Development of Characterization of Failure Modes for Mechanical Components
Navy STTR FY2014A - Topic N14A-T011
ONR - Steve Sullivan - steven.sullivan@navy.mil
Opens: March 5, 2014 - Closes: April 9, 2014 6:00am EST

N14A-T011 TITLE: Development of Characterization of Failure Modes for Mechanical Components

TECHNOLOGY AREAS: Ground/Sea Vehicles

ACQUISITION PROGRAM: PMS397, OHIO Replacement program.

RESTRICTION ON PERFORMANCE BY FOREIGN CITIZENS (i.e., those holding non-U.S. Passports): This topic is "ITAR Restricted". The information and materials provided pursuant to or resulting from this topic are restricted under the International Traffic in Arms Regulations (ITAR), 22 CFR Parts 120 - 130, which control the export of defense-related material and services, including the export of sensitive technical data. Foreign Citizens may perform work under an award resulting from this topic only if they hold the "Permanent Resident Card", or are designated as "Protected Individuals" as defined by 8 U.S.C. 1324b(a)(3). If a proposal for this topic contains participation by a foreign citizen who is not in one of the above two categories, the proposal will be rejected.

OBJECTIVE: The research and development needed is to characterize the failure modes of the mechanical components of submarine systems under extreme loadings, create a database of failure modes and develop a viable multiple component shock qualification process for components with similar failure modes that is automated via the development of a novel software tool.

DESCRIPTION: The Navy’s shock hardening (ref 1) program is a critical element of the commitment to ensuring the safety of its crew members and the mission capabilities of its war fighting vessels to extreme loadings (ref. 2-3), such as an underwater explosion (UNDEX) shock event. The Navy is also committed to reducing non-recurring engineering costs in the design of each new submarine class. Mission critical components are required to remain operable following a shock event. Demonstration that each component has met this requirement is currently accomplished through standard testing, applying validated analytical methods or demonstrating that a new component which is similar to a previously "qualified" component has equal or greater shock resistance as the previously "qualified" component. The latter method is known as an "extension". The extension process allows for the certification of shock worthiness of new components that are similar in physical aspect, shipboard installation and intended use (form, fit and function) to a previously "qualified" component. Components that do not meet the similarity criterion must be qualified by either a shock test or an extensive Transient Shock Analysis (TSA), which is also limited in its applicability, due to its inability to demonstrate the successful operation of mechanical components following a shock event. Both qualification via shock test and TSA incur more cost than qualification via the extension process. Thus, to meet both the Navy’s shock hardening requirements and ship design for affordability goals, the applicability of the more cost effective extension process must be expanded. The expansion of the extension process will reduce the labor hours (designer and approval authority) required to obtain shock qualification of systems to the Navy’s shock hardening program levels. Expanding the extension process requires the development of a novel criterion for component similarity that is based on component failure modes. The development of a failure mode similarity based extension process will establish the first ever database of component failure modes associated with a class of submarine components when responding to high intensity mechanical loading and a unique analytical tool (in the form of PC based software) for certifying the shock worthiness of submarine components via a comparison and assessment of component failure modes.

PHASE I: The company will develop a concept for establishing the submarine component failure mode database and an analytical methodology of certifying the shock worthiness of new submarine components that have similar failure modes. The company will demonstrate the feasibility of the concept in meeting Navy needs and will establish that the concept can be feasibly developed into a useful product for the Navy. Feasibility will be established by analytical modeling. A Phase I option, which is dependent upon results of Phase I Base, for conducting laboratory testing to verify analytical modeling efforts will be included. The company will provide a Phase II development plan which addresses technical risk reduction and provides performance goals and key technical milestones.

PHASE II: Based on the results of Phase I and the Phase II development plan, the company will populate submarine component failure mode database and develop the associated analytical method. The analytical method will be evaluated to determine its capability in meeting the performance goals defined in Phase II development plan and the Navy requirements for the analytical method. Validation of the analytical method will be demonstrated through a series of "building block" simplified testing and data analyses. Evaluation results will be used to refine the analytical method into a tool suitable for use by both design engineers and Navy survivability approval authorities according that will meet Navy requirements. The company will prepare a Phase III development plan to transition the technology to Navy use.

PHASE III: The company will be expected to support the Navy in transitioning the first ever database of component failure modes and the innovative analytical method of shock qualification for Navy use. The company will establish a component shock failure mode database that can be easily and continually updated by Navy engineers as more data is acquired. The company will also refine and finalize the tool developed. The company will support the Navy for test, validation and implementation of the tool for Navy use.

PRIVATE SECTOR COMMERCIAL POTENTIAL/DUAL-USE APPLICATIONS: An analytical method for assessing the resistance of multiple components with similar failure modes to high intensity loadings has potential commercial applications where high intensity loading are of concern, such as the automobile and aircraft industries.

REFERENCES:
1. Clements, E. W., Shipboard Shock and Navy Devices for its Simulation. Naval Research Lab Report 7396, 1972.

2. Cole, Robert, Underwater Explosions. Princeton, NJ: Princeton University Press, 1948.

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

KEYWORDS: shock hardness; shock qualification; shipboard shock; failure modes; shock testing of mechanical components; analytical method for assessing resistance

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