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This article begins by describing the need for a new method and tool for performing a sustainability assessment for manufacturing processes and systems. A brief literature survey is done to highlight the major existing methods and tools, their function, and their shortcomings. The article goes on to describe the general approach of the method before describing a computer aided tool that has been developed to implement the method. The article concludes with a walk through of a generic use case that describes where such a method would be useful and how such a tool would be implemented.

We present a new interval-based formulation for the static analysis of plane stress/strain problems with uncertain parameters in load, material and geometry. We exploit the Interval Finite Element Method (IFEM) to model uncertainties in the system. Overestimation due to dependency among interval variables is reduced using a new decomposition strategy for the structural stiffness matrix and the nodal equivalent load vector. Primary and derived quantities follow from minimization of the total energy and they are solved simultaneously and with the same accuracy by means of Lagrangian multipliers. Two different element assembly strategies are introduced in the formulation: one is Element-by-Element, and the other resembles conventional assembly. In addition, we implement a new variant of the interval iterative enclosure method to obtain outer and inner solutions. Numerical examples show that the proposed interval approach guarantees to enclose the exact system response.

This work contributes to the understanding of physical mechanisms that control flashback, or more appropriately combustion recession, in diesel sprays. A large dataset, comprising many fuels, injection pressures, ambient temperatures, ambient oxygen concentrations, ambient densities, and nozzle diameters is used to explore experimental trends for the behavior of combustion recession. Then, a reduced-order model, capable of modeling non-reacting and reacting conditions, is used to help interpret the experimental trends. Finally, the reduced-order model is used to predict how a controlled ramp-down rate-of-injection can enhance the likelihood of combustion recession for conditions that would not normally exhibit combustion recession. In general, fuel, ambient conditions, and the end-of-injection transient determine the success or failure of combustion recession.

Since, ice accretion can significantly degrade the performance and the stability of an airborne vehicle, it is imperative to be able to model it accurately. While ice accretion studies have been performed on airplane wings and helicopter blades in abundance, there are few that attempt to model the process on more complex geometries such as fuselages. This paper proposes a methodology that extends an existing in-house Extended Messinger solver to complex geometries by introducing the capability to work with unstructured grids and carry out spatial surface streamwise marching. For the work presented here commercial solvers such as STAR-CCM+ and ANSYS Fluent are used for the flow field and droplet dispersed phase computations. The ice accretion is carried out using an in-house icing solver called GT-ICE. The predictions by GT-ICE are compared to available experimental data, or to predictions by other solvers such as LEWICE and STAR-CCM+.

For a better understanding of soot formation and oxidation processes in conventional diesel and biodiesel spray flames, the morphology, microstructure and sizes of soot particles directly sampled in spray flames fuelled with US#2 diesel and soy-methyl ester were investigated using transmission electron microscopy (TEM). The soot samples were taken at 50mm from the injector nozzle, which corresponds to the peak soot location in the spray flames. The spray flames were generated in a constant-volume combustion chamber under a diesel-like high pressure and high temperature condition (6.7MPa, 1000K). Direct sampling permits a more direct assessment of soot as it is formed and oxidized in the flame, as opposed to exhaust PM measurements. Density of sampled soot particles, diameter of primary particles, size (gyration radius) and compactness (fractal dimension) of soot aggregates were analyzed and compared. No analysis of the soot micro-structure was made.

The blade crossing event of a coaxial counter-rotating rotor is a potential source of noise and impulsive blade loads. Blade crossings occur many times during each rotor revolution. In previous research by the authors, this phenomenon was analyzed by simulating two airfoils passing each other at specified speeds and vertical separation distances, using the compressible Navier-Stokes solver OVERFLOW. The simulations explored mutual aerodynamic interactions associated with thickness, circulation, and compressibility effects. Results revealed the complex nature of the aerodynamic impulses generated by upper/lower airfoil interactions. In this paper, the coaxial rotor system is simulated using two trains of airfoils, vertically offset, and traveling in opposite directions. The simulation represents multiple blade crossings in a rotor revolution by specifying horizontal distances between each airfoil in the train based on the circumferential distance between blade tips.

The environmental impact of aircraft, specifically in the areas of noise and NOx emissions, has been a growing community concern. Coupled with the increasing cost and diminishing supply of traditional fossil fuels, these concerns have fueled substantial interest in the research and development of alternative power sources for aircraft. In 2003, NASA and the Department of Defense awarded a five year research cooperative agreement to a team of researchers from three different universities to address the design and analysis of revolutionary aeropropulsion technologies.

A Stagnation Point Actuator is used to control the lateral dynamics of vortices generated over a sharp-pointed forebody, at high angles of attack, and the resulting rolling moment is studied. Effective roll control is demonstrated, including the ability to suppress the wing rock phenomenon. Piecewise-linear transfer functions are developed from experimental data for the changes in roll moment and pressure difference with actuator frequency content. These transfer functions are reduced to compact form in the frequency domain, and then to a time-domain model using 2 gains and 2 time scales. The roll response is classified according to angle of attack range. Some long time scales are observed in the surface pressure, velocity field and rolling moment, making the response relatively insensitive to speed. Thus over substantial speed ranges, linear transfer functions are shown to effectively describe the roll response to motion of the Stagnation Point Actuator.

The wind-driven dynamic manipulator is a device which uses the wind tunnel freestream energy to drive multi-axis maneuvers of test models. This paper summarizes work performed using the device in several applications and discusses current work on characterizing the aerodynamics of an X-38 vehicle model in pitch-yaw maneuvers. Previous applications in flow visualization, adaptive control and linear-domain parameter identification are now extended to multi-axis inverse force and moment measurement over large ranges of attitude. A pitch-yaw-roll version is operated with active roll to measure forces and moments during maneuvers. A 3-D look-up table generated from direct force calibration allows operation of the manipulator through nonlinear regimes where control wing stall and boom wake-wing interactions are allowed to occur. Hybrid designs combining conventional and wind-driven degrees of freedom are discussed.

As an element of a design optimization study of high speed civil transport (HSCT), response surface equations (RSEs) were developed with the goal of accurately predicting the sideline, takeoff, and approach noise levels for any combination of selected design variables. These RSEs were needed during vehicle synthesis to constrain the aircraft design to meet FAR 36, Stage 3 noise levels. Development of the RSEs was useful as an application of response surface methodology to a previously untested discipline. Noise levels were predicted using the Aircraft Noise Prediction Program (ANOPP), with additional corrections to account for inlet and exhaust duct lining, mixer-ejector nozzles, multiple fan stages, and wing reflection. The fan, jet, and airframe contributions were considered in the aircraft source noise prediction.

A supersonic channel airfoil (SCA) concept that can be applied to the leading edges of wings, tails, fins, struts, and other appendages of aircraft, atmospheric entry vehicles and missiles in supersonic flight for drag reduction is described. It is designed to be beneficial at conditions in which the leading edge is significantly blunted and the Mach number normal to the leading edge is supersonic. The concept is found to result in significantly reduced wave drag and total drag (including skin friction drag) and significantly increased L/D. While this reduction over varying flight conditions has been quantified, some leading edge geometries result in adverse increases in peak heat transfer rates. To evaluate the effectiveness of SCAs in reducing drag without paying any penalties in other areas like lifting capacity, heating rates or enclosed volume, the design space was studied in greater detail using MDO methods.

The objective of this paper is to illustrate the methods and tools developed to size and synthesize a stopped rotor/wing vehicle using a reaction drive system, including how this design capability is incorporated into a sizing and synthesis tool, VASCOMP II. This new capability is used to design a vehicle capable of performing a V-22 escort mission, and a sized vehicle description with performance characteristics is presented. The resulting vehicle is then compared side-by-side to a variable diameter tiltrotor designed for the same mission. Results of this analysis indicate that the reaction-driven rotor concept holds promise relative to alternative concepts, but that the variable diameter tiltrotor has several inherent performance advantages. Additionally, the stopped rotor/wing needs considerably more development to reach maturity.

Compressive load capacity of composite lattice structures are studied. The objective of this research is to investigate the buckling strength of composite lattice structures and to design the most weight efficient structure with the highest buckling load. Buckling strength of both the composite lattice cylindrical and conical shells under axial compressive loads are examined. The main emphasis is placed on the effects of geometric constraints and the optimal design of the structures. In this research, various constraints are studied and the optimal structure which gives the highest strength to weight ratio is obtained. Moreover, these structures can be constructed by filament winding, the manufacturing process can be automated, and the costs can be greatly reduced.

This paper outlines a comprehensive, structured, and robust methodology for decision making in the early phases ofaircraft design. The proposed approach is referred to as the Technology Identification, Evaluation, and Selection (TIES) method. The seven-step process provides the decision maker/designer with an ability to easily assess and trade-off the impact of various technologies in the absence of sophisticated, time-consuming mathematical formulations. The method also provides a framework where technically feasible alternatives can be identified with accuracy and speed. This goal is achieved through the use of various probabilistic methods, such as Response Surface Methodology and Monte Carlo Simulations. Furthermore, structured and systematic techniques are utilized to identify possible concepts and evaluation criteria by which comparisons could be made.

This paper looks at a method for decomposing a manufactured product into what is called an “activity space.” The method uses an activity based costing scheme to structure the model and organize the information. It is discussed how the activity space is used to perform sustainability assessments of a manufactured product and the manufacturing process from different viewpoints and perspectives. The way in which the activity space is used to perform an assessment from several viewpoints is discussed.

In this paper, we describe our work and experiences with integrating environmental and economic performance monitoring in a production facility of Interface Flooring Systems, Inc. The objective of the work is to create a ‘dashboard’ that integrates environmental and economic monitoring and assessment of manufacturing processes, and provides engineers and managers an easy to use tool for obtaining valid, comparable assessment results that can be used to direct attention towards necessary changes. To this purpose, we build upon existing and familiar cost management principles, in particular Activity-Based Costing and Management (ABC&ABM), and we extend those into environmental management in order to obtain a combined economic and environmental performance measurement framework (called Activity-Based Cost and Environmental Management).

“Dither” control recently has been experimentally demonstrated to be an effective means to suppress and prevent rotor mode disc brake squeal. Dither control employs a control effort at a frequency higher, oftentimes significantly higher, than the disturbance to be controlled. The control actuator used for the work presented in this paper is a piezoelectric stack actuator located within the piston of a floating caliper brake. The actuator is driven in open-loop control at a frequency greater than the squeal frequency. This actuator configuration and drive signal produces a small fluctuation about the mean clamping force of the brake. The control exhibits a threshold behavior, where complete suppression of brake squeal is achieved once the control effort exceeds a threshold value. This paper examines the dependency of the threshold effort upon the frequency of the dither control signal, applied to the suppression of a 5.6 kHz rotor squeal mode.

An architecture is proposed for on-demand rapid commuting across congested-traffic areas. A lighter-than-air (LTA) vehicle provides the efficient loitering and part of the lift, while a set of cycloidal rotors provides the lift for payload as well as propulsion. This combination offers low noise and low downwash. A standardized automobile carriage is slung below the LTA, permitting driveway to driveway boarding and off-loading for a luxury automobile. The concept exploration is described, converging to the above system. The 6-DOF aerodynamic load map of the carriage is acquired using the Continuous-Rotation method in a wind tunnel. An initial design with rear ramp access is modified to have ramps at both ends. The initial design shows a divergence sped in access of 100 mph. An effort to improve the ride quality using yaw stabilizers, failed as the dynamic behavior becomes unstable. The requirements for control surfaces and instrumentation are discussed.

The design of advanced rotorcraft requires knowledge of the flowfield and loads on the rotor blade at extreme advance ratios (ratios of the forward flight speed to rotor tip speed). In this domain, strong vortices form below the rotor, and their evolution has a sharp influence on the aero-dynamics loads experienced by the rotor, particularly the loads experienced at pitch links. To understand the load distribution, the surface pressure distribution must be captured. This has posed a severe problem in wind tunnel experiments. In our experiments, a 2-bladed teetering rotor with collective and cyclic pitch controls is used in a low speed subsonic wind tunnel in reverse flow. Stereoscopic particle image velocimetry is used to measure the three component spatial velocity field. Measurement accuracy is now adequate for velocity data, and can be converted to pressure both at and away from the blade surface.

Coaxial rotors are finding use in advanced rotorcraft concepts. Combined with lift offset rotor technology, they offer a solution to the problems of dynamic stall and reverse flow that often limit single rotor forward flight speeds. In addition, coaxial rotorcraft systems do not need a tail rotor, a major boon during operation in confined areas. However, the operation of two counter-rotating rotors in close proximity generates many possible aerodynamic interactions between rotor blades, blades and vortices, and between vortices. With two rotors, the parameter design space is very large, and requires efficient computations as well as basic experiments to explore aerodynamics of a coaxial rotor and the effects on performance, loads, and acoustics.