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NASA NTRS2004

An Interface Damage Model for the Simulation of Delamination Under Variable-Mode Ratio in Composite Materials

A thermodynamically consistent damage model for the simulation of progressive delamination under variable mode ratio is presented. The model is formulated in the context of the Damage Mechanics (DM). The constitutive equations that result from the variation of the free energy with damage are used to model the initiation and propagation of delamination. A new delamination initiation criterion is developed to assure that the formulation can account for changes in the loading mode in a thermodynamically consistent way. Interfacial penetration of two adjacent layers after complete decohesion is prevented by the formulation of the free energy. The model is implemented into the commercial finite element code ABAQUS by means of a user-written decohesion element. Finally, the numerical predictions given by the model are compared with experimental results.

Turon, Albert↗

NASA NTRS2004

Penalty-Based Interface Technology for Prediction of Delamination Growth in Laminated Structures

An effective interface element technology has been developed for connecting and simulating crack growth between independently modeled finite element subdomains (e.g., composite plies). This method has been developed using penalty constraints and allows coupling of finite element models whose nodes do not necessarily coincide along their common interface. Additionally, the present formulation leads to a computational approach that is very efficient and completely compatible with existing commercial software. The present interface element has been implemented in the commercial finite element code ABAQUS as a User Element Subroutine (UEL), making it easy to test the approach for a wide range of problems. The interface element technology has been formulated to simulate delamination growth in composite laminates. Thanks to its special features, the interface element approach makes it possible to release portions of the interface surface whose length is smaller than that of the finite elements. In addition, the penalty parameter can vary within the interface element, allowing the damage model to be applied to a desired fraction of the interface between the two meshes. Results for double cantilever beam DCB, end-loaded split (ELS) and fixed-ratio mixed mode (FRMM) specimens are presented. These results are compared to measured data to assess the ability of the present damage model to simulate crack growth.

Averill, Ronald C.↗

NASA NTRS2005

Measurement and Prediction of the Thermomechanical Response of Shape Memory Alloy Hybrid Composite Beams

Previous work at NASA Langley Research Center (LaRC) involved fabrication and testing of composite beams with embedded, pre-strained shape memory alloy (SMA) ribbons within the beam structures. That study also provided comparison of experimental results with numerical predictions from a research code making use of a new thermoelastic model for shape memory alloy hybrid composite (SMAHC) structures. The previous work showed qualitative validation of the numerical model. However, deficiencies in the experimental-numerical correlation were noted and hypotheses for the discrepancies were given for further investigation. The goal of this work is to refine the experimental measurement and numerical modeling approaches in order to better understand the discrepancies, improve the correlation between prediction and measurement, and provide rigorous quantitative validation of the numerical analysis/design tool. The experimental investigation is refined by a more thorough test procedure and incorporation of higher fidelity measurements such as infrared thermography and projection moire interferometry. The numerical results are produced by a recently commercialized version of the constitutive model as implemented in ABAQUS and are refined by incorporation of additional measured parameters such as geometric imperfection. Thermal buckling, post-buckling, and random responses to thermal and inertial (base acceleration) loads are studied. The results demonstrate the effectiveness of SMAHC structures in controlling static and dynamic responses by adaptive stiffening. Excellent agreement is achieved between the predicted and measured results of the static and dynamic thermomechanical response, thereby providing quantitative validation of the numerical tool.

Davis, Brian↗

NASA NTRS2005

Finite Element Analysis of Adaptive-Stiffening and Shape-Control SMA Hybrid Composites

The usage of shape memory materials has extended rapidly to many fields, including medical devices, actuators, composites, structures and MEMS devices. For these various applications, shape memory alloys (SMAs) are available in various forms: bulk, wire, ribbon, thin film, and porous. In this work, the focus is on SMA hybrid composites with adaptive-stiffening or morphing functions. These composites are created by using SMA ribbons or wires embedded in a polymeric based composite panel/beam. Adaptive stiffening or morphing is activated via selective resistance heating or uniform thermal loads. To simulate the thermomechanical behavior of these composites, a SMA model was implemented using ABAQUS user element interface and finite element simulations of the systems were studied. Several examples are presented which show that the implemented model can be a very useful design and simulation tool for SMA hybrid composites.

Gao, Xiu-Jie↗

NASA NTRS2005

Finite Element Analysis and Test Correlation of a 10-Meter Inflation-Deployed Solar Sail

Under the direction of the NASA In-Space Propulsion Technology Office, the team of L Garde, NASA Jet Propulsion Laboratory, Ball Aerospace, and NASA Langley Research Center has been developing a scalable solar sail configuration to address NASA's future space propulsion needs. Prior to a flight experiment of a full-scale solar sail, a comprehensive phased test plan is currently being implemented to advance the technology readiness level of the solar sail design. These tests consist of solar sail component, subsystem, and sub-scale system ground tests that simulate the vacuum and thermal conditions of the space environment. Recently, two solar sail test articles, a 7.4-m beam assembly subsystem test article and a 10-m four-quadrant solar sail system test article, were tested in vacuum conditions with a gravity-offload system to mitigate the effects of gravity. This paper presents the structural analyses simulating the ground tests and the correlation of the analyses with the test results. For programmatic risk reduction, a two-prong analysis approach was undertaken in which two separate teams independently developed computational models of the solar sail test articles using the finite element analysis software packages: NEiNastran and ABAQUS. This paper compares the pre-test and post-test analysis predictions from both software packages with the test data including load-deflection curves from static load tests, and vibration frequencies and mode shapes from vibration tests. The analysis predictions were in reasonable agreement with the test data. Factors that precluded better correlation of the analyses and the tests were uncertainties in the material properties, test conditions, and modeling assumptions used in the analyses.

Sleight, David W.↗

NASA NTRS2005

Structural Analysis of an Inflation-Deployed Solar Sail With Experimental Validation

Under the direction of the NASA In-Space Propulsion Technology Office, the team of L Garde, NASA Jet Propulsion Laboratory, Ball Aerospace, and NASA Langley Research Center has been developing a scalable solar sail configuration to address NASA s future space propulsion needs. Prior to a flight experiment of a full-scale solar sail, a comprehensive phased test plan is currently being implemented to advance the technology readiness level of the solar sail design. These tests consist of solar sail component, subsystem, and sub-scale system ground tests that simulate the vacuum and thermal conditions of the space environment. Recently, two solar sail test articles, a 7.4-m beam assembly subsystem test article and a 10-m four-quadrant solar sail system test article, were tested in vacuum conditions with a gravity-offload system to mitigate the effects of gravity. This paper presents the structural analyses simulating the ground tests and the correlation of the analyses with the test results. For programmatic risk reduction, a two-prong analysis approach was undertaken in which two separate teams independently developed computational models of the solar sail test articles using the finite element analysis software packages: NEiNastran and ABAQUS. This paper compares the pre-test and post-test analysis predictions from both software packages with the test data including load-deflection curves from static load tests, and vibration frequencies and mode shapes from structural dynamics tests. The analysis predictions were in reasonable agreement with the test data. Factors that precluded better correlation of the analyses and the tests were uncertainties in the material properties, test conditions, and modeling assumptions used in the analyses.

Sleight, David W.↗

NASA NTRS2005

In-Vacuum Photogrammetry of a 10-Meter Solar Sail

In July 2004, a 10-meter solar sail structure developed by L Garde, Inc. was tested in vacuum at the NASA Glenn 30-meter Plum Brook Space Power Facility in Sandusky, Ohio. The three main objections of the test were to demonstrate unattended deployment from a stowed configuration, to measure the deployed shape of the sail at both ambient and cryogenic room temperatures, and to measure the deployed structural dynamic characteristics (vibration modes). This paper summarizes the work conducted to fulfill the second test objective. The deployed shape was measured photogrammetrically in vacuum conditions with four 2-megapixel digital video cameras contained in custom made pressurized canisters. The canisters included high-intensity LED ring lights to illuminate a grid of retroreflective targets distributed on the solar sail. The test results closely matched pre-test photogrammetry numerical simulations and compare well with ABAQUS finite-element model predictions.

Meyer, Chris G.↗

NASA NTRS2005

Evaluation of Microbolometer-Based Thermography for Gossamer Space Structures

In August 2003, NASA's In-Space Propulsion Program contracted with our team to develop a prototype on-board Optical Diagnostics System (ODS) for solar sail flight tests. The ODS is intended to monitor sail deployment as well as structural and thermal behavior, and to validate computational models for use in designing future solar sail missions. This paper focuses on the thermography aspects of the ODS. A thermal model was developed to predict local sail temperature variations as a function of sail tilt to the sun, billow depth, and spectral optical properties of front and back sail surfaces. Temperature variations as small as 0.5 C can induce significant thermal strains that compare in magnitude to mechanical strains. These thermally induced strains may result in changes in shape and dynamics. The model also gave insight into the range and sensitivity required for in-flight thermal measurements and supported the development of an ABAQUS-coupled thermo-structural model. The paper also discusses three kinds of tests conducted to 1) determine the optical properties of candidate materials; 2) evaluate uncooled microbolometer-type infrared imagers; and 3) operate a prototype imager with the ODS baseline configuration. (Uncooled bolometers are less sensitive than cooled ones, but may be necessary because of restrictive ODS mass and power limits.) The team measured the spectral properties of several coated polymer samples at various angles of incidence. Two commercially available uncooled microbolometer imagers were compared, and it was found that reliable temperature measurements are feasible for both coated and uncoated sides of typical sail membrane materials.

Miles, Jonathan J.↗

NASA NTRS2004

Finite Element Modeling Used to Study Stress Distribution on the Foot

A method to study the stress distribution inside the forefoot during walking was developed at the Cleveland Clinic Foundation by a researcher from the NASA Glenn Research Center. In this method, a semiautomated process was outlined to create a three-dimensional, patient-specific, finite element model (FEM) of the forefoot using magnetic resonance images (MRI). The images were processed in Matlab using the k-nearest neighbor (k-NN) classification algorithm and Sobel edge detection to separate the different tissue types: bone, skin, fat, and muscle. This information was used to create curves and surfaces that were exported to an FEM preprocessor known as Truegrid. In Truegrid, eight-noded or brick elements were created by using surface mapping. The FEM was processed and postprocessed in Abaqus. Material properties of the models were obtained from past experiments such as fat pad confined compression, skin axial and biaxial tests, muscle in vivo compressive tests, and reference literature (bone properties). Nonlinear (hyperelastic) material models were used for the skin (epidermis and dermis), fat, and muscles; and a linear elastic model was used for the bones. Muscle activation during walking yielded uncertainties in the muscle material model since contracted muscles are stiffer than relaxed muscles. These uncertainties were resolved by performing a sensitivity analysis of the muscle material properties. The original properties were multiplied by arbitrary factors of 2, 3, 0.5, and 0.33. The strain and stress distributions, as well as the locations of peak values, were similar in all cases. The peak contact pressure P obtained for each case varied with respect to the applied factor f as follows:

Morales, Nelson↗

NASA NTRS2006

Design, fabrication, and testing of a SMA hybrid composite jet engine chevron

Control of jet noise continues to be an important research topic. Exhaust nozzle chevrons have been shown to reduce jet noise, but parametric effects are not well understood. Additionally, thrust loss due to chevrons at cruise suggests significant benefit from deployable chevrons. The focus of this study is development of an active chevron concept for the primary purpose of parametric studies for jet noise reduction in the laboratory and technology development to leverage for full scale systems. The active chevron concept employed in this work consists of a laminated composite structure with embedded shape memory alloy (SMA) actuators, termed a SMA hybrid composite (SMAHC). The actuators are embedded on one side of the middle surface such that thermal excitation generates a moment and deflects the structure. A brief description of the chevron design is given followed by details of the fabrication approach. Results from bench top tests are presented and correlated with numerical predictions from a model for such structures that was recently implemented in MSC.Nastran and ABAQUS. Excellent performance and agreement with predictions is demonstrated. Results from tests in a representative flow environment are also presented. Excellent performance is again achieved for both open- and closed-loop tests, the latter demonstrating control to a specified immersion into the flow. The actuation authority and immersion performance is shown to be relatively insensitive to nozzle pressure ratio (NPR). Very repeatable immersion control with modest power requirements is demonstrated.

Turner, Travis L.↗

NASA NTRS2006

Structural Analysis and Test Comparison of a 20-Meter Inflation-Deployed Solar Sail

Under the direction of the NASA In-Space Propulsion Technology Office, the team of L Garde, NASA Jet Propulsion Laboratory, Ball Aerospace, and NASA Langley Research Center has been developing a scalable solar sail configuration to address NASA s future space propulsion needs. Prior to a flight experiment of a full-scale solar sail, a comprehensive test program was implemented to advance the technology readiness level of the solar sail design. These tests consisted of solar sail component, subsystem, and sub-scale system ground tests that simulated the aspects of the space environment such as vacuum and thermal conditions. In July 2005, a 20-m four-quadrant solar sail system test article was tested in the NASA Glenn Research Center s Space Power Facility to measure its static and dynamic structural responses. Key to the maturation of solar sail technology is the development of validated finite element analysis (FEA) models that can be used for design and analysis of solar sails. A major objective of the program was to utilize the test data to validate the FEA models simulating the solar sail ground tests. The FEA software, ABAQUS, was used to perform the structural analyses to simulate the ground tests performed on the 20-m solar sail test article. This paper presents the details of the FEA modeling, the structural analyses simulating the ground tests, and a comparison of the pretest and post-test analysis predictions with the ground test results for the 20-m solar sail system test article. The structural responses that are compared in the paper include load-deflection curves and natural frequencies for the beam structural assembly and static shape, natural frequencies, and mode shapes for the solar sail membrane. The analysis predictions were in reasonable agreement with the test data. Factors that precluded better correlation of the analyses and the tests were unmeasured initial conditions in the test set-up.

Sleight, David W.↗

NASA NTRS2006

Time-dependent strains and stresses in a pumpkin balloon

This paper presents a study of pumpkin-shaped superpressure balloons, consisting of gores made from a thin polymeric film attached to high stiffness, meridional tendons. This type of design is being used for the NASA ULDB balloons. The gore film shows considerable time-dependent stress relaxation, whereas the behaviour of the tendons is essentially time-independent. Upon inflation and pressurization, the "instantaneous", i.e. linear-elastic strain and stress distribution in the film show significantly higher values in the meridional direction. However, over time, and due to the biaxial visco-elastic stress relaxation of the the material, the hoop strains increase and the meridional stresses decrease, whereas the remaining strain and stress components remain substantially unchanged. These results are important for a correct assessment of the structural integrity of a pumpkin balloon in a long-duration mission, both in terms of the material performance and the overall stability of the shape of the balloon. An experimental investigation of the time dependence of the biaxial strain distribution in the film of a 4 m diameter, 48 gore pumpkin balloon is presented. The inflated shape of selected gores has been measured using photogrammetry and the time variation in strain components at some particular points of these gores has been measured under constant pressure and temperature. The results show good correlation with a numerical study, using the ABAQUS finite-element package, that includes a widely used model of the visco-elastic response of the gore material:

Gerngross, T.↗

NASA NTRS2006

Verification of Numerical Solutions for the Deployment of the Highly Nonlinear MARSIS Antenna Boom Lenticular Joints

The MARSIS antenna booms are constructed using lenticular hinges between straight boom segments in a novel design which allows the booms to be extremely lightweight while retaining a high stiffness and well defined structural properties once they are deployed. Lenticular hinges are elegant in form but are complicated to model as they deploy dynamically and require highly specialized nonlinear techniques founded on carefully measured mechanical properties. Results from component level testing were incorporated into a highly specialized ADAMS model which employed an automated damping algorithm to account for the discontinuous boom lengths formed during the deployment. Additional models with more limited capabilities were also developed in both DADS and ABAQUS to verify the ADAMS model computations and to help better define the numerical behavior of the models at the component and system levels. A careful comparison is made between the ADAMS and DADS models in a series of progressive steps in order to verify their numerical results. Different trade studies considered in the model development are outlined to demonstrate a suitable level of model fidelity. Some model sensitivities to various parameters are explored using subscale and full system models. Finally, some full system DADS models are exercised to illustrate the limitations of traditional modeling techniques for variable geometry systems which were overcome in the ADAMS model.

Mars↗

NASA NTRS2006

A Framework for Performing Multiscale Stochastic Progressive Failure Analysis of Composite Structures

A framework is presented that enables coupled multiscale analysis of composite structures. The recently developed, free, Finite Element Analysis - Micromechanics Analysis Code (FEAMAC) software couples the Micromechanics Analysis Code with Generalized Method of Cells (MAC/GMC) with ABAQUS to perform micromechanics based FEA such that the nonlinear composite material response at each integration point is modeled at each increment by MAC/GMC. As a result, the stochastic nature of fiber breakage in composites can be simulated through incorporation of an appropriate damage and failure model that operates within MAC/GMC on the level of the fiber. Results are presented for the progressive failure analysis of a titanium matrix composite tensile specimen that illustrate the power and utility of the framework and address the techniques needed to model the statistical nature of the problem properly. In particular, it is shown that incorporating fiber strength randomness on multiple scales improves the quality of the simulation by enabling failure at locations other than those associated with structural level stress risers.

Bednarcyk, Brett A.↗

NASA NTRS2006

Porous Media Approach for Modeling Closed Cell Foam

In order to minimize boil off of the liquid oxygen and liquid hydrogen and to prevent the formation of ice on its exterior surface, the Space Shuttle External Tank (ET) is insulated using various low-density, closed-cell polymeric foams. Improved analysis methods for these foam materials are needed to predict the foam structural response and to help identify the foam fracture behavior in order to help minimize foam shedding occurrences. This presentation describes a continuum based approach to modeling the foam thermo-mechanical behavior that accounts for the cellular nature of the material and explicitly addresses the effect of the internal cell gas pressure. A porous media approach is implemented in a finite element frame work to model the mechanical behavior of the closed cell foam. The ABAQUS general purpose finite element program is used to simulate the continuum behavior of the foam. The soil mechanics element is implemented to account for the cell internal pressure and its effect on the stress and strain fields. The pressure variation inside the closed cells is calculated using the ideal gas laws. The soil mechanics element is compatible with an orthotropic materials model to capture the different behavior between the rise and in-plane directions of the foam. The porous media approach is applied to model the foam thermal strain and calculate the foam effective coefficient of thermal expansion. The calculated foam coefficients of thermal expansion were able to simulate the measured thermal strain during heat up from cryogenic temperature to room temperature in vacuum. The porous media approach was applied to an insulated substrate with one inch foam and compared to a simple elastic solution without pore pressure. The porous media approach is also applied to model the foam mechanical behavior during subscale laboratory experiments. In this test, a foam layer sprayed on a metal substrate is subjected to a temperature variation while the metal substrate is stretched to simulate the structural response of the tank during operation. The thermal expansion mismatch between the foam and the metal substrate and the thermal gradient in the foam layer causes high tensile stresses near the metal/foam interface that can lead to delamination.

Ghosn, Louis J.↗

NASA NTRS2007

A Framework for Performing Multiscale Stochastic Progressive Failure Analysis of Composite Structures

A framework is presented that enables coupled multiscale analysis of composite structures. The recently developed, free, Finite Element Analysis-Micromechanics Analysis Code (FEAMAC) software couples the Micromechanics Analysis Code with Generalized Method of Cells (MAC/GMC) with ABAQUS to perform micromechanics based FEA such that the nonlinear composite material response at each integration point is modeled at each increment by MAC/GMC. As a result, the stochastic nature of fiber breakage in composites can be simulated through incorporation of an appropriate damage and failure model that operates within MAC/GMC on the level of the fiber. Results are presented for the progressive failure analysis of a titanium matrix composite tensile specimen that illustrate the power and utility of the framework and address the techniques needed to model the statistical nature of the problem properly. In particular, it is shown that incorporating fiber strength randomness on multiple scales improves the quality of the simulation by enabling failure at locations other than those associated with structural level stress risers.

Bednarcyk, Brett A.↗

NASA NTRS2007

A Semi-Analytical Method for Determining the Energy Release Rate of Cracks in Adhesively-Bonded Single-Lap Composite Joints

A semi-analytical method for determining the strain energy release rate due to a prescribed interface crack in an adhesively-bonded, single-lap composite joint subjected to axial tension is presented. The field equations in terms of displacements within the joint are formulated by using first-order shear deformable, laminated plate theory together with kinematic relations and force equilibrium conditions. The stress distributions for the adherends and adhesive are determined after the appropriate boundary and loading conditions are applied and the equations for the field displacements are solved. Based on the adhesive stress distributions, the forces at the crack tip are obtained and the strain energy release rate of the crack is determined by using the virtual crack closure technique (VCCT). Additionally, the test specimen geometry from both the ASTM D3165 and D1002 test standards are utilized during the derivation of the field equations in order to correlate analytical models with future test results. The system of second-order differential field equations is solved to provide the adherend and adhesive stress response using the symbolic computation tool, Maple 9. Finite element analyses using J-integral as well as VCCT were performed to verify the developed analytical model. The finite element analyses were conducted using the commercial finite element analysis software ABAQUS. The results determined using the analytical method correlated well with the results from the finite element analyses.

Yang, Charles↗

NASA NTRS2006

Fatigue Life Methodology for Tapered Hybrid Composite Flexbeams

Nonlinear-tapered flexbeam specimens from a full-size composite helicopter rotor hub flexbeam were tested under combined constant axial tension and cyclic bending loads. Two different graphite/glass hybrid configurations tested under cyclic loading failed by delamination in the tapered region. A 2-D finite element model was developed which closely approximated the flexbeam geometry, boundary conditions, and loading. The analysis results from two geometrically nonlinear finite element codes, ANSYS and ABAQUS, are presented and compared. Strain energy release rates (G) associated with simulated delamination growth in the flexbeams are presented from both codes. These results compare well with each other and suggest that the initial delamination growth from the tip of the ply-drop toward the thick region of the flexbeam is strongly mode II. The peak calculated G values were used with material characterization data to calculate fatigue life curves for comparison with test data. A curve relating maximum surface strain to number of loading cycles at delamination onset compared well with the test results.

urri, Gretchen B.↗