Publications

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Rattlesnake is a combined-environments, multiple input/multiple output control system for dynamic excitation of structures under test. It provides capabilities to control multiple responses on the part using multiple exciters using various control strategies. Rattlesnake is written in the Python programming language to facilitate multiple input/multiple output vibration research by allowing users to prescribe custom control laws to the controller. Rattlesnake can target multiple hardware devices, or even perform synthetic control to simulate a test virtually. Rattlesnake has been used to execute control problems with up to 200 response channels and 12 drives. This document describes the functionality, architecture, and usage of the Rattlesnake controller to perform combined environments testing.

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Digital image correlation (DIC) is an established test technique in several fields including quasi-static displacement measurements. Recently there has been growing interest in using DIC to measure structural dynamic response and even extract modal parameters from that information. While high-speed cameras have become more ubiquitous, there are no commercial end-to-end packages for modal analysis based on image data, particularly when combined with traditional data acquisition systems. As such, the practitioner is left to develop several key data processing capabilities, hardware interface equipment, and testing practices themselves. This work highlights several practical aspects that have been encountered while establishing DIC as a viable modal testing capability in a laboratory environment.

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Laser vibrometry has become a mature technology for structural dynamics testing, enabling many measurements to be obtained in a short amount of time without mass-loading the part. Recently multi-point laser vibrometers consisting of 48 or more measurement channels have been introduced to overcome some of the limitations of scanning systems, namely the inability to measure multiple data points simultaneously. However, measuring or estimating the alignment (Euler angles) of many laser beams for a given test setup remains tedious and can require a significant amount of time to complete and adds an unquantified source of uncertainty to the measurement. This paper introduces an alignment technique for the multipoint vibrometer system that utilizes photogrammetry to triangulate laser spots from which the Euler angles of each laser head relative to the test coordinate system can be determined. The generated laser beam vectors can be used to automatically create a test geometry and channel table. While the approach described was performed manually for proof of concept, it could be automated using the scripting tools within the vibrometer system.

Understanding the dynamic response of a structure is critical to design. This is of extreme importance in high-consequence systems on which human life can depend. Historically, these structures have been modeled as linear, where response scales proportionally with excitation amplitude. However, most structures are nonlinear to the extent that linear models are no longer sufficient to adequately capture important dynamics. Sources of nonlinearity include, but are not limited to: large deflections (so called geometric nonlinearities), complex materials, and frictional interfaces/joints in assemblies between subcomponents. Joint nonlinearities usually cause the natural frequency to decrease and the effective damping ratio to increase with response amplitude due to microslip effects. These characteristics can drastically alter the dynamics of a structure and, if not well understood, could lead to unforeseen failure or unnecessarily over-designed features. Nonlinear structural dynamics has been a subject of study for many years, and provide a summary of recent developments and discoveries in this field. One topic discussed in these papers are nonlinear normal modes (NNMs) which are periodic solutions of the underlying conservative system. They provide a theoretical framework for describing the energy-dependence of natural frequencies and mode shapes of nonlinear systems, and lead to a promising method to validate nonlinear models. In and, a force appropriation testing technique was developed which allowed for the experimental tracking of undamped NNMs by achieving phase quadrature between the excitation and response. These studies considered damping to be small to moderate, and constant. Nonlinear damping of an NNM was studied in using power-based quantities for a structure with a discrete, single-bolt interface. In this work, the force appropriation technique where phase quadrature is achieved between force and response as described in is applied to a target mode of a structure with two bolted joints, one of which comprised a large, continuous interface. This is a preliminary investigation which includes a study of nonlinear natural frequency, mode shape, and damping trends extracted from the measured data.

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The Box Assembly with Removable Component (BARC) structure was developed as a challenge problem for those investigating boundary conditions and their effect on structural dynamic tests. To investigate the effects of boundary conditions on the dynamic response of the Removable Component, it was tested in three configurations, each with a different fixture and thus a different boundary condition. A “truth” configuration test with the component attached to its next-level assembly (the Box) was first performed to provide data that multi-axis tests of the component would aim to replicate. The following two tests aimed to reproduce the component responses of the first test through multi-axis testing. The first of these tests is a more “traditional” vibration test with the removable component attached to a “rigid” plate fixture. A second set of these tests replaces the fixture plate with flexible fixtures designed using topology optimization and created using additive manufacturing. These two test approaches are compared back to the truth test to determine how much improvement can be obtained in a laboratory test by using a fixture that is more representative of the compliance of the component’s assembly.

Multi-axis testing is growing in popularity in the testing community due to its ability to better match a complex three-dimensional excitation than a single-axis shaker test. However, with the ability to put a large number of shakers anywhere on the structure, the design space of such a test is enormous. This paper aims to investigate strategies for placement of shakers for a given test using a complex aerospace structure controlled to real environment data. Initially shakers are placed using engineering judgement, and this was found to perform reasonably well. To find shaker setups that improved upon engineering judgement, impact testing was performed at a large number of candidate excitation locations to generate frequency response functions that could be used to perform virtual control studies. In this way, a large number of shaker positions could be evaluated without needing to reposition the shakers each time. A brute force computation of all possible shaker setups was performed to find the set with the lowest error, but the computational cost of this approach is prohibitive for very large candidate shaker sets. Instead, an iterative approach was derived that found a suboptimal set that was nearly as good as the brute force calculation. Finally, an investigation into the number of shakers used for control was performed, which could help determine how many shakers might be necessary to perform a given test.

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Small components are becoming increasingly prevalent in today’s society. Springs are a commonly found piece-part in many mechanisms, and as these components become smaller, so do the springs inside of them. Because of their size, small manufacturing defects or other damage to the spring may become significant: a tiny gouge might end up being a significant portion of the cross-sectional area of the wire. However, their small size also makes it difficult to detect such flaws and defects in an efficient manner. This work aims to investigate the effectiveness of using dynamic measurements to detect damage to a miniature spring. Due to their small size, traditional instrumentation cannot be used to take measurements on the spring. Instead, the non-contact Laser Doppler Vibrometry technique is investigated. Natural frequencies and operating shapes are measured for a number of springs. These results are compared against springs that have been intentionally flawed to determine if the change in dynamic properties is a reasonable metric for damage detection.

Many methods have been proposed for updating finite element matrices using experimentally derived modal parameters. By using these methods, a finite element model can be made to exactly match the experiment. These techniques have not achieved widespread use in finite element modeling because they introduce non-physical matrices. Recently, Scanning Laser Doppler Vibrometery (SLDV) has enabled finer measurement point resolution and more accurate measurement point placement with no mass loading compared to traditional accelerometer or roving hammer tests. Therefore, it is worth reinvestigating these updating procedures with high-resolution data inputs to determine if they are able to produce finite element models that are suitable for substructuring. A rough finite element model of an Ampair Wind Turbine Blade was created, and a SLDV measurement was performed that measured three-dimensional data at every node on one surface of the blade. This data was used to update the finite element model so that it exactly matched test data. A simple substructuring example of fixing the base of the blade was performed and compared to previously measured fixed-base data.

Many test articles exhibit slight nonlinearities which result in natural frequencies shifting between data from different references. This shifting can confound mode fitting algorithms because a single mode can appear as multiple modes when the data from multiple references are combined in a single data set. For this reason, modal test engineers at Sandia National Laboratories often fit data from each reference separately. However, this creates complexity when selecting a final set of modes, because a given mode may be fit from a number of reference data sets. The color-coded complex mode indicator function was developed as a tool that could be used to reduce a complex data set into a manageable figure that displays the number of modes in a given frequency range and also the reference that best excites the mode. The tool is wrapped in a graphical user interface that allows the test engineer to easily iterate on the selected set of modes, visualize the MAC matrix, quickly resynthesize data to check fits, and export the modes to a report-ready table. This tool has proven valuable, and has been used on very complex modal tests with hundreds of response channels and a handful of reference locations.

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Modal testing was performed on the uncut BARC structure as a whole and broken into its two sub-assemblies. The structure was placed on soft foam during the test. Excitation was provided with a small modal hammer attached to an actuator. Responses were measured using a 3D Scanning Laser Doppler Vibrometer. Data, shapes, and geometry from this test can be downloaded in Universal File Format from the Sandia Connect SharePoint site.

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The 3D Scanning Laser Doppler Vibrometer (3D SLDV) has the ability to scan a large number of points with high accuracy compared to traditional roving hammer or accelerometer tests. The 3D SLDV has disadvantages, however, in that it requires line-of-sight from three scanning laser heads to the point being measured. This means that multiple scans can become necessary to measure large or complex parts, and internal components cannot typically be measured. In the past, large aerospace structures tested at Sandia National Laboratories typically have used a handful of accelerometer stations and instrumented internal components to characterize these test articles. This work describes two case studies that explore the advantages and difficulties in using a 3D SLDV to measure the same test articles with a much higher resolution scan of the exterior. This work proposes strategies for combining a large number of accelerometer channels with a high resolution laser scan. It explores the use of mirrors and laser head mounts to enable efficient re-alignment of the lasers with the test article when many scans are necessary, and it discusses the difficulties and pitfalls inherent with performing such a test.

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A previous study in the UK demonstrated that vibration response on a scaled-down model of a missile structure in a wind tunnel could be replicated in a laboratory setting with multiple shakers using an approach dubbed as impedance matching. Here we demonstrate on a full scale industrial structure that the random vibration induced from a laboratory acoustic environment can be nearly replicated at 37 internal accelerometers using six shakers. The voltage input to the shaker amplifiers is calculated using a regularized inverse of the square of the amplitude of the frequency response function matrix and the power spectral density responses of the 37 internal accelerometers. No cross power spectral density responses are utilized. The structure has hundreds of modes and the simulation is performed out to 4000 Hz.

The Structural Dynamics department at Sandia National Laboratories has acquired a 3D Scanning Laser Doppler Vibrometer system for making vibration and modal test measurements. This paper presents the results of testing performed to examine the capabilities and limitations of that system. The test article under consideration was a conical part with two different surface materials which allowed the examination of the effect of angle of incidence and surface reflectivity on the measurement. The system was operated in both 1D and 3D modes, and the results from the 1D scan were compared to a scan performed with a previous generation system to evaluate the improvements between the generations. Data from the laser systems were exported to standard curve fitting software, and modes were fit to the data.

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Sandia National Laboratories has recently purchased a Polytec 3D Scanning Laser Doppler Vibrometer for vibration measurement. This device has proven to be a very nice tool for making vibration measurements, and has a number of advantages over traditional sensors such as accelerometers. The non-contact nature of the laser vibrometer means there is no mass loading due to measuring the response. Additionally, the laser scanning heads can position the laser spot much more quickly and accurately than placing an accelerometer or performing a roving hammer impact. The disadvantage of the system is that a significant amount of time must be invested to align the lasers with each other and the part so that the laser spots can be accurately positioned. The Polytec software includes a number of nice tools to aid in this procedure; however, certain portions are still tedious. Luckily, the Polytec software is readily extensible by programming macros for the system, so tedious portions of the procedure can be made easier by automating the process. The Polytec Software includes a WinWrap (similar to Visual Basic) editor and interface to run macros written in that programming language. The author, however, is much more proficient in Python, and the latter also has a much larger set of libraries that can be used to create very complex macros, while taking advantage of Python’s inherent readability and maintainability.

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In the summer of 2020, the National Aeronautics and Space Administration (NASA) plans to launch a spacecraft as part of the Mars 2020 mission. One option for the rover on the proposed spacecraft uses a Multi-Mission Radioisotope Thermoelectric Generator (MMRTG) to provide continuous electrical and thermal power for the mission. NASA has prepared an Environmental Impact Statement (EIS) in accordance with the National Environmental Policy Act. The EIS includes information on the risks of mission accidents to the general public and on-site workers at the launch complex. The Nuclear Risk Assessment (NRA) addresses the responses of the MMRTG option to potential accident and abort conditions during the launch opportunity for the Mars 2020 mission and the associated consequences. This information provides the technical basis for the radiological risks of the MMRTG option for the EIS. This paper provides a summary of the methods and results used in the NRA.

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In previous work, a modal test of a large beam like structure on a vibration slip table was analytically constrained to fixed base providing estimates of the first three bending modes active in the direction of slip table motion. This work extends the frequency band of the method to extract the first ten fixed base modes of the test article. All ten fixed base modal frequencies are within two percent of the truth test fixed base modes. When compared to the truth test, the estimated damping of the lower modes has large error, but at higher frequencies the estimated damping converges on the truth value. © The Society for Experimental Mechanics, Inc. 2014.

This paper presents an example of the transmission simulator method of experimental dynamic substructuring combining two substructures of the Substructures Focus Group's test bed, the Ampair 600 Wind Turbine. The two substructures of interest are the hub-and-blade assembly and the tower assembly that remains after the hub is removed. The hub-and-blade substructure was developed from elastic modes of a free-free test of the hub and blades, and rigid body modes were constructed from measured mass properties. Elastic and rigid body modes were extracted from experimental data for the tower substructure. A bladeless hub was attached to the tower to serve as the transmission simulator for this substructure. Modes up to the second bending mode of the blades and tower were extracted. Substructuring calculations were then performed using the transmission simulator method, and a model of the full test bed was derived. The combined model was compared to truth data from a test on the full turbine. © The Society for Experimental Mechanics, Inc. 2014.

In the summer of 2020, the National Aeronautics and Space Administration (NASA) plans to launch a spacecraft as part of the Mars 2020 mission. One option for the rover on the proposed spacecraft uses a Multi-Mission Radioisotope Thermoelectric Generator (MMRTG) to provide continuous electrical and thermal power for the mission. An alternative option being considered is a set of solar panels for electrical power with up to 80 Light-Weight Radioisotope Heater Units (LWRHUs) for local component heating. Both the MMRTG and the LWRHUs use radioactive plutonium dioxide. NASA is preparing an Environmental Impact Statement (EIS) in accordance with the National Environmental Policy Act. The EIS will include information on the risks of mission accidents to the general public and on-site workers at the launch complex. This Nuclear Risk Assessment (NRA) addresses the responses of the MMRTG or LWRHU options to potential accident and abort conditions during the launch opportunity for the Mars 2020 mission and the associated consequences. This information provides the technical basis for the radiological risks of both options for the EIS.

The transmission simulator method of experimental dynamic substructuring has the capability to couple substructures with continuous connections. A hardware example with continuous connections is presented in which the method is used to couple an experimental substructure with a finite element substructure to predict full system response. The predicted response is compared with frequency response functions measured on the full system hardware. The experimental substructure captures the motion of a component packed in foam. This is coupled to a finite element model of a cylindrical metal case which contains the foam and is attached through a flange to a plate and beam structure. © The Society for Experimental Mechanics, Inc. 2014.

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