Publications

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Acoustic testing using commercial sound system components is becoming more popular as a cost effective way of generating the required environment both in and out of a reverberant chamber. This paper will present the development of such a sound system that uses a state-of-the-art random vibration controller to perform closed-loop control in the reverberant chamber at Sandia National Laboratories. Test data will be presented that demonstrates narrow-band controlability, performance and some limitations of commercial sound generation equipment in a reverberant chamber.

The dynamic response of critical aerospace components is often strongly dependent upon the dynamic behavior of bolted connections that attach the component to the surrounding structure. These bolted connections often provide the only structural load paths to the component. The bolted joint investigated in this report is an inclined lap-type joint with the interface inclined with respect to the line of action of the force acting on the joint. The accurate analytical modeling of these bolted connections is critical to the prediction of the response of the component to normal and high-level shock environmental loadings. In particular, it is necessary to understand and correctly model the energy dissipation (damping) of the bolted joint that is a nonlinear function of the forces acting on the joint. Experiments were designed and performed to isolate the dynamics of a single bolted connection of the component. Steady state sinusoidal and transient experiments were used to derive energy dissipation curves as a function of input force. Multiple assemblies of the bolted connection were also observed to evaluate the variability of the energy dissipation of the connection. These experiments provide insight into the complex behavior of this bolted joint to assist in the postulation and development of reduced order joint models to capture the important physics of the joint including stiffness and damping. The experiments are described and results presented that provide a basis for candidate joint model calibration and comparison.

The constitutive behavior of mechanical joints is largely responsible for the energy dissipation and vibration damping in weapons systems. For reasons arising from the dramatically different length scales associated with those dissipative mechanisms and the length scales characteristic of the overall structure, this physics cannot be captured adequately through direct simulation of the contact mechanics within a structural dynamics analysis. The only practical method for accommodating the nonlinear nature of joint mechanisms within structural dynamic analysis is through constitutive models employing degrees of freedom natural to the scale of structural dynamics. This document discusses a road-map for developing such constitutive models.

When embarking on an experimental program for purposes of discovery and understanding, it is only prudent to use appropriate analysis tools to aid in the discovery process. Due to the limited scope of experimental measurement analytical results can significantly complement the data after a reasonable validation process has occurred. In this manner the analytical results can help to explain certain measurements, suggest other measurements to take and point to possible modifications to the experimental apparatus. For these reasons it was decided to create a detailed nonlinear finite element model of the Sandia Microslip Experiment. This experiment was designed to investigate energy dissipation due to microslip in bolted joints and to identify the critical parameters involved. In an attempt to limit the microslip to a single interface a complicated system of rollers and cables was devised to clamp the two slipping members together with a prescribed normal load without using a bolt. An oscillatory tangential load is supplied via a shaker. The finite element model includes the clamping device in addition to the sequence of steps taken in setting up the experiment. The interface is modeled using Coulomb friction requiring a modest validation procedure for estimating the coefficient of friction. Analysis results have indicated misalignment problems in the experimental procedure, identified transducer locations for more accurate measurements, predicted complex interface motions including the potential for galling, identified regions where microslip occurs and during which parts of the loading cycle it occurs, all this in addition to the energy dissipated per cycle. A number of these predictions have been experimentally corroborated in varying degrees and are presented in the paper along with the details of the finite element model.

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During the last 20 years there has been a tremendous increase in computational capabilities. It seems to accelerate every year. Models are now constructed with millions of degrees of freedom. Sandia National Laboratories recently computed modes and transient response for a 4,000,000 degree of freedom model. There is also an increase in the cost of testing as the unit price of test items increases and manpower costs escalate. One is reminded of Augustine's Laws, ``Simple systems are not feasible because they require infinite testing.'' Or conversely, extremely complex systems require no testing. In his discussion he uses data from actual systems to show how increasing complexity of systems appears to require less testing. A hundred dollar item required several thousand developments tests, where a ten million dollar item required a few tens of development tests. Of course, this results from the large increase in test costs caused in large part by the large cost of the test hardware that comes with increasing complexity. The complex system (costly) is coupled with the perceived need to reduce nonessential costs. At Sandia National Laboratories they are also faced with the prospect that some of the tests they ran in the past are not even feasible to run today.