Perform - A performance optimizing computer program for dynamic systems subject to transient loadings

A description and applications of a computer capability for determining the ultimate optimal behavior of a dynamically loaded structural-mechanical system are presented. This capability provides characteristics of the theoretically best, or limiting, design concept according to response criteria dictated by design requirements. Equations of motion of the system in first or second order form include incompletely specified elements whose characteristics are determined in the optimization of one or more performance indices subject to the response criteria in the form of constraints. The system is subject to deterministic transient inputs, and the computer capability is designed to operate with a large linear programming on-the-shelf software package which performs the desired optimization. The report contains user-oriented program documentation in engineering, problem-oriented form. Applications cover a wide variety of dynamics problems including those associated with such diverse configurations as a missile-silo system, impacting freight cars, and an aircraft ride control system.

Pilkey, W. D.↗
NASA NTRS1992

Design and optimization of a self-deploying single axis tracking PV array

This study was performed in order to design a tracking photovoltaic (PV) array and optimize the design for maximum specific power. The design considerations were minimal deployment time, high reliability, and small stowage volume. The array design was self-deployable, from a compact stowage configuration, using a passive pressurized gas deployment mechanism. The array structural components consist of a combination of beams, columns, and cables used to deploy and orient a flexible PV blanket. Each structural component of the design was analyzed to determine the size necessary to withstand the various forces to which it would be subjected. An optimization was performed to determine the array dimensions and blanket geometry which produce the maximum specific power. The optimization was performed for both lunar and Martian environments with 4 types of PV blankets (silicon, GaAs/Ge, GaAs CLEFT, and amorphous silicon). For the lunar environment, the amorphous silicon array produced the highest specific power, whereas, for Mars the GaAs CLEFT array produced the highest specific power. A comparison was made to a fixed PV tent array of similar design. The tracking array produced a higher specific power with all types of the PV blankets examined except amorphous silicon at both locations.

Colozza, Anthony J.↗
NASA NTRS1992

Design and optimization of a self-deploying single axis tracking PV array

This study was performed in order to design a tracking photovoltaic (PV) array and optimize the design for maximum specific power. The design considerations were minimal deployment time, high reliability, and small stowage volume. The array design was self-deployable, from a compact stowage configuration, using a passive pressurized gas deployment mechanism. The array structural components consist of a combination of beams, columns, and cables used to deploy and orient a flexible PV blanket. Each structural component of the design was analyzer to determine the size necessary to withstand the various forces to which it would be subjected. An optimization was performed to determine the array dimensions and blanket geometry which produce the maximum specific power. The optimization was performed for both lunar and Martian environments with 4 types of PV blankets (silicon, GaAs/Ge, GaAs CLEFT, and amorphous Silicon). For the lunar environment, the amorphous silicon array produced the highest specific power, whereas, for Mars the GaAs CLEFT array produced the highest specific power. A comparison was made to a fixed PV tent array of similar design. The tracking array produced a higher specific power with all types of the PV blankets examined except amorphous silicon at both locations.

Colozza, Anthony J.↗