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Daniel Guggenheim School of Aerospace Engineering

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https://hdl.handle.net/1853/70742

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College of Engineering

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Aerospace Design Group

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Aerospace Systems Design Laboratory (ASDL)

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Air Transportation Laboratory

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Cognitive Engineering Center

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Space Systems Design Laboratory (SSDL)

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Publication Search Results

Now showing 1 - 10 of 20

A comparative study and application of continuously variable transmission to a single main rotor heavy lift helicopter

(Georgia Institute of Technology, 2009-10-19) Hameer, Sameer Hameer Jaffer

Rotorcraft transmission design is limited by empirical weight trends that are proportional to the power/torque raised to the two-thirds coupled with the relative inexperience industry has with the employment of variable speed transmission to heavy lift helicopters of the order of 100,000 lbs gross weight and 30,000 installed horsepower. The advanced rotorcraft transmission program objectives are to reduce transmission weight by at least 25%, reduce sound pressure levels by at least 10 dB, have a 5000 hr mean time between removal, and also incorporate the use of split torque technology in rotorcraft drivetrains of the future. The major obstacle that challenges rotorcraft drivetrain design is the selection, design, and optimization of a variable speed transmission in the goal of achieving a 50% reduction in rotor speed and its ability to handle high torque with light weight gears, as opposed to using a two-speed transmission which has inherent structural problems and is highly unreliable due to the embodiment of the traction type transmission, complex clutch and brake system. This thesis selects a nontraction pericyclic continuously variable transmission (P-CVT) as the best approach for a single main rotor heavy lift helicopter to target the above mentioned obstacle for drivetrain design and provides advancement in the state of the art of drivetrain design over existing planetary and split torque transmissions currently used in helicopters. The goal of the optimization process was to decrease weight, decrease noise, increase efficiency, and increase safety and reliability. The objective function utilized the minimization of the weight and the constraint is the tooth bending stress of the facegears. The most important parameters of the optimization process are weight, maintainability, and reliability which are cross-functionally related to each other, and these parameters are related to the torques and operating speeds. The analysis of the split torque type P-CVT achieved a weight reduction of 42.5% and 40.7% over planetary and split torque transmissions respectively. In addition, a 19.5 dB sound pressure level reduction was achieved using active gear struts, and also the use of fabricated steel truss like housing provided a higher maintainability and reliability, low cost, and low weight over cast magnesium housing currently employed in helicopters. The static finite element analysis of the split torque type P-CVT, both 2-D and 3-D, yielded stresses below the allowable bending stress of the material. The goal of the finite element analysis is to see if the designed product has met its functional requirements. The safety assessment of the split torque type P-CVT yielded a 99% probability of mission success based on a Monte Carlo simulation using stochastic- petri net analysis and a failure hazard analysis. This was followed by an FTA/RBD analysis which yielded an overall system failure rate of 140.35 failures per million hours, and a preliminary certification and time line of certification was performed. The use of spherical facegears and pericyclic kinematics has advanced the state of the art in drivetrain design primarily in the reduction of weight and noise coupled with high safety, reliability, and efficiency.
A plm implementation for aerospace systems engineering-conceptual rotorcraft design

(Georgia Institute of Technology, 2009-04-08) Hart, Peter Bartholomew

The thesis will discuss the Systems Engineering phase of an original Conceptual Design Engineering Methodology for Aerospace Engineering-Vehicle Synthesis. This iterative phase is shown to benefit from digitization of Integrated Product&Process Design (IPPD) activities, through the application of Product Lifecycle Management (PLM) technologies. Requirements analysis through the use of Quality Function Deployment (QFD) and 7 MaP tools is explored as an illustration. A "Requirements Data Manager" (RDM) is used to show the ability to reduce the time and cost to design for both new and legacy/derivative designs. Here the COTS tool Teamcenter Systems Engineering (TCSE) is used as the RDM. The utility of the new methodology is explored through consideration of a legacy RFP based vehicle design proposal and associated aerospace engineering. The 2001 American Helicopter Society (AHS) 18th Student Design Competition RFP is considered as a starting point for the Systems Engineering phase. A Conceptual Design Engineering activity was conducted in 2000/2001 by Graduate students (including the author) in Rotorcraft Engineering at the Daniel Guggenheim School of Aerospace Engineering at the Georgia Institute of Technology, Atlanta GA. This resulted in the "Kingfisher" vehicle design, an advanced search and rescue rotorcraft capable of performing the "Perfect Storm" mission, from the movie of the same name. The associated requirements, architectures, and work breakdown structure data sets for the Kingfisher are used to relate the capabilities of the proposed Integrated Digital Environment (IDE). The IDE is discussed as a repository for legacy knowledge capture, management, and design template creation. A primary thesis theme is to promote the automation of the up-front conceptual definition of complex systems, specifically aerospace vehicles, while anticipating downstream preliminary and full spectrum lifecycle design activities. The thesis forms a basis for additional discussions of PLM tool integration across the engineering, manufacturing, MRO and EOL lifecycle phases to support business management processes.
Optimal maintenance of a multi-unit system under dependencies

(Georgia Institute of Technology, 2008-11-17) Sung, Ho-Joon

The availability, or reliability, of an engineering component greatly influences the operational cost and safety characteristics of a modern system over its life-cycle. Until recently, the reliance on past empirical data has been the industry-standard practice to develop maintenance policies that provide the minimum level of system reliability. Because such empirically-derived policies are vulnerable to unforeseen or fast-changing external factors, recent advancements in the study of topic on maintenance, which is known as optimal maintenance problem, has gained considerable interest as a legitimate area of research. An extensive body of applicable work is available, ranging from those concerned with identifying maintenance policies aimed at providing required system availability at minimum possible cost, to topics on imperfect maintenance of multi-unit system under dependencies. Nonetheless, these existing mathematical approaches to solve for optimal maintenance policies must be treated with caution when considered for broader applications, as they are accompanied by specialized treatments to ease the mathematical derivation of unknown functions in both objective function and constraint for a given optimal maintenance problem. These unknown functions are defined as reliability measures in this thesis, and theses measures (e.g., expected number of failures, system renewal cycle, expected system up time, etc.) do not often lend themselves to possess closed-form formulas. It is thus quite common to impose simplifying assumptions on input probability distributions of components' lifetime or repair policies. Simplifying the complex structure of a multi-unit system to a k-out-of-n system by neglecting any sources of dependencies is another commonly practiced technique intended to increase the mathematical tractability of a particular model. This dissertation presents a proposal for an alternative methodology to solve optimal maintenance problems by aiming to achieve the same end-goals as Reliability Centered Maintenance (RCM). RCM was first introduced to the aircraft industry in an attempt to bridge the gap between the empirically-driven and theory-driven approaches to establishing optimal maintenance policies. Under RCM, qualitative processes that enable the prioritizing of functions based on the criticality and influence would be combined with mathematical modeling to obtain the optimal maintenance policies. Where this thesis work deviates from RCM is its proposal to directly apply quantitative processes to model the reliability measures in optimal maintenance problem. First, Monte Carlo (MC) simulation, in conjunction with a pre-determined Design of Experiments (DOE) table, can be used as a numerical means of obtaining the corresponding discrete simulated outcomes of the reliability measures based on the combination of decision variables (e.g., periodic preventive maintenance interval, trigger age for opportunistic maintenance, etc.). These discrete simulation results can then be regressed as Response Surface Equations (RSEs) with respect to the decision variables. Such an approach to represent the reliability measures with continuous surrogate functions (i.e., the RSEs) not only enables the application of the numerical optimization technique to solve for optimal maintenance policies, but also obviates the need to make mathematical assumptions or impose over-simplifications on the structure of a multi-unit system for the sake of mathematical tractability. The applicability of the proposed methodology to a real-world optimal maintenance problem is showcased through its application to a Time Limited Dispatch (TLD) of Full Authority Digital Engine Control (FADEC) system. In broader terms, this proof-of-concept exercise can be described as a constrained optimization problem, whose objective is to identify the optimal system inspection interval that guarantees a certain level of availability for a multi-unit system. A variety of reputable numerical techniques were used to model the problem as accurately as possible, including algorithms for the MC simulation, imperfect maintenance model from quasi renewal processes, repair time simulation, and state transition rules. Variance Reduction Techniques (VRTs) were also used in an effort to enhance MC simulation efficiency. After accurate MC simulation results are obtained, the RSEs are generated based on the goodness-of-fit measure to yield as parsimonious model as possible to construct the optimization problem. Under the assumption of constant failure rate for lifetime distributions, the inspection interval from the proposed methodology was found to be consistent with the one from the common approach used in industry that leverages Continuous Time Markov Chain (CTMC). While the latter does not consider maintenance cost settings, the proposed methodology enables an operator to consider different types of maintenance cost settings, e.g., inspection cost, system corrective maintenance cost, etc., to result in more flexible maintenance policies. When the proposed methodology was applied to the same TLD of FADEC example, but under the more generalized assumption of strictly Increasing Failure Rate (IFR) for lifetime distribution, it was shown to successfully capture component wear-out, as well as the economic dependencies among the system components.
A new methodology for sizing and performance predictions of a rotary wing ejector

(Georgia Institute of Technology, 2008-10-07) Moodie, Alex Montfort

The application of an ejector nozzle integrated with a reaction drive rotor configuration for a vertical takeoff and landing rotorcraft is considered in this research. The ejector nozzle is a device that imparts energy from a high speed airflow source to a lower speed secondary airflow inside a duct. The overall nozzle exhaust mass flow rate is increased through fluid entrainment, while the exhaust gas velocity is simultaneously decreased. The exhaust gas velocity is strongly correlated to the jet noise produced by the nozzle, making the ejector a good candidate for propulsion system noise reduction. Ejector nozzles are mechanically simple in that there are no moving parts. However, coupled fluid dynamic processes are involved, complicating analysis and design. Geometric definitions of the ejector nozzle are determined through a reduced fidelity, multi-disciplinary, representation of the rotary wing ejector. The resulting rotary wing ejector geometric sizing procedure relates standard vehicle and rotor design parameters to the ejector. Additionally, a rotary wing ejector performance procedure is developed to compare this rotor configuration to a conventional rotor. Performance characteristics and aerodynamic effects of the rotor and ejector nozzle are analytically studied. Ejector nozzle performance, in terms of exit velocities, is compared to the primary reaction drive nozzle; giving an indication of the potential for noise reduction. Computational fluid dynamics are paramount in predicting the aerodynamic effects of the ejector nozzle located at the rotor blade tip. Two-dimensional, steady-state, Reynolds-averaged Navier-Stokes (RANS) models are implemented for sectional lift and drag predictions required for the rotor aerodynamic model associated with both the rotary wing ejector sizing and performance procedures. A three-dimensional, unsteady, RANS simulation of the rotary wing ejector is performed to study the aerodynamic interactions between the ejector nozzle and rotor. Overall performance comparisons are made between the two- and three-dimensional models of the rotary wing ejector, and a similar conventional rotor.
Composite skid landing gear design investigation

(Georgia Institute of Technology, 2008-06-27) Shrotri, Kshitij

A composite skid landing gear design investigation has been conducted. Limit Drop Test as per Federal Aviation Regulations (FAR) Part 27.725 and Crash test as per MIL STD 1290A (AV) were simulated using ABAQUS to evaluate performance of multiple composite fiber-matrix systems. Load factor developed during multiple landing scenarios and energy dissipated during crash were computed. Strength and stiffness based constraints were imposed. Tsai-Wu and LaRC04 physics based failure criteria were used for limit loads. Hashin s damage initiation criteria with Davila-Camanho s energy based damage evolution law were used for crash. Initial results indicate that an all single-composite skid landing gear may not be feasible due to strength concerns in the cross member bends. Hybridization of multiple composites with elasto-plastic aluminum 7075 showed proof of strength under limit loads. Laminate tailoring for load factor optimization under limit loads was done by parameterization of a single variable fiber orientation angle for multiple laminate families. Tsai-Wu failure criterion was used to impose strength constraints. A quasi-isotropic N = 4 (pi/4) 48 ply IM7/8552 laminate was shown to be the optimal solution with a load factor under level landing condition equaling 4.17g s. LaRC04 predicts that failures will be initiated as matrix cracking under compression and fiber kinking under in-plane shear and longitudinal compression. All failures under limit loads being reported in the metal-composite hybrid joint, the joint was simulated by adhesive bonding and filament winding, separately. Simply adhesive bonding the metal and composite regions does not meet strength requirements. Filament wound bolted metal-composite joint shows proof of strength. Filament wound composite bolted to metal cross member radii is the final joining methodology. Finally, crash analysis was conducted as per requirements from MIL STD 1290A (AV). Crash at 42 ft/sec with 1 design gross weight (DGW) lift was simulated using ABAQUS. Plastic and friction energy dissipation in the reference aluminum skid landing gear were compared with plastic, friction and damage energy dissipation in the hybrid metal-composite design. Damage in composites was modeled as progressive damage with Hashin s damage initiation criteria and Davila-Camanho s energy based damage evolution law. The latter meets requirements of aircraft kinetic energy dissipation up to 20 ft/sec (67.6 kJ) as per MIL STD 1290A (AV). Weight saving possibility of up to 49% over conventional metal skid landing gear is reported. The final design recommended includes Ke49/PEEK skids, 48 ply IM7/8552 cross member tapered beams and, Al 7075 cross member bend radii bolted to the filament wound composite tapered beam. Concerns in composite skid landing gear designs, testing requirements and future opportunities are addressed.
Optimal aeroelastic trim for rotorcraft with constrained, non-unique trim solutions

(Georgia Institute of Technology, 2008-02-15) Schank, Troy C.

New rotorcraft configurations are emerging, such as the optimal speed helicopter and slowed-rotor compound helicopter which, due to variable rotor speed and redundant lifting components, have non-unique trim solution spaces. The combination of controls and rotor speed that produce the best steady-flight condition is sought among all the possible solutions. This work develops the concept of optimal rotorcraft trim and explores its application to advanced rotorcraft configurations with non-unique, constrained trim solutions. The optimal trim work is based on the nonlinear programming method of the generalized reduced gradient (GRG) and is integrated into a multi-body, comprehensive aeroelastic rotorcraft code. In addition to the concept of optimal trim, two further developments are presented that allow the extension of optimal trim to rotorcraft with rotors that operate over a wide range of rotor speeds. The first is the concept of variable rotor speed trim with special application to rotors operating in steady autorotation. The technique developed herein treats rotor speed as a trim variable and uses a Newton-Raphson iterative method to drive the rotor speed to zero average torque simultaneously with other dependent trim variables. The second additional contribution of this thesis is a novel way to rapidly approximate elastic rotor blade stresses and strains in the aeroelastic trim analysis for structural constraints. For rotors that operate over large angular velocity ranges, rotor resonance and increased flapping conditions are encountered that can drive the maximum cross-sectional stress and strain to levels beyond endurance limits; such conditions must be avoided. The method developed herein captures the maximum cross-sectional stress/strain based on the trained response of an artificial neural network (ANN) surrogate as a function of 1-D beam forces and moments. The stresses/strains are computed simultaneously with the optimal trim and are used as constraints in the optimal trim solution. Finally, an optimal trim analysis is applied to a high-speed compound gyroplane configuration, which has two distinct rotor speed control methods, with the purpose of maximizing the vehicle cruise efficiency while maintaining rotor blade strain below endurance limit values.
Design Methodology for Developing Concept Independent Rotorcraft Analysis and Design Software

(Georgia Institute of Technology, 2007-11-16) Davis, Joseph Hutson

Throughout the evolution of rotorcraft design, great advancements have been made in developing performance analysis and sizing tools to assist designers during the preliminary and detailed design phases. However, very few tools exist to assist designers during the conceptual design phase. Most performance analysis tools are very discipline or concept specific, and many are far too cumbersome to use for comparing vastly different concepts in a timely manner. Consequently, many conceptual decisions must be made qualitatively. A need exists to develop a single software tool which is capable of modeling any type of feasible rotorcraft concept using different levels of detail and accuracy in order to assist in the decision making throughout the conceptual and preliminary design phases. This software should have a very intuitive and configurable user interface which allows users of different backgrounds and experience levels to use it, while providing a broad capability of modeling traditional, innovative, and highly complex design concepts. As an illustration, a newly developed Concept Independent Rotorcraft Analysis and Design Software (CIRADS) will be presented to prove the applicability of such software tools. CIRADS is an object oriented application with a Graphical User Interface (GUI) for specifying mission requirements, aircraft configurations, weight component breakdowns, engine performance, and airfoil characteristics. Input files from the GUI are assembled to form analysis and design project files which are processed using algorithms developed in MATLAB but compiled as a stand alone executable and imbedded in the GUI. The performance calculations are based primarily upon a modified momentum theory with empirical correction factors and simplified blade stall models. The ratio of fuel (RF) sizing methodology is used to size the aircraft based on the mission requirements specified by the user. The results of the analysis/design simulations are then displayed in tables and Text Fields in the GUI. The intent for CIRADS is to become a primary conceptual sizing and performance estimation tool for the Georgia Institute of Technology rotorcraft design teams for use in the annual American Helicopter Society Rotorcraft Design Competition.
A Hybrid Optimization Scheme for Helicopters with Composite Rotor Blades

(Georgia Institute of Technology, 2007-05-18) Ku, Jieun

Rotorcraft optimization is a challenging problem due to its conflicting requirements among many disciplines and highly coupled design variables affecting the overall design. Also, the design process for a composite rotor blade is often ambiguous because of its design space. Furthermore, analytical tools do not produce acceptable results compared with flight test when it comes to aerodynamics and aeroelasticity unless realistic models are used, which leads to excessive computer time per iteration. To comply these requirements, computationally efficient yet realistic tools for rotorcraft analysis, such as VABS and DYMORE were used as analysis tools. These tools decompose a three-dimensional problem into a two-dimensional cross-sectional and a one-dimensional beam analysis. Also, to eliminate the human interaction between iterations, a previously VABS-ANSYS macro was modified and automated. The automated tool shortened the computer time needed to generate the VABS input file for each analysis from hours to seconds. MATLAB was used as the wrapper tool to integrate VABS, DYMORE and the VABS-ANSYS macro into the methodology. This methodology uses Genetic Algorithm and gradient-based methods as optimization schemes. The baseline model is the rotor system of generic Georgia Tech Helicopter (GTH), which is a three-bladed, soft-in-plane, bearingless rotor system. The resulting methodology is a two-level optimization, global and local. Previous studies showed that when stiffnesses are used as design variables in optimization, these values act as if they are independent and produce design requirements that cannot be achieved by local-level optimization. To force design variables at the global level to stay within the feasible design space of the local level, a surrogate model was adapted into the methodology. For the surrogate model, different ``design of experiments" (DOE) methods were tested to find the most computationally efficient DOE method. The response surface method (RSM) and Kriging were tested for the optimization problem. The results show that using the surrogate model speeds up the optimization process and the Kriging model shows superior performance over RSM models. As a result, the global-level optimizer produces requirements that the local optimizer can achieve.
Preliminary Turboshaft Engine Design Methodology for Rotorcraft Applications

(Georgia Institute of Technology, 2006-11-20) Suhr, Stephen Andrew

In the development of modern rotorcraft vehicles, many unique challenges emerge due to the highly coupled nature of individual rotorcraft design disciplines therefore, the use of an integrated product and process development (IPPD) methodology is necessary to drive the design solution. Through the use of parallel design and analysis, this approach achieves the design synthesis of numerous product and process requirements that is essential in ultimately satisfying the customers demands. Over the past twenty years, Georgia Techs Center for Excellence in Rotorcraft Technology (CERT) has continuously focused on refining this IPPD approach within its rotorcraft design course by using the annual American Helicopter Society (AHS) Student Design Competition as the design requirement catalyst. Despite this extensive experience, however, the documentation of this preliminary rotorcraft design approach has become out of date or insufficient in addressing a modern IPPD methodology. In no design discipline is this need for updated documentation more prevalent than in propulsion system design, specifically in the area of gas turbine technology. From an academic perspective, the vast majority of current propulsion system design resources are focused on fixed-wing applications with very limited reference to the use of turboshaft engines. Additionally, most rotorcraft design resources are centered on aerodynamic considerations and largely overlook propulsion system integration. This research effort is aimed at bridging this information gap by developing a preliminary turboshaft engine design methodology that is applicable to a wide range of potential rotorcraft propulsion system design problems. The preliminary engine design process begins by defining the design space through analysis of the initial performance and mission requirements dictated in a given request for proposal (RFP). Engine cycle selection is then completed using tools such as GasTurb and the NASA Engine Performance Program (NEPP) to conduct thorough parametric and engine performance analysis. Basic engine component design considerations are highlighted to facilitate configuration trade studies and to generate more detailed engine performance and geometric data. Throughout this approach, a comprehensive engine design case study is incorporated based on a two-place, turbine training helicopter known as the Georgia Tech Generic Helicopter (GTGH). This example serves as a consistent propulsion system design reference highlighting the level of integration and detail required for each step of the preliminary turboshaft engine design methodology.
Development and Implementation of Rotorcraft Preliminary Design Methodology using Multidisciplinary Design Optimization

(Georgia Institute of Technology, 2006-11-14) Khalid, Adeel S.

A formal framework is developed and implemented in this research for preliminary rotorcraft design using IPPD methodology. All the technical aspects of design are considered including the vehicle engineering, dynamic analysis, stability and control, aerodynamic performance, propulsion, transmission design, weight and balance, noise analysis and economic analysis. The design loop starts with a detailed analysis of requirements. A baseline is selected and upgrade targets are identified depending on the mission requirements. An Overall Evaluation Criterion (OEC) is developed that is used to measure the goodness of the design or to compare the design with competitors. The requirements analysis and baseline upgrade targets lead to the initial sizing and performance estimation of the new design. The digital information is then passed to disciplinary experts. This is where the detailed disciplinary analyses are performed. Information is transferred from one discipline to another as the design loop is iterated. To coordinate all the disciplines in the product development cycle, Multidisciplinary Design Optimization (MDO) techniques e.g. All At Once (AAO) and Collaborative Optimization (CO) are suggested. The methodology is implemented on a Light Turbine Training Helicopter (LTTH) design. Detailed disciplinary analyses are integrated through a common platform for efficient and centralized transfer of design information from one discipline to another in a collaborative manner. Several disciplinary and system level optimization problems are solved. After all the constraints of a multidisciplinary problem have been satisfied and an optimal design has been obtained, it is compared with the initial baseline, using the earlier developed OEC, to measure the level of improvement achieved. Finally a digital preliminary design is proposed. The proposed design methodology provides an automated design framework, facilitates parallel design by removing disciplinary interdependency, current and updated information is made available to all disciplines at all times of the design through a central collaborative repository, overall design time is reduced and an optimized design is achieved.