Piezoelectric stack actuators can convert an electrical stimulus into a mechanical displacement, which facilitates their use as a vibration-excitation mechanism for modal and vibration testing. Due to their compact nature, they are especially suitable for applications where typical electrodynamic shakers may not be physically feasible, e.g., on small-scale centrifuge/vibration (vibrafuge) testbeds. As such, this work details an approach to extract modal parameters using a distributed set of stack actuators incorporated into a vibrafuge system to provide the mechanical inputs. A derivation that considers a lumped-parameter stack actuator model shows that the transfer functions relating the mechanical responses to the piezoelectric voltages are in a similar form to conventional transfer functions relating the mechanical responses to mechanical forces, which enables typical curve-fitting algorithms to extract the modal parameters. An experimental application consisted of extracting modal parameters from a simple research structure on the centrifuge’s arm excited by the vibrafuge’s stack actuators. A modal test that utilized a modal hammer on the same structure with the centrifuge arm stationary produced similar modal parameters as the modal parameters extracted from the combined-environments testing with low-level inertial loading.
Aerospace structures are often subjected to combined inertial acceleration and vibration environments during operation. Traditional qualification approaches independently assess a system under inertial and vibration environments but are incapable of addressing couplings in system response under combined environments. Considering combined environments throughout the design and qualification of a system requires development of both analytical and experimental capabilities. Recent ground testing efforts have improved the ability to replicate flight conditions and aid qualification by incorporating combined centrifuge acceleration and vibration environments in a “vibrafuge” test. Modeling these loading conditions involves the coupling of multiple physical phenomena to accurately capture dynamic behavior. In this work, finite element analysis and model validation of a simple research structure was conducted using Sandia’s SIERRA analysis suite. Geometric preloading effects due to an applied inertial load were modeled using SIERRA coupled analysis capability, and structural dynamics analysis was performed to evaluate the updated structural response compared to responses under vibration environments alone. Results were validated with vibrafuge testing, using a test setup of amplified piezoelectric actuators on a centrifuge arm.
Calibrating a finite element model to test data is often required to accurately characterize a joint, predict its dynamic behavior, and determine fastener fatigue life. In this work, modal testing, model calibration, and fatigue analysis are performed for a bolted structure, and various joint modeling techniques are compared. The structure is designed to test a single bolt to fatigue failure by utilizing an electrodynamic modal shaker to axially force the bolted joint at resonance. Modal testing is done to obtain the dynamic properties, evaluate finite element joint modeling techniques, and assess the effectiveness of a vibration approach to fatigue testing of bolts. Results show that common joint models can be inaccurate in predicting bolt loads, and even when updated using modal test data, linear structural models alone may be insufficient in evaluating fastener fatigue.
Flight testing provides an opportunity to characterize a system under realistic, combined environments. Unfortunately, the prospect of characterizing flight environments is often accompanied by restrictive instrumentation budgets, thereby limiting the information collected during flight testing. Instrumentation selection is often a result of bargaining to characterize environments at key locations/sub-systems, but may be inadequate to characterize the overall environments or performance of a system. This work seeks to provide an improved method for flight environment characterization through a hybrid experimental-analytical method, modal response extraction, and model expansion. Topics of discussion will include hardware design, assessment of hardware under flight environments, instrumentation planning, and data acquisition challenges. Ground testing and model updating to provide accurate models for expansion will also be presented.
The root mean square (RMS) von Mises stress is a criterion used for assessing the reliability of structures subject to stationary random loading. This work investigates error in RMS von Mises stress and its relationship to the error in acceleration for random vibration analysis. First, a theoretical development of stress-acceleration error is introduced for a simplified problem based on modal stress analysis. Using results from the example as a basis, a similar error relationship is determined for random vibration problems. Finite element analyses of test structures subject to an input acceleration auto-spectral density are performed and results from parametric studies are used to determine error. For a given error in acceleration, a relationship to the error in RMS von Mises stress is established. The resulting relation is used to calculate a bound on the RMS von Mises stress based on the computed accelerations. This error bound is useful in vibration analysis, especially where uncertainty and variability must be thoroughly considered.