ALBERT

Description: Analytical and experimental studies were performed to investigate the effect of gear rim thickness on crack propagation life. The FRANC (FRacture ANalysis Code) computer program was used to simulate crack propagation. The FRANC program used principles of linear elastic fracture mechanics, finite element modeling, and a unique re-meshing scheme to determine crack tip stress distributions, estimate stress intensity factors, and model crack propagation. Various fatigue crack growth models were used to estimate crack propagation life based on the calculated stress intensity factors. Experimental tests were performed in a gear fatigue rig to validate predicted crack propagation results. Test gears were installed with special crack propagation gages in the tooth fillet region to measure bending fatigue crack growth. Good correlation between predicted and measured crack growth was achieved when the fatigue crack closure concept was introduced into the analysis. As the gear rim thickness decreased, the compressive cyclic stress in the gear tooth fillet region increased. This retarded crack growth and increased the number of crack propagation cycles to failure.

Description: The Stirling space power machine incorporates a linear alternator to generate electrical power. The alternator is a reciprocating device that is driven by a solar or nuclear-powered Stirling engine. The power piston and cylinder are made of titanium 6A1-4V (Ti6-4) alloy, and are designed to be lubricated by a hydrodynamically-generated gas film. Rubbing occurs during starts and stops and there is a possibility of an occasional high speed rub. Since titanium is known to have a severe galling tendency in sliding contacts, a 'backup,' self-lubricating coating on the cylinder and/or the piston is needed. This report describes the results of a research program to study the lubrication of Ti6-4 with the following chromium carbide based materials: plasma-sprayed PS212 coatings and sintered PM212 counterfaces. Program objectives are to achieve adherent coatings on Ti6-4 and to measure the friction and wear characteristics of the following sliding combinations under conditions simulative of the Stirling-driven space power linear alternator: Ti6-4/Ti6-4 baseline, Ti6-4/PS212 coated Ti6-4, and Ps212 coated Ti6-4/PM212

Description: At the Miyazaki test track today, the new test vehicle, MLU002N, is under test run to obtain necessary data for Yamanashi test track where the construction is underway, the test vehicle has been ordered and the first tunnel was completed in December 1993. Superconducting magnetohydrodynamic drive ship, MHDS, 'Yamato 1' has completed its experiment in 1992 and it is now under preparation to exhibit to the public in___1994. Furthermore, to promote the research development of MHDS, the detailed discussion is underway on the magnetohydrodynamic drive equipment as well as the research on the future scheme. Neither an automobile nor railway but a new transport system called EQUOS LIM CAR(ELC) has been proposed. By using the rotating magnetic field, it will levitate on the aluminum like reaction plate. On the normal road, it will run by rolling the wheels like an electric car but on the highway, it will levitate on the guideway resulting to less noise, less vibration and pollution free drive. To understand the concept of the ELC, the model was built and experimented by using permanent magnet. The same model was donated to the MUSEUM OF SCIENCE AND INDUSTRY in Chicago and was displayed to the public. Today, the trial superconducting magnet has been made and the research development of the subsystem is underway. Research development of superconducting elevator, equipment for the launching of spaceship, tube transportation system and others are in progress for the superconducting applied transportation system.

Description: The role of surface-sensitive chemical analysis (ESCA, AES, and SIMS) in a study to select a process to replace 1, 1, 1-trichloroethane (TCA) vapor degreasing as a steel and aluminum bonding surface preparation method is described. The effort was primarily concerned with spray-in-air cleaning processes involving aqueous alkaline and semi-aqueous cleaners and a contamination sensitive epoxy-to-metal bondline. While all five cleaners tested produced bonding strength results equal to or better than those produced by vapor degreasing, the aqueous alkaline cleaners yielded results which were superior to those produced by the semi-aqueous cleaners. The main reason for the enhanced performance appears to be a silicate layer left behind by the aqueous alkaline cleaners. The silicate layer increases the polarity of the surface and enhances epoxy-to-metal bonding. On the other hand, one of the semi-aqueous cleaners left a nonpolar carbonaceous residue which appeared to have a negative effect on epoxy-to-metal bonding. Differences in cleaning efficiency between cleaners/processes were also identified. These differences in surface chemistry, which were sufficient to affect bonding, were not detected by conventional chemical analysis techniques.

Description: This paper will discuss how the Kennedy Space Center intends to perform precision cleaning verification by Air/Water Impingement in lieu of chlorofluorocarbon-113 gravimetric nonvolatile residue analysis (NVR). Test results will be given that demonstrate the effectiveness of the Air/Water system. A brief discussion of the Total Carbon method via the use of a high temperature combustion analyzer will also be given. The necessary equipment for impingement will be shown along with other possible applications of this technology.

Description: Auxiliary bearings are a critical feature of any magnetic bearing system. They protect the soft iron core of the magnetic bearing during an overload or failure. An auxiliary bearing typically consists of a rolling element bearing or bushing with a clearance gap between the rotor and the inner race of the support. The dynamics of such systems can be quite complex. It is desired to develop a rotordynamic model which describes the dynamic behavior of a flexible rotor system with magnetic bearings including auxiliary bearings. The model is based upon an experimental test facility. Some simulation studies are presented to illustrate the behavior of the model. In particular, the effects of introducing sideloading from the magnetic bearing when one coil fails is studied.

Description: This paper presents a study of the dynamic behavior of a rotor system supported by auxiliary bearings. The steady-state behavior of a simulation model based upon a production jet engine is explored over a wide range of operating conditions for varying rotor imbalance, support stiffness, and damping. Interesting dynamical phenomena, such as chaos, subharmonic responses, and double-valued responses, are presented and discussed.

Description: This paper investigates the steady-state responses of a rotor system supported by auxiliary bearings in which there is a clearance between the rotor and the inner race of the bearing. A simulation model based upon the rotor of a production jet engine is developed and its steady-state behavior is explored over a wide range of operating conditions for various parametric configurations. Specifically, the influence of rotor imbalance, support stiffness, and damping is studied. It is found that imbalance may change the rotor responses dramatically in terms of frequency contents at certain operating speeds. Subharmonic responses of 2nd order through 10th order are all observed except the 9th order. Chaotic phenomenon is also observed. Jump phenomena (or double-valued responses) of both hard-spring type and soft-spring type are shown to occur at low operating speeds for systems with low auxiliary bearing damping or large clearance even with relatively small imbalance. The effect of friction between the shaft and the inner race of the bearing is also discussed.

Description: This presentation covers the results of tire footprint studies conducted in the Landing Gear Development Facility of the USAF Wright Laboratory at the Wright Patterson Air force Base, OH. Tire footprint studies are essential in understanding tire wear mechanisms and computing tire tread wear rates. The power input into the tread is the driving force for tread wear. Variables needed for power input calculations include the footprint pressure and slip velocity distributions. Studies were performed on the effects of power input distributions due to vertical load, camber, yaw, inflation pressure, and tire construction. For the present study, two tire constructions, one radial and the other bias, were selected. These tires were for the F-16 Block 30 fighter aircraft, both of which were previously worn. The present study was limited to steady straight roll with a 14,000 lb vertical load, a 310 psi inflation pressure, and zero yaw and camber. All tests were conducted on the Tire Force Machine (TFM) with a specialized sensor plate with embedded pressure sensors (X, Y, and Z) and slip sensors (X and Y). All tests were conducted for a table speed of 1 in/s. Tests on the TFM show that the power intensity distributions and total power for both tire constructions are quite similar for straight roll. Later on, tests were also conducted on a modified dynamometer which was overlaid with a grit wear surface. The tire speed was maintained at 40 miles per hour and yaw was set to four degrees. Dynamometer tests showed that radial tires have more tread wear than the bias tire; however, in the field, radial tires have longer life.

Description: HD-2 grease is deliberately applied to Shuttle Redesigned Solid Rocket Motor (RSRM) D6AC steel hardware parts as a temporary protective coating for storage and shipping. This HD-2 grease is the most common form of surface contamination on RSRM hardware and must be removed prior to subsequent surface treatment. Failure to achieve an acceptable level of cleanliness (HD-2 calcium grease removal) is a common cause of defect incidence. Common failures from ineffective cleaning include poor adhesion of surface coatings, reduced bond performance of structural adhesives, and failure to pass cleanliness inspection standards. The RSRM hardware is currently cleaned and refurbished using methyl chloroform (1,1,1-trichloroethane). This chlorinated solvent is mandated for elimination due to its ozone depleting characteristics. This report describes an experimental study of an aqueous cleaning system (which uses Brulin 815 GD) as a replacement for methyl chloroform. Evaluation of process control parameters for this cleaner are discussed as well as cleaning mechanisms for a spray-in-air process.

Description: The NASA Kennedy Space Center (KSC) Materials Science Laboratory (MSL) has developed a totally aqueous process for precision cleaning and verification of small components. In 1990 the Precision Cleaning Facility at KSC used approximately 228,000 kg (500,000 lbs) of chlorofluorocarbon (CFC) 113 in the cleaning operations. It is estimated that current CFC 113 usage has been reduced by 75 percent and it is projected that a 90 percent reduction will be achieved by the end of calendar year 1994. The cleaning process developed utilizes aqueous degreasers, aqueous surfactants, and ultrasonics in the cleaning operation and an aqueous surfactant, ultrasonics, and Total Organic Carbon Analyzer (TOCA) in the nonvolatile residue (NVR) and particulate analysis for verification of cleanliness. The cleaning and verification process is presented in its entirety, with comparison to the CFC 113 cleaning and verification process, including economic and labor costs/savings.

Description: Tomco Equipment Company has participated in the dry ice (solid carbon dioxide, CO2) cleaning industry for over ten years as a pioneer in the manufacturer of high density, dry ice cleaning pellet production equipment. For over four years Tomco high density pelletizers have been available to the dry ice cleaning industry. Approximately one year ago Tomco introduced the DI-250, a new dry ice blast unit making Tomco a single source supplier for sublimable media, particle blast, cleaning systems. This new blast unit is an all pneumatic, single discharge hose device. It meters the insertion of 1/8 inch diameter (or smaller), high density, dry ice pellets into a high pressure, propellant gas stream. The dry ice and propellant streams are controlled and mixed from the blast cabinet. From there the mixture is transported to the nozzle where the pellets are accelerated to an appropriate blasting velocity. When directed to impact upon a target area, these dry ice pellets have sufficient energy to effectively remove most surface coatings through dry, abrasive contact. The meta-stable, dry ice pellets used for CO2 cleaning, while labeled 'high density,' are less dense than alternate, abrasive, particle blast media. In addition, after contacting the target surface, they return to their equilibrium condition: a superheated gas state. Most currently used grit blasting media are silicon dioxide based, which possess a sharp tetrahedral molecular structure. Silicon dioxide crystal structures will always produce smaller sharp-edged replicas of the original crystal upon fracture. Larger, softer dry ice pellets do not share the same sharp-edged crystalline structures as their non-sublimable counterparts when broken. In fact, upon contact with the target surface, dry ice pellets will plastically deform and break apart. As such, dry ice cleaning is less harmful to sensitive substrates, workers and the environment than chemical or abrasive cleaning systems. Dry ice cleaning system components include: a dry ice pellet supply, a non-reactive propellant gas source, a pellet and propellant metering device, and a media transport and acceleration hose and nozzle arrangement. Dry ice cleaning system operating parameters include: choice of propellant gas, its pressure and temperature, dry ice mass flow rate, dry ice pellet size and shape, and acceleration nozzle configuration. These parameters may be modified to fit different applications. The growth of the dry ice cleaning industry will depend upon timely data acquisition of the effects that independent changes in these parameters have on cleaning rates, with respect to different surface coating and substrate combinations. With this data, optimization of cleaning rates for particular applications will be possible. The analysis of the applicable range of modulation of these parameters, within system component mechanical constraints, has just begun.

Description: Within the framework of the Mars 94 mission, it was decided to design and build a new vertical axis seismometer in order to continuously record the seismic events occurring on the Mars planet. The mission requirements lead to very stringent constraints on power, volume, mass and shock resistance at the landing. The seismometer must be capable of automatic leveling and automatic fitting to the local gravity. This paper deals with the mechanisms designed for this seismometer. Due to the short allotted time for its development and low cost, the baseline was to apply the rules of spatial tribology and, when it was possible, to customize existing components for space applications.

Description: In the frame work of the project Shuttle Plume Impingement Flight Experiment (SPIFEX), a Load Measurement System was developed and fabricated to measure the impingement force of Shuttle Reaction Control System (RCS) jets. The Load Measurement System is a force sensing system that measures any combination of normal and shear forces up to 40 N (9 lbf) in the normal direction and 22 N (5 lbf) in the shear direction with an accuracy of +/- 0.04 N (+/- 0.01 lbf) Since high resolution is required for the force measurement, the Load Measurement System is built with highly sensitive load cells. To protect these fragile load cells in the non-operational mode from being damaged due to flight loads such as launch and landing loads of the Shuttle vehicle, a motor driven device known as the Load Cell Lock-Out Mechanism was built. This Lock-Out Mechanism isolates the load cells from flight loads and re-engages the load cells for the force measurement experiment once in space. With this highly effective protection system, the SPIFEX load measurement experiment was successfully conducted on STS-44 in September 1994 with all load cells operating properly and reading impingement forces as expected.

Description: Installing and removing experiment racks in a Space Station Logistics Module will become a repetitive operation at Kennedy Space Center (KSC) in the near future. A Rack Insertion Device (RID) consisting of an Extendible Boom, End Effector, and Positioning Base is being developed for the task. This paper discusses the key elements of the RlD's function and design. Prototype test results for the RlD's Extendible Boom and End Effector are presented. Also discussed are future end effectors that will further enhance the RlD's Space Station processing capability.

Description: This paper describes the mechanical design, analysis, fabrication, testing, and lessons learned by developing a uniquely designed spaceflight-like actuator. The Linear Proof Mass Actuator (LPMA) was designed to attach to both a large space structure and a ground test model without modification. Previous designs lacked the power to perform in a terrestrial environment while other designs failed to produce the desired accelerations or frequency range for spaceflight applications. Thus, the design for a unique actuator was conceived and developed at NASA Langley Research Center. The basic design consists of four large mechanical parts (Mass, Upper Housing, Lower Housing, and Center Support) and numerous smaller supporting components including an accelerometer, encoder, and four drive motors. Fabrication personnel were included early in the design phase of the LPMA as part of an integrated manufacturing process to alleviate potential difficulties in machining an already challenging design. Operational testing of the LPMA demonstrated that the actuator is capable of various types of load functions.

Description: Running torque data of SR6 ball bearings are presented for different temperatures and speeds. The data are discussed in contrast to generally used torque prediction models and point out the need to obtain empirical data in critical applications. Also, the effects of changing bearing washing techniques from old, universally used CFC-based systems to CFC-free aqueous/alkaline solutions are discussed. Data on wettability, torque and lubricant life using SR3 ball bearings are presented. In general, performance is improved using the new aqueous washing techniques.

Description: The X-ray Timing Explorer (XTE) spacecraft is a NASA science low-earth orbit explorer-class satellite to be launched in 1995, and is an in-house Goddard Space Flight Center (GSFC) project. It has two deployable aluminum honeycomb solar array wings with each wing being articulated by a single axis solar array drive assembly. This paper will address the design, the qualification testing, and the development problems as they surfaced of the Solar Array Deployment and Drive System.

Description: Bearings generate disturbances that, when combined with structural gains of a momentum wheel, contribute to induced vibration in the wheel. The frequencies generated by a ball bearing are defined by the bearing's geometry and defects. The amplitudes at these frequencies are dependent upon the actual geometry variations from perfection; therefore, a geometrically perfect bearing will produce no amplitudes at the kinematic frequencies that the design generates. Because perfect geometry can only be approached, emitted vibrations do occur. The most significant vibration is at the spin frequency and can be balanced out in the build process. Other frequencies' amplitudes, however, cannot be balanced out. Momentum wheels are usually the single largest source of vibrations in a spacecraft and can contribute to pointing inaccuracies if emitted vibrations ring the structure or are in the high-gain bandwidth of a sensitive pointing control loop. It is therefore important to be able to provide an a priori knowledge of possible amplitudes that are singular in source or are a result of interacting defects that do not reveal themselves in normal frequency prediction equations. This paper will describe the computer model that provides for the incorporation of bearing geometry errors and then develops an estimation of actual amplitudes and frequencies. Test results were correlated with the model. A momentum wheel was producing an unacceptable 74 Hz amplitude. The model was used to simulate geometry errors and proved successful in identifying a cause that was verified when the parts were inspected.

Description: The paper investigates three critical areas in cable-driven rigid-panel solar arrays: First, the variation of deployment and retraction cable tensions due to friction at the hinges; Second, the change in deployment dynamics associated with different deployment histories; Third, the relationship between the level of pre-tension in the closed contact loops and the synchronization of deployment. A small scale model array has been made and tested, and its behavior has been compared to numerical simulations.

Description: The Fast On-Orbit Recording of Transient Events (FORTE) satellite being built by Los Alamos National Laboratory (LANL) and Sandia National Laboratories (SNL) has as its most prominent feature a large deployable (11 m by 5 m) log periodic antenna to monitor emissions from electrical storms on the Earth. This paper describes the antenna and the design for the long elements and explains the dynamics of their deployment and the damping system employed. It also describes the unique paraffin-actuated reusable tie-down and release mechanism employed in the system.

Description: NASA's Mars Pathfinder mission, to be launched in 1996, reflects a new philosophy of exploiting new technologies to reduce mission cost and accelerate the pace of space exploration. One of the experiments on board Pathfinder will demonstrate the first use in space of a multi-cycle, electrically-activated, shape-memory alloy (SMA) actuator. SMA's are metal alloys which, when heated, undergo a crystalline phase change. This change in phase alters the alloy lattice-constant, resulting in a change of dimension. Upon cooling, the alloy returns to its original lattice formation. Wire drawn from an SMA contracts in length when heated. The reversible change in length is 3 percent to 5 percent. The wire used in this actuator is a nickel-titanium alloy known as nitinol.

Description: This paper describes the preliminary development of a high force thermal latch (HFTL). The HFTL has one moving part which is restrained in the latched position by a low melting temperature or fusible metal alloy. When heated the fusible alloy flows to a receiving chamber and in so doing at first releases the tension load in the latch bolt and later releases the bolt itself. The HFTL can be used in place of pyrotechnically activated spacecraft release devices in those instances where the elimination of both pyrotechnic shock-loading and rapid strain-energy release take precedence over the near instantaneous release offered by ordnance initiated devices.

Description: Spool-based non-explosive actuator (NEA) devices are used for three important holddown and release functions during the establishment of the ORBCOMM (TM) constellation. Non-explosive separation nuts are used to restrain and release the 26 individual satellites into low earth orbit. Cable release mechanisms based on the same technology are used to release the solar arrays and antenna boom.

Description: A new basic space fastener has been developed and tested by the GSFC. The purposes of this fastener are to permit assembly and servicing in space by astronauts and/or robots and to facilitate qualification of payloads on Earth prior to launch by saving time and money during the systems integration and component testing and qualification processes. The space fastener is a rework of the basic machine screw such that crossthreading is impossible; it is self-locking and will not work its way out during launch (vibration proof); it will not wear out despite repeated use; it occupies a small foot print which is comparable to its machine screw equivalent, and it provides force and exhibits strength comparable to its machine screw equivalent. Construction is ultra-simple and cost effective and the principle is applicable across the full range of screw sizes ranging from a #10 screw to 2.5 cm (1 in) or more. In this paper, the fastener principles of operation will be discussed along with test results and construction details. The new fastener also has considerable potential in the commercial sector. A few promising applications will be presented.

Description: A new tubular boom deployment mechanism has been designed, built, and flown as part of the second Waves In Space Program (WISP-2) through Cornell University. For this program, two booms were needed to form a dipole antenna but existing units were found to be too complicated and costly. A low-cost alternative was developed which combined flight-proven tubular boom technology with a new support and deployment mechanism. The simplicity of this new design was a major factor in providing a highly reliable and cost-effective system.

Description: This paper describes a Solar Array Deployment Mechanism (SADM) used to deploy a rigid solar array panel on a commercial spacecraft. The application required a deployment mechanism design that was not only lightweight, but also could be produced and installed at the lowest possible cost. This paper covers design, test, and analysis of a mechanism that meets these requirements.

Description: A detailed description of the Hold Down and Release Mechanisms designed for a 70+ constellation of spacecraft is presented. The design is reviewed to understand the practical implications of severely constraining cost. Strategies for adapting the traditional aerospace design paradigm to a more commercial, cost driven paradigm are discussed and practical examples are cited.

Description: This paper describes the ongoing work in fault tolerance at the University of Texas at Austin. The paper describes the technical goals the group is striving to achieve and includes a brief description of the individual projects focusing on fault tolerance. The ultimate goal is to develop and test technology applicable to all future missions of NASA (lunar base, Mars exploration, planetary surveillance, space station, etc.).

Description: The Latching End Effector (LEE) forms part of the Space Station Remote Manipulator System (SSRMS) for which Spar Aerospace Ltd, Space Systems Division is the prime contractor. The design, testing and performance evaluation of the Latching End Effector mechanisms is the subject of this paper focusing on: (1) ambient, thermal and vibration testing; (2) snare/rigidize performance testing and interaction during payload acquisition; and (3) latch/umbilical test results and performance.

Description: The European Robotic Arm (ERA) is a contribution to the Russian Segment of the International Space Station Alpha. It will start operating on the Russian Segment during the assembly phase. ERA is designed and produced by a large industrial consortium spread over Europe with Fokker Space & Systems as prime contractor. In this paper, we will describe some of the overall design aspects and focus on the development of several mechanisms within ERA. The operation of ERA during the approach of its end effector towards the grapple interface and the grapple operation is discussed, with a focus on mechanisms. This includes the geometry of the end effector leading edge, which is carefully designed to provide the correct and complete tactile information to a torque-force sensor (TFS). The data from this TFS are used to steer the arm such that forces and moments are kept below 20 N and 20 N.m respectively during the grappling operation. Two hardware models of the end effector are built. The problems encountered are described as well as their solutions. The joints in the wrists and the elbow initially used a harmonic drive lubricated by MoS2. During development testing, this combination showed an insufficient lifetime in air to survive the acceptance test program. The switch-over to a system comprising planetary gearboxes with grease lubrication is described. From these development efforts, conclusions are drawn and recommendations are given for the design of complex space mechanisms.

Description: This presentation summarizes the capabilities in the ANSYS program that relate to the computational modeling of tires. The power and the difficulties associated with modeling nearly incompressible rubber-like materials using hyperelastic constitutive relationships are highlighted from a developer's point of view. The topics covered include a hyperelastic material constitutive model for rubber-like materials, a general overview of contact-friction capabilities, and the acoustic fluid-structure interaction problem for noise prediction. Brief theoretical development and example problems are presented for each topic.

Description: The modeling of tires and the simulation of tire behavior are complex problems. The MacNeal-Schwendler Corporation (MSC) has a number of finite element analysis products that can be used to address the complexities of tire modeling and simulation. While there are many similarities between the products, each product has a number of capabilities that uniquely enable it to be used for a specific aspect of tire behavior. This paper discusses the following programs: (1) MSC/NASTRAN - general purpose finite element program for linear and nonlinear static and dynamic analysis; (2) MSC/ADAQUS - nonlinear statics and dynamics finite element program; (3) MSC/PATRAN AFEA (Advanced Finite Element Analysis) - general purpose finite element program with a subset of linear and nonlinear static and dynamic analysis capabilities with an integrated version of MSC/PATRAN for pre- and post-processing; and (4) MSC/DYTRAN - nonlinear explicit transient dynamics finite element program.

Description: Some recent developments in reduction techniques, as applied to predicting the tire contact response and evaluating the sensitivity coefficients of the different response quantities, are reviewed. The sensitivity coefficients measure the sensitivity of the contact response to variations in the geometric and material parameters of the tire. The tire is modeled using a two-dimensional laminated anisotropic shell theory with the effects of variation in geometric and material parameters, transverse shear deformation, and geometric nonlinearities included. The contact conditions are incorporated into the formulation by using a perturbed Lagrangian approach with the fundamental unknowns consisting of the stress resultants, the generalized displacements, and the Lagrange multipliers associated with the contact conditions. The elemental arrays are obtained by using a modified two-field, mixed variational principle. For the application of reduction techniques, the tire finite element model is partitioned into two regions. The first region consists of the nodes that are likely to come in contact with the pavement, and the second region includes all the remaining nodes. The reduction technique is used to significantly reduce the degrees of freedom in the second region. The effectiveness of the computational procedure is demonstrated by a numerical example of the frictionless contact response of the space shuttle nose-gear tire, inflated and pressed against a rigid flat surface. Also, the research topics which have high potential for enhancing the effectiveness of reduction techniques are outlined.

Description: A semi-automated procedure is described for the accurate determination of geometrical characteristics using a scanned image of the tire cross-section. The procedure can be useful for cases when CAD drawings are not available or when a description of the actual cured tire is desired. Curves representing the perimeter of the tire cross-section are determined by an edge tracing scheme, and the plyline and cord-end positions are determined by locations of color intensities. The procedure provides an accurate description of the perimeter of the tire cross-section and the locations of plylines and cord-ends. The position, normals, and curvatures of the cross-sectional surface are included in this description. The locations of the plylines provide the necessary information for determining the ply thicknesses and relative position to a reference surface. Finally, the locations of the cord-ends provide a means to calculate the cord-ends per inch (epi). Menu driven software has been developed to facilitate the procedure using the commercial code, PV-Wave by Visual Numerics, Inc., to display the images. From a single user interface, separate modules are executed for image enhancement, curve fitting the edge trace of the cross-sectional perimeter, and determining the plyline and cord-end locations. The code can run on SUN or SGI workstations and requires the use of a mouse to specify options or identify items on the scanned image.

Description: Aircraft tires are composite structures manufactured with viscoelastic materials such as carbon black filled rubber and nylon cords. When loaded they experience large deflections and moderately large strains. Detailed structural models of tires require the use of either nonlinear shell or nonlinear three dimensional solid finite elements. Computational predictions of the dynamic response of tires must consider the composite viscoelastic material behavior in a realistic fashion. We describe a modification to a nonlinear anisotropic shell finite element so it can be used to model viscoelastic stresses during general deformations. The model is developed by introducing internal variables of the type used to model elastic strain energy. The internal variables are strains, curvatures, and transverse shear angles which are in a one-to-one correspondence with the generalized coordinates used to model the elastic strain energy for nonlinear response. A difference-relaxation equation is used to relate changes in the observable strain field to changes in the internal strain field. The internal stress state is introduced into the equilibrium equations by converting it to nodal loads associated with the element's displacement degrees of freedom. In this form the tangent matrix in the Newton-Raphson solution algorithm is not modified from its form for the nonlinear statics problem. Only the gradient vector is modified and the modification is not computationally costly. The existing finite element model for the Space Shuttle nose gear tire is used to provide examples of the algorithm. In the first example, the tire's rim is displaced at a constant rate up to a fixed value. In the second example, the tire's rim is enforced to follow a saw tooth load and unload curve to generate hysteresis loops.

Description: The history, requirements, and theoretical basis of a new energy based constitutive model for (rubber) material elasticity, hysteresis, and failure are presented. Energy based elasticity is handled by many constitutive models, both in one dimension and in three dimensions. Conversion of mechanical energy to heat can be modeled with viscoelasticity or as structural hysteresis. We are seeking unification of elasticity, hysteresis, and failure mechanisms such as fatigue and wear. An energy state characterization for failure criteria of (rubber) materials may provide this unification and also help explain the interaction of temperature effects with failure mechanisms which are described as creation of growth of internal crack surface. Improved structural modeling of tires with FEM should result from such a unified constitutive theory. The theory will also guide experimental work and should enable better interpretation of the results of computational stress analyses.

Description: The perfluoropolyether (PEPE) class of liquid lubricants has been used for space applications for over two decades. At first, these fluids performed satisfactorily, as early spacecraft placed few demands on their performance. However, as other spacecraft components have become more reliable and lifetimes have been extended, PEPE lubricant deficiencies have been exposed. Therefore, the objective of this paper is to review the PEPE properties that are important for successful long term operation in space.

Description: Computational strategies are presented for the modeling and analysis of tires in contact with pavement. A procedure is introduced for simple and accurate determination of tire cross-sectional geometric characteristics from a digitally scanned image. Three new strategies for reducing the computational effort in the finite element solution of tire-pavement contact are also presented. These strategies take advantage of the observation that footprint loads do not usually stimulate a significant tire response away from the pavement contact region. The finite element strategies differ in their level of approximation and required amount of computer resources. The effectiveness of the strategies is demonstrated by numerical examples of frictionless and frictional contact of the space shuttle Orbiter nose-gear tire. Both an in-house research code and a commercial finite element code are used in the numerical studies.

Description: Hybrid superconductor magnet bearings (HSMB's) utilize high temperature superconductors (HTS's) together with permanent magnets to form a frictionless interface between relatively rotating parts. They are low mass, stable, and do not incur expenditure of energy during normal operation. There is no direct physical contact between rotor and stator, and hence there is no wear and tear. However, just as any other applications of HTS's, it requires a very cold temperature to function. Whereas this might be perceived as a disadvantage on earth, it is of no great concern in space or on the moon. To astronomers, the moon is an excellent site for an observatory, but the cold and dusty vacuum environment on the moon precludes the use of mechanical bearings on the telescope mounts. Furthermore, drive mechanisms with very fine steps, and hence bearings with extremely low friction are needed to track a star from the moon, because the moon rotates very slowly. All aspects considered, the HSMB is about the only candidate that fits in naturally. Here, we present a design for one such bearing, capable of supporting a telescope that weighs about 3 lbs on Earth.

Description: A tire and landing gear test facility has been developed and incorporated into a Convair 990 aircraft. The system can simulate tire vertical load profiles to 250,000 lb, sideslip angles to 15 degrees, and wheel braking on actual runways. Onboard computers control the preprogrammed test profiles through a feedback loop and also record three axis loads, tire slip angle, and tire condition. The aircraft to date has provided tire force and wear data for the Shuttle Orbiter tire on three different runways and at east and west coast landing sites. This report discusses the role of this facility in complementing existing ground tire and landing gear test facilities, and how this facility can simultaneously simulate the vertical load, tire slip, velocity, and surface for an entire aircraft landing. A description is given of the aircraft as well as the test system. An example of a typical test sequence is presented. Data collection and reduction from this facility are discussed, as well as accuracies of calculated parameters. Validation of the facility through ground and flight tests is presented. Tests to date have shown that this facility can operate at remote sites and gather complete data sets of load, slip, and velocity on actual runway surfaces. The ground and flight tests have led to a successful validation of this test facility.

Description: A releasable coupling device for connecting two members to one another where a collet type fastener has normally retracted latching fingers insertable into a latching recess and a longitudinally movable expander for activating the fastener is described. The longitudinal movement is retained with a paraffin actuated system which can reset. The longitudinal movement of the expander in one direction is through a one way threaded ratchet system which provides an automatic locking action and the expander is movable in either direction by an independently operated threaded action.

Description: A simple or unsophisticated robot incapable of effecting straight-line motion at the end of its arm is presented. This robot inserts a key held in its end effector or hand into a door lock with nearly straight-line motion by gently thrusting its back heels downwardly so that it pivots forwardly on its front toes while holding its arm stationary. The relatively slight arc traveled by the robot's hand is compensated by a complaint tool with which the robot hand grips the door key. A visible beam is projected through the axis of the hand or gripper on the robot arm end at an angle to the general direction in which the robot thrusts the gripper forward. As the robot hand approaches a target surface, a video camera on the robot wrist watches the beam spot on the target surface fall from a height proportional to the distance between the robot hand and the target surface until the beam spot is nearly aligned with the top of the robot hand. Holes in the front face of the hand are connected through internal passages inside the arm to an on-board chemical sensor. Full rotation of the hand or gripper about the robot arm's wrist is made possible by slip rings in the wrist which permit passage of the gases taken in through the nose holes in the front of the hand through the wrist regardless of the rotational orientation of the wrist.

Description: This report contains a compilation of some of the most basic equations governing simple preloaded joint systems and discusses the more common modes of failure associated with such hardware. It is intended to provide the mechanical designer with the tools necessary for designing a basic bolted joint. Although the information presented is intended to aid in the engineering of space flight structures, the fundamentals are equally applicable to other forms of mechanical design.

Description: A mobile, self-powered, self-contained, and remote-controlled robot is presented. The robot is capable of safely operating in a combustible atmosphere and providing information about the atmosphere to the operator. The robot includes non-sparking and non-arcing electro-mechanical and electronic components designed to prevent the robot from igniting the combustible atmosphere. The robot also includes positively pressurized enclosures that house the electromechanical and electronic components of the robot and prevent intrusion of the combustible atmosphere into the enclosures. The enclosures are interconnected such that a pressurized gas injected into any one of the enclosures is routed to all the other enclosures through the interconnections. It is preferred that one or more sealed internal channels through structures intervening between the enclosures be employed. Pressure transducers for detecting if the pressure within the enclosures falls below a predetermined level are included. The robot also has a sensing device for determining the types of combustible substances in the surrounding atmosphere, as well as the concentrations of each type of substance relative to a pre-determined lower explosive limit (LEL). In addition, the sensing device can determine the percent level of oxygen present in the surrounding atmosphere.

Description: While the vibration analysis of gear systems has been developed, a systematic approach to the reduction of gearbox vibration has been lacking. The technique of reducing vibration by shifting natural frequencies is proposed here for gearboxes and other thin-plate structures using the theories of finite elements, modal analysis, and optimization. A triangular shell element with 18 degrees of freedom is developed for structural and dynamic analysis. To optimize, the overall vibration energy is adopted as the objective function to be minimized at the excitation frequency by varying the design variable (element thickness) under the constraint of overall constant weight. Modal analysis is used to determine the sensitivity of the vibration energy as a function of the eigenvalues and eigenvectors. The optimum design is found by the gradient projection method and a unidimensional search procedure. By applying the computer code to design problems for beams and plates, it was verified that the proposed method is effective in reducing vibration energy. The computer code is also applied to redesign the NASA Lewis gear noise rig test gearbox housing. As one example, only the shape of the top plate is varied, and the vibration energy levels of all the surfaces are reduced, yielding an overall reduction of 1/5 compared to the initial design. As a second example, the shapes of the top and two side plates are varied to yield an overall reduction in vibration energy of 1/30.

Description: Hundreds of satellites have been launched to date. Some have operated extremely well and others have not. In order to learn from past operating experiences, a study was conducted to determine the conditions under which space mechanisms (mechanically moving components) have previously worked or failed. The study consisted of: (1) an extensive literature review that included both government contractor reports and technical journals; (2) communication and visits (when necessary) to the various NASA and DOD centers and their designated contractors (this included contact with project managers of current and prior NASA satellite programs as well as their industry counterparts); (3) requests for unpublished information to NASA and industry; and (4) a mail survey designed to acquire specific mechanism experience. The information obtained has been organized into two volumes. Volume 1 provides a summary of the lessons learned, the results of a needs analysis, responses to the mail survey, a listing of experts, a description of some available facilities and a compilation of references. Volume 2 contains a compilation of the literature review synopsis.

Description: In recent years, Total Quality Management has swept across the country. Many companies and the Government have started looking at every aspect on how business is done and how money is spent. The idea or goal is to provide a service that is better, faster and cheaper. The first step in this process is to document or measure the process or operation as it stands now. For Lewis Research Center, this report is the first step in the analysis of heating plant operations. This report establishes the original benchmark that can be referred to in the future. The report also provides a comparison to other organization's heating plants to help in the brainstorming of new ideas. The next step is to propose and implement changes that would meet the goals as mentioned above. After the changes have been implemented the measuring process starts over again. This provides for a continuous improvement process.

Description: Progress made in the current year is listed, and the following papers are included in the appendix: Steady-State Dynamic Behavior of an Auxiliary Bearing Supported Rotor System; Dynamic Behavior of a Magnetic Bearing Supported Jet Engine Rotor with Auxiliary Bearings; Dynamic Modelling and Response Characteristics of a Magnetic Bearing Rotor System with Auxiliary Bearings; and Synchronous Dynamics of a Coupled Shaft/Bearing/Housing System with Auxiliary Support from a Clearance Bearing: Analysis and Experiment.

Description: This study examines the response of a flexible rotor supported by load sharing between linear bearings and an auxiliary clearance bearing. The objective is to develop a better understanding of the dynamical behavior of a magnetic bearing supported rotor system interacting with auxiliary bearings during a critical operating condition. Of particular interest is the effect of coupling between the bearing/housing and shaft vibration on the rotordynamical responses. A simulation model is developed and a number of studies are performed for various parametric configurations. An experimental investigation is also conducted to compare and verify the rotordynamic behavior predicted by the simulation studies. A strategy for reducing synchronous shaft vibration through appropriate design of coupled shaft/bearing/housing vibration modes is identified.

Description: The main research activities have been directed toward the study of the Robot Operated Materials Processing System (ROMPS), developed at GSFC under a flight project to investigate commercially promising in-space material processes and to design reflyable robot automated systems to be used in the above processes for low-cost operations. The research activities can be divided into two phases. Phase 1 dealt with testing of ROMPS robot mechanical interfaces and compliant device using a Stewart Platform testbed and Phase 2 with computer simulation study of the ROMPS robot control system. This report provides a summary of the results obtained in Phase 1 and Phase 2.

Description: The aerodynamic evaluation of two highly loaded compact radial turbine rotors was conducted at the NASA Lewis Research Center Small Engine Component Test Facility (SECTF). The experimental results were used for proof-of-concept, for modeling radial inflow turbine rotors, and for providing data for code verification. Two rotors were designed to have a shorter axial length, up to a 10-percent reduced diameter, a lighter weight, and equal or higher efficiencies with those of conventional radial inflow turbine rotors. Three configurations were tested: rotor 1, having a 40-percent shorter axial length, with the design stator (stator 1); rotor 1 with the design stator vanes closed down (stator 2); and rotor 2, slightly shorter axially and having higher loading, with stator 2. The stator had 36 vanes and the rotors each had 14 solid blades. Although presently uncooled, the rotor blades were designed for thicknesses which would allow cooling passages to be added. The overall stage performance measurements and the rotor and stator exit flow field surveys were obtained. Measurements of steady state temperatures, pressures, mass flow rates, flow angles, and output power were made at various operating conditions. Data were obtained at corrected speeds of 80, 90, 100, 110, and 120 percent of design over a range of equivalent inlet-to-exit pressure ratios of 3.5, 4.0, 4.5, and 5.0, the maximum pressure ratio achieved. The test showed that the configuration of rotor 1 with stator 1 running at the design pressure ratio produced a flow rate which was 5.6 percent higher than expected. This result indicated the need to close down the stator flow area to reduce the flow. The flow area reduction was accomplished by restaggering the vanes. Rotor 1 was retested with the closed-down stator vanes and achieved the correct mass flow. Rotor 2 was tested only with the restaggered vanes. The test results of the three turbine configurations were nearly identical. Although the measured efficiencies of the compact designs fell 2 to 3 points below the predicted efficiency of 91 percent, they did meet and exceed by up to 2.5 percentage points the efficiences of state-of-the-art turbines found in the literature.

Description: Utilizing high-frequency data from a highly instrumented rotor assembly, seeded bearing defect signatures are characterized using both conventional linear approaches, such as power spectral density analysis, and recently developed nonlinear techniques such as bicoherence analysis. Traditional low-frequency (less than 20 kHz) analysis and high-frequency envelope analysis of both accelerometer and acoustic emission data are used to recover characteristic bearing distress information buried deeply in acquired data. The successful coupling of newly developed nonlinear signal analysis with recovered wideband envelope data from accelerometers and acoustic emission sensors is the innovative focus of this research.

Description: A plasma arc welding torch is discussed. A first plasma gas is directed through the body of the welding torch and out of the body across the tip of a welding electrode disposed at the forward end of the body. A second plasma gas is disposed for flow through a longitudinal bore in the electrode. The second plasma gas enters one end of the electrode and exits the electrode at the tip thereof for co-acting with the electric welding arc to produce the desired weld. A shield gas is directed through the torch body and circulates around the head of the torch adjacent to the electrode tip.

Description: This is the final report of research project NAS8-39131 #33 sponsored by NASA's George C. Marshall Space Flight Center (MSFC) and carried out by the Civil Engineering Department of Auburn University (Auburn, Alabama) and personnel of MSFC. The objective of this study was to identify the main design parameters contributing to the loosening of bolts due to vibration and to identify their relative importance and degree of contribution to bolt loosening. Vibration testing was conducted on a shaketable with a controlled-random input in the dynamic testing laboratory of the Structural Test Division of MSFC. Test specimens which contained one test bolt were vibrated for a fixed amount of time and a percentage of pre-load loss was measured. Each specimen tested implemented some combination of eleven design parameters as dictated by the design of experiment methodology employed. The eleven design parameters were: bolt size (diameter), lubrication on bolt, hole tolerance, initial pre-load, nut locking device, grip length, thread pitch, lubrication between mating materials, class of fit, joint configuration, and mass of configuration. These parameters were chosen for this experiment because they are believed to be the design parameters having the greatest impact on bolt loosening. Two values of each design parameter were used and each combination of parameters tested was subjected to two different directions of vibration and two different g-levels of vibration. One replication was made for each test to gain some indication of experimental error and repeatability and to give some degree of statistical credibility to the data, resulting in a total of 96 tests being performed. The results of the investigation indicated that nut locking devices, joint configuration, fastener size, and mass of configuration were significant in bolt loosening due to vibration. The results of this test can be utilized to further research the complex problem of bolt loosening due to vibration.

Description: The development of high fidelity models of mechanical systems with flexible components is in flux. Many working models of these devices assume the elastic motion is small and can be superimposed on the overall rigid body motion. A drawback associated with this type of modeling technique is that it is required to regenerate the linear modal model of the device if the elastic motion is sufficiently far from the base rigid motion. An advantage to this type of modeling is that it uses NASTRAN modal data which is the NASA standard means of modal information exchange. A disadvantage to the linear modeling is that it fails to accurately represent large motion of the system, unless constant modal updates are performed. In this study, which is a continuation of a project started last year, the drawback of the currently used modal snapshot modeling technique is addressed in a rigorous fashion by novel and easily applied means.

Description: Bacteria capable of degrading trichloroethylene (TCE) were isolated from contaminated wastewaters and soil sites. The aerobic cultures were identified as Pseudomonas aeruginosa (four species) and Pseudomonas fluorescens. The optimal conditions for the growth of aerobic cultures were determined. The minimal inhibitory concentration values of TCE for Pseudomonas sps. were also determined. The aerobic cells were immobilized in calcium alginate in the form of beads. Degradation of TCE by the anaerobic and dichloroethylene (DCE) by aerobic cultures was studied using dual reactors - anaerobic biofilm and aerobic immobilized bed reactor. The minimal mineral salt (MMS) medium saturated with TCE was pumped at the rate of 1 ml per hour into the anaerobic reactor. The MMS medium saturated with DCE and supplemented with xylenes and toluene (3 ppm each) was pumped at the rate of 1 ml per hour into the fluidized air-uplift-type reactor containing the immobilized aerobic cells. The concentrations of TCE and DCE and the metabolites formed during their degradation by the anaerobic and aerobic cultures were monitored by GC. The preliminary study suggests that the anaerobic and aerobic cultures of our isolates can degrade TCE and DCE.

Description: An advanced turbine/CO2 pellet accelerator is being evaluated as a depaint technology at Oak Ridge National Laboratory (ORNL). The program, sponsored by Warner Robins Air Logistics Center (ALC), Robins Air Force Base, Georgia, has developed a robot-compatible apparatus that efficiently accelerates pellets of dry ice with a high-speed rotating wheel. In comparison to the more conventional compressed air 'sandblast' pellet accelerators, the turbine system can achieve higher pellet speeds, has precise speed control, and is more than ten times as efficient. A preliminary study of the apparatus as a depaint technology has been undertaken. Depaint rates of military epoxy/urethane paint systems on 2024 and 7075 aluminum panels as a function of pellet speed and throughput have been measured. In addition, methods of enhancing the strip rate by combining infra-red heat lamps with pellet blasting and by combining the use of environmentally benign solvents with the pellet blasting have also been studied. The design and operation of the apparatus will be discussed along with data obtained from the depaint studies.

Description: Future rotorcraft transmissions require key emerging material and component technologies using advanced and innovative design practices in order to meet the requirements for a reduced weight to power ratio, a decreased noise level, and a substantially increased reliability. The specific goals for the future rotorcraft transmission when compared with a current state-of-the-art transmission (SOAT) are: (1) a 25 percent weight reduction; (2) a 10 dB reduction in the transmitted noise level; and (3) a system reliability of 5000 hours mean-time-between-removal (MTBR) for the transmission. This report summarizes the work conducted by Bell Helicopter Textron, Inc. to achieve these goals under the Advanced Rotorcraft Transmission (ART) program from 1988 to 1995. The reference aircraft selected by BHTI for the ART program was the Tactical Tiltrotor which is a 17,000 lb gross weight aircraft. A tradeoff study was conducted comparing the ART with a Selected SOAT. The results showed the ART to be 29 percent lighter and up to 13 dB quieter with a calculated MTBR in excess of 5000 hours. The results of the following high risk component and material tests are also presented: (1) sequential meshing high contact ratio planetary with cantilevered support posts; (2) thin dense chrome plated M50 NiL double row spherical roller planetary bearings; (3) reduced kinematic error and increased bending strength spiral bevel gears; (4) high temperature WE43 magnesium housing evaluation and coupon corrosion tests; (5) flexure fatigue tests of precision forged coupons simulating precision forged gear teeth; and (6) flexure fatigue tests of plasma carburized coupons simulating plasma carburized gear teeth.

Description: Graphite/epoxy composites are extensively used in the aerospace and sporting goods industries due to their superior engineering properties compared to those of metals. However, graphite/epoxy is extremely susceptible to impact damage which can cause considerable and sometimes undetected reduction in strength. An inelastic impact model was developed to predict damage due to low-velocity impact. A transient dynamic finite element formulation was used in conjunction with the 3D Tsai-Wu failure criterion to determine and incorporate failure in the materials during impact. Material degradation can be adjusted from no degradation to partial degradation to full degradation. The developed software is based on an object-oriented implementation framework called Extensible Implementation Framework for Finite Elements (EIFFE).

Description: The geometrical parameters for a wormgear intended to be used as the transmission in advanced helicopters are finalized. The resulting contact pattern of the meshing tooth surfaces is suitable for the implementation of hydrostatic lubrication Fluid film lubrication of the contact is formulated considering external pressurization as well as hydrodynamic wedge and squeeze actions. The lubrication analysis is aimed at obtaining the oil supply pressure needed to separate the worm and gear surfaces by a prescribed minimum film thickness. The procedure of solving the mathematical problem is outlined.

Description: Assemblies are disclosed for cleaning the inside walls of pipes and tubes. A first embodiment includes a small turbine with angled blades axially mounted on one end of a standoff support. An O-ring for stabilizing the assembly within the pipe is mounted in a groove within the outer ring. A replaceable circular brush is fixedly mounted on the opposite end of the standoff support and can be used for cleaning tubes and pipes of various diameters, lengths and configurations. The turbine, standoff support, and brush spin in unison relative to a hub bearing that is fixedly attached to a wire upstream of the assembly. The nonrotating wire is for retaining the assembly in tension and enabling return of the assembly to the pipe entrance. The assembly is initially placed in the pipe or tube to be cleaned. A pressurized water or solution source is provided at a required flow-rate to propel the assembly through the pipe or tube. The upstream water pressure propels and spins the turbine, standoff support and brush. The rotating brush combined with the solution cleans the inside of the pipe. The solution flows out of the other end of the pipe with the brush rotation controlled by the flow-rate. A second embodiment is similar to the first embodiment but instead includes a circular shaped brush with ring backing mounted in the groove of the exterior ring of the turbine, and also reduces the size of the standoff support or eliminates the standoff support.

Description: An apparatus for testing and evaluating the spray pattern of high pressure fuel injector elements for use in supplying fuel to combustion engines is presented. Prior art fuel injector elements were normally tested by use of low pressure apparatuses which did not provide a purge to prevent mist from obscuring the injector element or to prevent frosting of the view windows; could utilize only one fluid during each test; and had their viewing ports positioned one hundred eighty (180 deg) apart, thus preventing optimum use of laser diagnostics. The high pressure fluid injector test apparatus includes an upper hub, an upper weldment or housing, a first clamp and stud/nut assembly for securing the upper hub to the upper weldment, a standoff assembly within the upper weldment, a pair of window housings having view glasses within the upper weldment, an injector block assembly and purge plate within the upper weldment for holding an injector element to be tested and evaluated, a lower weldment or housing, a second clamp and stud/nut assembly for securing the lower weldment to the upper hub, a third clamp and stud/nut assembly for securing the lower hub to the lower weldment, mechanisms for introducing fluid under high pressure for testing an injector element, and mechanisms for purging the apparatus to prevent frosting of view glasses within the window housings and to permit unobstructed viewing of the injector element.

Description: The objective is to develop the advanced thermal seals to a technology readiness level (TRL) of 6 to support the rapid turnaround time and low maintenance requirements of the X-33 and the future reusable launch vehicle (RLV). This program is divided into three subtasks: (1) orbiter thermal seals operation history review; (2) material, process, and design improvement; and (3) fabrication and evaluation of the advanced thermal seals.

Description: The geometry of non-symmetric tooth profiles, i.e. tooth profiles with different pressure angles on the two sides of the tooth, is studied. A feasible non-symmetric tooth profile for application in helicopter transmissions is laid out as the best compromise among several conflicting factors. The non-symmetric tooth profile is then compared with the symmetric tooth profile studied previously. Based on the detailed comparisons it is concluded that the use of the non-symmetric tooth profile would severely limit the face width of the worm, consequently reduce the number of meshing teeth and cause much higher normal load on the individual gear teeth.

Description: A wheeled exploratory vehicle is under construction at the Mars Mission Research Center at North Carolina State University. In order to serve as more than an inspection tool, this vehicle requires the ability to interact with its surroundings. A crane-type manipulator, as well as the necessary control hardware and software, has been developed for use as a sample gathering tool on this vehicle. The system is controlled by a network of four Motorola M68HC11 microcontrollers. Control hardware and software were developed in a modular fashion so that the system can be used to test future control algorithms and hardware. Actuators include three stepper motors and one solenoid. Sensors include three optical encoders and one cable tensiometer. The vehicle supervisor computer provides the manipulator system with the approximate coordinates of the target object. This system maps the workspace surrounding the given location by lowering the claw, along a set of evenly spaced vertical lines, until contact occurs. Based on this measured height information and prior knowledge of the target object size, the system determines if the object exists in the searched area. The system can find and retrieve a 1.25 in. diameter by 1.25 in. tall cylinder placed within the 47.5 sq in search area in less than 12 minutes. This manipulator hardware may be used for future control algorithm verification and serves as a prototype for other manipulator hardware.

Description: A cooling apparatus includes a container filled with a quantity of coolant fluid initially cooled to a solid phase, a cooling loop disposed between a heat load and the container, a pump for circulating a quantity of the same type of coolant fluid in a liquid phase through the cooling loop, and a pair of couplings for communicating the liquid phase coolant fluid into the container in a direct interface with the solid phase coolant fluid.

Description: This invention relates to a carrier-less, anti-backlash planetary gear system that has an input sun gear, a force-balancing and planet-alignment 'speeder' gear above the sun gear, a split ring gear that has a fixed lower ring gear coaxial with the sun gear and a rotating upper ring gear also coaxial with the sun gear. A preload bolt is used for securing the split ring gears together. Within the split ring gear is an even number of planet gears between the split ring gear and the sun gear. Each planet gear consists of an upper planet gear, and lower planet gear with the upper and lower planet gears splined together and pushed apart by a spring which causes separation and relative twist between the upper and lower planet gears. The lower planet gear meshes with the input sun gear and the fixed ring gear while the upper planet gear is driven by the lower planet gear and meshes with the rotating ring gear.

Description: The NASA Lewis Research Center (LeRC) has been testing free-piston Stirling engine/linear alternators (FPSE/LA) to develop advanced power convertors for space-based electrical power generation. Tests reported herein were performed to evaluate the interaction and transient behavior of FPSE/LA-based power systems with typical user loads. Both resistive and small induction motor loads were tested with the space power research engine (SPRE) power system. Tests showed that the control system could maintain constant long term voltage and stable periodic operation over a large range of engine operating parameters and loads. Modest resistive load changes were shown to cause relatively large voltage and, therefore, piston and displacer amplitude excursions. Starting a typical small induction motor was shown to cause large and, in some cases, deleterious voltage transients. The tests identified the need for more effective controls, if FPSE/LAs are to be used for stand-alone power systems. The tests also generated a large body of transient dynamic data useful for analysis code validation.

Description: This report describes the use of computer program 'SEEK' which works in conjunction with two user-written subroutines and an input data file to perform an optimization procedure on a user's problem. The optimization method uses a modified feasible directions gradient technique. SEEK is written in ANSI standard Fortran 77, has an object size of about 46K bytes, and can be used on a personal computer running DOS. This report describes the use of the program and discusses the optimizing method. The program use is illustrated with four example problems: a bushing design, a helical coil spring design, a gear mesh design, and a two-parameter Weibull life-reliability curve fit.

Description: An experimental and analytical study of the thermal behavior of spiral bevel gears is presented. Experimental data were taken using thermocoupled test hardware and an infrared microscope. Many operational parameters were varied to investigate their effects on the thermal behavior. The data taken were also used to validate the boundary conditions applied to the analytical model. A finite element-based solution sequence was developed. The three-dimensional model was developed based on the manufacturing process for these gears. Contact between the meshing gears was found using tooth contact analysis to describe the location, curvatures, orientations, and surface velocities. This information was then used in a three-dimensional Hertzian contact analysis to predict contact ellipse size and maximum pressure. From these results, an estimate of the heat flux magnitude and the location on the finite element model was made. The finite element model used time-averaged boundary conditions to permit the solution to attain steady state in a computationally efficient manner.Then time- and position-varying boundary conditions were applied to the model to analyze the cyclic heating and cooling due to the gears meshing and transferring heat to the surroundings, respectively. The model was run in this mode until the temperature behavior stabilized. The transient flash temperature on the surface was therefore described. The analysis can be used to predict the overall expected thermal behavior of spiral bevel gears. The experimental and analytical results were compared for this study and also with a limited number of other studies. The experimental and analytical results attained in the current study were basically within 10% of each other for the cases compared. The experimental comparison was for bulk thermocouple locations and data taken with an infrared microscope. The results of a limited number of other studies were compared with those obtained herein and predicted the same basic behavior.

Description: This semiannual status report lists specific accomplishments made on the research of the influence of backup bearings and support structure dynamics on the behavior of rotors with active supports. Papers have been presented representing work done on the T-501 engine model; an experimental/simulation study of auxiliary bearing rotordynamics; and a description of a rotordynamical model for a magnetic bearing supported rotor system, including auxiliary bearing effects. A finite element model for a foil bearing has been developed. Additional studies of rotor/bearing/housing dynamics are currently being performed as are studies of the effects of sideloading on auxiliary bearing rotordynamics using the magnetic bearing supported rotor model.

Description: This final report describes the work performed from June 1993 to January 1995. The purpose of this contract was to provide optomechanical engineering and fabrication support to the Solar X-ray Imager (SXI) program in the areas of mirror, optical bench and camera assemblies of the telescope. The Center for Applied Optics (CAO) worked closely with the Optics and S&E technical staff of MSFC to develop and investigate the most viable and economical options for the design and fabrication of a number of parts for the various telescope assemblies. All the tasks under this delivery order have been successfully completed within budget and schedule.

Description: This invention relates to a preload release mechanism comprising a preload spring assembly adapted to apply a preload to a first connector member which is mounted on a support structure and adapted for connection with a second connector member on an object. The assembly comprises telescoped bushings and a preload spring. A tubular shaft extends through the spring assembly and openings in the first connector member and support structure, on which it is clamped. A plunger rod in the shaft is provided with a tip end and a recess in the rod near the other end thereof. A retainer precludes passage of the rod through the shaft in one direction and an end cap closes the bore of the shaft at the other end and provides a shoulder which extends radially of the shaft. A plunger return spring biases the plunger rod against the plunger retainer with the plunger tip protruding from the shaft and a spring assembly return spring engages at its ends the shoulder of the end cap and one end of the spring assembly. Detents received in lateral openings in the tubular shaft are held captive by the plunger rod and one end of the spring assembly to lock the spring assembly on the tubular shaft and apply a preload to the first connector member. Upon completion of the connection, detents and spring assembly are released by plunger contact with the object to be connected, thereby releasing the preload while the connection is maintained.

Description: Internal spur gear teeth are normally stronger than pinion teeth of the same pitch and face width since external teeth are smaller at the base. However, ring gears which are narrower have an unequal addendum or are made of a material with a lower strength than that of the meshing pinion may be loaded more critically in bending. In this study, a model for the bending strength of an internal gear tooth as a function of the applied load pressure angle is presented which is based on the inscribed Lewis constant strength parabolic beam. The bending model includes a stress concentration factor and an axial compression term which are extensions of the model for an external gear tooth. The geometry of the Lewis factor determination is presented, the iteration to determine the factor is described, and the bending strength J factor is compared to that of an external gear tooth. This strength model will assist optimal design efforts for unequal addendum gears and gears of mixed materials.

Description: This document summarizes the minutes of the second NASA-Wide Fastener Technical Interchange Meeting (TIM) held November 15-16, 1994, and compiles the viewgraph presentations at the TIM by NASA and contractor personnel. The information in this document may be of value to the NASA and contractor fastener engineering community in determining the fastener controls and initiatives that existed at the time of the TIM.

Description: An experimental and analytical study of spiral bevel gears operating in an aerospace environment has been performed. Tests were conducted within a closed loop test stand at NASA Lewis Research Center. Tests were conducted to 537 kW (720 hp) at 14,400 rpm. The effects of various operating conditions on spiral bevel gear steady state and transient temperature are presented. Also, a three-dimensional analysis of the thermal behavior was conducted using a nonlinear finite element analysis computer code. The analysis was compared to the experimental results attained in this study. The results agreed well with each other for the cases compared and were no more than 10 percent different in magnitude.

Description: This paper presents results of dynamic strain gage measurements performed on the NASA gear-noise rig. The experiments were part of a joint research program between NASA and the U.S. Army Research Laboratory to advance the technology of rotorcraft transmissions. Tests were performed on six sets of low contact ratio spur gears with different tooth profile modifications. Results presented include static and dynamic measurements of gear tooth strain taken over a matrix of operating conditions. The results demonstrate that a well-designed tooth profile modification can significantly reduce dynamic loads in spur gears, especially for gears which operate at high speed and under high torque. The two parabolic modifications tested were not as effective as linear modifications, possibly because the modification zone was too long.

Description: The Control System for the Mod-2 wind turbine system is required to provide not only for startup, RPM regulation, maximizing or regulating power, and stopping the rotor, but also for load limiting, especially in the power train. Early operations with above-rated winds revealed an instability which was caused primarily by coupling between the quill shaft and the rotor air loads. This instability caused the first of several major Mod-2 Control System changes which are reviewed in the paper.

Description: This paper provides descriptions of the requirements analysis, hardware development and software development phases of the Control System design for the MOD-5A 7.3 mW Wind Turbine Generator. The system, designed by General Electric Company, Advanced Energy Programs Department, under contract DEN 3-153 with NASA Lewis Research Center and DOE, provides real time regulation of rotor speed by control of both generator torque and rotor torque. A variable speed generator system is used to provide both airgap torque control and reactive power control. The wind rotor is designed with segmented ailerons which are positioned to control blade torque. The central component of the control system, selected early in the design process, is a programmable controller used for sequencing, alarm monitoring, communication, and real time control. Development of requirements for use of aileron controlled blades and a variable speed generator required an analytical simulation that combined drivetrain, tower and blade elastic modes with wind disturbances and control behavior. An orderly two phase plan was used for controller software development. A microcomputer based turbine simulator was used to facilitate hardware and software integration and test.

Description: Split path gearboxes can be attractive alternatives to the common planetary designs for rotorcraft, but because they have seen little use, they are relatively high risk designs. To help reduce the risk of fielding a rotorcraft with a split path gearbox, the vibration and dynamic characteristics of such a gearbox were studied. A mathematical model was developed by using the Lagrangian method, and it was applied to study the effect of three design variables on the natural frequencies and vibration energy of the gearbox. The first design variable, shaft angle, had little influence on the natural frequencies. The second variable, mesh phasing, had a strong effect on the levels of vibration energy, with phase angles of 0 deg and 180 deg producing low vibration levels. The third design variable, the stiffness of the shafts connecting the spur gears to the helical pinions, strongly influenced the natural frequencies of some of the vibration modes, including two of the dominant modes. We found that, to achieve the lowest level of vibration energy, the natural frequencies of these two dominant modes should be less than those of the main excitation sources.

Description: This paper presents an analytical study on the effect of hob offset on the dynamic tooth strength of spur gears. The study was limited to equal and opposite offset values applied to the pinion and gear to maintain the standard operating center distance. The analysis presented in this paper was performed using a new version of the NASA gear dynamics code DANST. The operating speed of the transmission has a significant influence on the amount of hob offset required to equalize the dynamic stresses in the pinion and gear. In the transmission studied, at low speeds, the optimum hob offset value was found to fluctuate. At higher speeds, the optimum value was constrained by the minimum allowed thickness at the tip of the pinion tooth. For gears that must operate over a range of speeds, an average offset value may be used. Spur gears designed with the procedure presented here can have significant improvements in load capacity.

Description: A connectionist network is introduced for fault diagnosis of helicopter gearboxes that incorporates knowledge of the gearbox structure and characteristics of the vibration features as its fuzzy weights. Diagnosis is performed by propagating the abnormal features of vibration measurements through this Structure-Based Connectionist Network (SBCN), the outputs of which represent the fault possibility values for individual components of the gearbox. The performance of this network is evaluated by applying it to experimental vibration data from an OH-58A helicopter gearbox. The diagnostic results indicate that the network performance is comparable to those obtained from supervised pattern classification.

Description: A finite-element analysis (FEA) of a generic, dimensionally normalized inner race of an angular-contact ball bearing was performed under varying conditions of speed and the press (or interference) fit of the inner-race bore on a journal. The FEA results at the ball-race contact were used to derive an equation from which was obtained the radius of an equivalent cylindrical bearing race with the same or similar hoop stress. The radius of the equivalent cylinder was used to obtain a generalized closed-form approximation of the hoop stresses at the ball-inner-race contact in an angular-contact ball bearing. A life analysis was performed on both a 45- and a 120-mm-bore, angular-contact ball bearing. The predicted lives with and without hoop stress were compared with experimental endurance results obtained at 12000 and 25000 rpm with the 120-mm-bore ball bearing. A life factor equation based on hoop stress is presented.

Description: Nearly five decades have passed since G. Lundberg and A. Palmgren published their life theory in 1947 and 1952 and it was adopted as an ANSI/ABMA and ISO standard in 1950 and 1953. Subsequently, many variations and deviations from their life theory have been proposed, the most recent being that of E. Ioannides and T.A. Harris in 1985. This paper presents a critical analysis comparing the results of different life theories and discussing their implications in the design and analysis of rolling-element bearings. Variations in the stress-life relation and in the critical stress related to bearing life are discussed using stress fields obtained from three-dimensional, finite-element analysis of a ball in a nonconforming race under varying load. The results showed that for a ninth power stress-life exponent the Lundberg-Palmgren theory best predicts life as exhibited by most air-melted bearing steels. For a 12th power relation reflected by modern bearing steels, a Zaretsky-modified Weibull equation is superior. The assumption of a fatigue-limiting stress distorts the stress-life exponent and overpredicts life.

Description: The NASA Lewis Research Center and the U.S. Army Research Laboratory are involved in a joint research program to advance the technology of aerospace transmissions. Within the last six years, a transmission diagnostics research team was formed to address current and future technology barriers in transmission diagnostics. The diagnostics team conducted a survey to determine critical needs of the diagnostics community. Survey results indicated that experimental verification of gear and bearing fault detection methods and damage magnitude assessment were considered the two most critical research areas of a highly reliable health and usage monitoring system. A plan was implemented by the diagnostics team to address these key research areas, by in-house research and university grants. A variety of transmission fault detection methods were applied to experimentally obtained fatigue data. Failure modes of the fatigue tests include a variety of gear pitting failures, tooth wear, tooth fracture, and bearing spalling failures. Accomplishments to date include verification of several specific gear diagnostic methods, verification of a new pattern recognition method to determine failure, and development of a new method to model gear tooth damage. This paper presents the results of these accomplishments in transmission diagnostics research at NASA Lewis Research Center.

Description: The results of research projects directed at the reduction of noise caused by misalignment of the following gear drives: double-circular arc helical gears, modified involute helical gears, face-milled spiral bevel gears, and face-milled formate cut hypoid gears are presented. Misalignment in these types of gear drives causes periodic, almost linear discontinuous functions of transmission errors. The period of such functions is the cycle of meshing when one pair of teeth is changed for the next. Due to the discontinuity of such functions of transmission errors high vibration and noise are inevitable. A predesigned parabolic function of transmission errors that is able to absorb linear discontinuous functions of transmission errors and change the resulting function of transmission errors into a continuous one is proposed. The proposed idea was successfully tested using spiral bevel gears and the noise was reduced a substantial amount in comparison with the existing design. The idea of a predesigned parabolic function is applied for the reduction of noise of helical and hypoid gears. The effectiveness of the proposed approach has been investigated by developed TCA (tooth contact analysis) programs. The bearing contact for the mentioned gears is localized. Conditions that avoid edge contact for the gear drives have been determined. Manufacturing of helical gears with new topology by hobs and grinding worms has been investigated.

Description: This two year program will investigate Vacuum Gas Tungsten Arc Welding (VGTAW) as a method to modify or improve the weldability of normally difficult-to-weld materials. VGTAW appears to offer a significant improvement in weldability because of the clean environment and lower heat input needed. The overall objective of the program is to develop the VGTAW technology and implement it into a manufacturing environment that will result in lower cost, better quality and higher reliability aerospace components for the space shuttle and other NASA space systems. Phase 1 of this program was aimed at demonstrating the process's ability to weld normally difficult-to-weld materials. Phase 2 will focus on further evaluation, a hardware demonstration and a plan to implement VGTAW technology into a manufacturing environment. During Phase 1, the following tasks were performed: (1) Task 11000 Facility Modification - an existing vacuum chamber was modified and adapted to a GTAW power supply; (2) Task 12000 Materials Selection - four difficult-to-weld materials typically used in the construction of aerospace hardware were chosen for study; (3) Task 13000 VGTAW Experiments - welding experiments were conducted under vacuum using the hollow tungsten electrode and evaluation. As a result of this effort, two materials, NARloy Z and Incoloy 903, were downselected for further characterization in Phase 2; and (4) Task 13100 Aluminum-Lithium Weld Studies - this task was added to the original work statement to investigate the effects of vacuum welding and weld pool vibration on aluminum-lithium alloys.

Description: This paper summarized the results of a study in which three different vibration diagnostic methods were used to detect gear tooth fracture in a high contact ratio face gear mesh. The NASA spiral bevel gear fatigue test rig was used to produce unseeded fault, natural failures of four face gear specimens. During the fatigue tests, which were run to determine load capacity and primary failure mechanisms for face gears, vibration signals were monitored and recorded for gear diagnostic purposes. Gear tooth bending fatigue and surface pitting were the primary failure modes found in the tests. The damage ranged from partial tooth fracture on a single tooth in one test to heavy wear, severe pitting, and complete tooth fracture of several teeth on another test. Three gear fault detection techniques, FM4, NA4*, and NB4, were applied to the experimental data. These methods use the signal average in both the time and frequency domain. Method NA4* was able to conclusively detect the gear tooth fractures in three out of the four fatigue tests, along with gear tooth surface pitting and heavy wear. For multiple tooth fractures, all of the methods gave a clear indication of the damage. It was also found that due to the high contact ratio of the face gear mesh, single tooth fractures did not significantly affect the vibration signal, making this type of failure difficult to detect.

Description: A new hydrodynamic bearing concept, the wave journal bearing, is being developed because it has better stability characteristics than plain journal bearings while maintaining similar load capacity. An analysis code to predict the steady state and dynamic performance of the wave journal bearing is also part of the development. To verify numerical predictions and contrast the wave journal bearing's stability characteristics to a plain journal bearing, tests were conducted at NASA Lewis Research Center using an air bearing test rig. Bearing film pressures were measured at 16 ports located around the bearing circumference at the middle of the bearing length. The pressure measurements for both a plain journal bearing and a wave journal bearing compared favorably with numerical predictions. Both bearings were tested with no radial load to determine the speed threshold for self-excited fractional frequency whirl. The plain journal bearing started to whirl immediately upon shaft start-up. The wave journal did not incur self-excited whirl until 800 to 900 rpm as predicted by the analysis. Furthermore, the wave bearing's geometry limited the whirl orbit to less than the bearing's clearance. In contrast, the plain journal bearing did not limit the whirl orbit, causing it to rub.

Description: A wave journal bearing concept features a waved inner bearing diameter of the non-rotating bearing side and it is an alternative to the plain journal bearing. The wave journal bearing has a significantly increased load capacity in comparison to the plain journal bearing operating at the same eccentricity. It also offers greater stability than the plain circular bearing under all operating conditions. The wave bearing's design is relatively simple and allows the shaft to rotate in either direction. Three wave bearings are sensitive to the direction of an applied stationary side load. Increasing the number of waves reduces the wave bearing's sensitivity to the direction of the applied load relative to the wave. However, the range in which the bearing performance can be varied decreases as the number of waves increases. Therefore, both the number and the amplitude of the waves must be properly selected to optimize the wave bearing design for a specific application. It is concluded that the stiffness of an air journal bearing, due to hydrodynamic effect, could be doubled and made to run stably by using a six or eight wave geometry with a wave amplitude approximately half of the bearing radial clearance.

Description: Two groups of spur gears manufactured from two different materials and heat treatments were endurance tested for surface fatigue life. One group was manufactured from AISI 1552 and was finished ground to a 0.4 micron (16 micro-in.) rms surface finish and then dual frequency contour induction hardened. The second group was manufactured from CEVM AISI 9310 and was carburized, hardened, and ground to a 0.4 micron (16 micro-in.) rms surface finish. The gear pitch diameter was 8.89 cm (3.5 in.). Test conditions were a maximum Hertz stress of 1.71 GPa (248 ksi), a bulk gear temperature of approximately 350 K (170 F) and a speed of 10,000 rpm. The lubricant used for the tests was a synthetic paraffinic oil with an additive package. The test results showed that the 10 percent surface fatigue (pitting) life of the contour hardened AISI 1552 test gears was 1.7 times that of the carburized and hardened AISI 9310 test gears. Also there were two early failures of the AISI 1552 gears by bending fatigue.

Description: A proof-of-feasibility demonstration showed that high temperature superconductor (HTS) coils can be used in a high-load, active magnetic bearing in liquid nitrogen. A homopolar radial bearing with commercially wound HTS (Bi 2223) bias and control coils produced over 200 lb (890 N) radial load capacity (measured non-rotating) and supported a shaft to 14000 rpm. The goal was to show that HTS coils can operate stably with ferromagnetic cores in a feedback controlled system at a current density similar to that in Cu in liquid nitrogen. Design compromises permitted use of circular coils with rectangular cross section. Conductor improvements will eventually permit coil shape optimization, higher current density and higher bearing load capacity. The bias coil, wound with non-twisted, multifilament HTS conductor, required negligible power to carry its direct current. The control coils were wound with monofilament HTS sheathed in Ag. These dissipated negligible power for direct current (i.e. for steady radial load components). When an alternating current (AC) was added, the AC component dissipated power which increased rapidly with frequency and quadratically with AC amplitude. In fact at frequencies above about 2 hz, the effective resistance of the control coil conductor actually exceeds that of the silver which is in electrical parallel with the oxide superconductor. This is at least qualitatively understandable in the context of a Bean-type model of flux and current penetration into a Type II superconductor. Fortunately the dynamic currents required for bearing stability are of small amplitude. These results show that while twisted multifilament conductor is not needed for stable levitation, twisted multifilaments will be required to reduce control power for sizable dynamic loads, such as those due to unbalance.

Description: This third semi-annual progress report covers the reporting period from August 16, 1994 through February 15, 1995 on NASA Grant NAG8-240, 'Design and Application of Electromechanical Actuators for Deep Space Missions'. There are two major report sections: Motor Control Status/Electrical Experiment Planning and Experiment Planning and Initial Results. The primary emphasis of our efforts during the reporting period has been final construction and testing of the laboratory facilities. As a result, this report is dedicated to that topic.

Description: To improve hydrodynamic journal bearing steady-state and dynamic performance, a new bearing concept, the wave journal bearing, was developed at the author's lab. This concept features a waved inner bearing diameter. Compared to other alternative bearing geometries used to improve bearing performance such as spiral or herring-bone grooves, steps, etc., the wave bearing's design is relatively simple and allows the shaft to rotate in either direction. A three-wave bearing operating with a compressible lubricant, i.e., gas is analyzed using a numerical code. Its performance is compared to a plain (truly) circular bearing over a broad range of bearing working parameters, e.g., bearing numbers from 0.01 to 100.

Description: An electronically controlled mechanical seal for use as the purge gas seal in a liquid oxygen turbopump has been fabricated and tested under transient operating conditions. The thickness of the lubricating film is controlled by adjusting the coning of the carbon face. This is accomplished by applying a voltage to a piezoelectric actuator to which the carbon face is bonded. The seal has been operated with a closed-loop control system that utilizes either the leakage rate or seal face temperature as the feedback. Both speed and pressure transients have been imposed on the seal. The transient tests have demonstrated that the seal is capable of maintaing low leakage rates while limiting face temperatures.

Description: A spacecraft payload flown on a launch vehicle experiences dynamic loads. The dynamic loads are caused by various phenomena ranging from the start-up of the launch vehicle engine to wind gusts. A spacecraft payload should be designed to meet launch vehicle dynamic loads. One of the major steps taken towards determining the dynamic loads is to correlate the finite element model of the spacecraft with the test results of a modal survey test. A test-verified finite element model of the spacecraft should possess the same spatial properties (stiffness, mass, and damping) and modal properties (frequencies and mode shapes) as the test hardware representing the spacecraft. The test-verified and correlated finite element model of the spacecraft is then coupled with the finite element model of the launch vehicle for analysis of loads and stress. Modal survey testing, verification of a finite element model, and modification of the finite element model to match the modal survey test results can easily be accomplished if the spacecraft structure is simple. However, this is rarely the case. A simple structure here is defined as a structure where the influence of nonlinearity between force and displacement (uncertainty in a test, for example, with errors in input and output), and the influence of damping (structural, coulomb, and viscous) are not pronounced. The objective of this study is to develop system identification and correlation methods with the focus on the structural systems that possess nonproportional damping. Two approaches to correct the nonproportional damping matrix of a truss structure were studied, and have been implemented on truss-like structures such as the National Aeronautics and Space Administration's space station truss. The results of this study showed nearly 100 percent improvement of the correlated eigensystem over the analytical eigensystem. The first method showed excellent results with up to three modes used in the system identification process. The second method could handle more modes, but required more computer usage time, and the results were less accurate than those of the first method.

Description: As one of the activities of the NASA/MSFC Turbine Technology Team, the present effort focused on using CFD in the design and analysis of high performance rocket engine pumps. A three-dimensional Navier-Stokes code was used for various turbine flow field calculations, with emphasis on the tip clearance flow and the associated losses. Both a baseline geometry and an advanced-concept geometry (with a mini-shroud at the blade tip) were studied at several tip clearances. The calculations performed under the present effort demonstrate that a state-of-the-art CFD code can be applied successfully to turbine design and the development of advanced hardware concepts.

Description: In controller design for flexible structures, certain system modes are extremely important for the overall performance of the structure. A reduced-order model (ROM) based control focuses on these modes, providing a viable, active control algorithm for large systems. Unfortunately, unmodeled structure dynamics can interact with the ROM controller (CSI) and cause crippling deterioration of system performance, possibly to the point that system stability is lost. A residual model filter (RMF) eliminates one channel of control structure interaction (CSI), while adding only a simple, second-order filter to the control loop. Thus, the ROM controller can be designed independently, based strictly on performance criteria, and residual mode filters can then be selected to compensate for CSI. A flexible robot manipulator is used for preliminary experimentation with the ROM/RMF design methodology. Since the controller was to be implemented both with, and without compensation for CSI, the ROM control gains are carefully chosen such that closed loop stability is never compromised. In this way, RMF effectiveness is easily evaluated in terms of the improvement in system performance resulting from CSI compensation.