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At least 163 records · Page 9

The in situ transverse lamina strength of composite laminates

The objective of the work reported in this presentation is to determine the in situ transverse strength of a lamina within a composite laminate. From a fracture mechanics standpoint, in situ strength may be viewed as constrained cracking that has been shown to be a function of both lamina thickness and the stiffness of adjacent plies that serve to constrain the cracking process. From an engineering point of view, however, constrained cracking can be perceived as an apparent increase in lamina strength. With the growing need to design more highly loaded composite structures, the concept of in situ strength may prove to be a viable means of increasing the design allowables of current and future composite material systems. A simplified one dimensional analytical model is presented that is used to predict the strain at onset of transverse cracking. While it is accurate only for the most constrained cases, the model is important in that the predicted failure strain is seen to be a function of a lamina's thickness d and of the extensional stiffness bE theta of the adjacent laminae that constrain crack propagation in the 90 deg laminae.

Flaggs, D. L.↗

Laboratory experience with voltage breakdown

Voltage breakdown failures in photovoltaic module electrical insulations lead to loss of entire source circuits and require costly maintenance and replacement. Avoiding such catastrophes requires that modules be designed so that voltage breakdown either never occurs or occurs so rarely that it affects the least life cycle energy costs insignificantly. To achieve this desired balance of cost and reliability, the module design engineer must understand the failure mechanisms and use data on materials and failue rates to suppress or retard them. Recently obtained failure mechanism information, rate data and materials property data and a qualitative model of module failure prediction are presented.

Mon, G. R.↗

Investigation of non-linear contact for a clearance-fit bolt in a graphite/epoxy laminate

Numerous analytical studies have been published for the nonlinear load-contact variations in clearance-fit bolted joints. In these studies, stress distributions have been obtained and failure predictions have been made. However, very little experimental work has been reported regarding the contact or the stresses. This paper describes a fiber-optic technique for measuring the angle of contact in a clearance-fit bolt-loaded hole. Measurements of the contact angle have been made in a quasi-isotropic graphite-epoxy laminate by the optical as well as an electrical technique, and the results have been compared with those obtained from a finite-element analysis. The results from the two experimental techniques show excellent agreement; the finite-element results show some discrepancy, probably due to the interfacial frictions.

Prabhakaran, R.↗

Traveling-wave maser closed-cycle refrigerator data acquisition and display system

A data acquisition and display system that automatically monitors the performance of the 4.5-K closed-cycle refrigerators used to cryogenically cool traveling-wave masers is described. The system displays and stores operating parameters for the purpose of providing status information, failure prediction, and analysis. A prototype of this system will be installed at Deep Space Network 12 in the near future. The advantages of using commercial data acquisition hardware with installed operating systems and BASIC programs for this application are discussed.

Fowler, L.↗

Hubble Space Telescope servicing - Experience base for a new era

An account is given of the conceptual evolution of the Hubble Space Telescope's (HST) maintenance methodology, and the belated recognition of its long-term support requirements, as well as measures conceived for the extension of this orbiting observatory's service life, and the prospective benefits derivable by comparable programs from HST experience. Attention is given to HST cost and capability tradeoffs, the maintenance concept's definition, the integrated logistic support planning instituted by the program and its failure-prediction methods, as well as the institutional support base employed.

Welch, James C.↗

Efficient 3-D finite element failure analysis of compression loaded angle-ply plates with holes

Finite element stress analysis and the tensor polynomial failure criterion predict that failure always initiates at the interface between layers on the hole edge for notched angle-ply laminates loaded in compression. The angular location of initial failure is a function of the fiber orientation in the laminate. The dominant stress components initiating failure are shear. It is shown that approximate symmetry can be used to reduce the computer resources required for the case of unaxial loading.

Burns, S. W.↗

Nonlinear response of a blade-stiffened graphite-epoxy panel with a discontinuous stiffener: Work in progress

The problem of calculating detailed stress distributions around discontinuities in buckled, composite structural components for use with the various analytical failure prediction techniques has not been thoroughly explored. The purpose here is the application of computational methods to the detailed stress analysis problem which is the focus of this session of the workshop. One approach to uncovering the difficulties of this type of analysis and to providing specific directions for future research in this area is a direct attack on the problem using currently available analysis tools. A candidate problem has been selected and experiences from calculating its structural response are described.

Knight, Norman F., Jr.↗

An improved error analysis of finite element solutions for postbuckled plates

The accurate calculation of stresses at boundaries and interfaces where FEM analysis may be unreliable is presently undertaken by an error analysis that derives a continuous approximation to discrete finite-element data, which can be differentiated to compute continuous stresses for component-failure predictions. An evaluation is conducted of this approximation in the context of the nonlinear PDEs. A novel interpolation formula which is a simple modification of the double Fourier sine series is used to reduce truncation errors near the rectangular plate boundary by means of an 'extended grid'. Results are presented from a FEM solution, a conventional double-Fourier series' continuous approximation, and a solution applying interpolation on the extended grid, which yields superior convergence properties near the plate boundaries.

Sistla, Rajaram↗

Error analysis of finite element results on plates with nonuniform grids

Discrete Dirac delta functions in two dimensions and the governing plate differential equations are used to produce continuous approximations from discrete finite-element data on nonuniform grids. The resulting continuous approximation when compared to the discrete data provides an error analysis. Moreover, the continuous approximation can be differentiated to compute continuous stresses needed for component failure prediction. Stresses can then be calculated accurately at boundaries and at interfaces where finite-element analysis alone may not provide reliable results. The continuous solution along with the differential equations also provides a residual error which is used in the error analysis. This is a unique feature of this approach. Two application examples of the procedure are provided. One example involves the linear response of a clamped square plate under uniform transverse load. Results from finite-element analysis and the continuous solution from the present analysis are compared to a closed-form elasticity solution. The continuous solution is used in a Zienkiewicz-Zhu error estimator to assess the performance of the present analysis. The continuous solution is observed to dramatically correct the finite-element results. In a second example, results for the nonlinear response of a stiffened panel are compared to the finite-element solution.

Sistla, Rajaram↗

Evaluation of advanced materials through experimental mechanics and modelling

Composite materials have been frequently used in aerospace vehicles. Very often defects are inherited during the manufacture and damages are inherited during the construction and services. It becomes critical to understand the mechanical behavior of such composite structure before it can be further used. One good example of these composite structures is the cylindrical bottle of solid rocket motor case with accidental impact damages. Since the replacement of this cylindrical bottle is expensive, it is valuable to know how the damages affects the material, and how it can be repaired. To reach this goal, the damage must be characterized and the stress/strain field must be carefully analyzed. First the damage area, due to impact, is surveyed and identified with a shearography technique which uses the principle of speckle shearing interferometry to measure displacement gradient. Within the damage area of a composite laminate, such as the bottle of solid rocket motor case, all layers are considered to be degraded. Once a lamina being degraded the stiffness as well as strength will be drastically decreased. It becomes a critical area of failure to the whole bottle. And hence the stress/strain field within and around a damage should be accurately evaluated for failure prediction. To investigate the stress/strain field around damages a Hybrid-Numerical method which combines experimental measurement and finite element analysis is used. It is known the stress or strain at the singular point can not be accurately measured by an experimental technique. Nevertheless, if the location is far away from the singular spot, the displacement can be found accurately. Since it reflects the true displacement field locally regardless of the boundary conditions, it is an excellent input data for a finite element analysis to replace the usually assumed boundary conditions. Therefore, the Hybrid-Numerical method is chosen to avoid the difficulty and to take advantage of both experimental technique and finite element analysis. Experimentally, the digital image correlation technique is employed to measure the displacement field. It is done by comparing two digitized images, before and after loading. Numerically, the finite element program, ABAQUS (version 5.2), is used to analyze the stress and strain field. It takes advantage of the high speed and huge memory size of modern supercomputer, CRAY Y-MP, at NASA Marshall Space Flight Center.

Yang, Yii-Ching↗

Mechanically fastened composite laminates subjected to combined bearing-bypass and shear loading

Bolts and rivets provide a means of load transfer in the construction of aircraft. However, they give rise to stress concentrations and are often the source and location of static and fatigue failures. Furthermore, fastener holes are prone to cracks during take-off and landing. These cracks present the most common origin of structural failures in aircraft. Therefore, accurate determination of the contact stresses associated with such loaded holes in mechanically fastened joints is essential to reliable strength evaluation and failure prediction. As the laminate is subjected to loading, the contact region, whose extent is not known, develops between the fastener and the hole boundary through this contact region, which consists of slip and no-slip zones due to friction. The presence of the unknown contact stress distribution over the contact region between the pin and the composite laminate, material anisotropy, friction between the pin and the laminate, pin-hole clearance, combined bearing-bypass and shear loading, and finite geometry of the laminate result in a complex non-linear problem. In the case of bearing-bypass loading in compression, this non-linear problem is further complicated by the presence of dual contact regions. Previous research concerning the analysis of mechanical joints subjected to combined bearing-bypass and shear loading is non-existent. In the case of bearing-bypass loading only, except for the study conducted by Naik and Crews (1991), others employed the concept of superposition which is not valid for this non-linear problem. Naik and Crews applied a linear finite element analysis with conditions along the pin-hole contact region specified as displacement constraint equations. The major shortcoming of this method is that the variation of the contract region as a function of the applied load should be known a priori. Also, their analysis is limited to symmetric geometry and material systems, and frictionless boundary conditions. Since the contact stress distribution and the contact region are not known a priori, they did not directly impose the boundary conditions appropriate for modelling the contact and on-contact regions between the fastener and the hole. Furthermore, finite element analysis is not suitable for iterative design calculations for optimizing laminate construction in the presence of fasteners under complex loading conditions. In this study, the solution method developed by Madenci and Ileri (1992a,b) has been extended to determine the contact stresses in mechanical joints under combined bearing-bypass and shear loading, and bearing-bypass loading in compression resulting in dual contact regions.

Madenci, Erdogan↗

Development of thermoplastic composite aircraft structures

Efforts focused on the use of thermoplastic composite materials in the development of structural details associated with an advanced fighter fuselage section with applicability to transport design. In support of these designs, mechanics developments were conducted in two areas. First, a dissipative strain energy approach to material characterization and failure prediction, developed at the Naval Research Laboratory, was evaluated as a design/analysis tool. Second, a finite element formulation for thick composites was developed and incorporated into a lug analysis method which incorporates pin bending effects. Manufacturing concepts were developed for an upper fuel cell cover. A detailed trade study produced two promising concepts: fiber placement and single-step diaphragm forming. Based on the innovative design/manufacturing concepts for the fuselage section primary structure, elements were designed, fabricated, and structurally tested. These elements focused on key issues such as thick composite lugs and low cost forming of fastenerless, stiffener/moldine concepts. Manufacturing techniques included autoclave consolidation, single diaphragm consolidation (SDCC) and roll-forming.

Renieri, Michael P.↗

Mechanical failure probability of glasses in Earth orbit

Results of five years of earth-orbital exposure on mechanical properties of glasses indicate that radiation effects on mechanical properties of glasses, for the glasses examined, are less than the probable error of measurement. During the 5 year exposure, seven micrometeorite or space debris impacts occurred on the samples examined. These impacts were located in locations which were not subjected to effective mechanical testing, hence limited information on their influence upon mechanical strength was obtained. Combination of these results with micrometeorite and space debris impact frequency obtained by other experiments permits estimates of the failure probability of glasses exposed to mechanical loading under earth-orbit conditions. This probabilistic failure prediction is described and illustrated with examples.

Kinser, Donald L.↗

Design, analysis, and testing of a metal matrix composite web/flange intersection

An experimental and analytical program to study the local design details of a typical T-shaped web/flange intersection made from a metal matrix composite is described. Loads creating flange bending were applied to specimens having different designs and boundary conditions. Finite element analyses were conducted on models of the test specimens to predict the structural response. The analyses correctly predict failure load, mode, and location in the fillet material in the intersection region of the web and the flange when specimen quality is good. The test program shows the importance of fabrication quality in the intersection region. The full-scale test program that led to the investigation of this local detail is also described.

Biggers, S. B.↗

Conversion-Integration of MSFC Nonlinear Signal Diagnostic Analysis Algorithms for Realtime Execution of MSFC's MPP Prototype System

NASA's advanced propulsion system Small Scale Magnetic Disturbances/Advanced Technology Development (SSME/ATD) has been undergoing extensive flight certification and developmental testing, which involves large numbers of health monitoring measurements. To enhance engine safety and reliability, detailed analysis and evaluation of the measurement signals are mandatory to assess its dynamic characteristics and operational condition. Efficient and reliable signal detection techniques will reduce the risk of catastrophic system failures and expedite the evaluation of both flight and ground test data, and thereby reduce launch turn-around time. During the development of SSME, ASRI participated in the research and development of several advanced non- linear signal diagnostic methods for health monitoring and failure prediction in turbomachinery components. However, due to the intensive computational requirement associated with such advanced analysis tasks, current SSME dynamic data analysis and diagnostic evaluation is performed off-line following flight or ground test with a typical diagnostic turnaround time of one to two days. The objective of MSFC's MPP Prototype System is to eliminate such 'diagnostic lag time' by achieving signal processing and analysis in real-time. Such an on-line diagnostic system can provide sufficient lead time to initiate corrective action and also to enable efficient scheduling of inspection, maintenance and repair activities. The major objective of this project was to convert and implement a number of advanced nonlinear diagnostic DSP algorithms in a format consistent with that required for integration into the Vanderbilt Multigraph Architecture (MGA) Model Based Programming environment. This effort will allow the real-time execution of these algorithms using the MSFC MPP Prototype System. ASRI has completed the software conversion and integration of a sequence of nonlinear signal analysis techniques specified in the SOW for real-time execution on MSFC's MPP Prototype. This report documents and summarizes the results of the contract tasks; provides the complete computer source code; including all FORTRAN/C Utilities; and all other utilities/supporting software libraries that are required for operation.

Jong, Jen-Yi↗

Structural Qualification of Composite Airframes

The development of fundamental approaches for predicting failure and elongation characteristics of fibrous composites are summarized in this document. The research described includes a statistical formulation for individual fiber breakage and fragmentation and clustered fiber breakage, termed macrodefects wherein the aligned composite may represent a structural component such as a reinforcing bar element, a rebar. Experimental work conducted in support of the future exploitation of aligned composite rebar elements is also described. This work discusses the experimental challenges associated with rebar tensile test evaluation and describes initial numerical analyses performed in support of the experimental program.

Kedward, Keith T.↗

Structural Reliability Analysis and Optimization: Use of Approximations

This report is intended for the demonstration of function approximation concepts and their applicability in reliability analysis and design. Particularly, approximations in the calculation of the safety index, failure probability and structural optimization (modification of design variables) are developed. With this scope in mind, extensive details on probability theory are avoided. Definitions relevant to the stated objectives have been taken from standard text books. The idea of function approximations is to minimize the repetitive use of computationally intensive calculations by replacing them with simpler closed-form equations, which could be nonlinear. Typically, the approximations provide good accuracy around the points where they are constructed, and they need to be periodically updated to extend their utility. There are approximations in calculating the failure probability of a limit state function. The first one, which is most commonly discussed, is how the limit state is approximated at the design point. Most of the time this could be a first-order Taylor series expansion, also known as the First Order Reliability Method (FORM), or a second-order Taylor series expansion (paraboloid), also known as the Second Order Reliability Method (SORM). From the computational procedure point of view, this step comes after the design point identification; however, the order of approximation for the probability of failure calculation is discussed first, and it is denoted by either FORM or SORM. The other approximation of interest is how the design point, or the most probable failure point (MPP), is identified. For iteratively finding this point, again the limit state is approximated. The accuracy and efficiency of the approximations make the search process quite practical for analysis intensive approaches such as the finite element methods; therefore, the crux of this research is to develop excellent approximations for MPP identification and also different approximations including the higher-order reliability methods (HORM) for representing the failure surface. This report is divided into several parts to emphasize different segments of the structural reliability analysis and design. Broadly, it consists of mathematical foundations, methods and applications. Chapter I discusses the fundamental definitions of the probability theory, which are mostly available in standard text books. Probability density function descriptions relevant to this work are addressed. In Chapter 2, the concept and utility of function approximation are discussed for a general application in engineering analysis. Various forms of function representations and the latest developments in nonlinear adaptive approximations are presented with comparison studies. Research work accomplished in reliability analysis is presented in Chapter 3. First, the definition of safety index and most probable point of failure are introduced. Efficient ways of computing the safety index with a fewer number of iterations is emphasized. In chapter 4, the probability of failure prediction is presented using first-order, second-order and higher-order methods. System reliability methods are discussed in chapter 5. Chapter 6 presents optimization techniques for the modification and redistribution of structural sizes for improving the structural reliability. The report also contains several appendices on probability parameters.

Grandhi, Ramana V.↗

BMI Sandwich Wing Box Analysis and Test

A composite sandwich single bay wing box test article was developed by Northrop Grumman and tested recently at NASA Langley Research Center. The objectives for the wing box development effort were to provide a demonstration article for manufacturing scale up of structural concepts related to a high speed transport wing, and to validate the structural performance of the design. The box concept consisted of highly loaded composite sandwich wing skins, with moderately loaded composite sandwich spars. The dimensions of the box were chosen to represent a single bay of the main wing box, with a spar spacing of 30 inches, height of 20 inches constant depth, and length of 64 inches. The bismaleimide facesheet laminates and titanium honeycomb core chosen for this task are high temperature materials able to sustain a 300F service temperature. The completed test article is shown in Figure 1. The tests at NASA Langley demonstrated the structures ability to sustain axial tension and compression loads in excess of 20,000 lb/in, and to maintain integrity in the thermal environment. Test procedures, analysis failure predictions, and test results are presented.

Palm, Tod↗