Introduction to Aerospace Engineering

Lecture slides

Challenge the future 1

Selection of material & structure
Space
Faculty of Aerospace Engineering
12-12-2011

Delft
University of
Technology

Challenge the future

Learning objectives
Student should be able to…

• Describe the basic steps in dimensioning a spacecraft structure

• Design simplified structure for minimum natural frequency

requirements

Selection of material & structure 2 | 28

Spacecraft structures
Typical structures

• Spacecraft
• Struts
• Central cylinder
• Launch vehicle
• Fairings
• Stage structure
• Thrust structure
• Adaptors

Selection of material & structure 3 | 28

Spacecraft structures
Typical structures
See Envisat in study collection!

• Spacecraft
• Struts
• Central cylinder
• Launch vehicle
• Fairings
• Stage structure
• Thrust structure
• Adaptors

• Characteristics
• Central thrust-load-bearing member (cone/cylinder)
• All systems attached at strong points directly, or
by combinations of Struts/Platforms/Shear webs

Selection of material & structure 4 | 28

Spacecraft structures
Typical structures

• Spacecraft
• Launch vehicle
• Fairings
• Stage structure
• Thrust structure
• Adaptors

Selection of material & structure 5 | 28

Spacecraft structures
Typical structures

• Spacecraft
• Launch vehicle
• Fairings
• Stage structure
• Thrust structure
• Adaptors

Saturn V S-II

Selection of material & structure 6 | 28

Spacecraft structures
Typical structures

• Spacecraft
• Launch vehicle - Semi-monocoque (load bearing skin
• Fairings internally stiffened)

• Stage structure - External skin, internal tanks separated

by longerons and cricular stiffeners
• Thrust structure
• Adaptors

Selection of material & structure 7 | 28

Spacecraft structures
Typical structures

• Spacecraft
• Launch vehicle
• Fairings
• Stage structure
• Thrust structure
Example: ARIANE 5 ~ 1200 tons of thrust!!
• Adaptors

Selection of material & structure 8 | 28

Spacecraft structures
Typical structures

• Spacecraft
• Launch vehicle
• Fairings
• Stage structure
• Thrust structure
• Adaptors

Selection of material & structure 9 | 28

Spacecraft structures
Typical structures

• Spacecraft
• Launch vehicle
• Fairings
• Stage structure
• Thrust structure
• Adaptors

Hipparcos main structure and fuel tanks

Selection of material & structure 10 | 28

Spacecraft structures
Mission requirements

• Minimum mass
• High stiffness
• Withstand the loads (= high strength)

• Accommodate payload + equipment

• High reliability
• Low cost
• Accessibility, manufacturability

Selection of material & structure 11 | 28

Material selection criteria
Material properties

Selection of material & structure 12 | 28

Material selection criteria
Frequency

• Limiting the natural frequencies of spacecraft is essential to avoid

resonance between launch vehicle and spacecraft

• Low dynamic coupling results in lower loads for spacecraft

Selection of material & structure 13 | 28

Material selection criteria
Natural frequency

• Oscillations can be damped or excited

• Example: aerodynamic flutter

(recall the flutter of horizontal & vertical tail planes)

Selection of material & structure 14 | 28

Material selection criteria
Frequency

• Requirements are launcher dependent:

• ARIANE 4
• Launch direction >31 Hz
• Lateral >10 Hz Launch direction

• STS
• Launch direction >13 Hz
Lateral
• Lateral >13 Hz

Natural Frequency [Hz]

M
1 k
f = k
n 2π m
k = stiffness = load/deflection

Selection of material & structure 15 | 28

Material selection criteria
Frequency

• Dimensioning the primary structure

• First
• Lowest natural frequencies > minimum required natural frequencies!

• Then
• Design for quasi-static loads

Selection of material & structure 16 | 28

Material selection criteria
Frequency – Example on stiffness sizing

• Mass concentrated at end of clamped beam

EI , A M x
B
L

y
• Define single degree of freedom system

M M
EA 3EI
k = k =
kx x L ky y L3

Selection of material & structure 17 | 28

Material selection criteria
Frequency – Example on stiffness sizing

• Axially loaded beam

P

E, A
k ∆L
P P
P = k ∆L
L ∆L
∆L

• Strain
∆L P σ
ε= = =
L EA E M
EA
• Elongation k =
kx x L
L
∆L = P
EA

Selection of material & structure 18 | 28

Material selection criteria
Frequency – Example on stiffness sizing

• Laterally loaded beam

P
P
E, I k ∆L
P
P = k ∆L
L ∆L
∆L

• Deflection
PL3 M
δ=
3EI 3EI
k =
ky y L3

Selection of material & structure 19 | 28

Material selection criteria
Frequency – Example on stiffness sizing

• The natural frequency is

1 k
f = [ Hz ]
n 2π m
• Which means for the stiffness

( ) EA
( )
2
3EI 2

3
≥ 2π f M ≥ 2π f M
L n L n

M M
EA 3EI
k = k =
kx x L ky y L3
SMAD III, Fig. 11-42
Equations 11-57,11-58

Selection of material & structure 20 | 28

Material selection criteria
Frequency

• Dimensioning the primary structure

• First
• Lowest natural frequencies > minimum required natural frequencies!

• Then
• Design for quasi-static loads

Selection of material & structure 21 | 28

Sizing Example Strength
Frequency – Example on stiffness sizing

• Maximum stress at clamping

M ±g
EI , A x
B Structure/geometry
L - Define I and A
Material
±g
y
- Select material with E
g M F
• Axial σx = x
=
A A
σ tot = σ x + σ y ≤ σ allowable
g MLy FLy
• Lateral σ y = =
y
SMAD III
I I Equations 11-48,11-49

Selection of material & structure 22 | 28

Sizing Example Strength
Frequency – Example on stiffness sizing

• Buckling load
M ±g
EI , A x
B Structure/geometry
L - Define I and L
Material
±g
y
- Select material with E
⇒ Bending stiffness EI!
π 2 EI
• Euler F = 2
≤g M
euler 4L x

SMAD III
Equations 11-48,11-49

Selection of material & structure 23 | 28

Material selection criteria
Example

• Required wall thickness

• ARIANE 4
• Launch direction >31 Hz
• Lateral >10 Hz Launch direction

• Conditions
M Lateral
• M=250 kg
• E = 72 GPa (aluminium)
• Max. axial acceleration
5m
= 6 g (launch load)
• Payload = point mass
• Mcylinder = 0
1m

Selection of material & structure 24 | 28

Material selection criteria
Example
M
• Required wall thickness (frequency)
• Launch direction >31 Hz
5m
1 k
f = ≥ 31 Hz
n 2π m
1m
• With m=250 kg
EA
k=
L

mL
( )
2
⇒ A≥ 2π f with A = 2π rt ⇒ t~1 mm
E 1

Selection of material & structure 25 | 28

Material selection criteria
Example
M
• Required wall thickness (quasi-static loads)
• Axial acceleration = 6 g
• Lateral direction = 1.5 g 5m

g M F 1m
• Axial σx = x
=
A A
σ tot = σ x + σ y ≤ σ allowable
g MLy FLy
• Lateral σ y = =
y

I I

• With σallowable = σultimate / safety factor ⇒ A & I

Selection of material & structure 26 | 28

Summary
Space

• Typical spacecraft & launch vehicle structures

• Steps in dimensioning a spacecraft structure

• Natural frequency
• Quasi-static loads

• Example simplified structure for minimum natural frequency

requirements

Selection of material & structure 27 | 28