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The research is reported concerning the development of a system of mathematical solutions and computer programs for one- and two-dimensional analyses for thermal stresses. Reports presented include: the investigation of thermal stress and buckling of tantalum and columbium sheet; and analysis of two dimensional thermal strains and metal movement during welding.
A method is presented for configuration optimization of finite element structures, given a reasonable initial geometry. The objective is to minimize weight or cost. Design variables include geometric as well as member sizing parameters. The number of elements and joints, and the element-joint relationships are prescribed and are not changed during the optimization process. However, the joint locations are changed. The structure is assumed to be linearly elastic and may be statically indeterminate. Multiple loading conditions are allowed. Constraints include limits on stiffness as well as strength. The method is demonstrated with application to truss design, subject to minimum size, strength, buckling, and displacement constraints. Major design improvements are achieved through configurations changes.
A program to develop lightweight beaded and tubular structural panels is described. Applications include external surfaces, where aerodynamically acceptable, and primary structure protected by heat shields. The design configurations were optimized and selected with a computer code which iterates geometric parameters to satisfy strength, stability, and weight constraints. Methods of fabricating these configurations are discussed. Nondestructive testing produced extensive combined compression, shear, and bending test data on local buckling specimens and large panels. The optimized design concepts offer 25 to 30% weight savings compared to conventional stiffened sheet construction.
The investigation reported demonstrates that in the case considered perturbation methods can be used in a straightforward manner to obtain reanalysis information. A perturbation formula for the buckling loads of a general shell of revolution is derived. The accuracy of the obtained relations and their range of application is studied with the aid of a specific example involving a particular stiffened shell of revolution.
A program was performed to determine the repairability of boron/aluminum aerospace structural components. During the program, a list of repair guidelines was prepared to aid in determining the proper repair techniques for a given structure. These guidelines included specifying types of repair material and their applicability, corrosion prevention procedures, design criteria, and inspection criteria. Six sets of boron/aluminum structural components were repaired and tested to compare as-fabricated and repaired performance. The specimens included a honeycomb-stiffened panel, elastically buckled tubes, a skin-stringer panel, a tube combining bending and tension, a splice joint specimen, and a tension field panel. All but one set of specimens, when repaired, exceeded the strength of the original specimens. The repairs resulted in an average weight increase per structure of 9% and an average performance increase of 27%. It is concluded that metal-matrix composite material, damaged in service, can be repaired by techniques not very different from those currently in use for conventional materials.
Potential weight efficiency for bead-stiffened panels has been demonstrated through fabrication and testing. Theoretically optimum design concepts were identified, and small specimens were tested under combined compression, shear, and bending to determine local buckling failure loads and to verify theory. Large optimized panels were then designed and tested under combined loads. Correlation of test data for large circular tubular panels with theory was conservative and consistent, and indicated reliable and acceptable design theory. Tests of fluted tubular panels indicated general instability failures at loads far below the design values due to nonlinear distortions. Further study of the fluted tubular configuration will be required if its potential weight efficiency is to be attained.
Six compatible computer programs analyze stress, vibration, and buckling characteristics of general shells of revolution.
System of processor programs performs stress, buckling, and vibrational analysis of large linear finite element systems in excess of 50,000 degrees of freedom, while minimizing processing cost, execution time, central memory storage, and secondary data storage requirements. Programs use sparse matrix solution techniques and other computational and data management procedures.
Simple, inexpensive, one-shot load device uses thin-walled soft-metal tube to absorb kinetic energy by controlled buckling.
Minimum mass honeycomb sandwich panels were sized for transmitting a concentrated load to a uniform reaction through various distances. The form skin gages were fully stressed with a finite element computer code. The panel general stability was evaluated with a buckling computer code labeled STAGS-B. Two skin materials were considered; aluminum and graphite-epoxy. The core was constant thickness aluminum honeycomb. Various panel sizes and load levels were considered. The computer generated data were generalized to allow preliminary least mass panel designs for a wide range of panel sizes and load intensities. An assessment of panel fabrication cost was also conducted. Various comparisons between panel mass, panel size, panel loading, and panel cost are presented in both tabular and graphical form.
Results for cylindrical configurations using the STAGS computer program were presented. Discontinuities were imposed upon the shell's skin by incorporating symmetrical cutout openings. In addition, the surface is stiffened with both stringer and ring-stringer arrangements. The cutout problem has been shown to be highly nonlinear for smooth surface shells, but it was found that bifurcation and collapse loads are close when one is considering stiffened skin configurations. In order to arrive at this conclusion, it was necessary to evaluate the following: (1) comparison between smeared and discrete stiffener theory for linear solutions, (2) numerical finite difference convergence as directed toward buckling determination, (3) collapse load results with the various skin stiffeners. A linear bifurcation study relating to stiffening effects around cutout areas present within stringer and ring-stringer shell surfaces was included. Comparisons were made between a variety of geometric positions considering cutout frame and thickened skin additions.
Research on the optimization of wing structures under multiple constraint such as strength, displacement, buckling, flutter, and divergence limits is reported. Advances were made in improving mathematical programming techniques as well as in improving the efficiency of constraint calculation. The WIDOWAC (Wing Design Optimization With Aeroelastic Constraints) computer program served as the main vehicle for this research. The methods developed were implemented in a general user oriented finite element program.
The attrition assessment of the aft segments of Solid Rocket Motor due to water impact requires the establishment of a correlation between loading occurrences and structural capability. Each discrete load case, as identified by the water impact velocities and angle, varies longitudinally and radially in magnitude and distribution of the external pressure. The distributions are further required to be shifted forward or aft one-fourth the vehicle diameter to assure minimization of the effect of test instrumentation location for the load determinations. The asymmetrical load distributions result in large geometric nonlinearities in structural response. The critical structural response is progressive buckling of the case. Discrete stiffeners have been added to these aft segments to aid in gaining maximum structural capability for minimum weight addition for resisting these loads. This report presents the development of the attrition assessment of the aft segments and includes the rationale for eliminating all assessable conservatisms from this assessment.
The functions and operating rules of the SPAR system, which is a group of computer programs used primarily to perform stress, buckling, and vibrational analyses of linear finite element systems, were given. The following subject areas were discussed: basic information, structure definition, format system matrix processors, utility programs, static solutions, stresses, sparse matrix eigensolver, dynamic response, graphics, and substructure processors.
The development of the tridiagonal reduction method and its implementation in NASTRAN are described for real eigenvalue analysis as typified by structural vibration and buckling problems. This method is an automatic matrix reduction scheme whereby the eigensolutions in the neighborhood of a specified point in the eigenspectrum can be accurately extracted from a tridiagonal eigenvalue problem whose order is much lower than that of the full problem. The process is effected without orbitrary lumping of masses or other physical quantities at selected node points and thus avoids one of the basic weaknesses of other techniques.
Some examples in which the high-speed computer has been used to improve the static stability analysis capability for general shells are examined. The fundamental concepts of static stability are reviewed with emphasis on the differences between linear bifurcation buckling and nonlinear collapse. The analysis is limited to the stability of conservative systems. Three examples are considered. The problem of cylinders subjected to bending loads is used as an example to illustrate that a simple structure can have a sufficiently complicated nonlinear behavior to require a computer analysis for accurate results. An analysis of the problems involved in the modeling of stiffening elements in plate and shell structures illustrates the necessity that the analyst recognizes all important deformation modes. The stability analysis of the Skylab structure indicates the size of problems that can be solved with current state-of-the-art capability.
The advantageous structural uses of advanced filamentary composites are demonstrated by design, fabrication, and test of three boron-epoxy reinforced C-130 center wing boxes. The advanced development work necessary to support detailed design of a composite reinforced C-130 center wing box was conducted. Activities included the development of a basis for structural design, selection and verification of materials and processes, manufacturing and tooling development, and fabrication and test of full-scale portions of the center wing box. Detailed design drawings, and necessary analytical structural substantiation including static strength, fatigue endurance, flutter, and weight analyses are considered. Some additional component testing was conducted to verify the design for panel buckling, and to evaluate specific local design areas. Development of the cool tool restraint concept was completed, and bonding capabilities were evaluated using full-length skin panel and stringer specimens.