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At least 163 records · Page 9

Design Optimization and Analysis of a Composite Honeycomb Intertank

Intertanks, the structure between tanks of launch vehicles, are prime candidates for weight reduction of rockets. This paper discusses the optimization and detailed analysis of a 96 in (2.44 m) diameter, 77 in (1.85 m) tall intertank. The structure has composite face sheets and an aluminum honeycomb core. The ends taper to a thick built up laminate for a double lap bolted shear joint. It is made in 8 full length panels joined with bonded double lap joints. The nominal load is 4000 lb/in (7 x 10(exp 5) N/m). Optimization is by Genetic Algorithm and minimizes weight by varying C, core thickness, number and orientation of acreage and buildup plies, and the size, number and spacing of bolts. A variety of cases were run with populations up to 2000 and chromosomes as long as 150 bits. Constraints were buckling, face stresses (normal, shear, wrinkling and dimpling, bolt stress, and bolt hole stresses (bearing, net tension, wedge splitting, shear out and tension/shear out). Analysis is by a combination of theoretical solutions and empirical data. After optimization, a series of coupon tests were performed in conjunction with a rigorous analysis involving a variety of finite element models. The analysis and test resulted in several small changes to the optimized design. The intertank has undergone a 250,000 lb (1.1 x 10(exp 6) N) limit load test and been mated with a composite liquid hydrogen tank. The tank/intertank unit is being installed in a test stand where it will see 200 thermal/load cycles. Afterwards the intertank will be demated and loaded in compression to failure.

Finckenor, Jeffrey

Design Optimization and Analysis of a Composite Honeycomb Intertank

Intertanks, the structure between tanks of launch vehicles, are prime candidates for weight reduction of rockets. This paper discusses the optimization and detailed follow up analysis and testing of a 96 in. diameter, 77 in. tall intertank. The structure has composite face sheets with an aluminum honeycomb core. The ends taper to a thick built up laminate for a double lap bolted splice joint interface. It is made in 8 full length panels joined with bonded double lap joints. The nominal load is 4000 lb/in. Optimization is by Genetic Algorithm and minimizes weight by varying core thickness, number and orientation of acreage and buildup plies, and the size, number and spacing of bolts. A variety of design cases were run with populations up to 2000 and chromosomes as long as 150 bits. Constraints were buckling; face stresses (normal, shear, wrinkling and dimpling); bolt stress; and bolt hole stresses (bearing, net tension, wedge splitting, shear out and tension/shear out). Analysis is by a combination of elasticity solutions and empirical data. After optimization, a series of coupon tests were performed in conjunction with a rigorous analysis involving a variety of finite element models. This analysis and testing resulted in several small changes to the optimized design. The equation used for hole bearing strength was found to be inadequate, resulting in thicker ends. The core thickness increased 0.05", and potting compound was added in the taper to strengthen the facesheet bond. The intertank has undergone a 250,000 lb limit load test and been mated with a composite liquid hydrogen tank. The tank/intertank unit is being installed in a test stand where it will see 200 thermal/load cycles. Afterwards the intertank will be demated and loaded in compression to failure.

Finckenor, Jeff

Computer and photogrammetric general land use study of central north Alabama

The object of this report is to acquaint potential users with two computer programs, developed at NASA, Marshall Space Flight Center. They were used in producing a land use survey and maps of central north Alabama from Earth Resources Technology Satellite (ERTS) digital data. The report describes in detail the thought processes and analysis procedures used from the initiation of the land use study to its completion, as well as a photogrammetric study that was used in conjunction with the computer analysis to produce similar land use maps. The results of the land use demonstration indicate that, with respect to computer time and cost, such a study may be economically and realistically feasible on a statewide basis.

Jayroe, R. R.

Residual stresses of thin, short rectangular plates

The analysis of the residual stresses in thin, short rectangular plates is presented. The analysis is used in conjunction with a shadow moire interferometry technique by which residual stresses are obtained over a large spatial area from a strain measurement. The technique and analysis are applied to a residual stress measurement of polycrystalline silicon sheet grown by the edge-defined film growth technique.

Andonian, A. T.

Small Particle Impact Damage on Different Glass Substrates

Impact experiments using sand particles were performed on four distinct glass substrates. The sand particles were characterized using the X-Ray micro-CT technique; 3-D reconstruction of the particles was followed by further size and shape analyses. High-speed video footage from impact tests was used to calculate the incoming and rebound velocities of the individual sand impact events, as well as particle volume. Further, video analysis was used in conjunction with optical and scanning electron microscopy to relate the incoming velocity and shape of the particles to subsequent fractures, including both radial and lateral cracks. Analysis was performed using peridynamic simulations.

Waxman, R.

An NDE Approach for Characterizing Quality Problems in Polymer Matrix Composites

Polymer matrix composite (PMC) materials are periodically identified appearing optically uniform but containing a higher than normal level of global nonuniformity as indicated from preliminary ultrasonic scanning. One such panel was thoroughly examined by nondestructive (NDE) and destructive methods to quantitatively characterize the nonuniformity. The NDE analysis of the panel was complicated by the fact that the panel was not uniformly thick. Mapping of ultrasonic velocity across a region of the panel in conjunction with an error analysis was necessary to (1) characterize properly the porosity gradient that was discovered during destructive analyses and (2) account for the thickness variation effects. Based on this study, a plan for future NDE characterization of PMC's is presented to the PMC community.

Roth, Don J.

Variable-complexity aerodynamic-structural design of a high-speed civil transport wing

A variable-complexity strategy of combining simple and detailed analysis methods is presented for the design optimization of a high-speed civil transport (HSCT) wing. Two sets of results are shown: the aerodynamic design of the wing using algebraic weight equations for structural considerations, and optimization results of the internal wing structure for a fixed wing configuration. We show example results indicating that using simple analysis methods alone for the calculation of a critical constraint can allow an optimizer to exploit weaknesses in the analysis. The structural optimization results provide a valuable check for the weight equations used in the aerodynamic design. In addition, these results confirm the need for using simple, algebraic models in conjunction with more detailed analysis methods. A strategy of interlaced aerodynanic-structural design is proposed.

Hutchison, M. G.

Thermal Radiation Analyzer

Thermal Radiation Analyzer System TRASYS II solves radiation related aspects of thermal analysis problems. TRASYS II provides for calculation of internode radiation interchange data and for calculation of incident and absorbed heat rate data originating from environmental radiant heat sources. When TRASYS II used in conjunction with generalized thermal analysis program such as Systems Improved Numerical Differencing Analyzer (SINDA), any thermal problem expressed in terms of lumped parameter RC thermal network solved.

Vogt, R. A.

Effect of Fuel-Air Ratio, Inlet Temperature, and Exhaust Pressure on Detonation

An accurate determination of the end-gas condition was attempted by applying a refined method of analysis to experimental results. The results are compared with those obtained in Technical Report no. 655. The experimental technique employed afforded excellent control over the engine variables and unusual cyclic reproducibility. This, in conjunction with the new analysis, made possible the determination of the state of the end-gas at any instant to a fair degree of precision. Results showed that for any given maximum pressure the maximum permissible end-gas temperature increased as the fuel-air ratio was increased. The tendency to detonate was slightly reduced by an increase in residual gas content resulting from an increase in exhaust backpressure with inlet pressure constant.

Taylor, E S

Setting the Bar for the Replacement of the Probability of Collision Metric

To date, satellite conjunction assessment (CA) risk analysis has largely embraced the probability of collision (Pc) as the omnibus metric to evaluate collision likelihood, and its use in such assessments has mostly been straightforward: at the point at which a conjunction mitigation decision is required, the calculated Pc is compared to a threshold; and if the calculated Pc exceeds that threshold, then a mitigation action is warranted. With only minor variation, this approach is employed by major CA risk assessment centers (e.g., NASA, EUSST, CNES, JAXA) and is advanced as the preferred method in the published CA best practices handbooks. Despite this near unanimity of operational practice, there is a major strain of secondary literature critical of the Pc and willing to propose alternatives. Alfano (2005) pointed out the ability of the Pc to underrepresent the risk in certain situations and counselled a maximum Pc construct. Carpenter (2017, 2019) reiterated this criticism and proposed using instead a confidence interval on the miss distance. Balch et al. (2019) identified what they argued was a defect in the entire Bayesian Pc construct and believed that the use of a more conservative methodology based on covariance ellipsoid overlap was necessary. Delande (2022) introduced the framework of collision “plausibility” to the risk assessment process and sketched out how this might be used operationally. Elkantassi (2022) published a full development of the miss distance confidence interval approach and applied it to several worked examples. While these different approaches to collision risk assessment do differ in their details, they all converge on two central points: first, the Pc’s failure to give an adequate expression of the risk in dilution region situations is a fatal flaw; and second, a conjunction should be presumed risky and in need of mitigation until the evidence of the situation can establish otherwise. These criticisms, if correct, would counsel a number of modifications to current CA operational practice; as such, they force a re-examination of fundamental aspects of the CA problem, including the following: 1. Is the CA risk assessment a probability problem, a statistics problem, or something else? 2. If it is a statistics problem, does it lend itself naturally to a hypothesis test construction? 3. If it can be construed as a hypothesis test, what form should the null hypothesis take, to wit: what constraints exist on the choice of the null hypothesis, what selections are in best alignment with all of the attendant parameters of the problem, and what is implied philosophically by different choices? 4. What are the implications of using the different proposed risk assessment parameters for CA? This question should be answered both in determining how frequently the dilution region situation cited by the critics of the Pc actually appears in an operationally significant manner and the missed detection and false alarm rates of all of the proposed risk assessment metrics, compared both to the Pc and to each other. This paper explores and offers preliminary answers to the above questions, presenting a researched treatment of the philosophical nature of the CA problem and the null hypothesis choice that achieves the greatest consistency with all of the different aspects of operational CA conduct. It then profiles all of the different proposed risk assessment metrics enumerated in the earlier paragraph against an extremely large database of conjunction events at both the 550km and 700km altitudes. The combination of the philosophical exploration of the CA problem and the results of the profiling activity articulates what a risk assessment metric will need to demonstrate, in terms of both innate construction and performance, in order to be a true competitor to the Pc.

conjunction assessment

SRM Internal Flow Tests and Computational Fluid Dynamic Analysis: Titan, ASRM, and Subscale Motor Analyses - Volume 3

A computational fluid dynamics (CFD) analysis has been performed on the aft slot region of the Titan 4 Solid Rocket Motor Upgrade (SRMU). This analysis was performed in conjunction with MSFC structural modeling of the propellant grain to determine if the flow field induced stresses would adversely alter the propellant geometry to the extent of causing motor failure. The results of the coupled CFD/stress analysis have shown that there is a continual increase of flow field resistance at the aft slot due to the aft segment propellant grain being progressively moved radially toward the centerline of the motor port. This 'bootstrapping' effect between grain radial movement and internal flow resistance is conducive to causing a rapid motor failure.

Source record

A CFD/CSD Interaction Methodology for Aircraft Wings

With advanced subsonic transports and military aircraft operating in the transonic regime, it is becoming important to determine the effects of the coupling between aerodynamic loads and elastic forces. Since aeroelastic effects can contribute significantly to the design of these aircraft, there is a strong need in the aerospace industry to predict these aero-structure interactions computationally. To perform static aeroelastic analysis in the transonic regime, high fidelity computational fluid dynamics (CFD) analysis tools must be used in conjunction with high fidelity computational structural fluid dynamics (CSD) analysis tools due to the nonlinear behavior of the aerodynamics in the transonic regime. There is also a need to be able to use a wide variety of CFD and CSD tools to predict these aeroelastic effects in the transonic regime. Because source codes are not always available, it is necessary to couple the CFD and CSD codes without alteration of the source codes. In this study, an aeroelastic coupling procedure is developed which will perform static aeroelastic analysis using any CFD and CSD code with little code integration. The aeroelastic coupling procedure is demonstrated on an F/A-18 Stabilator using NASTD (an in-house McDonnell Douglas CFD code) and NASTRAN. In addition, the Aeroelastic Research Wing (ARW-2) is used for demonstration of the aeroelastic coupling procedure by using ENSAERO (NASA Ames Research Center CFD code) and a finite element wing-box code (developed as part of this research).

Bhardwaj, Manoj K.

A-Train Data Depot: Integrating and Exploring Data Along the A-Train Tracks

The immense potential for new science findings as a result of inter-instrument data analysis has led to the development of a new data portal at GSFC: the A-train Data Depot. The power and utility of this new service to the general public is amplified immensely when the archived data are used in conjunction with online data analysis services like Giovanni. This presentation details some of the challenges of data usage from multiple distinct missions and how the tool sets we have developed can help to overcome these challenges, considerably cut down on analysis overhead and promote science exploration in an otherwise very challenging arena.

Leptoukh, G.

Assessment and Validation of Collision "Consequence" Method of Assessing Orbital Regime Risk Posed by Potential Satellite Conjunctions

Collision risk management theory requires a thorough assessment of both the likelihood and consequence of potential collision events. Satellite conjunction risk assessment has produced a highly-developed theory for assessing the likelihood of collision but neglects to account for the consequences of a given collision. While any collision may compromise the operational survival of a spacecraft, the amount of debris produced by the potential collision, and therefore the degree to which the orbital corridor may be compromised, can vary greatly among satellite conjunctions. Previous studies leveraged work on satellite collision modeling to develop a method to estimate whether a particular collision is likely to produce a relatively large or relatively small amount of resultant debris. The approximation of the number of debris pieces is dependent on a mass estimation process for the secondary objects utilizing the radar cross section of said object. This study examines the validity of the mass estimation process and establishes uncertainty bounds on the secondary object mass, which will be used to best approximate the possible consequences of a potential collision. This process is then applied to a large set of historical conjunctions to assess the frequency at which possible collisions may significantly augment the orbital debris environment in operational spacecraft.

Collision Consequence

Dominant modes of mechanical systems

To obtain a reduced model of a mechanical system, one can identify the dominant modes and retain those as the reduced model. Two widely used schemes for selection of dominant modes are modal cost analysis (MCA) and balancing, but neither of these methods guarantees that the model error is small, where model error measures the difference between the output of the full model and the output of the reduced model. The authors introduce a set of coordinates called pseudo uncorrelated modal coordinates (PUnc) that can be used in conjunction with component cost analysis to select dominant modes yielding a reduced model with minimum model error. Furthermore, unlike MCA and balancing, the accuracy of the reduced model (the model error) in PUnc coordinates can be evaluated before reduction.

Breida, M.

Predicting Selective Laser Printing Print Quality of Polymer Powders through Melt Flow Index

Selective Laser Sintering (SLS) uses a precisely controlled laser to fuse polymer powder to build complex 3D shapes. While SLS covers a wide application space, the processing knowledge of polymer powder is limited, restricting the number of commercial powders available. This study serves to expand the processing knowledge of polypropylene and polyethylene in parallel with a “mature” SLS feedstock, nylon, through melt flow index (MFI) characterization. Differential Scanning Calorimetry (DSC) was used to explore the sintering window of the polymers. Polyethylene and polypropylene exhibited a relatively narrow sintering window between 4 – 5 °C, whereas the sintering window of nylon was much wider, between 23 – 24 °C. This suggests that the print quality between polyethylene and polypropylene would be similar; however, X-ray computed tomography revealed a higher volume of print defects, voids, and de lamination in polyethylene than in polypropylene. MFI analysis provided additional insight into the difference in print quality, as the MFI of polyethylene was 7.16 g/10 min, 9.95 g/10 min for polypropylene, and 17.23 g/10 min for nylon. MFI is inversely correlated to melt viscosity, and a low melt viscosity is desired for proper coalescing between the layers and particles. These results suggest that MFI is a promising tool, in conjunction with traditional thermal analysis, for screening candidate powder feedstocks for SLS and optimization of print parameters for novel powders.

36 MATERIALS SCIENCE

Implementation Recommendations and Usage Boundaries for the Two-Dimensional Probability of Collision Calculation

The two-dimensional (2D) probability of collision (𝑃𝑐) estimation method relies on several assumptions that must be satisfied for accurate results. Monte Carlo analysis of ~44,000 conjunctions indicates that 2D-𝑃(sub 𝑐) pro-vides accurate estimates for most typical conjunctions, but occasionally underestimates 𝑃(sub 𝑐) significantly, indicating an assumption violation. A test to detect large-amplitude underestimation inaccuracies can be based on how much “offset-from-TCA” 2D-𝑃(sub 𝑐) values vary during a well-defined time interval bracketing closest approach. The test successfully detects all large-amplitude 2D-𝑃(sub 𝑐) underestimations found to date, but with a high false-alarm rate. The analysis also provides implementation recommendations and usage boundaries for the 2D-𝑃(sub 𝑐) method.

Hall, Doyle T.

Implementation Recommendations and Usage Boundaries for the Two-Dimensional Probability of Collision Calculation

The two-dimensional (2D) probability of collision (𝑃𝑐) estimation method relies on several assumptions that must be satisfied for accurate results. Monte Carlo analysis of ~44,000 conjunctions indicates that 2D-𝑃(sub 𝑐) pro-vides accurate estimates for most typical conjunctions, but occasionally underestimates 𝑃(sub 𝑐) significantly, indicating an assumption violation. A test to detect large-amplitude underestimation inaccuracies can be based on how much “offset-from-TCA” 2D-𝑃(sub 𝑐) values vary during a well-defined time interval bracketing closest approach. The test successfully detects all large-amplitude 2D-𝑃(sub 𝑐) underestimations found to date, but with a high false-alarm rate. The analysis also provides implementation recommendations and usage boundaries for the 2D-𝑃(sub 𝑐) method.

Hall, Doyle T.