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The field of automotive engineering has devoted much research to reduce fuel consumption to attain sustainable energy usage. Friction reductions in powertrain components can improve engine fuel economy. Quantitative accounting of friction is complex because it is affected by many physical aspects such as oil viscosity, temperature, surface roughness and component rotation speed. The purpose of this paper is two-fold: first, to develop a useful tool for evaluating the friction in engine and accessories based on test data; second, to exercise the tool to evaluate the fuel economy gain in a drive cycle for several friction reduction technologies.

A review of the research accomplished in 2009 in the System-Level Design, Analysis and Simulation Tools (SLDAST) of the NASA's Airspace Systems Program is presented. This research thrust focuses on the integrated system-level assessment of component level innovations, concepts and technologies of the Next Generation Air Traffic System (NextGen) under research in the ASP program to enable the development of revolutionary improvements and modernization of the National Airspace System. The review includes the accomplishments on baseline research and the advancements on design studies and system-level assessment, including the cluster analysis as an annualization standard of the air traffic in the U.S. National Airspace, and the ACES-Air MIDAS integration for human-in-the-loop analyzes within the NAS air traffic simulation.

To address the growing need for detailed chemistry in engine simulations, new software tools and validated data sets are being developed under an industry-funded consortium involving members from the automotive and fuels industry. The results described here include systematic comparison and validation of detailed chemistry models using a wide range of fundamental experimental data, and the development of software tools that support the use of detailed mechanisms in engineering simulations. Such tools include the automated reduction of reaction mechanisms for targeted simulation conditions. Selected results are presented and discussed.

Design, operations and maintenance activities in aviation involve analysis of variety of aviation data. This data is typically in disparate formats making it difficult to use with different software packages. Use of a self-describing and extensible standard called XML provides a solution to this interoperability problem. While self-describing nature of XML makes it easy to reuse, it also increases the size of data significantly. A natural solution to the problem is to compress the data using suitable algorithm and transfer it in the compressed form. We found that XML-specific compressors such as Xmill and XMLPPM generally outperform traditional compressors. However, optimal use of Xmill requires of discovery of optimal options to use while running Xmill. Manual discovery of optimal setting can require an engineer to experiment for weeks.

Samples of Mars surface material will return to Earth in 2014. Prior to curation and distribution to the scientific community the returned samples will be isolated in a special facility until their biological safety has been assessed following protocols established by NASA’s Planetary Protection Office. The primary requirements for the pre-release handling of the Martian samples include protecting the samples from the Earth and protecting the Earth from the sample. A testbed will be established to support the design of such a facility and to test the planetary protection protocols. One design option that is being compared to the conventional Biological Safety Level 4 facility is a double walled differential pressure chamber with airlocks and automated equipment for analyzing samples and transferring them from one instrument to another.

The US Air Force (USAF) has evolved a policy for the acquisition of fighter jet engines (FJE). In the 1970s and 1980s that policy placed a premium on FJE performance primarily measured by the metric: thrust/engine weight. In the 1990s, the USAF policy changed from an emphasis on performance to reduced life-cycle cost with a premium on sustainment. This paper reports the results of a study of how the USAF and Corporation Alpha (Alpha) have adapted their processes, practices, and policies to design, develop, manufacture, test, and sustain a family of FJEs. Each member of the family of FJEs is sequentially linked relative to insertion of technology designed to reduce sustainment costs. In addition to the technology linkages, the development of the family of FJEs selected for this case study is also tracked relative to US Department of Defense and USAF policy and industry design, build, and maintain processes, methods, and tools.

The On-line Project Information System (OPIS) is a LAMP-based (Linux, Apache, MySQL, PHP) system being developed at NASA Ames Research Center to improve Agency information transfer and data availability, largely for improvement of system analysis and engineering. The tool will enable users to investigate NASA technology development efforts, connect with experts, and access technology development data. OPIS is currently being developed for NASA's Exploration Life Support (ELS) Project. Within OPIS, NASA ELS Managers assign projects to Principal Investigators (PI), track responsible individuals and institutions, and designate reporting assignments. Each PI populates a “Project Page” with a project overview, team member information, files, citations, and images. PI's may also delegate on-line report viewing and editing privileges to specific team members. Users can browse or search for project and member information.

A novel system for the forming of three dimensional sheet metal parts is described that can form a variety of part shapes without the need for fixed tooling, and given only geometry (CAD) information about the desired part. The central elements of this system are a tooling concept based on a programmable discrete die surface and closed-loop shape control. The former give the process the degrees of freedom to change shape rapidly, and the latter is used to insure that the correct shape is formed with a minimum of forming trials. A 540 kN (60 ton) lab press has been constructed with a 0.3 m (12 in) square pair of discrete tools that can be rapidly re-shaped between forming trials. The shape control system uses measured part shapes to determine a shape error and to correct the tooling shape. This correction is based on a unique “Deformation Transfer Function” approach using a spatial frequency decomposition of the surface.

A three country effort (U.S., Russia, and Bulgaria) has upgraded the plant growth facilities on the Mir Space Station and used the new facility to grow wheat for 90 days. The Svet plant-growth facility was reactivated and used in an initial experiment as part of the Shuttle/Mir program, August to November, 1995. The Svet system, used first to grow cabbage and radish during a 1990 experiment, was augmented by the addition of a U.S. developed Gas Exchange Measurement System (GEMS) that measures a range of environmental parameters plus transpiration, photosynthesis, and possibly respiration. Environmental parameters include cabin, chamber, root-zones, and leaf temperatures. Light levels, relative humidity, oxygen, and atmospheric pressure are also measured. High-accuracy water-vapor and carbon-dioxide concentrations and differences are measured using specially developed IRGA systems.

During 1995, we tested instruments and attempted a seed-to-seed experiment with Super-Dwarf wheat in the Russian Space Station Mir. Utah instrumentation included four IR gas analyzers (CO2 and H2O vapor, calculate photosynthesis, respiration, and transpiration) and sensors for air and leaf (IR) temperatures, O2, pressure, and substrate moisture (16 probes). Shortly after planting on August 14, three of six fluorescent lamp sets failed; another failed later. Plastic bags, necessary to measure gas exchange, were removed. Hence, gases were measured only in the cabin atmosphere. Other failures led to manual watering, control of lights, and data transmission. The 57 plants were sampled five times plus final harvest at 90 d. Samples and some equipment (including hard drives) were returned to earth on STS-74 (Nov. 20). Plants were disoriented and completely vegetative. Maintaining substrate moisture was challenging, but the moisture probes functioned well.

Eigenvalues of a simple rotating flexible disk-shaft system are obtained using different methods. The shaft is supported radially by non-rigid bearings, while the disk is situated at one end of the shaft. Eigenvalues from a finite element and a multi-body dynamic tool are compared against an established analytical formulation. The Campbell diagram based on natural frequencies obtained from the tools differ from the analytical values because of oversimplification in the analytical model. Later, detailed whirl analysis is performed using AVL Excite multi-body tool that includes understanding forward and reverse whirls in absolute and relative coordinate systems and their relationships. Responses to periodic force and base excitations at a constant rotational speed of the shaft are obtained and a modified Campbell diagram based on this is developed. Whirl of the center of the disk is plotted as an orbital or phase plot and its rotational direction noted.

The concept of free flight introduces many challenges for both air and ground aviation operations. Of considerable concern has been the issue of moving from centralized control and responsibility to decentralized control and distributed responsibility for aircraft separation. Data from capacity studies suggest that we will reach our capacity limits with ATC centralized control within the next 2 decades, if not sooner. Based on these predictions, research on distributed air-ground concepts was under taken by NASA Advanced Air Transportation Technologies Program to identify and develop air-ground concepts in support of free-flight operations. This paper will present the results of a full mission air-ground simulation conducted in the NASA Crew Vehicle Systems Research Facility. The purpose of the study was to evaluate the effect of advanced displays with “intent” (4-D flight plans) information on flight crew and ATC performance during limited free-flight operations.

Low volume manufacturing has become increasingly important for the automotive industry. Globalization trends have led automakers and their suppliers to operate in developing regions where minimum efficient scales can not always be achieved. With proper maintenance, standard cast iron stamping tools can be used to produce millions of parts, but require large investments. Thus at high production volumes, the impact of the tooling investment on individual piece costs is minimized. However, at low volumes there is a substantial cost penalty. In light of the trends towards localized manufacturing and relatively low demands in some developing markets, low cost stamping tools are needed. Several alternate tooling technologies exist, each of which require significantly lower initial investments, but suffer from greatly reduced tool lives. However, the use of these technologies at intermediate to high volumes requires multiple tool sets thus eliminating their cost advantage.

Ames Research Center’s Life Sciences Division has developed and flown an extensive array of spaceflight experiment unique equipment (EUE) during the last decade of the twentieth century. Over this ten year span, the EUE developed at ARC supported a vital gravitational biology flight research program executed on several different platforms, including the Space Shuttle, Spacelab, and Space Station Mir. This paper highlights some of the key EUE elements developed at ARC and flown during the period 1990-1999. Resulting lessons learned will be presented that can be applied to the development of similar equipment for the International Space Station.

A new multi-scale curved beam based model was developed for piston-ring designs. This tool is able to characterize the behavior of a ring with any cross section design. This paper describes the conformability and ring static twist calculation. The conformability part model the static behavior of the ring in working engine conditions. The model employs the computation scheme that separates the meshing of the structure and local force generation. Additional to the conventional static ring-bore conformability analysis, the conformability model is designed to examine ring-bore and ring-groove interactions in a running engine under varying driving forces and localized lubrication conditions. We made Improvements on the way to handle the effects of the radial temperature gradient compared to the existing models. Examples are given on the effects of ring rotation on the interaction of the ring and a distorted bore as well as the change of local lubrication conditions.

A new multi-scale curved beam based model was developed for piston-ring designs. This paper describes the free-shape, force in circular bore and closed shape within a flexible band (ovality) related parts. Knowing any one of these distributions, this model determines the other two. This tool is useful in the sense that the characterization of the ring is carried out by measuring its closed shape within a flexible band which is more accurate than measuring its free shape or force distribution in circular bore. Thus, having a model that takes the closed shape within a flexible band as an input is more convenient and useful based on the experiments carried out to characterize the ring.

Within NASA's Aviation Safety Program, the Aviation System Monitoring and Modeling (ASMM) Project addresses the need to provide decision makers with the tools to identify and evaluate predisposing conditions that could lead to accidents. This Project is developing a set of automated tools to facilitate efficient, comprehensive, and accurate analyses of data collected in large, heterogeneous databases throughout the National Aviation System. This report is a brief overview of the ASMM Project as an introduction to the rest of the presentations in this session on one of its key elements---the Performance Data Analysis and Reporting System (PDARS).