N141-032 TITLE: Simulation of Mechanical System Kinematic Operation Subsequent to High Intensity Loading.

TECHNOLOGY AREAS: Ground/Sea Vehicles

ACQUISITION PROGRAM: PMS 397, OHIO Replacement Program Office.

OBJECTIVE: Develop an innovative solution to simulate kinematic operation of a mechanical system subsequent to high intensity loading.

DESCRIPTION: The Navy’s shock hardening program is a critical element of the commitment to ensuring crew safety and mission capabilities of its war fighting vessels to extreme loadings. To certify complex mechanical systems meet Navy shock hardening requirements, the current practice is to install the system in a test vehicle, detonate an explosive charge near the vehicle, and subsequently demonstrate the system operates properly (ref 1). Tests of large, complex systems can be prohibitively costly, sometimes greater than $10M. Systems too large to be tested on Navy standard test vehicles can be certified using either the Dynamic Design Analysis Method (DDAM) or transient shock analysis. These methods typically evaluate structural integrity of the system; however, they infer, rather than demonstrate, operational capabilities.

A method, which moves away from shock tests of mission critical systems, is required to meet both the Navy’s shock hardening requirements and ship design for affordability goals. There is no proven method that allows for the certification of shock worthiness of complex mechanical systems other than a shock test. An innovative approach which applies kinematic modeling to simulate the operation of complex mechanical components, such as submarine hatches, will allow shock certification of these complex components via test simulation.

Kinematic modeling involves simulating contact and friction between surfaces, large deformations, and non-linear material behavior. Several approaches exist to treat these phenomena (ref 2). Solution convergence when simulating contact between surfaces can be problematic (ref 3).

The expected product is software capable of accurately simulating kinematic operation of complex mechanical systems.

PHASE I: The small business will develop a concept process for successful application of kinematic simulation to complex mechanical systems. The small business will demonstrate feasibility of meeting Navy needs and will establish that the process can be feasibly developed into a useful product for the Navy. Feasibility will be established by accurately simulating simple contact and sliding friction problems. The small business will provide a Phase II development plan with performance goals and key technical milestones, and that addresses technical risk reduction.

PHASE II: Based on the results of Phase I and the Phase II development plan, the small business will develop prototype software for evaluation. The small business will perform the laboratory tests outlined in phase II development plan. The company will simulate the laboratory tests and compare the results to the data. Evaluation results will be used to refine the prototype into an initial design that will meet Navy requirements. The company will prepare a Phase III development plan to transition the technology to Navy use.

PHASE III: The small business will be expected to support the Navy in transitioning the technology for Navy use. The small business will develop the software according to the Phase III development plan for evaluation to determine its validity against a set of existing data for kinematic operation of a mechanical system subsequent to intense loading. The company will support the Navy for test and validation to certify and qualify the software for Navy use.

PRIVATE SECTOR COMMERCIAL POTENTIAL/DUAL-USE APPLICATIONS: An analytical method for demonstrating operability of a complex component subjected to high intensity loadings has potential commercial applications where high intensity loading are of concern, such as the automobile and aircraft industries.

REFERENCES:
1. Scavuzzo, Rudolph and H. Pusey, Naval Shock Analysis and Design. Arvonia, VA: SAVIAC/HI-TEST Laboratories, Inc. 2009.

2. Belytschko, Ted, et. al., Nonlinear Finite Elements for Continua and Structures, Chichester: John Wiley & Sons Ltd, 2000.

3. Bathe, Klaus-Jürgen, Finite Element Procedures, Upper Saddle River: Prentice Hall, 1996.

KEYWORDS: Kinematic contact modeling; modeling sliding surfaces; modeling sliding friction; Hertzian contact stresses; large displacement modeling; underwater explosions

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