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Spacecraft Bulkhead Design: Weight, Cost, and Manufacturing Materials

Explore internal structure, mounting, and materials for bulkhead tank skin and nozzle in AAE 450 Spring 2008 project. Consider options, dimensions, stress analysis, and manufacturing costs.

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Spacecraft Bulkhead Design: Weight, Cost, and Manufacturing Materials

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  1. Jesii Doyle1/31/2008Internal Structure, Mounting MaterialsBulkhead Weight and Cost AAE 450 Spring 2008

  2. Bulkhead Tank External Skin Engine Nozzle Nozzle Dia. Bulkhead Inner Radius Bulkhead Weight and Cost • Assumptions • Max G-loading: 2G’s • Bulkhead position as shown in Figure 1 • Bulkhead loading as shown in Figure 1 • Propulsion Options • LOX/LH2 • H2O2/RP-1 • HTPB/AP/Al *Dimensions and weights for each option provided by Dana Lattibeaudiere Figure 1: Bulkhead Configuration AAE 450 Spring 2008 Structures

  3. Bulkhead Weight and Cost Future Work • Internal support structure • CAD models - Internal structure AAE 450 Spring 2008 Structures

  4. Backup Slides • Prop. Specifications AAE 450 Spring 2008 Structures

  5. Backup Slides • Prop. Specifications (Cont.) AAE 450 Spring 2008

  6. Backup Slides • MATLAB Code Results – Config. 2 AAE 450 Spring 2008

  7. Backup Slides • MATLAB Code Results – Config. 2 (Cont.) AAE 450 Spring 2008

  8. Backup Slides • Global Governing Equations • Variables: • Gs = Max. G-loading • g = Gravitational constant = 9.80665 m/s^2 • m = Weight applied to bulkhead (kg) • rnozzle = Nozzle radius (m) • w = Applied unit line load (Pa) • a = Rocket stage radius (m) • b = Inner bulkhead radius (m) • t = Bulkhead thickness (m) • Requirements: • Displacement <= Max. Displacement (y = -0.01m) • Applied Stress <= Yield Stress AAE 450 Spring 2008

  9. Backup Slides • Governing Equations – Config. 2 • Calculation of Thickness • Maximum Displacement • E = Modulus of Elasticity (Pa) • ν = Poisson’s ratio AAE 450 Spring 2008

  10. Backup Slides • Governing Equations - Config. 2 (Cont.) • Applied Stress • Assume cantilever beam with square cross-section • F.S. = Factor of Safety AAE 450 Spring 2008

  11. Backup Slides • Manufacturing Cost Estimations • Aluminum manufacturing: 1.2x Mat’l Cost • Steel manufacturing: 1.6x Aluminum • Titanium manufacturing: 2x Aluminum • Fiberglass structure manufacturing: 1.7x Aluminum • Additional Safety Factor 3.0 Required • Carbon fiber manufacturing: 2x Aluminum AAE 450 Spring 2008

  12. Tank External Skin Engine Nozzle Bulkhead F Nozzle Diameter Bulkhead Inner Radius Stage Diameter Backup Slides • Bulkhead Configuration 1 AAE 450 Spring 2008

  13. Backup Slides • MATLAB Code Results – Config. 1 AAE 450 Spring 2008

  14. Backup Slides • MATLAB Code Results – Config. 1 (Cont.) AAE 450 Spring 2008

  15. Backup Slides • Governing Equations – Config. 1 • Calculation of Thickness • Maximum Displacement • E = Modulus of Elasticity (Pa) • ν = Poisson’s ratio AAE 450 Spring 2008

  16. Backup Slides • Governing Equations - Config. 1 (Cont.) • Applied Stress • Assume cantilever beam with square cross-section • F.S. = Factor of Safety AAE 450 Spring 2008

  17. Backup Slides • Manufacturing Cost Estimations • Cost/Rivet: $0.73/rivet • Labor hour/Rivet: 0.049 hr/rivet • Cost/Labor Hour: $52.00/hr • # Rivets = 6 * Circumference AAE 450 Spring 2008

  18. Backup Slides • References Cyr, Kelley, “NASA New Start Index Inflation Calculator,” Cost Estimating Web Site, NASA, May 2007. [http://cost.jsc.nasa.gov/inflation/nasa /inflateNASA.html. Accessed 1/28/08] Design Manual: Fiberglass Grating and Structural Products, Delta Composites, L.L.C., Houston, TX, 2007. Green, E.A., and Coulon, J.F., “Cost Considerations in Using Titanium,” AIAA Paper 67-400, Jun. 1967. Noton, Bryan R., “ICAM - Manufacturing Cost Design Guide,” AIAA Paper 81-0855, May 1981. AAE 450 Spring 2008

  19. Backup Slides • References (Cont.) Young, W.C., and Budynas, R.G., Roark’s Formulas for Stress and Strain (7th Edition), McGraw-Hill, 2002. AAE 450 Spring 2008

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