BIOGRAPHY

Mr. Manifold joined The Center for Electromechanics in 1985.  He is involved in structural and rotordynamic analyses of high speed homopolar generators and compensated pulsed alternators, and has developed finite element codes for that purpose.  The codes include a general purpose rotordynamics code that solves for damped, gyroscopic rotor critical speeds, as well as transient and synchronous response of a rotor-bearing system; and several specialized two and three-dimensional finite element codes that solve linear elasticity problems in an anisotropic material under various loading conditions.  Mr. Manifold has also performed extensive modeling and analysis of structures using ABAQUS finite element software.  Most recently, he has been involved in the design, analysis, and manufacture of high speed compulsator and flywheel rotors fabricated primarily of fiber-reinforced composite materials.

Mr. Manifold played a key part in the successful design and development of composite growth-matching arbor technology for the U.S. Army’s Electric Gun program that allows a very high generator rim tip speed of 825 m/s while maintaining structural integrity with a metallic shaft.  As part of this effort, he developed software that constructs two-dimensional axisymmetric and three-dimensional ABAQUS finite element models of candidate arbor designs.  Composite material properties are defined on an element by element basis and are based on winding layups that vary continuously throughout the structure.  Use of this code resulted in an optimized arbor design that was successfully tested to design over-speed rpm and survived cyclic testing with over 1000 speed cycles.

Mr. Manifold was the lead structural analyst in the design and manufacture of a generator for the U.S. Navy’s Electromagnetic Aircraft Launch System (EMALS).  He performed extensive three-dimensional structural finite element analysis and fatigue life analysis to ensure a generator design that met the Navy’s stringent 50-year life expectancy for the system.  He also performed transient rotordynamics analysis of the generator to ensure survivability of the generator when subjected to shock loading.

Mr. Manifold was lead structural analyst in the design and manufacture of a 500 MJ flywheel for the Federal Railroad Administration’s Advanced Locomotive Propulsion System (ALPS).  Mr. Manifold designed and analyzed the steel and composite flywheel.

Prior to joining UT-CEM, Mr. Manifold worked for the Heavy Industrial Motor Division of Westinghouse Electric Corporation, where he was responsible for structural dynamics testing and analysis of motor frames and other structural parts.  He was also responsible for the design of ac and dc motors and generators, including design of shafts, frames, ventilation enclosures, and specification of bearing systems, as well as new standardized product line development.

CURRENT PROJECTS

• U.S. Army Electromagnetic Gun Program:
• Designed and performed structural finite element design of Multi-Arbor Spin Test rotor, resulting in successful spin and cyclic testing and completion of critical program milestone.
• Completed structural finite element analyses of EMGUN rotor, resulting in successful LL-IDR and permission to build rotors.  Analyses included:
• Two-dimensional axisymmetric FEA of complete rotor for determining assembly interferences throughout the rotor.
• Detailed three-dimensional analysis of output conductor penetrations in rotor, resulting in redesign of pin assembly and risk reduction during rotor operation and determination of strain capability requirements in B1 ring of rotor.
• Detailed three-dimensional analysis of cooling and power arbors, resulting in high degree of confidence in the arbor design and culminating in successful MAST.
• Detailed three-dimensional analysis of output conductor petal, including material non-linearity (plasticity).  Performed a strain based fatigue life analysis based on the FEA results to demonstrate a fatigue life exceeding the expected machine life by a factor of ten.
• Several detailed two-dimensional planar and three-dimensional finite element analyses of next generation conceptual designs, including an analysis of field coil endturns with metal plasticity.
• Supported successful testing of rotor B1 rings to determine strain to failure of graphite rings with penetrations.
• FRA 500 MJ Flywheel: Performed finite element analyses as needed to support assembly efforts, resulting in successful assembly of rotor composite rings onto rotor.
• EMALS: Performed finite element analyses as needed to support successful testing of EMALS generator.

RESEARCH AREAS/AREAS OF INTEREST

• Computational mechanics, as applied to rotating machinery and composite material

ABOUT ME (Awards, Memberships, etc.)

• Registered professional engineer, Texas

EDUCATION

• M.S., Engineering, University of Texas at Austin, 1986

Graduate research involved an adaptive Petrov-Galerkin finite element method with a-posteriori error estimation for convection dominated convection-diffusion problems

• B.S., Mechanical Engineering, University of Texas at Austin, 1980

PUBLICATIONS

• C.S. Hearn, J.J. Hahne, S.M. Manifold, and S.P. Pish, “Field coil insulation testing for pulsed power alternators,” 13th Electromagnetic Launch Technology Symposium, Potsdam (Berlin), Germany, May 22-25, 2006, IEEE Transactions on Magnetics, vol. 43, no. 1, January 2007, pp. 234-237 (PR 415).

• V. Lelos, S.M. Manifold, and J.J. Granier, “Structural properties and testing of a composite banding used in high-speed rotors,” 13th Electromagnetic Launch Technology Symposium, Potsdam (Berlin), Germany, May 22-25, 2006, IEEE Transactions on Magnetics, vol. 43, no. 1, January 2007, pp. 250-253 (PR 411).

• J.R. Kitzmiller, et al., “Predicted vs. actual performance of a model scale compulsator system,” IEEE Transactions on Magnetics, vol. 37, no. 1, January 2001, pp. 362-366 (PR 276).

• J.H. Beno, R.C. Thompson, M.D. Werst, S.M. Manifold, and J. Zierer, “End-of-life design for composite rotors [flywheel systems], IEEE Transactions on Magnetics, vol. 37, no. 1, January 2001, pp. 284-289 (PR 282).

• K.G. Cook, B.T. Murphy, S.M. Manifold, T. Park, M.D. Werst, J.R. Kitzmiller, W.A. Walls, A. Alexander, K. Twigg, “Subscale rotor spin testing for compulsator component development,” IEEE Transactions on Magnetics, vol. 35, no. 1, January 1999, pp. 277-282 (PR 252).

• J.D. Herbst, et al., “Design, fabrication, and testing of 10MJ composite flywheel energy storage rotors,” Proceedings, 1998 SAE Aerospace Power Systems Conference, April 21-23, 1998, pp. 235-244 (PR 262).

• B.T. Murphy, S.M. Manifold, and J.R. Kitzmiller, “Compulsator rotordynamics and suspension design,” IEEE Transactions on Magnetics, vol. 33, no. 1, January 1997, pp. 474-479 (PR 207).

• S.M. Manifold, W.G. Brinkman, and E.G. Estes, “Fabrication of a rotor for a field based self-excited compulsator power supply for a 9 MJ railgun demonstrator,” IEEE Transactions on Magnetics, vol. 29, no. 1, January 1993, pp. 1021-1026(PR 161).

• A.W. Walls, et al., “A field based, self-excited compulsator power supply for a 9 MJ railgun demonstrator,” IEEE Transactions on Magnetics, vol. 27, no. 1, January 1991, pp. 335-349 (PR 100).

• W.A. Walls, et al., “Design of a 20 GW, self-excited, air-core compensated pulsed alternator railgun power supply,” International Conference on Electrical Machines, 1990 (PR 126).

• W.A. Walls, et al., “Design of a self-excited, air-core compulsator for a skid-mounted, repetitive fire 9 MJ railgun system,” IEEE Transactions on Magnetics, vol. 25, no. 1, January 1989, pp. 574-579 (PR 64).

• W.A. Walls, et al., “Improved energy density homopolar generator,” IEEE Transactions on Magnetics, vol. Mag-22, no. 6, November 1986, pp. 1793-1798 (PR 47).

• S.B. Pratap, S.M. Manifold, W.A. Walls, M.L. Spann, and W.F. Weldon, “9 MJ/pulse air core compulsator,” 6th IEEE Pulsed Power Conference, Arlington, Virginia, U.S.A., June 29-July 1, 1987 (PN 115).

• W.A. Walls and S.M. Manifold, “Applications of lightweight composite materials in pulsed rotating electrical generators,” 6th IEEE Pulsed Power Conference, Arlington, Virginia, U.S.A., June 29-July 1, 1987 (PN 118).

PATENTS

Awarded

• Methods for Making Reinforced Composite Flywheels and Shafts, (with W. Alan Walls, Elvin Estes, Michael L. Spann, and John H. Gully), U.S. Patent No. 4,996,016, issued February 26, 1991.
• Reinforced Composite Flywheels and Shafts, (with W. Alan Walls, Elvin Estes, Michael L. Spann, and John H. Gully), U.S. Patent No. 5,285,699, issued February 15, 1994.

Filed as Records of Invention

• High Strength Induction Machine, Rotor, Rotor Cage End Ring and Bar Joint, Rotor End Ring, and Related Methods, (with Matthew Caprio, Vasileios Lelos, John Herbst, and Howard Jordan), UT Tech ID OTC-2928-CAP, submitted January 2005, pending.
• Method for clamping laminations in a high speed electric machine, (with Mike Werst, Michael C. Lewis, and Jon Kitzmiller), UT Tech ID OTC-2923-WER, submitted October 2004, pending.
• Flywheel Motor Generator with Power Electronics for the Formula One Kinetic Energy Recovery System, (with Richard Thompson, Hamid Ouroua, Richard Hayes, Brian Murphy, Mark Flynn, and Clay Hearn), UT Tech ID OTC-5260-THO, submitted March 2007, pending.