The primary goal of any laboratory test is to expose the unit-under-test to conservative realistic representations of a field environment. Satisfying this objective is not always straightforward due to laboratory equipment constraints. For vibration and shock tests performed on shakers over-testing and unrealistic failures can result because the control is a base acceleration and mechanical shakers have nearly infinite impedance. Force limiting and response limiting are relatively standard practices to reduce over-test risks in random-vibration testing. Shaker controller software generally has response limiting as a built-in capability and it is done without much user intervention since vibration control is a closed loop process. Limiting in shaker shocks is done for the same reasons, but because the duration of a shock is only a few milliseconds, limiting is a pre-planned user in the loop process. Shaker shock response limiting has been used for at least 30 years at Sandia National Laboratories, but it seems to be little known or used in industry. This objective of this paper is to re-introduce response limiting for shaker shocks to the aerospace community. The process is demonstrated on the BARBECUE testbed.
Satellites and launch vehicles are subject to pyroshock events that come from the actuation of separation devices. The shocks are high frequency transients that decay quickly—within 5-20 ms—and can be damaging events for satellites and their components. The damage risk can be reduced by good design practice, taking advantage of the attenuating properties of structural features in the load path. NASA and MIL handbooks provide general guidelines for estimating the attenuating effects of distance, joints, and other structural features in the load path between the shock source and the shock sensitive component. One of the challenges is adequately modeling the dissipative mechanisms in structural features to better understand the risk to shock sensitive components. Previously, we examined the modeling of pyroshock attenuation in a cylindrical structure and used peak acceleration to evaluate how much shocks are attenuated by distance and structural features in a cylindrical structure. In this work, we investigated different quantities to gain more insight into how and why pyroshocks get attenuated by a bulkhead. We found that the bulkhead affects the SRS peak more than the SRS ramp and that approximately 30% of the structural intensity of the pyroshock flows into the bulkhead regardless of the thickness.
Resonant plate testing is a shock test method that is frequently used to simulate pyroshock events in the laboratory. Recently, it was discovered that if the unit under test is installed at an off-center location, a tri-axial accelerometer would record a shock response in three directions and the resulting shock response spectra implied that the test may have qualified the component in three directions simultaneously. The purpose of this research project was to evaluate this idea of multi-axis shock testing to determine if it was truly a multi-axis shock environment and if such a test could be used as an equivalent component qualification test. A study was conducted using generic, additively manufactured components tested on a resonant plate, along with an investigation of plate motion to evaluate the component response to off- center plate excitation. The data obtained here along with the analytical simulations performed indicate that off-center resonant plate tests are actually not three-axis shock tests, but rather single axis shocks at an arbitrary angle dictated by the location of the unit under test on the plate. This conclusion is supported by the fact that only one vectored shock input is provided to the component in a resonant plate test. Thus, the output response is a coupled response of the transverse plate vibration and the rotational motion of the component on the plate. Additionally, a multi-axis shock test defined by three single axis test environments always results in a significant component over-test in one direction.
Pyroshock events from the actuation of separation devices in satellites and launch vehicles are potentially damaging, very short, high intensity events with high frequency content. The pyroshock damage risk is mitigated somewhat by the fact that the shock intensity is attenuated by the spacecraft structure. The NASA and MIL standards, developed from extensive tests performed in the 1960’s, provide pyroshock attenuation guidelines for various structures common to spacecraft and launch vehicles. In this paper, we present the results from a numerical investigation of pyroshock attenuation in cylindrical shell structures. Pyroshock events were modeled using Sandia National Laboratories’ engineering mechanics simulation codes, specifically Sierra/SD. Upon verifying the numerical simulation results against a NASA-HDBK-7005 curve, various structural features were added and design variables were varied to investigate their effects on pyroshock wave propagation and attenuation. The results showed that current numerical simulation tools, given appropriate tuning parameters, are capable of modeling pyroshock events in a simple cylindrical geometry at a reasonable cost. The numerical simulations showed that the presence of geometric features had greater attenuating effects than previously understood. However, shock attenuation levels were less sensitive to design variables of the structural features than expected.
When designing or analyzing a mechanical system, energy quantities provide insight into the severity of shock and vibration environments; however, the energy methods in the literature do not address localized behavior because energy quantities are usually computed for an entire structure. The main objective of this paper is to show how to compute the energy in the components of a mechanical system. The motivation for this work is that most systems fail functionally due to component failure, not because the primary structure was overloaded, and the ability to easily compute the spatial distribution of energy helps identify failure sensitive components. The quantity of interest is input energy. That input energy can be decoupled modally is well known. What is less appreciated is that input energy can be computed at the component level exactly, using the component effective modal mass. We show the steady state input energy can be decomposed both spatially and modally and computed using input power spectra. A numerical example illustrates the spatial and modal decomposition of input energy and its utility in identifying components at risk of damage in random vibration and shock environments. Our work shows that the modal properties of the structure and the spectral content of the input must be considered together to assess damage risk. Because input energy includes absorbed energy as well as relative kinetic energy and dissipated energy, it is the recommended energy quantity for assessing the severity for both random vibration and shock environments on a structure.
This report summarizes Sandia National Laboratories (SNL) contribution to ATA Engineering, Inc's (ATA) project for the Naval Air Systems Command (NAVAIR), entitled "Optimization of Fatigue Test Signal Compression Using the Wavelet Transform." Sandia National Laboratories were a subcontractor to ATA. We were involved because this was a Small Business Technology Transfer (STTR) project that required ATA to partner with a national laboratory or academic institution. ATA selected SNL, and specifically the Environments Engineering Department (1557) because ATA has a long-standing working relationship with this department and the department staff have experience in environment definition, signal processing, fatigue testing protocols and traditional methods of generating inputs for accelerated fatigue testing.
Several programs at Sandia National Laboratories have adopted energy spectra as a metric to relate the severity of mechanical insults to structural capacity. The purpose being to gain insight into the system's capability, reliability, and to quantify the ultimate margin between the normal operating envelope and the likely system failure point -- a system margin assessment. The fundamental concern with the use of energy metrics was that the applicability domain and implementation details were not completely defined for many problems of interest. The goal of this WSEAT project was to examine that domain of applicability and work out the necessary implementation details. The goal of this project was to provide experimental validation for the energy spectra based methods in the context of margin assessment as they relate to shock environments. The extensive test results concluded that failure predictions using energy methods did not agree with failure predictions using S-N data. As a result, a modification to the energy methods was developed following the form of Basquin's equation to incorporate the power law exponent for fatigue damage. This update to the energy-based framework brings the energy based metrics into agreement with experimental data and historical S-N data.