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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 145 records · Page 8
All sourcesNASA NTRSDOE OSTI
NASA NTRS2010

Acoustic Noise Prediction of the Amine Swingbed ISS ExPRESS Rack Payload

Acoustics plays a vital role in maintaining the health, safety, and comfort of crew members aboard the International Space Station (ISS). In order to maintain this livable and workable environment, acoustic requirements have been established to ensure that ISS hardware and payload developers account for the acoustic emissions of their equipment and develop acoustic mitigations as necessary. These requirements are verified by an acoustic emissions test of the integrated hardware. The Amine Swingbed ExPRESS (Expedite the PRocessing of ExperimentS to Space) rack payload creates a unique challenge to the developers in that the payload hardware is transported to the ISS in phases, making an acoustic emissions test on the integrated flight hardware impossible. In addition, the payload incorporates a high back pressure fan and a diaphragm vacuum pump, which are recognized as significant and complex noise sources. In order to accurately predict the acoustic emissions of the integrated payload, the individual acoustic noise sources and paths are first characterized. These characterizations are conducted though a series of acoustic emissions tests on the individual payload components. Secondly, the individual acoustic noise sources and paths are incorporated into a virtual model of the integrated hardware. The virtual model is constructed with the use of hybrid method utilizing the Finite Element Acoustic (FEA) and Statistical Energy Analysis (SEA) techniques, which predict the overall acoustic emissions. Finally, the acoustic model is validated though an acoustic characterization test performed on an acoustically similar mock-up of the flight unit. The results of the validated acoustic model are then used to assess the acoustic emissions of the flight unit and define further acoustic mitigation efforts.

Welsh, David↗
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 NTRS1998

Finite Element Analysis of the Microisolation Valve

Agenda: Design and Use of the Microisolation Valve; Geometry of the Microisolation Valve; FEA Model Objectives; Results of the 10 and 50 microns Thick Wall Models; Results of the Thermally-Induced Stresses.

Microisolation Valve Finite Element Thermally-Indu↗
NASA NTRS2002

Dynamic Stability of Uncertain Laminated Beams Under Subtangential Loads

Because of the inherent complexity of fiber-reinforced laminated composites, it can be challenging to manufacture composite structures according to their exact design specifications, resulting in unwanted material and geometric uncertainties. In this research, we focus on the deterministic and probabilistic stability analysis of laminated structures subject to subtangential loading, a combination of conservative and nonconservative tangential loads, using the dynamic criterion. Thus a shear-deformable laminated beam element, including warping effects, is derived to study the deterministic and probabilistic response of laminated beams. This twenty-one degrees of freedom element can be used for solving both static and dynamic problems. In the first-order shear deformable model used here we have employed a more accurate method to obtain the transverse shear correction factor. The dynamic version of the principle of virtual work for laminated composites is expressed in its nondimensional form and the element tangent stiffness and mass matrices are obtained using analytical integration The stability is studied by giving the structure a small disturbance about an equilibrium configuration, and observing if the resulting response remains small. In order to study the dynamic behavior by including uncertainties into the problem, three models were developed: Exact Monte Carlo Simulation, Sensitivity Based Monte Carlo Simulation, and Probabilistic FEA. These methods were integrated into the developed finite element analysis. Also, perturbation and sensitivity analysis have been used to study nonconservative problems, as well as to study the stability analysis, using the dynamic criterion.

Goyal, Vijay K.↗
NASA NTRS2004

Design/Analysis of Metal/Composite Bonded Joints for Survivability at Cryogenic Temperatures

A major design and analysis challenge for the JWST ISM structure is the metal/composite bonded joints that will be required to survive down to an operational ultra-low temperature of 30K (-405 F). The initial and current baseline design for the plug-type joint consists of a titanium thin walled fitting (1-3mm thick) bonded to the interior surface of an M555/954-6 composite truss square tube with an axially stiff biased lay-up. Metallic fittings are required at various nodes of the truss structure to accommodate instrument and lift-point bolted interfaces. Analytical experience and design work done on metal/composite bonded joints at temperatures below liquid nitrogen are limited and important analysis tools, material properties, and failure criteria for composites at cryogenic temperatures are virtually nonexistent. Increasing the challenge is the difficulty in testing for these required tools and parameters at 30K. A preliminary finite element analysis shows that failure due to CTE mismatch between the biased composite and titanium or aluminum is likely. Failure is less likely with Invar, however an initial mass estimate of Invar fittings demonstrates that Invar is not an automatic alternative. In order to gain confidence in analyzing and designing the ISM joints, a comprehensive joint development testing program has been planned and is currently running. The test program is designed for the correlation of the analysis methodology, including tuning finite element model parameters, and developing a composite failure criterion for the effect of multi-axial composite stresses on the strength of a bonded joint at 30K. The testing program will also consider stress mitigation using compliant composite layers and potential strength degradation due to multiple thermal cycles. Not only will the finite element analysis be correlated to the test data, but the FEA will be used to guide the design of the test. The first phase of the test program has been completed and the preliminary analysis has been revisited based on the test data In this work, we present an overview of the test plan, results today, and resulting design improvements.

Bartoszyk, Andrew E.↗
NASA NTRS2020

Design and Analysis of Buckling-Critical Large-Scale Sandwich Composite Cylindrical Test Articles

It has long been established in the literature that the buckling response of thin-shell structures can be very sensitive to the presence of small geometric and loading imperfections. The Shell Buckling Knockdown Factor Project (SBKF) was established by the NASA Engineering and Safety Center (NESC) to develop analysis-based shell buckling design recommendations for stiffened-metallic and composite launch-vehicle shell structures. Large-scale buckling tests were used to validate the modeling and analysis methods applied in developing these analysis-based recommendations. Herein, the test article design methodology for 8-ft-diameter, honeycomb-core sandwich composite cylinder validation tests is discussed and cylinder designs are presented. In this methodology, first, the sandwich composite design space was defined using several nondimensional parameters, and the desired test article design space was determined by examining the designs of launch-vehicle cylinder structures. Essentially all test article designs within certain design parameters were generated and then downselected based on simple closed-form failure calculations and the nondimensional design-space parameters. Four of these designs that spanned a significant portion of the design space of interest and had global buckling as the first predicted failure mode were selected and subjected to higher-fidelity finite element analyses (FEAs): shell-element-based analyses, axisymmetric-element-based analyses, and global-local analyses. The analysis flow discussed in this report supported the design objective. As the analysis flow progressed, designs were downselected so the fidelity of the analysis methods, and consequently their computational cost and accuracy, was increased. The selection of the FEA types created an analysis framework where particular methods complemented each other and reduced the uncertainty of the predicted test article responses. The analysis results are illustrated using several designs when the computationally expeditious closed-form analysis stage is discussed. Once this stage is complete, the higher-fidelity FEA types are illustrated using one selected detailed test article design. Both perfect and imperfect test article geometries were considered.

Buckling↗
NASA NTRS2014

Engine Load Path Calculations - Project Neo

A mathematical model of the engine and actuator geometry was developed and used to perform a static force analysis of the system with the engine at different pitch and yaw angles. This analysis yielded the direction and magnitude of the reaction forces at the mounting points of the engine and actuators. These data were used to validate the selection of the actuators installed in the system and to design a new spherical joint to mount the engine on the test fixture. To illustrate the motion of the system and to further interest in the project, a functional 3D printed version of the system was made, featuring the full mobility of the real system.

geometry↗
NASA NTRSDate not supplied

RESIDUAL DEFORMATION ANALYSIS IN COMPOSITE SHELL STRUCTURES MANUFACTURED USING AUTOMATED FIBER PLACEMENT

The manufacturing of composites typically produces residual stresses that can significantly affect the final shape of the structure. The process of automated fiber placement (AFP) has become a prominent manufacturing technique in developing layups with tailored, variable stiffness morphology. The steered patterns of fiber tows with and without overlaps produce residual deformations that are distinctive from traditional layups. Digital image correlation was used to measure the AFP lamina coefficients of thermal expansion, which were incorporated into finite element analyses (FEA) to model the cooling phase of the cure cycle. The effects of nonlinear analysis and temperature-dependent lamina properties calculated using self-consistent field micromechanics, on the resulting residual deformation of shells, were also modeled. The predicted residual deformation was analyzed by considering out-of-roundness in cylindrical shells and compared to the experimental results. The shell FEA results were well-correlated with the overall deformed shape of the AFP cylinder with overlaps, while the shell FEA model of the AFP cylinder without overlaps did not show as good of qualitative match of the deformation pattern. Analytical correlation with measured results were insensitive to material softening at elevated temperatures, geometric nonlinearities, and variations in measured lamina thermal properties. To improve the accuracy of the residual deformation analysis, these results suggest that the thermo-chemical shrinkages preceding the cooldown should be considered, as well as possible variations in ply level microstructure due to the presence of the embedded fiber tow gaps and overlaps.

Composites↗
NASA NTRS2006

Advanced Damage Tolerance Analysis of International Space Station Pressure Wall Welds

EM20/MSFC has sponsored technology in the area of advanced damage tolerance analysis tools used to analyze the International Space Station (ISS) pressure wall welds. The ISS European modules did not receive non-destructive evaluation (NDE) inspection after proof test. In final assembly configuration, most welds could only be inspected from one side, and some welds were uninspectible. Therefore, advanced damage tolerance analysis was required to determine the critical initial flaw sizes and predicted safe life for the pressure wall welds. EM20 sponsored the development of a new finite element tools using FEA-Crack and WARP3D to solve the problem. This presentation gives a brief overview of the new analytical tools and the analysis results.

Allen, Phillip A.↗
NASA NTRS2007

Finite Element Analysis of Elastomeric Seals for LIDS

Objective: Create a means of evaluating seals w/o prototypes. Motivation: Cost Prototype 54" seal approx.$100k per seal pair FEA license + high end workstation approx. $30k per year. Development time: 6 months lead time for a new seal design Many designs per day (solution time <1 minute) Understanding: Difficult to experimentally measure strains, contact pressure profile, stresses, displacements

Oswald, Jay J.↗
NASA NTRS2019

Automatic Incorporation of Flaws into Cad and FEA Models Based On Measured NDE Data

Automatic incorporation of non-destructive evaluation (NDE) data into CAD and finite element (FE) models for structural analysis is essential for accurate residual-life and strength analyses of composite structures. Currently, two significant but independent challenges exist for incorporating NDE data in such analyses: interpretation of the NDE signals to locate and characterize the structural defects and the incorporation of that information into structural analysis tools. The first challenge will be addressed through linear inversion of calculated synthetic responses generated by a simulation engine to evaluate flaw size, location, and other characteristics. The second challenge will be addressed by building on prior and parallel defect modeling efforts to integrate suitable flaw models into the CAD/finite-element representation of a specimen. Ultrasonic NDE information is usually represented using C-Scans of time-of-flight or intensity information. Other modalities such as thermography and computed tomography (CT) could also be used to characterize the structure. This information will first be projected into material coordinates and then aligned with the specimen’s finite element mesh. The NDE data can then be incorporated by inserting flaw geometry into the CAD and FE analysis model and automatic modification of local material properties and boundary conditions. This process will enable the use of structural analysis tools even for practical modalities such as ultrasound and thermography which may not directly give accurate-enough geometric information to fully define the flaw. The full flaw characteristics will be inferred using prior expert and modeling knowledge to categorize flaw signatures. Outputs for this project will include demonstrated methods for creating structural analysis geometric models that incorporate flaw characterization information; these models can then be used directly in popular commercial FEA software. In addition, the primary deliverable for the project will include a software that will be able to automatically incorporate different kinds of flaws into an existing FE models. The models will be generated in standard file formats to enable direct import into the analysis software.

Adarsh Krishnamurthy↗
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 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 NTRS2010

Micromechanics-Based Structural Analysis (FEAMAC) and Multiscale Visualization within Abaqus/CAE Environment

A unified framework is presented that enables coupled multiscale analysis of composite structures and associated graphical pre- and postprocessing within the Abaqus/CAE environment. The recently developed, free, Finite Element Analysis--Micromechanics Analysis Code (FEAMAC) software couples NASA's Micromechanics Analysis Code with Generalized Method of Cells (MAC/GMC) with Abaqus/Standard and Abaqus/Explicit to perform micromechanics based FEA such that the nonlinear composite material response at each integration point is modeled at each increment by MAC/GMC. The Graphical User Interfaces (FEAMAC-Pre and FEAMAC-Post), developed through collaboration between SIMULIA Erie and the NASA Glenn Research Center, enable users to employ a new FEAMAC module within Abaqus/CAE that provides access to the composite microscale. FEA IAC-Pre is used to define and store constituent material properties, set-up and store composite repeating unit cells, and assign composite materials as sections with all data being stored within the CAE database. Likewise FEAMAC-Post enables multiscale field quantity visualization (contour plots, X-Y plots), with point and click access to the microscale i.e., fiber and matrix fields).

Arnold, Steven M.↗
NASA NTRS1997

Profiled Roller Stress/Fatigue Life Analysis Methodology and Establishment of an Appropriate Stress/Life Exponent

The objective of this work was to determine the three dimensional volumetric stress field, surface pressure distribution and actual contact area between a 0.50" square roller with different crown profiles and a flat raceway surface using Finite Element Analysis. The 3-dimensional stress field data was used in conjunction with several bearing fatigue life theories to extract appropriate values for stress-life exponents. Also, results of the FEA runs were used to evaluate the laminated roller model presently used for stress and life prediction.

Source record↗
NASA NTRSDate not supplied

LS-DYNA User-Defined Internal Ballistic Modeling

- LS-DYNA Explicit Finite Element Analysis software and CADPROG Internal Ballistic Analysis code are integrated as a single modeling tool to analyze pyro-mechanical devices. - Combining these two codes allows the ballistic calculations to be performed without modeling the propellant in an FEA mesh. At each LS-DYNA time step, CADPROG is analytically run using the kinematic data (stroke, velocity, chamber volume) fed back from the LS-DYNA simulation. Calculated pressure is then applied to a piston or any applicable surface mesh in LS-DYNA model interactively. -All external loads such as friction, damping loads, assisting/resisting loads, locking/unlocking loads are modeled in LS-DYNA and coupled with pressure loads from CADPROG to create a fully defined equation of motion -Both codes are written in Fortran 77. CADPROG is inserted in LS-DYNA source code as a user-defined subroutine and re-compiled to generate a custom executable.

pyrotechnics↗
NASA NTRSDate not supplied

LS-DYNA User-Defined Internal Ballistic Modeling

LS-DYNA Explicit Finite Element Analysis software and CADPROG Internal Ballistic Analysis code are integrated as a single modeling tool to analyze pyro-mechanical devices. Coupling these two codes allows the ballistic calculations to be performed without modeling the propellant in an FEA mesh. At each LS-DYNA time step, CADPROG is run analytically using the kinematic data (stroke, velocity, chamber volume) fed back from the LS-DYNA simulation. The calculated pressure is then applied to a piston or any applicable surface mesh in LS-DYNA model interactively. All external loads such as friction, damping loads, assisting/resisting loads, locking/unlocking loads are modeled in LS-DYNA and coupled with pressure loads from CADPROG to create a fully defined equation of motion Both codes are written in Fortran 77. CADPROG is integrated in the LS-DYNA source code as a user-defined subroutine and recompiled to generate a custom executable.

pyrotechnics↗