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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 analyze the frequency response of structural dynamic systems with uncertainties in load and material properties. We introduce uncertainties in the system as interval numbers, and use Interval Finite Element Method (IFEM). Overestimation due to dependency is reduced using a new decomposition for the stiffness and mass matrices, as well as for the nodal equivalent load. In addition, primary and derived quantities are simultaneously obtained by means of Lagrangian multipliers that are introduced in the total energy of the system. The obtained interval equations are solved by means of a new variant of the iterative enclosure method resulting in guaranteed enclosures of relevant quantities. Several numerical examples show the accuracy and efficiency of the new formulation.

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+.

Two-scale command shaping is a recently proposed feedforward control method aimed at mitigating undesirable vibrations in nonlinear systems. The TSCS strategy uses a scale separation to cancel oscillations arising from nonlinear behavior of the system, and command shaping of the remaining linear problem. One promising application of TSCS is in reducing engine restart and shutdown vibrations found in conventional and in hybrid electric vehicle powertrains equipped with start-stop features. The efficacy of the TSCS during internal combustion engine restart has been demonstrated theoretically and experimentally in the authors’ prior works. The present article presents simulation results and describes the verified experimental apparatus used to study TSCS as applied to the ICE shutdown case. The apparatus represents a typical HEV powertrain and consists of a 1.03 L three-cylinder diesel ICE coupled to a permanent magnet alternating current electric machine through a spur gear coupling.

Turboelectric propulsion is a technology that can potentially reduce aircraft noise, increase fuel efficiency, and decrease harmful emissions. In a turbo-electric system, the propulsor (fans) is no longer connected to the turbine through a mechanical connection. Instead, a superconducting generator connected to a gas turbine produces electrical power which is delivered to distributed fans. This configuration can potentially decrease fuel burn by 10% [1]. One of the primary challenges in implementing turboelectric electric propulsion is designing the power distribution system to transmit power from the generator to the fans. The power distribution system is required to transmit 40 MW of power from the generator to the electrical loads on the aircraft. A conventional aircraft distribution cannot efficiently or reliably transmit this large amount of power; therefore, new power distribution technologies must be considered.

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.

In order to improve understanding of the primary atomization process for diesel-like sprays, a collaborative experimental and computational study was focused on the near-nozzle spray structure for the Engine Combustion Network (ECN) Spray D single-hole injector. These results were presented at the 5th Workshop of the ECN in Detroit, Michigan. Application of x-ray diagnostics to the Spray D standard cold condition enabled quantification of distributions of mass, phase interfacial area, and droplet size in the near-nozzle region from 0.1 to 14 mm from the nozzle exit. Using these data, several modeling frameworks, from Lagrangian-Eulerian to Eulerian-Eulerian and from Reynolds-Averaged Navier-Stokes (RANS) to Direct Numerical Simulation (DNS), were assessed in their ability to capture and explain experimentally observed spray details. Due to its computational efficiency, the Lagrangian-Eulerian approach was able to provide spray predictions across a broad range of conditions.

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 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.

A mean value based sizing and simulation model has been developed for use in the conceptual design and sizing of hydrogen fueled spark-ignition internal combustion engines (HICE) in the aerospace industry, here ‘mean value’ includes mean effective pressure (MEP), mean piston speed, mean specific power, etc. This model is developed since there is currently no such model readily available for this purpose. When sizing the HICE, statistical data and common practice for gasoline internal combustion engines (GICE) are used to obtain preliminary sizes of the HICE, such as total cylinder volume, bore and stroke; to capture the effect of low volumetric efficiency, the preliminary results are adjusted by a volumetric correction factor until the cycle parameters of HICE are reasonable. A non-dimensional combustion model with hydrogen as fuel is incorporated with existing GICE methods. With this combustion model, the high combustion temperature and high combustion pressure are captured.

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.

The objective of this paper is to examine ways in which to implement probabilistic design methods in the aircraft engine preliminary design process. Specifically, the focus is on analytically determining the impact of uncertainty in engine component performance on the overall performance of a notional large commercial transport, particularly the impact on design range, fuel burn, and engine weight. The emphasis is twofold: first is to find ways to reduce the impact of this uncertainty through appropriate engine cycle selections, and second is on finding ways to leverage existing design margin to squeeze more performance out of current technology. One of the fundamental results shown herein is that uncertainty in component performance has a significant impact on the overall aircraft performance (it is on the same order of magnitude as the impact of the cycle itself).

Several research institutions and universities have taken on the challenge of providing solutions for accessible and universally designed workplace accommodations with a focus on people with disabilities. Accessible Design is a subset of what is termed Universal Design. Where Universal Design covers the design of products, systems and environments for all people and encompasses all design principles, Accessible Design focuses on principles that extend the standard design process to those people with some type of performance limitation. In order for individuals with disabiltities to gain better access to the work environments and the products that facilitate independence, health, safety, and social participation a multi-disciplined approach to the research is needed to identify needs and challenges of the targeted population.

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.

In gasoline direct injection engines, fuel is injected into the port walls and the valve. During the engine startup cycle, the temperature of these parts is not adequate to evaporate all the fuel that impacts the walls. As a result, a fraction of the injected fuel does not contribute to the combustion cycle. This fraction forms fuel puddles (wall-wetting) and a portion of it passes to the crankcase. The efficiency of the engine during the startup cycle is decreased and hydrocarbon emissions increased. It is obvious that a control strategy is necessary to minimize the effects of this transient performance of the engine. This paper investigates a modeling framework for the valve, and simulation results validate model performance when compared to available experimental data. The simulation studies lead to a conceptual control design, which is briefly outlined.

Market forecasts predict a potentially large market for a Quiet Supersonic Business Jet provided that several technical hurdles are overcome prior to fielding such a vehicle. In order to be economically viable, the QSJ must be able to fly at supersonic speeds overland and operate from regional airports in addition to meeting government noise and emission requirements. As a result of these conflicting constraints on the design, the process of selecting a configuration for low sonic boom is a difficult one. Response Surface Methodology along with physics-based analysis tools were used to create an environment in which the sonic boom can be studied as a function of design and mission parameters. Ten disciplinary codes were linked with a sizing and synthesis code by using a commercial wrapper in order to calculate the required responses with the desired level of fidelity.