VULCAIN 2 Nozzle Extension - intales...VULCAIN 2 Nozzle Extension Tools and Work packages AS...

VULCAIN 2 Nozzle ExtensionTools and Work packages

AS 9100-certified

- Stefan Müller -1st Workshop

on Nonlinear Analysis of Shell Structures

INTALES GmbH, ACOSTA Workshop, Natters/TYROL, 15/06/2010

A nice trip to . . .

1. Starting a journey – The V2-Nozzle model

2. On the highway to Results

a. Mapping the Tools

b. Straight roads: The linear Preselection

INTALES GmbH, 1st NLA Workshop, Natters/TYROL, 15/06/2010 2


c. Random directions: Using Monte Carlo

d. Branched paths: The deterministic analysis

3. Via ferrata – Non-Linear LC selection

4. Reaching the summit – Fruits of the labour

Starting the journey…General model set up

• Model of the VULCAIN 2 Nozzle

• 1.794.690 D.O.F.– User defined elements: 336.952– Internal elements: 61.632– User defined nodes: 276.742


– Internal nodes: 126.526

• 937.75 kg (un-reinforced)

• 288 cooling tubes modeled in detail

• Boundary conditions:– The DOF 1-4 are disabled at the top

nodes


INTALES GmbH, 1st NLA Workshop, Natters/TYROL, 15/06/2010


• Detailed model of the VULCAIN 2 Nozzle with reinforcements

• 1.998.582 D.O.F.– User defined elements: 368.638– Internal elements: 61.632– User defined nodes: 304.194


– User defined nodes: 304.194– Internal nodes: 142.198

• 1038.57 kg (incl. reinf-jacket)

• Jacket and flat bands are welded to the cold wall

• Welds have elastic properties– Modulated with bar element

On the highway to ResultsMapping Tools

• Large models and excessive I/O especially in NLA are calling for automated TOOLs

•


• Needs:- Extracting state variables from result files- Selection process from numerous load cases (LC) (lin / non-lin)- Steering load scenarios based on a generally respected

philosophy

On the highway to ResultsLinear Preselection

• First part of the load case selection process

• Linear analysis of all LC


• Linear analysis of all LC

• Extraction of state variables to classify the LC

• Selecting the dimensioning LC among a class

On the highway to ResultsLinear Preselection

• Results:– Reduction from 268 different LC to 13 classes (2 to 84 LC)– Reduction factor: 20.61

DJ11 DEC112 EAP61 DJ14 EPC94 EAP42 DEC11DEC91 EPC164 EAP104 EAP63 BUF01

BUF50 EPC64 BUF71 DEC 133

INTALES GmbH, 1st NLA Workshop, Natters/TYROL, 15/06/2010

EAP122 EPC101 BUF15 DEC141DJ14 …

CLASS_1 CLASS_2 CLASS_3 CLASS_4 …

On the highway to ResultsUsing Monte Carlo simulation

• “Stand alone” tool of the Sensitivity Study

• Creates random combination of user input due to user defined thresholds and distributions- Normal distributed


- Normal distributed- Uniform distribution

• Un-correlation procedure:- n different combination vectors- Correlation factor lower than a user specified threshold- Latin hypercube algorithm

On the highway to ResultsThe deterministic analysis

• Set-up for the deterministic analysis- One LC from each class of the linear preselection- Physical reasonable order (Flight scenario)


• Non-Linear and consecutive analysis run - History of the LCs are of main importance

• Follow the branched path of the structure - As close as possible- With customized user input

On the highway to ResultsThe deterministic analysis

Customized user input available

When to perform a buckling analysis?

How close shall the EV be to zero?

What kind of imperfections to apply?


Which increment size to run the analysis?

What kind of imperfections to apply?

Factor for the ultimate load level?

When to rise the loads to ultimate load?Usage of user subroutines requested?

And more to come…Which results to extract?

Via ferrataNon-Linear LC selection

Non-Linear LC selection is based on


State Variables History Plots Eigenvalues

State Variables

Via ferrata Non-Linear LC selection

Palstic equivalent strain (PEEQ)


Palstic equivalent strain (PEEQ)

v. Mises Stresses (MISES)

Elastic energy density (SENER)

Plastic energy density (PENER)

Displacements (U1,U2,U3)

. . .


History Plots


PEEQ

0

0.005

0.01

0.015

0.02

0.025

0.03

0.035

0.04

1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0 10.0 11.0 12.0 13.0 14.0 15.0 16.0

StepTime

PE

EQ

11060007511100008611140009611820007511900008611900009512980007513020

MISES

0

100

200

300

400

500

600

700

800

900

1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0 10.0 11.0 12.0 13.0 14.0 15.0 16.0

StepTime

MIS

ES stre

sses

110600075111000086111400096

118200075119000086

119000095129800075130200086130600096245532

300001203400001148


4.0

Eigenvalues


-8.0

-6.0

-4.0

-2.0

0.0

2.0

4.0

3 4 5 6 7 8 9 10 11 12 13

Laoding Time

Eig

enva

lue

1. EV2. EV3. EV4. EV5. EV6. EV7. EV8. EV9. EV10. EV11. EV12. EV13. EV14. EV15. EV16. EV17. EV18. EV19. EV20. EV21. EV22. EV23. EV24. EV25. EV26. EV27. EV28. EV29. EV30. EV31. EV32. EV33. EV34. EV35. EV36. EV37. EV38. EV39. EV40. EV

Reaching the summitWhat do we gain?

Knowledge …

… about the model behavior…… about branching points…… about history of state variables…… about real flight scenarios…


… about real flight scenarios…

… based on:

Repeatable routines that prevent human errors for a

clarified judgment of results

The end

Thank you for your attention!


Questions?

VULCAIN 2 Nozzle Extension - intales...VULCAIN 2 Nozzle Extension Tools and Work packages AS...

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