An Advanced Extensible Parametric Geometry Engine for Multi-Fidelity and Multi-Physics Analysis in Conceptual Design

Rob McDonald & David Marshall Cal Poly Andy Ko . JR Gloudemans NASA Glenn July 23, 2012

Motivation
2.2 Robust Aircraft Conceptual Design Geometric Modeling Objective The objective of this topic is to enhance the ability to employ higher-order, physics-based analysis during conceptual design through robust, easy to create geometry models. The research goal is to automate the rigorous steps required for intelligent conversion of a conceptual level parametric geometry model into the detailed representation necessary for higher-order analysis. Conceptual design is the starting point for a new engine or aircraft development. A successful design is highly dependent on accurate geometric representations, since they are used throughout the computational engineering process. Over the past several decades computational capability has drastically improved as has the understanding of human-computer interfaces. These advances have enabled less experienced users to perform far more sophisticated tasks without the requirement of extensive training time. More accurate geometry representations will advance the state-of-art in conceptual design by enabling more routine use of higher-order analysis tools. Approach A key need of conceptual design is the ability to quickly articulate ideas and engineering concepts into a digital 3-D database. While this can be accomplished through building a CAD (computer aided design) model of the geometry, it would be valuable to have the ability to parameterize the geometrys characteristics. Parametric overlays to CAD programs can be performed, but there can be negative implications to this approach. For instance, it requires users to obtain often expensive software, and there can be inherent limitations with a given CAD package. Therefore, a prerequisite of any valuable conceptual design geometry solution is that it be parametric-input based and use aircraft design terminology to communicate effectively with the user (e.g., span, aspect ratio, chord). Currently, there are no accepted standards for parametric-based geometry representations to facilitate sharing of geometry. There is a need to create a generalized standard for parametric geometry and an approach to transfer geometry models in that standard to CADbased models. These new approaches to streamline the conversion of conceptual geometry to the geometry representation needs of more detailed analysis, however, should not diminish the ability to rapidly explore the conceptual design space using a parametric geometry tool. NASA has made prior investments in the development of a parametric geometry tool for conceptual design [i.e., Vehicle Sketch Pad (VSP)]. There is a need, however, to create better coupling between higher-order engineering analysis codes and geometry tools like VSP. The developed geometry methods should be flexible in nature and must be compatible with, and support, NASAs existing ModelCenter-based systems analysis and conceptual design process. An overview of the tools used in a ModelCenter environment is available in the Other Documents section at: http://nspires.nasaprs.com/external/solicitations. Expected Outcome The new capability shall provide parametric-based geometry modeling and analysis methodologies that enable conceptual designers to accomplish analyses in a faster, easier manner. In addition, the geometric representation will enable transferring of key geometry for use with higher-order aerodynamics, structural, mass properties, propulsion, control, aeroelastic, aeroacoustic, and aeropropulsive tools. However, developing an export capability/linkage to another tool is not sufficient. The goal is to embed in the tools the rigorous steps required for intelligent conversion of the geometric database into the necessary information for the higher-order analysis. This typically involves modification of the geometry through meshing to meet specific needs. Currently these intermediate steps are very time consuming and transitioning between tools loses necessary parametric definitions that could provide valuable sensitivity analyses. Being able to accomplish these steps in more intelligent ways, with less labor would provide timely access to more sophisticated tools. Such capability is not merely about attaching geometry interfaces to the most powerful CFD (computational fluid dynamics) or FEA (finite element analysis) tools it is about bringing all levels of analysis capability to the designer in an easier and more rapid fashion, with less data loss from geometric translations.

Motivation
2.2 Robust Aircraft Conceptual Design Geometric Modeling Objective The objective of this topic is to enhance the ability to employ higher-order, physics-based analysis during conceptual design through robust, easy to create geometry models. The research goal is to automate the rigorous steps required for intelligent conversion of a conceptual level parametric geometry model into the detailed representation necessary for higher-order analysis. Conceptual design is the starting point for a new engine or aircraft development. A successful design is highly dependent on accurate geometric representations, since they are used throughout the computational engineering process. Over the past several decades computational capability has drastically improved as has the understanding of human-computer interfaces. These advances have enabled less experienced users to perform far more sophisticated tasks without the requirement of extensive training time. More accurate geometry representations will advance the state-of-art in conceptual design by enabling more routine use of higher-order analysis tools.

2.2 Robust Aircraft Conceptual Design Geometric Modeling Objective The objective of this topic is to enhance the ability to employ higher-order, physics-based Approach analysis during conceptual design through robust, easy to create geometry models. The A key need of conceptual design is the ability to quickly articulate ideas and engineering concepts into a digital 3-D database. While this can be accomplished through building a CAD (computer aided design) of the geometry, be valuable to have the ability to parameterize the geometrys characteristics. Parametric research goal is to model automate theit would rigorous steps required for intelligent conversion of a overlays to CAD programs can be performed, but there can be negative implications to this approach. For instance, it requires users to obtain often expensive conceptual level parametric geometry model into the detailed representation necessary software, and there can be inherent limitations with a given CAD package. Therefore, a prerequisite of any valuable conceptual design geometry solution is that it for be parametric-input based and use aircraft design terminology to communicate effectively with the user (e.g., span, aspect ratio, chord). Currently, there are no accepted higher-order analysis. Conceptual design the There starting point a new engine or aircraft standards for parametric-based geometry representations to facilitate sharing ofis geometry. is a need to createfor a generalized standard for parametric geometry and an approach to transfer geometry models in that standard to CADbased models. These new approaches to streamline the conversion of conceptual geometry to A ofsuccessful design isnot highly dependent on accurate geometric the development. geometry representation needs more detailed analysis, however, should diminish the ability to rapidly explore the conceptual design space using a parametric geometry tool. representations, since they are used throughout the computational engineering process. NASA has made prior investments in the development of a parametric geometry tool for conceptual design [i.e., Vehicle Sketch Pad (VSP)]. There is a need, Over the better past several computational capability has drastically as has however, to create coupling betweendecades higher-order engineering analysis codes and geometry tools like VSP. The developed improved geometry methods should be the flexible in nature and must be compatible with, and support, NASAs existing ModelCenter-based systems analysis and conceptual design process. An overview of the understanding of human-computer interfaces. These advances have enabled less tools used in a ModelCenter environment is available in the Other Documents section at: http://nspires.nasaprs.com/external/solicitations. experienced users to perform far more sophisticated tasks without the requirement of Expected Outcome Theextensive new capability shall provide parametric-based geometry modeling and analysis methodologies that enable conceptual designers to accomplish analyses in a training time. More accurate geometry representations will advance the state-offaster, easier manner. In addition, the geometric representation will enable transferring of key geometry for use with higher-order aerodynamics, structural, mass art in conceptual design by enabling moretools. routine of higher-order analysis properties, propulsion, control, aeroelastic, aeroacoustic, and aeropropulsive However,use developing an export capability/linkage to another tools. tool is not sufficient.
The goal is to embed in the tools the rigorous steps required for intelligent conversion of the geometric database into the necessary information for the higher-order analysis. This typically involves modification of the geometry through meshing to meet specific needs. Currently these intermediate steps are very time consuming and transitioning between tools loses necessary parametric definitions that could provide valuable sensitivity analyses. Being able to accomplish these steps in more intelligent ways, with less labor would provide timely access to more sophisticated tools. Such capability is not merely about attaching geometry interfaces to the most powerful CFD (computational fluid dynamics) or FEA (finite element analysis) tools it is about bringing all levels of analysis capability to the designer in an easier and more rapid fashion, with less data loss from geometric translations.

Proposed Work

Task Breakdown
VSP to CFD Validation CBAero/VSP Integration VSP Plug-In Updates Foster OpenVSP Community Cart3D/VSP Shape Optimization Separate Geometry Kernel From VSP GUI NASA Prioritized Features and Bug Fixes Multi-Fidelity, Multi-Physics Analysis VSP to CAD Interoperability Modularization and Development of API User Defined VSP Components Fuselage Structure Support Improved Wing Structure

VSP ModelCenter Integration

The VSP plug-in is used to load an existing VSP model. The user exposes a set of parametric input variables, and exports a CART3D mesh. CART3D reads the mesh, executes, and generates a pressure field.

A second instance of the VSP Plug-In is used to create a NASTRAN mesh from the underlying VSP geometry and to map the pressure loads from the CART3D mesh onto this NASTRAN mesh.

The displacements computed by the NASTRAN could optionally be mapped back to the CART3D mesh.

User Defined Components

VSP To CAD Interoperability

VSP Parameters AR, S, , , t/c

Surface Mesh Assisted Parameterization Smooth Surface Export

Surface Mesh

CAD Model / CFD Grid Gen

VSP Re-design
Application
API (C++) ModelCenter ModelCenter

Service

VSP

VSP User

VSP Geometry Engine

VSP GUI

Custom Application Custom Application

Fuselage Structures
Representative fuselage structures Similar sophistication to current wing structure Model major fuselage structural features
Bulkhead Floor Wing-body join

No plan for complex features at this time

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Modeling Approach
Structural features
Same question exists for wing structure Frame & Stringer Windows & Doublers Discretize into primitive elements Specify material properties Discretize into beam elements Specify material & beam properties Ignore feature in discretization Specify equivalent material properties Model frames & smear stringers Resolve web & model caps 11

Resolve

Model

Smear

Hybrid

Enhanced Wing Structure

Mesh Trimming Automatic Rib Layout

Modeling Questions
Resolve / Model / Smear? Structural features
Skin stiffeners Spar caps Flanges

User-Defined Mesh

Rib Cutout

Non-planar Spar

Mesh Trimming

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VSP Open Sourcing & Support

Foster Open Source Community Develop high quality project-centered web site & community
Web server, hosting, maintenance, backups, etc. Distributed version control, mailing list, user/developer blogs, links, issue tracker, etc. Model database, application database, automated build & packaging, etc. Issue tracker maintenance, community participation, etc. VSP Meetings
Workshop ASM Session

Perform NASA prioritized fixes & upgrades

Ultimate goal is to foster a self-sustaining community of VSP users and developers 13

Shape Optimization

Formal Shape Optimization

VSP Driven
High-level parameters Complex configuration Quick baseline

Cart3D (Euler)
Adjoint sensitivities

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VSP/Cart3D Shape Optimization

Develop useful parametric shape optimization based on VSP & Cart3D Integrate VSP into Cart3D optimization framework Develop load distribution matching optimization Validate parametric optimization technique
Elliptical wing planform driven to minimize CD Elliptical wing planform driven to match load distribution Sears Haack body driven to minimize CD

Demonstrate parametric optimization on aircraft configurations

Wing-body wing twist driven to match load distribution OWN integration driven to minimize CD

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Task Breakdown
VSP to CFD Validation CBAero/VSP Integration VSP Plug-In Updates Foster OpenVSP Community Cart3D/VSP Shape Optimization Separate Geometry Kernel From VSP GUI NASA Prioritized Features and Bug Fixes Multi-Fidelity, Multi-Physics Analysis VSP to CAD Interoperability Modularization and Development of API User Defined VSP Components Fuselage Structure Support Improved Wing Structure

Well Under Way

Initiated

Out Years

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Curvature Based Meshing

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CBAero Wake Modeling

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Inaugural OpenVSP Workshop

August 22-24, San Luis Obispo CA Presentations & Hands-on Tutorial Sessions
Modeling Meshing Cart3D CBAero Structures etc.

Registration is Closed, weve exceeded our cap (50)

Industry Boeing Lockheed Northrop Grumman Gulfstream Bell Helicopter Pratt & Whitney Rocketdyne General Atomics Government NASA ARC NASA DFRC NASA GRC NASA LaRC USAF AFRL USAF NASIC US Army AMRDEC Academia Cal Poly GA Tech GT / NIA PSU UC Davis UT Austin VA Tech Small Business Desktop Aeronautics General Cryo Phoenix Integration ES Aero

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Questions?

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