On Structural Design of a Mobile Lunar Habitat with Multi-Layered Environmental Shielding

The future human lunar missions are expected to undertake far more ambitious activities than those of the Apollo program with the possibility of some missions lasting up to several months. Such extended missions require the use of large-size lunar outposts to accommodate living quarters for the astronauts as well as indoor laboratory facilities. The greatest obstacle to the prolonged human presence on the Moon is the threat posed by the harsh lunar environment that is plagued with multi-source high-energy radiation exposure as well as frequent barrage of meteoroids. Hence, for such extended missions to succeed, it is vital that the future lunar outposts be designed to provide a safe habitat for the astronauts. Over the past few years, a variety of ideas and concepts for future lunar outposts and bases have been proposed. With shielding as the primary concern, some have suggested the use of natural structures such as lava tubes while others have taken a more industrial approach and suggested the construction of fixed structures in the form of inflatable, inflatable with rigid elements, and tent-style membrane. For evaluation of these structural design concepts, Drake and Richter1 have proposed a rating system based on such factors as effectiveness, importance, and timing. While all of these designs, in general, benefit from in-situ resource utilization (i.e., lunar regolith) for shielding, they share a common disadvantage of being fixed to one particular location that would limit exploration to the region in close proximity of the outpost

Manufacturing and Cost Considerations in Multidisciplinary Aircraft Design (Research on Mathematical Modeling of Manufacturability Factors)

The identification of airframe Manufacturability Factors/Cost Drivers (MFCD) and the method by which the relationships between MFCD and designer-controlled parameters could be properly modeled are described

Wing design for a civil tiltrotor transport aircraft: A preliminary study

A preliminary study was conducted on the design of the wing-box structure for a civil tiltrotor transport aircraft. The wing structural weight is to be minimized subject to structural and aeroelastic constraints. The composite wing-box structure is composed of skin, stringers, ribs, and spars. The design variables include skin ply thicknesses and orientations and spar cap and stringer cross-sectional areas. With the total task defined, an initial study was conducted to learn more about the intricate dynamic and aeroelastic characteristics of the tiltrotor aircraft and their roles in the wing design. Also, some work was done on the wing finite-element modeling (via PATRAN) which would be used in structural analysis and optimization. Initial studies indicate that in order to limit the wing/rotor aeroelastic and dynamic interactions in the preliminary design, the cruise speed, rotor system, and wing geometric attributes must all be held fixed

Thin tailored composite wing for civil tiltrotor

The tiltrotor aircraft is a flight vehicle which combines the efficient low speed (i.e., take-off, landing, and hover) characteristics of a helicopter with the efficient cruise speed of a turboprop airplane. A well-known example of such vehicle is the Bell-Boeing V-22 Osprey. The high cruise speed and range constraints placed on the civil tiltrotor require a relatively thin wing to increase the drag-divergence Mach number which translates into lower compressibility drag. It is required to reduce the wing maximum thickness-to-chord ratio t/c from 23% (i.e., V-22 wing) to 18%. While a reduction in wing thickness results in improved aerodynamic efficiency, it has an adverse effect on the wing structure and it tends to reduce structural stiffness. If ignored, the reduction in wing stiffness leads to susceptibility to aeroelastic and dynamic instabilities which may consequently cause a catastrophic failure. By taking advantage of the directional stiffness characteristics of composite materials the wing structure may be tailored to have the necessary stiffness, at a lower thickness, while keeping the weight low. The goal of this study is to design a wing structure for minimum weight subject to structural, dynamic and aeroelastic constraints. The structural constraints are in terms of strength and buckling allowables. The dynamic constraints are in terms of wing natural frequencies in vertical and horizontal bending and torsion. The aeroelastic constraints are in terms of frequency placement of the wing structure relative to those of the rotor system. The wing-rotor-pylon aeroelastic and dynamic interactions are limited in this design study by holding the cruise speed, rotor-pylon system, and wing geometric attributes fixed. To assure that the wing-rotor stability margins are maintained a more rigorous analysis based on a detailed model of the rotor system will need to ensue following the design study. The skin-stringer-rib type architecture is used for the wing-box structure. The design variables include upper and lower skin ply thicknesses and orientation angles, spar and rib web thicknesses and cap areas, and stringer cross-sectional areas. These design variables will allow the maximum tailoring of the structure to meet the design requirements most efficiently. Initial dynamic analysis has been conducted using MSC/NASTRAN to determine the baseline wing's frequencies and mode shapes. For the design study we intend to use the finite-element based code called WIDOWAC (Wing Design Optimization With Aeroeastic Constraints) that was developed at NASA Langley in early 1970's for airplane wing structural analysis and preliminary design. Currently, the focus is on modification and validation of this code which will be used for the civil tiltrotor design efforts

Wing design for a civil tiltrotor transport aircraft

The goal of this research is the proper tailoring of the civil tiltrotor's composite wing-box structure leading to a minimum-weight wing design. With focus on the structural design, the wing's aerodynamic shape and the rotor-pylon system are held fixed. The initial design requirement on drag reduction set the airfoil maximum thickness-to-chord ratio to 18 percent. The airfoil section is the scaled down version of the 23 percent-thick airfoil used in V-22's wing. With the project goal in mind, the research activities began with an investigation of the structural dynamic and aeroelastic characteristics of the tiltrotor configuration, and the identification of proper procedures to analyze and account for these characteristics in the wing design. This investigation led to a collection of more than thirty technical papers on the subject, some of which have been referenced here. The review of literature on the tiltrotor revealed the complexity of the system in terms of wing-rotor-pylon interactions. The aeroelastic instability or whirl flutter stemming from wing-rotor-pylon interactions is found to be the most critical mode of instability demanding careful consideration in the preliminary wing design. The placement of wing fundamental natural frequencies in bending and torsion relative to each other and relative to the rotor 1/rev frequencies is found to have a strong influence on the whirl flutter. The frequency placement guide based on a Bell Helicopter Textron study is used in the formulation of frequency constraints. The analysis and design studies are based on two different finite-element computer codes: (1) MSC/NASATRAN and (2) WIDOWAC. These programs are used in parallel with the motivation to eventually, upon necessary modifications and validation, use the simpler WIDOWAC code in the structural tailoring of the tiltrotor wing. Several test cases were studied for the preliminary comparison of the two codes. The results obtained so far indicate a good overall agreement between the two codes

Integrated Reliability and Sizing Optimization of a Large Composite Structure

In this paper, we present the application of probabilistic design modeling and reliability-based design optimization (RBDO) methodology to the sizing optimization of a composite advanced submarine sail structure under parametric uncertainty. With the help of probabilistic sensitivity analysis, the influence of individual random variables on each structural failure mode is examined, and the critical modes are treated as probabilistic design constraints under consistent lower bounds on the corresponding reliability indices. Whereas the failure modes are applied to structural components in the solution of the RBDO problem, the overall system reliability is also evaluated as a post-optimization step. The results indicate that in comparison to a deterministic optimum design, the structural mass of the probabilistic optimum design is slightly higher when consistent probabilistic constraints are imposed, and the overall structural stiffness is found to be more critical than individual component laminate ply thicknesses in meeting the specified design constraints. Moreover, the post-optimality analysis shows that the overall system failure probability of the probabilistic optimum design is more than 50% lower than that of the deterministic optimal design with less than 5% penalty in structural mass

Reliability-based Optimization of Fiber-reinforced Polymer Composite Bridge Deck Panels

A reliability-based optimization (RBO) procedure is developed and applied to minimize the weight of eight fiber-reinforced polymer composite bridge deck panel configurations. The method utilizes interlinked finite element, optimization, and reliability analysis procedures to solve the weight minimization problem with a deterministic strength constraint and two probabilistic deflection constraints. Panels are composed of an upper face plate, lower face plate, and a grid of interior stiffeners. Different panel depths and stiffener layouts are considered. Sensitivity analyses are conducted to identify significant design and random variables. Optimization design variables are panel component ply thicknesses while random variables include load and material resistance parameters. It was found that panels were deflection-governed, with the optimization algorithm yielding little improvement for shallow panels, but significant weight savings for deeper panels. The best design resulted in deep panels with close stiffener spacing to minimize local upper face plate deformations under the imposed traffic (wheel) loads

Reliability Sensitivity Analysis and Design Optimization of Composite Structures Based on Response Surface Methodology

This report discusses the development and application of two alternative strategies in the form of global and sequential local response surface (RS) techniques for the solution of reliability-based optimization (RBO) problems. The problem of a thin-walled composite circular cylinder under axial buckling instability is used as a demonstrative example. In this case, the global technique uses a single second-order RS model to estimate the axial buckling load over the entire feasible design space (FDS) whereas the local technique uses multiple first-order RS models with each applied to a small subregion of FDS. Alternative methods for the calculation of unknown coefficients in each RS model are explored prior to the solution of the optimization problem. The example RBO problem is formulated as a function of 23 uncorrelated random variables that include material properties, thickness and orientation angle of each ply, cylinder diameter and length, as well as the applied load. The mean values of the 8 ply thicknesses are treated as independent design variables. While the coefficients of variation of all random variables are held fixed, the standard deviations of ply thicknesses can vary during the optimization process as a result of changes in the design variables. The structural reliability analysis is based on the first-order reliability method with reliability index treated as the design constraint. In addition to the probabilistic sensitivity analysis of reliability index, the results of the RBO problem are presented for different combinations of cylinder length and diameter and laminate ply patterns. The two strategies are found to produce similar results in terms of accuracy with the sequential local RS technique having a considerably better computational efficiency

Design of Composite Structures for Reliability and Damage Tolerance

A summary of research conducted during the first year is presented. The research objectives were sought by conducting two tasks: (1) investigation of probabilistic design techniques for reliability-based design of composite sandwich panels, and (2) examination of strain energy density failure criterion in conjunction with response surface methodology for global-local design of damage tolerant helicopter fuselage structures. This report primarily discusses the efforts surrounding the first task and provides a discussion of some preliminary work involving the second task