Engineering Papers⌕ Search

SEARCH · Engineering Papers

Results for “Rapid Process 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.

Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.

At least 127 records · Page 7
All sourcesNASA NTRSDOE OSTI
NASA NTRSDate not supplied

Trace Contaminant Control Test Bed for Evaluation of TCC Prototypes with Vacuum Regenerable and Non-Regenerable Sorbents

A new Space Suit Exploration Portable Life Support System (xPLSS) is being designed, built, integrated, and tested into the Extra-Vehicular Mobility Unit (xEMU). The Trace Contaminant Control (TCC) system is a component in the oxygen ventilation loop of xPLSS that removes contaminants generated by the crewmembers’ metabolic processes. The primary trace contaminants that must be removed include ammonia (NH3), carbon monoxide (CO), formaldehyde (CH2O), and methyl mercaptan (CH3SH). The current state-of-the-art TCC sorbent is non-regenerable activated carbon. As a non-regenerable sorbent, its use negatively impacts the logistics for future missions. Thus, an ideal solution can be a vacuum-regenerable sorbent integrated with the xPLSS CO2/H2O removal system. To test new designs and sorbents, XploSafe has constructed a recirculating test bed that mimics the environment within the xPLSS by providing concentrations of the trace contaminant analytes generated at the operating temperature, humidity, pressure, and flow rates of the xPLSS. This system can perform regeneration or desorption by exposing the sorbent to a pressure swing from 4.3 psia to <1 torr over approximately 2 minutes. Using this test system, XploSafe evaluated various TCC prototypes constructed using rapid prototyping techniques and identified a process that allows vacuum regenerative TCC designs to be quickly examined for flow, pressure drop, and performance. By using toluene as a segregate for volatile organics, this test system was evaluated using both vacuum regenerable and non-regenerable sorbents to demonstrate the operational effectiveness of these sorbents in maintaining the concentrations of the trace contaminant analytes below the 7-day Spacecraft Maximum Allowable Concentrations.

Nicholas Materer↗
NASA NTRSDate not supplied

Bridging the Gap Between Finite Element Modeling and Wavefront Analysis for Streamlined Optical System Design

Traditionally, evaluating the optical performance of mirrors derived from finite element (FEA), with third-party software requires cumbersome manual effort – which impacts efficient design optimization. This paper presents a process that seamlessly integrates FEA results with wavefront analysis software, significantly simplifying performance assessment and enabling rapid design iteration. We leverage the 4D technology interferometer and "4Sight" wavefront analysis software for performance measurement and comparison with FEA predictions. Recognizing the need for efficient data exchange, we developed an application that converts FEA data into a format compatible with 4Sight. The software takes two user-defined inputs: optical surface position and deformation information, typically provided as CSV or TXT files. Within a second, it generates an output file suitable for direct import into 4Sight, enabling immediate visualization of key optical performance metrics.

Zernike Polynomial↗
NASA NTRS1993

The automated ground network system

The primary goal of the Automated Ground Network System (AGNS) project is to reduce Ground Network (GN) station life-cycle costs. To accomplish this goal, the AGNS project will employ an object-oriented approach to develop a new infrastructure that will permit continuous application of new technologies and methodologies to the Ground Network's class of problems. The AGNS project is a Total Quality (TQ) project. Through use of an open collaborative development environment, developers and users will have equal input into the end-to-end design and development process. This will permit direct user input and feedback and will enable rapid prototyping for requirements clarification. This paper describes the AGNS objectives, operations concept, and proposed design.

Smith, Miles T.↗
DOE OSTI2024

An Organic, Direct Bonded Copper, Multi-Layered, Ultra-Low Inductance Package for High-Power UWBG MOSFETs

The most common metalized substrates used in high-power switching packages consist of a ceramic layer such as Aluminum Nitride (AlN) sandwiched between two copper layers. Ceramic substrates are used because it has the key characteristic of having high dielectric strength while being thermally conductive. A large drawback to ceramic substrates is that they do not allow for a multi-layered circuit design. By replacing the traditional ceramic substrate with organic direct bonded copper (ODBC) we can open a wide range of possibilities when it comes to power module layout such as multi-layered circuits and double-sided cooling. Both benefits are critical while packaging high-performance Gallium Oxide (Ga2O3) MOSFETs. Because of Ga2O3's relatively poor thermal conductivity, a double-sided cooled package becomes necessary. Therefore, the use of ODBC provides the flexibility to fabricate copper traces carrying much higher currents, and by creating a multi-layered package, we can drastically reduce the parasitic inductance inside the power module. Achieving lower parasitic inductance is critical for an ultra-fast Ga2O3 package to avoid excessive voltage overshoot and ringing. Using ODBC, we have designed novel packages capable of handling the challenges presented by fast Ga2O3 switching. Using multi-physics modeling software, we can validate our design before building the prototype. Due to the simple process parameters needed to work with ODBC, we can rapidly create prototypes without using external vendors. This flexibility allows us to quickly design, build, and validate highly complex switching power modules to accommodate next generation, Ga2O3 switching devices.

ADVANCED PROPULSION SYSTEMS,ENGINEERING↗
DOE OSTI2016

Quaternary organic solar cells enhanced by cocrystalline squaraines with power conversion efficiencies >10%

The incorporation of multiple donors into the bulk-heterojunction layer of organic polymer solar cells (PSCs) has been demonstrated as a practical and elegant strategy to improve photovoltaics performance. However, it is challenging to successfully design and blend multiple donors, while minimizing unfavorable interactions (e.g., morphological traps, recombination centers, etc.). Here, a new Förster resonance energy transfer-based design is shown utilizing the synergistic nature of three light active donors (two small molecules and a high-performance donor–acceptor polymer) with a fullerene acceptor to create highly efficient quaternary PSCs with power conversion efficiencies (PCEs) of up to 10.7%. Within this quaternary architecture, it is revealed that the addition of small molecules in low concentrations broadens the absorption bandwidth, induces cocrystalline molecular conformations, and promotes rapid (picosecond) energy transfer processes. Finally, these results provide guidance for the design of multiple-donor systems using simple processing techniques to realize single-junction PSC designs with unprecedented PCEs.

77 NANOSCIENCE AND NANOTECHNOLOGY↗
NASA NTRS2014

Coupled Solid Rocket Motor Ballistics and Trajectory Modeling for Higher Fidelity Launch Vehicle Design

Multi-stage launch vehicles with solid rocket motors (SRMs) face design optimization challenges, especially when the mission scope changes frequently. Significant performance benefits can be realized if the solid rocket motors are optimized to the changing requirements. While SRMs represent a fixed performance at launch, rapid design iterations enable flexibility at design time, yielding significant performance gains. The streamlining and integration of SRM design and analysis can be achieved with improved analysis tools. While powerful and versatile, the Solid Performance Program (SPP) is not conducive to rapid design iteration. Performing a design iteration with SPP and a trajectory solver is a labor intensive process. To enable a better workflow, SPP, the Program to Optimize Simulated Trajectories (POST), and the interfaces between them have been improved and automated, and a graphical user interface (GUI) has been developed. The GUI enables real-time visual feedback of grain and nozzle design inputs, enforces parameter dependencies, removes redundancies, and simplifies manipulation of SPP and POST's numerous options. Automating the analysis also simplifies batch analyses and trade studies. Finally, the GUI provides post-processing, visualization, and comparison of results. Wrapping legacy high-fidelity analysis codes with modern software provides the improved interface necessary to enable rapid coupled SRM ballistics and vehicle trajectory analysis. Low cost trade studies demonstrate the sensitivities of flight performance metrics to propulsion characteristics. Incorporating high fidelity analysis from SPP into vehicle design reduces performance margins and improves reliability. By flying an SRM designed with the same assumptions as the rest of the vehicle, accurate comparisons can be made between competing architectures. In summary, this flexible workflow is a critical component to designing a versatile launch vehicle model that can accommodate a volatile mission scope.

Ables, Brett↗
NASA NTRS1996

An Open Computing Infrastructure that Facilitates Integrated Product and Process Development from a Decision-Based Perspective

Computer applications for design have evolved rapidly over the past several decades, and significant payoffs are being achieved by organizations through reductions in design cycle times. These applications are overwhelmed by the requirements imposed during complex, open engineering systems design. Organizations are faced with a number of different methodologies, numerous legacy disciplinary tools, and a very large amount of data. Yet they are also faced with few interdisciplinary tools for design collaboration or methods for achieving the revolutionary product designs required to maintain a competitive advantage in the future. These organizations are looking for a software infrastructure that integrates current corporate design practices with newer simulation and solution techniques. Such an infrastructure must be robust to changes in both corporate needs and enabling technologies. In addition, this infrastructure must be user-friendly, modular and scalable. This need is the motivation for the research described in this dissertation. The research is focused on the development of an open computing infrastructure that facilitates product and process design. In addition, this research explicitly deals with human interactions during design through a model that focuses on the role of a designer as that of decision-maker. The research perspective here is taken from that of design as a discipline with a focus on Decision-Based Design, Theory of Languages, Information Science, and Integration Technology. Given this background, a Model of IPPD is developed and implemented along the lines of a traditional experimental procedure: with the steps of establishing context, formalizing a theory, building an apparatus, conducting an experiment, reviewing results, and providing recommendations. Based on this Model, Design Processes and Specification can be explored in a structured and implementable architecture. An architecture for exploring design called DREAMS (Developing Robust Engineering Analysis Models and Specifications) has been developed which supports the activities of both meta-design and actual design execution. This is accomplished through a systematic process which is comprised of the stages of Formulation, Translation, and Evaluation. During this process, elements from a Design Specification are integrated into Design Processes. In addition, a software infrastructure was developed and is called IMAGE (Intelligent Multidisciplinary Aircraft Generation Environment). This represents a virtual apparatus in the Design Experiment conducted in this research. IMAGE is an innovative architecture because it explicitly supports design-related activities. This is accomplished through a GUI driven and Agent-based implementation of DREAMS. A HSCT design has been adopted from the Framework for Interdisciplinary Design Optimization (FIDO) and is implemented in IMAGE. This problem shows how Design Processes and Specification interact in a design system. In addition, the problem utilizes two different solution models concurrently: optimal and satisfying. The satisfying model allows for more design flexibility and allows a designer to maintain design freedom. As a result of following this experimental procedure, this infrastructure is an open system that it is robust to changes in both corporate needs and computer technologies. The development of this infrastructure leads to a number of significant intellectual contributions: 1) A new approach to implementing IPPD with the aid of a computer; 2) A formal Design Experiment; 3) A combined Process and Specification architecture that is language-based; 4) An infrastructure for exploring design; 5) An integration strategy for implementing computer resources; and 6) A seamless modeling language. The need for these contributions is emphasized by the demand by industry and government agencies for the development of these technologies.

Hale, Mark A.↗
NASA NTRS2004

Optimal Synthesis of Compliant Mechanisms using Subdivision and Commercial FEA (DETC2004-57497)

The field of distributed-compliance mechanisms has seen significant work in developing suitable topology optimization tools for their design. These optimal design tools have grown out of the techniques of structural optimization. This paper will build on the previous work in topology optimization and compliant mechanism design by proposing an alternative design space parameterization through control points and adding another step to the process, that of subdivision. The control points allow a specific design to be represented as a solid model during the optimization process. The process of subdivision creates an additional number of control points that help smooth the surface (for example a C(sup 2) continuous surface depending on the method of subdivision chosen) creating a manufacturable design free of some traditional numerical instabilities. Note that these additional control points do not add to the number of design parameters. This alternative parameterization and description as a solid model effectively and completely separates the design variables from the analysis variables during the optimization procedure. The motivation behind this work is to create an automated design tool from task definition to functional prototype created on a CNC or rapid-prototype machine. This paper will describe the proposed compliant mechanism design process and will demonstrate the procedure on several examples common in the literature.

Hull, Patrick V.↗
DOE OSTI2026

Phenomena-based graph representations and applications to chemical process simulation

Rapid and robust simulation of chemical processes is critical to conduct process design, optimization, techno-economic analysis, and sustainability analysis. Yet, efficiently solving simulation models remains a challenge due to the highly coupled and nonlinear nature of the underlying algebraic equations that capture the physical phenomena taking place in the process (e.g., material and energy conservation, phase equilibrium, reactions). In this work, we show that graph-theoretic representations of the physical phenomena within unit operations can help navigate and decompose equations to systematically identify alternative approaches for fast and robust numerical solutions. Specifically, we present a graph-theoretic abstraction that captures the connectivity between the model variables/equations and use this abstraction to group variables/equations into fundamental phenomena. We show that phenomena-based decomposition of the underlying equations can help decouple nonlinearities and enforce material/energy conservation at the process level to accelerate convergence. The proposed decomposition approach differs from the more traditional sequential modular simulation approach, in which equations are grouped and decomposed by unit operations. We implemented the phenomena-based decomposition in BioSTEAM—an open-source process simulation platform in Python—and demonstrated that this approach can converge a variety of separation process models. Compared to sequential modular simulation, the phenomena-based approach can converge idealized systems faster, but it can be slower for (or even fail to converge) highly coupled and nonideal process systems.

Convergence↗
DOE OSTI2015

WE-EF-BRA-05: Experimental Design for High-Throughput In-Vitro RBE Measurements Using Protons, Helium and Carbon Ions

Purpose: To design and validate experimental setups for investigation of dose and LET effects in cell kill for protons, helium and carbon ions, in high throughput and high accuracy cell experiments. Methods: Using the Geant4 Monte Carlo toolkit, we designed 3 custom range compensators to simultaneously expose cancer cells to different doses and LETs from selected portions of pristine ion beams from the entrance to points just beyond the Bragg peak. To minimize the spread of LET, we utilized mono-energetic uniformly scanned beams at the HIT facility with support from the DKFZ. Using different entrance doses and LETs, a matrix of cell survival data was acquired leading to a specific RBE matrix. We utilized the standard clonogenic assay for H460 and H1437 lung-cancer cell lines grown in 96-well plates. Using these plates, the data could be acquired in a small number of exposures. The ion specific compensators were located in a horizontal beam, designed to hold two 96-wells plates (12 columns by 8 rows) at an angle of 30o with respect to the beam direction. Results: Using about 20 hours of beam time, a total of about 11,000 wells containing cancer cells could be irradiated. The H460 and H1437 cell lines exhibited a significant dependence on LET when they were exposed to comparable doses. The results were similar for each of the investigated ion species, and indicate the need to incorporate RBE into the ion therapy planning process. Conclusion: The experimental design developed is a viable approach to rapidly acquire large amounts of accurate in-vitro RBE data. We plan to further improve the design to achieve higher accuracy and throughput, thereby facilitating the irradiation of multiple cell types. The results are indicative of the possibility to develop a new degree of freedom (variable RBE) for future clinical ion therapy optimization. Work supported by the Sister Institute Network Fund (SINF), University of Texas MD Anderson Cancer Center.

60 APPLIED LIFE SCIENCES↗
NASA NTRS2020

An Experimental Approach to a Rapid Propulsion and Aeronautics Concepts Testbed

Modern aircraft design tools have limitations for predicting complex propulsion-airframe interactions. The demand for new tools and methods addressing these limitations is high based on the many recent Distributed Electric Propulsion (DEP) Vertical Take-Off and Landing (VTOL) concepts being developed for Urban Air Mobility (UAM) markets. We propose that low cost electronics and additive manufacturing can support the conceptual design of advanced autonomy-enabled concepts, by facilitating rapid prototyping for experimentally driven design cycles. This approach has the potential to reduce complex aircraft concept development costs, minimize unique risks associated with the conceptual design, and shorten development schedule by enabling the determination of many "unknown unknowns" earlier in the design process and providing verification of the results from aircraft design tools. A modular testbed was designed and built to evaluate this rapid design-build-test approach and to support aeronautics and autonomy research targeting UAM applications utilizing a complex, transitioning-VTOL aircraft configuration. The testbed is a modular wind tunnel and flight model. The testbed airframe is approximately 80% printed, with labor required for assembly. This paper describes the design process, fabrication process, ground testing, and initial wind tunnel structural and thermal loading of a proof-of-concept aircraft, the Langley Aerodrome 8 (LA-8).

McSwain, Robert G.↗
DOE OSTI2016

Microstructure and mechanical properties of a novel rapidly solidified, high-temperature Al-alloy

Rapid solidification (RS) processing, as a production method, offers a variety of unique properties based on far-from-equilibrium microstructures obtained through rapid cooling rates. In this study, we seek to investigate the microstructures and properties of a novel Al-alloy specifically designed for high temperature mechanical stability. Synthesis of, AlFe{sub 11.4}Si{sub 1.8}V{sub 1.6}Mn{sub 0.9} (wt.%), was performed by two approaches: rotating cup atomization (“shot”) and melt spinning (“flake”). These methods were chosen because of their ability to produce alloys with tailored microstructures due to their inherent differences in cooling rate. The as-solidified precursor materials were microstructurally characterized with electron microscopy. The results show that the higher cooling rate flake material exhibited the formation of nanocrystalline regions as well additional phase morphologies not seen in the shot material. Secondary dendritic branching in the flake material was on the order of 0.1–0.25 μm whereas branching in the shot material was 0.5–1.0 μm. Consolidated and extruded material from both precursor materials was mechanically evaluated at both ambient and high (300 °C) temperature. The consolidated RS flake material is shown to exhibit higher strengths than the shot material. The ultimate tensile strength of the melt spun flake was reported as 544.2 MPa at room temperature and 298.0 MPa at 300 °C. These results forecast the ability to design alloys and processing approaches with unique non-equilibrium microstructures with robust mechanical properties at elevated temperatures. - Highlights: • A novel alloy, AlFe{sub 11.4}Si{sub 1.8}V{sub 1.6}Mn{sub 0.9} was fabricated by rapid solidification. • Room temperature yield strength exceeded 500 MPa. • Elevated temperature (300 °C) yield strength exceeded 275 MPa. • Forging, after extrusion of the alloy resulted in microstructural coarsening. • Decreased strength and ductility was identified as a result of forging.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Abstract for CRADA between the National Energy Technology Laboratory and West Virginia University Research Corporation (AGMT-0891)

Microwave-assisted technologies for coal conversion processes could provide an avenue for new processing windows to be achieved via a modular reactor design. The benefits primarily come from the rapid and selective heating associated with microwave power, which can overcome significant lag times in heating the medium over conventional, thermal heating. Beyond selective heating, a non-thermal microwave effect has been proposed as a possible explanation for enhanced conversion and selectivity in reaction processes, which can produce yield beyond equilibrium values. However, the detailed mechanisms of microwave-assisted processes are not completely known. NETL and West Virginia University Research Corporation will investigate the microwave conversion process using a computational modeling approach coupled with experimental validation would provide insight into the microwave mechanism that is essential for designing efficient microwave-based coal conversion technologies.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2023

Surface Roughness Effects from Additive Manufacturing in High Efficiency Gas Turbine Combustion Systems

In the past, clean combustion systems were characterized by high system development costs due to growing complexity and escalating manufacturing costs from conventional manufacturing processes. As a result, high efficiency concepts are difficult to design and more difficult to be cost-effectively manufactured. In recent years, with the introduction of additive manufacturing (AM) technologies, the rapid prototyping and mass production processes of clean combustion systems are promising to be significantly simplified with significant reduction in terms of engine manufacturing cost and engine energy cost. Compared with conventional manufacturing built parts, the AM process enabled a simpler design to be adopted for the nozzle, reducing the number of required braze and weld joints from twenty-five to just five. The resulting nozzle was 25% lighter and five times more durable and contributed to a 15% reduction in fuel burn in comparison with the previous model produced. Applying these improvements to a fleet of 5,000 turbofan engines at 150 kN thrust would result in fuel cost savings of $ \$ $6B annually (at $ \$ $5/gallon Jet-A fuel price, 700 gallon/hour fuel consumption rate, and 2,300 operational hours per year), and reduce CO2 emissions by more than 25 million tons per year. These advances support core Department of Energy (DOE) missions in energy efficiency, improving productivity, and environmental sustainability. Maximizing the benefit of these new capabilities will require high prediction capability of high speed turbulent flow with wall modeled Large Eddy Simulation (LES). GE Aviation maintains that advanced simulation technology and supercomputing is required in order to provide the appropriate boundary conditions to realize the maximum potential of AM and Ceramic Matrix Composite to reduce cooling flow, a first order penalty on the Brayton cycle. The algorithm developed using the ANSYS/Fluent software would provide the foundation for entirely new avenues of research and development with potential multi-billion dollar impact to the US economy, and significant reduction in carbon based emissions across the aerospace and power generation industries. The formulation of this iWLES (integral wall model for LES) is generic and allows to capture the changes in flow dynamics that have a significant impact on the wall bounded flow characteristics, such as swirler effective area, bulk swirl number, local pressure distribution, exit velocity profile, and turbulence kinetic energy profile. A periodic channel flow with rough flat plate is simulated using LES (Wall-Adapting Local Eddy-viscosity) model to verify the implementation of iWLES in the Fluent User Defined Function (UDF). As the flow fields are highly sensitive due to surface roughness of the wall bounded flows in the combustion systems, there is significant potential to conduct further LES studies focusing on the turbulence boundary layer interaction. Accurately capturing near wall physics will elucidate the impact of rough surfaces on combustor flow and aero-thermal interactions.

42 ENGINEERING↗
DOE OSTI2023

Surface Roughness Effects from Additive Manufacturing in High Efficiency Gas Turbine Combustion Systems

In the past, clean combustion systems were characterized by high system development costs due to growing complexity and escalating manufacturing costs from conventional manufacturing processes. As a result, high efficiency concepts are difficult to design and more difficult to be cost-effectively manufactured. In recent years, with the introduction of additive manufacturing (AM) technologies, the rapid prototyping and mass production processes of clean combustion systems are promising to be significantly simplified with significant reduction in terms of engine manufacturing cost and engine energy cost. Compared with conventional manufacturing built parts, the AM process enabled a simpler design to be adopted for the nozzle, reducing the number of required braze and weld joints from twenty-five to just five. The resulting nozzle was 25% lighter and five times more durable and contributed to a 15% reduction in fuel burn in comparison with the previous model produced. Applying these improvements to a fleet of 5,000 turbofan engines at 150 kN thrust would result in fuel cost savings of $6B annually (at $5/gallon Jet-A fuel price, 700 gallon/hour fuel consumption rate, and 2,300 operational hours per year),and reduce CO2 emissions by more than 25 million tons per year. These advances support core Department of Energy (DOE)missions in energy efficiency, improving productivity, and environmental sustainability. Maximizing the benefit of these new capabilities will require high prediction capability of high speed turbulent flow with wall modeled Large Eddy Simulation (LES). GE Aviation maintains that advanced simulation technology and supercomputing is required in order to provide the appropriate boundary conditions to realize the maximum potential of AM and Ceramic Matrix Composite to reduce cooling flow, a first order penalty on the Brayton cycle. The algorithm developed using the ANSYS/Fluent software would provide the foundation for entirely new avenues of research and development with potential multi-billion dollar impact to the US economy, and significant reduction in carbon based emissions across the aerospace and power generation industries. The formulation of this iWLES (integral wall model for LES) is generic and allows to capture the changes in flow dynamics that have a significant impact on the wall bounded flow characteristics, such as swirler effective area, bulk swirl number, local pressure distribution, exit velocity profile, and turbulence kinetic energy profile. A periodic channel flow with rough flat plate is simulated using LES (Wall-Adapting Local Eddy-viscosity) model to verify the implementation of iWLES in the Fluent User Defined Function (UDF). As the flow fields are highly sensitive due to surface roughness of the wall bounded flows in the combustion systems, there is significant potential to conduct further LES studies focusing on the turbulence boundary layer interaction. Accurately capturing near wall physics will elucidate the impact of rough surfaces on combustor flow and aero-thermal interactions.

99 GENERAL AND MISCELLANEOUS↗
DOE OSTI2020

DUCTED ASSEMBLY STEADY STATE HEAT TRANSFER SOFTWARE

The Ducted Assembly Steady State Heat transfer software (DASSH) performs full core, steady state, subchannel temperature calculations for hexagonal, ducted assemblies. DASSH is targeted for use in the early stages of the reactor design process when assembly characteristics may not be defined or are undergoing considerable changes. DASSH provides a relatively rapid assessment of the temperature and flow distribution to inform reactor design updates and analysis.

ATZ, MILOSIVO↗
NASA NTRS2012

Creation of a Rapid High-Fidelity Aerodynamics Module for a Multidisciplinary Design Environment

In the traditional aerospace vehicle design process, each successive design phase is accompanied by an increment in the modeling fidelity of the disciplinary analyses being performed. This trend follows a corresponding shrinking of the design space as more and more design decisions are locked in. The correlated increase in knowledge about the design and decrease in design freedom occurs partly because increases in modeling fidelity are usually accompanied by significant increases in the computational expense of performing the analyses. When running high fidelity analyses, it is not usually feasible to explore a large number of variations, and so design space exploration is reserved for conceptual design, and higher fidelity analyses are run only once a specific point design has been selected to carry forward. The designs produced by this traditional process have been recognized as being limited by the uncertainty that is present early on due to the use of lower fidelity analyses. For example, uncertainty in aerodynamics predictions produces uncertainty in trajectory optimization, which can impact overall vehicle sizing. This effect can become more significant when trajectories are being shaped by active constraints. For example, if an optimal trajectory is running up against a normal load factor constraint, inaccuracies in the aerodynamic coefficient predictions can cause a feasible trajectory to be considered infeasible, or vice versa. For this reason, a trade must always be performed between the desired fidelity and the resources available. Apart from this trade between fidelity and computational expense, it is very desirable to use higher fidelity analyses earlier in the design process. A large body of work has been performed to this end, led by efforts in the area of surrogate modeling. In surrogate modeling, an up-front investment is made by running a high fidelity code over a Design of Experiments (DOE); once completed, the DOE data is used to create a surrogate model, which captures the relationships between input variables and responses into regression equations. Depending on the dimensionality of the problem and the fidelity of the code for which a surrogate model is being created, the initial DOE can itself be computationally prohibitive to run. Cokriging, a modeling approach from the field of geostatistics, provides a desirable compromise between computational expense and fidelity. To do this, cokriging leverages a large body of data generated by a low fidelity analysis, combines it with a smaller set of data from a higher fidelity analysis, and creates a kriging surrogate model with prediction fidelity approaching that of the higher fidelity analysis. When integrated into a multidisciplinary environment, a disciplinary analysis module employing cokriging can raise the analysis fidelity without drastically impacting the expense of design iterations. This is demonstrated through the creation of an aerodynamics analysis module in NASA’s OpenMDAO framework. Aerodynamic analyses including Missile DATCOM, APAS, and USM3D are leveraged to create high fidelity aerodynamics decks for parametric vehicle geometries, which are created in NASA’s Vehicle Sketch Pad (VSP). Several trade studies are performed to examine the achieved level of model fidelity, and the overall impact to vehicle design is quantified.

Aerodynamic Properties↗
NASA NTRS1992

Application of integrated structural analysis to the high speed civil transport

The Integrated Structural Analysis (ISA) system was developed in response to the need to define lightweight structures early in the design process for military aircraft. The objective of the ISA system is to permit rapid development of an optimized skin and big-bones structure that insures that the requirements of strength, dynamics, loads, and weight are met. While the system was originally developed for fighter aircraft, it is applicable to commercial transports or any other structures. The design requirements dictate the structural arrangement and sizing limitations to be imposed.

Saff, C. R.↗