Nonlinear structural analysis for fiber-reinforced superalloy turbine blades

A computational capability for predicting the nonlinear thermomechanical structural response of fiber-reinforced superalloy (FRS) turbine blades is described. This capability is embedded in a special purpose computer code (COBSTRAN) developed at the NASA Lewis Research Center. Special features of this computational capability include accounting for: fiber/matrix reaction, nonlinear and anisotropic material behavior, complex stress distribution due to local and global heterogeneity, and residual stresses due to initial fabrication and/or inelastic behavior during subsequent missions. Numerical results are presented from analyses of a hypothetical FRS turbine blade subjected to a fabrication process and subsequent mission cycle. The results demonstrate the capabilities of this computational tool to; predict local stress/strain response and capture trends of local nonlinear and anisotropic material behavior, relate the effects of this local behavior to the global response of a multilayered fiber-composite turbine blade, and trace material history from fabrication through successive missions

Fault-tolerance thresholds for the surface code with fabrication errors

The construction of topological error correction codes requires the ability to fabricate a lattice of physical qubits embedded on a manifold with a non-trivial topology such that the quantum information is encoded in the global degrees of freedom (i.e. the topology) of the manifold. However, the manufacturing of large-scale topological devices will undoubtedly suffer from fabrication errors---permanent faulty components such as missing physical qubits or failed entangling gates---introducing permanent defects into the topology of the lattice and hence significantly reducing the distance of the code and the quality of the encoded logical qubits. In this work we investigate how fabrication errors affect the performance of topological codes, using the surface code as the testbed. A known approach to mitigate defective lattices involves the use of primitive SWAP gates in a long sequence of syndrome extraction circuits. Instead, we show that in the presence of fabrication errors the syndrome can be determined using the supercheck operator approach and the outcome of the defective gauge stabilizer generators without any additional computational overhead or the use of SWAP gates. We report numerical fault-tolerance thresholds in the presence of both qubit fabrication and gate fabrication errors using a circuit-based noise model and the minimum-weight perfect matching decoder. Our numerical analysis is most applicable to 2D chip-based technologies, but the techniques presented here can be readily extended to other topological architectures. We find that in the presence of 8% qubit fabrication errors, the surface code can still tolerate a computational error rate of up to 0.1%.Comment: 10 pages, 15 figure

Transferring Unit Cell Based Tissue Scaffold Design to Solid Freeform Fabrication

Designing for the freeform fabrication of heterogeneous tissue scaffold is always a challenge in Computer Aided Tissue Engineering. The difficulties stem from two major sources: 1) limitations in current CAD systems to assembly unit cells as building blocks to form complex tissue scaffolds, and 2) the inability to generate tool paths for freeform fabrication of unit cell assemblies. To overcome these difficulties, we have developed an abstract model based on skeletal representation and associated computational methods to assemble unit cells into an optimized structure. Additionally we have developed a process planning technique based on internal architecture pattern of unit cells to generate tool paths for freeform fabrication of tissue scaffold. By modifying our optimization process, we are able to transfer an optimized design to our fabrication system via our process planning technique.Mechanical Engineerin

Beyond developable: computational design and fabrication with auxetic materials

We present a computational method for interactive 3D design and rationalization of surfaces via auxetic materials, i.e., flat flexible material that can stretch uniformly up to a certain extent. A key motivation for studying such material is that one can approximate doubly-curved surfaces (such as the sphere) using only flat pieces, making it attractive for fabrication. We physically realize surfaces by introducing cuts into approximately inextensible material such as sheet metal, plastic, or leather. The cutting pattern is modeled as a regular triangular linkage that yields hexagonal openings of spatially-varying radius when stretched. In the same way that isometry is fundamental to modeling developable surfaces, we leverage conformal geometry to understand auxetic design. In particular, we compute a global conformal map with bounded scale factor to initialize an otherwise intractable non-linear optimization. We demonstrate that this global approach can handle non-trivial topology and non-local dependencies inherent in auxetic material. Design studies and physical prototypes are used to illustrate a wide range of possible applications

Raising new opportunities for the Next Economy by exploring variable user needs for Computational Co-Design

Digital Fabrication promises to revolutionize manufacturing, bringing both economic, social and environmental benefits. Combined with Computational CoDesign it can raise the creative potential of both designers and users. However, today the productive use of Digital Fabrication and Computational Design requires significant effort and specialised know-how, so valorising these practices calls for the identification of the application fields that benefit the most from them. This paper presents a tool for helping the discovery of design opportunities across comprehensive, ramified lists of product categories, where designers can identify possible points of intervention. The web-based tool allows the rapid evaluation of numerous product categories according to an extendable set of factors and inspiring questions related to the necessity of personalization, aiming to stimulate designers to consider unexpected frontiers of innovation. Beyond the scope of the research project, this tool has the potential to assist designers in finding applications also for other emerging technologies in a structured and scalable wa

Computational simulation for concurrent engineering of aerospace propulsion systems

Results are summarized for an investigation to assess the infrastructure available and the technology readiness in order to develop computational simulation methods/software for concurrent engineering. These results demonstrate that development of computational simulation methods for concurrent engineering is timely. Extensive infrastructure, in terms of multi-discipline simulation, component-specific simulation, system simulators, fabrication process simulation, and simulation of uncertainties--fundamental to develop such methods, is available. An approach is recommended which can be used to develop computational simulation methods for concurrent engineering of propulsion systems and systems in general. Benefits and issues needing early attention in the development are outlined

Mitigation of welding distortion and residual stresses via cryogenic CO2 cooling - a numerical investigation

Fusion welding remains the most common and convenient fabrication method for large, thinplate welded structures. However, the resulting tendency to out-of-plane distortion exacts severe design and fabrication penalties in terms of poorer buckling performance, lack of fairness in external appearance, poor fit-up and frequent requirements for expensive rework. There are several ways to mitigate welding distortion and this study concentrates on the use of cryogenic CO2 cooling to reduce distortion. A feasible combination of welding process and cooling parameters, was investigated computationally and the resulting effects on final deformation were predicted. Three different computational strategies were developed and applied to butt-welding and fillet-welding processes, with and without the inclusion of cryogenic cooling. In the first method, a fully transient, uncoupled thermo-elastoplastic model was investigated. This method is comprehensive but not readily applicable to predict welding distortions in complex, industrial-scale, welded structures, due to the large computational requirement. More computationally efficient models are needed therefore and two further models of this type are suggested in this study. The results show good agreement between the different models, despite substantial differences in computational budget. In butt-welded plates, a significant decrease in out-of-plane distortion is obtained when cryogenic cooling is applied. In fillet-welded plates, cooling had much less effect on welding distortion. This was largely due to the size and configuration of the test case assemblies and the fact that the attached stiffener greatly increased the overall stiffness and resistance to contraction forces

Probabilistic composite analysis

Formal procedures are described which are used to computationally simulate the probabilistic behavior of composite structures. The computational simulation starts with the uncertainties associated with all aspects of a composite structure (constituents, fabrication, assembling, etc.) and encompasses all aspects of composite behavior (micromechanics, macromechanics, combined stress failure, laminate theory, structural response, and tailoring) optimization. Typical cases are included to illustrate the formal procedure for computational simulation. The collective results of the sample cases demonstrate that uncertainties in composite behavior and structural response can be probabilistically quantified