Spacecraft Structures!Space System Design, MAE 342, Princeton University!

Robert Stengel

Copyright 2016 by Robert Stengel. All rights reserved. For educational use only.http://www.princeton.edu/~stengel/MAE342.html

•! Discrete (lumped-mass) structures

•! Distributed structures•! Buckling•! Fracture and fatigue•! Structural dynamics•! Finite-element analysis

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•! Spacecraft protected from atmospheric heating and loads by fairing

•! Fairing jettisoned when atmospheric effects become negligible

•! Spacecraft attached to rocket by adapter, which transfers loads between the two

•! Spacecraft (usually) separated from rocket at completion of thrusting

•! Clamps and springs for attachment and separation

Spacecraft Mounting for Launch

2

Communications Satellite and Delta II Launcher

3

Satellite Systems •!Structure–!Skin, frames, ribs, stringers, bulkheads–!Propellant tanks–!Heat/solar/ micrometeoroid shields, insulation–!Articulation/ deployment mechanisms–!Gravity-gradient tether–!Re-entry system (e.g., sample return)

•! Power and Propulsion–!Solar cells–! Kick motor/ payload assist module (PAM)–!Attitude-control/orbit-adjustment/station-keeping thrusters–!Batteries, fuel cells–!Pressurizing bottles–!De-orbit/

graveyard systems

•!Electronics–!Payload–!Control computers–!Control sensors and actuators–!Control flywheels–!Radio transmitters and receivers–!Radar transponders–!Antennas

4

Typical Satellite Mass Breakdown

Satellite without on-orbit propulsionKick motor/ PAM can add significant massTotal mass: from a few kg to > 30,000 kg

Landsat-3

5

Pisacane, 2005

Fairing Constraints for Various Launch Vehicles

•! Static envelope•! Dynamic envelope accounts

for launch vibrations, with sufficient margin for error

•! Various appendages stowed for launch

•! Large variation in spacecraft inertial properties when appendages are deployed

6

Pisacane, 2005

•! Spacecraft structure typically consists of–! Beams–! Flat and cylindrical panels–! Cylinders and boxes

•! Primary structure is the rigid skeleton of the

spacecraft•! Secondary structure may

bridge the primary structure to hold components

Solar TErrestrial RElations Observatory

STEREO Spacecraft Primary Structure

Configuration

7Pisacane, 2005

•! Primary Structure provides–! Support for 10 scientific

instruments–! Maintains instrument

alignment boresights–! Interfaces to launch vehicle

(SSV)•! Secondary Structure

supports–! 6 equipment benches–! 1 optical bench–! Instrument mounting links–! Solar array truss–! Several instruments have

kinematic mounts

Upper-Atmosphere Research Satellite (UARS) Primary and

Secondary Structure

8

Expanded Views of Spacecraft Structures

9

Structural Material Properties•! Stress, !: Force per unit area•! Strain, ": Elongation per unit length

! = E "•! Proportionality factor, E: Modulus of elasticity, or Young s modulus•! Strain deformation is reversible below the elastic limit•! Elastic limit = yield strength•! Proportional limit ill-defined for many materials•! Ultimate stress: Material breaks

Poisson s ratio, #:

! = " lateral"axial

typically 0.1 to 0.35Thickening under compression

Thinning under tension

10

Nice explanation athttp://silver.neep.wisc.edu/~lakes/

PoissonIntro.html

Uniform Stress ConditionsAverage axial stress, !

! = P A = Load Cross Sectional AreaAverage axial strain, "

! = "L L

Effective spring constant, ks

! = P A = E" = E #LL

P = AEL

#L = ks#L

11

P : Load, NA : Cross-sectional area, m2

L : Length, m

Pisacane, 2005

Stresses in Pressurized, Thin-Walled Cylindrical Tanks

•! For the cylinder R : radiusT : wall thickness

p : pressure! : stress

! hoop = pR /T! axial = pR / 2T

! radial " negligible

•! For the spherical end cap! hoop =! axial = pR / 2T! radial " negligible

Hoop stress is limiting factor12

Weight Comparison of Thin-Walled Spherical and Cylindrical Tanks

Pressure vessels have same volume and maximum shell stresses due to internal pressure; hydraulic head* is neglected

Rc = cylindrical radiusRs = spherical radius

* Hydraulic head = Liquid pressure per unit of weight x load factor 13

Sechler, Space Technology, 1959

Staged Spherical vs. Cylindrical Tanks

Pressure vessels have same volume and same maximum shell stresses due to internal pressure with and without hydraulic head

(with full tanks)Numerical example for load factor of 2.5

Cylindrical tanks lighter than comparable spherical tanks14

Sechler, Space Technology, 1959

Critical Axial Stress in Thin-Walled Cylinders

•! Compressive axial stress can lead to buckling failure

•! Critical stress, "c, can be increased by–! Increasing E–! Increasing wall thickness, t

•! solid material•! honeycomb

–! Adding rings to decrease effective length

–! Adding longitudinal stringers–! Fixing axial boundary

conditions–! Pressurizing the cylinder

! c

E= 9 t

R"#$

%&'1.6

+ 0.16 tL

"#$

%&'1.3

no internal pressure[ ]

15

Sechler, Space Technology, 1959

SM-65/Mercury Atlas•! Launch vehicle originally designed with

balloon propellant tanks to save weight–! Monocoque design (no internal bracing or

stiffening)–! Stainless steel skin 0.1- to 0.4-in thick–! Vehicle would collapse without internal

pressurization–! Filled with nitrogen at 5 psi when not fuelled

to avoid collapse

Pressure stiffening effectNo internal pressure

! c

E= 9 t

R"#$

%&'1.6

+ 0.16 tL

"#$

%&'1.3

With internal pressure

! c = Ko + Kp( )E tRwhere

Ko = 9tR

"#$

%&'0.6

+ 0.16 RL

"#$

%&'1.3 t

R"#$

%&'0.3

Kp = 0.191pE

"#$

%&'

Rt

"#$

%&'2

16Sechler, Space

Technology, 1959

Quasi-Static Loads

17

Fortescue, 2003

Oscillatory Components

!!!x = fx m = "kd!!x " ks!x + forcing function( ) m

!!!x + kd

m!!x + ks

m!x = forcing function

m

!˙ ̇ x + 2"#n!˙ x + #n2!x = #n

2!u! n = natural frequency, rad/s

" = damping ratio#x = displacement, m

#u = disturbance or control

Newton s second law leads to a 2nd-order dynamic system for

each discrete mass

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Examples of Oscillatory Discrete Components

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Springs and Dampers

fx = !ks"x = !ks x ! xo( ) ; k = springconstant

fx = !kd"!x = !kd"v = !kd v ! vo( ) ; k = dampingconstant

Force due to linear spring

Force due to linear damper

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Response to Initial Condition

•! Lightly damped system has a decaying, oscillatory transient response

•! Forcing by step or impulse produces a similar transient response

! n = 6.28 rad/sec" = 0.05

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Oscillations

!x = Asin "t( )

!!x = A" cos "t( )= A" sin "t +# 2( )

!!!x = "A# 2 sin #t( )= A# 2 sin #t +$( )

•! Phase angle of velocity (wrt displacement) is $/2 rad (or 90°)•! Phase angle of acceleration is $ rad (or 180°)•! As oscillatory input frequency, % varies

–! Velocity amplitude is proportional to %–! Acceleration amplitude is proportional to %2

22

Response to Oscillatory Input

Compute Laplace transform to find transfer function

L !x(t)[ ] = !x(s) = !x(t)e" st dt0

#

$ ,

s =% + j& , ( j = i = "1)

L !!x(t)[ ] = s!x(s)L !!!x(t)[ ] = s2!x(s)

Neglecting initial conditions

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Transfer Function

or L !!!x + 2"# n!!x +# n

2!x( ) = L # n2!u( )

s2 + 2!"ns+ "n2( )#x(s) = "n

2#u(s)

Transfer function from input to displacement

!x(s)!u(s)

= "n2

s2 + 2#"ns+ "n2( )

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Transfer Functions of Displacement, Velocity, and Acceleration

!x(s)!u(s)

= "n2

s2 + 2#"ns + "n2( )

!˙ x (s)!u(s)

= "n2s

s2 + 2#"ns + "n2( )

!˙ ̇ x (s)!u(s)

= "n2s2

s2 + 2#"ns + "n2( )

•! Input to velocity: multiply by s

•! Input to acceleration: multiply by s2

•! Transfer function from input to displacement

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From Transfer Function to Frequency Response

Displacement frequency response (s = j#)

!x( j")!u( j")

= "n2

j"( )2 + 2#"n j"( ) + "n2

!x(s)!u(s)

= "n2

s2 + 2#"ns+ "n2( )

Displacement transfer function

Real and imaginary components

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Frequency Response!!n: natural frequency of the system

!!: frequency of a sinusoidal input to the system

!x( j" )!u( j" )

= " n2

j"( )2 + 2#" n j"( ) +" n2

= " n2

" n2 $" 2( ) + 2#" n j"( ) %

" n2

c "( ) + jd "( )

= " n2

c "( ) + jd "( )&

'(

)

*+c "( )$ jd "( )c "( )$ jd "( )

&

'(

)

*+ =

" n2 c "( )$ jd "( )&' )*c2 "( ) + d 2 "( )

% a(" )+ jb(" ) % A(" )e j, (" )

Frequency response is a complex functionReal and imaginary components, or

Amplitude and phase angle27

Frequency Response of the 2nd-Order System

•! Convenient to plot response on logarithmic scale

ln A(!)e j" (! )[ ] = lnA(!) + j"(!)

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•! Bode plot–! 20 log(Amplitude Ratio) [dB] vs. log %–! Phase angle (deg) vs. log !!

•! Natural frequency characterized by–! Peak (resonance) in amplitude

response–! Sharp drop in phase angle

•! Acceleration frequency response has the same peak

Acceleration Response of the 2nd-Order System

•! Important points:–! Low-frequency acceleration

response is attenuated–! Sinusoidal inputs at natural

frequency resonate, I.e., they are amplified

–! Component natural frequencies should be high enough to minimize likelihood of resonant response

29

Spacecraft Stiffness* Requirements for Primary Structure

* Natural frequency30

Typical Spacecraft Layout •! Atlas IIAS launch vehicle•! Spacecraft structure meets

primary stiffness requirements

•! What are axial stiffness requirements for Units A and B?–! Support deck natural

frequency = 50 Hz

Octave Rule: Component natural frequency & 2 x

natural frequency of supporting structure

Unit A: 2 x 15 Hz = 30 Hz, supported by primary structureUnit B: 2 x 50 Hz = 100 Hz, supported by secondary structure

31

Pisacane, 2005

Factors and Margins of SafetyFactor of Safety

Typical values: 1.25 to 1.4

Allowable load (yield stress)Expected limit load (stress)!Design factor of safety

"1

Margin of Safetythe amount of margin that exists above the material allowables for the applied loading

condition (with the factor of safety included)Skullney, Ch. 8, Pisacane, 2005

Load (stress) that causes yield or failureExpected service load

32

Worst-Case Axial Stress on a Simple Beam

Axial stress due to bending

! = My I

! =M h /2( )

I

Maximum stress

Worst-case axial stress due to bending and axial force

!wc = ± PA

" # $

% & ' max

±M h /2( )

I33

Pisacane, 2005

Stress on Spacecraft Adapter

•! Spacecraft weight = 500 lb•! Atlas IIAS launch vehicle•! Factor of safety = 1.25•! Maximum stress on

spacecraft adapter?

Atlas IIAS Limit Loads (g)

34

Pisacane, 2005

Example, con t.

Worst-case axial load at BECO (5±0.5 g)

!wc = ± PA

" # $

% & ' max

± McI

A = 2!rt = 7.1 in2

I = !r3t = 286 in4

Worst-case stress

! wc =500 " 5.57.1

+ 500 " 0.5 " 42 " 9286

#$%

&'("1.25 = 897.1 psi

Worst-case lateral load at BECO (2.5 ± 1 g) or Maximum Flight Winds (2.7 ± 0.8 g)

! wc =500 " 3.57.1

+ 500 " 2 " 42 " 9286

#$%

&'("1.25 = 1960 psi

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Force and Moments on a Slender Cantilever (Fixed-Free) Beam

•! Idealization of –! Launch vehicle tied-down to a

launch pad–! Structural member of a

payload•! For a point force

–! Force and moment must be opposed at the base

–! Shear distribution is constant–! Bending moment increases as

moment arm increases–! Torsional moment and moment

arm are fixed36

Structural Stiffness•! Geometric stiffening property of a structure is

portrayed by the area moment of inertia•! For bending about a y axis (producing distortion along

an x axis)

•! Area moment of inertia for simple cross-sectional shapes

•! Solid rectangle of height, h, and width, w:

•! Solid circle of radius, r:

•! Circular cylindrical tube with inner radius, ri: and outer radius, ro:

Iy = wh3 /12

Iy = !r4 /4

Iy = ! ro4 " ri

4( ) /4

Ix = x z( )z2 dzzmin

zmax

!

37

Bending Stiffness•! Neutral axis neither shrinks nor stretches in bending•! For small deflections, the bending radius of

curvature of the neutral axis is

r = EIM

•! Deflection at a point characterized by displacement and angle:

38

Bending Deflection

Second derivative of z and first derivative of "" are inversely proportional to the bending radius:

d2zdx 2

= d!dx

=My

EIy39

Maximum Deflection and Bending Moment of Beams!

(see Fundamentals of Space Systems for additional cases)

Fixed-Free Beam Fixed-Fixed Beam Pinned-Pinned Beam

Ymax = maximum deflection Mmax = maximum bending moment

40Pisacane, 2005

Maximum Deflection and Bending Moment of Plates!

(see Fundamentals of Space Systems for additional cases)

Circular Plate

Rectangular Plate

m =1/!

41Pisacane, 2005

Typical Cross-Sectional Shear Stress Distribution for a Uniform BeamShear stress due to bending moment is highest

at the neutral axis

Maximum values for various cross sectons (see Fundamentals of Space Systems)

42

Pisacane, 2005

Buckling

•! Predominant steady stress during launch is compression

•! Thin columns, plates, and shells are subject to elastic instability in compression

•! Buckling can occur below the material s elastic limit

! cr = C" 2EL /#( )2

= PA

Critical buckling stress of a column (Euler equation)

C = function of end "fixity"E = modulus of elasticity

L = column length

! = I A = radius of gyrationPcr = critical buckling loadA = cross sectional area 43

Effect of Fixity on Critical Loads for Beam Buckling

•! Euler equation–! Slender columns–! Critical stress below the

elastic limit–! Relatively thick column

walls•! Local collapse due to thin

walls is called crippling

Crippling vs. Buckling

44

Pisacane, 2005

45

Critical Stress for Plate and Cylinder Buckling

Pisacane, 2005

Deflection is found by four integrations of the deflection equation

d2

dx 2EIy

d2zdx 2

!

" #

$

% & x= xs

= N 'y xs( )

N y(xs)

My x( ) = Ny(x)xmin

xmax

! x " xcm( )dx

= N 'y(x)xmin

xmax

! dx x " xcm( )dxxmin

xmax

!N '(x) = normal force variation with length

46

Bending Moment and Linear Deflection due to a Distributed Normal Force

Bending Vibrations of a Free-Free Uniform Beam

EIyd4zdx 4 x= xs

= k = !m' d2zdt 2 x= xs

EIy = constantm' =mass variation with length (constant)

k = effective spring constant

Solution by separation of variables requires that left and right sides equal a constant, k

An infinite number of separation constants, ki, existTherefore, there are an infinite number of vibrational

response modes47

Bending Vibrations of a Free-Free Uniform Beam

•! In figure, (u = z, y = x)•! Left side determines

vibrational mode shape•! Right side describes

oscillation•! Natural frequency of

each mode proportional to (ki)1/2

Mode shapes of bending vibrations

EIyd4zdx 4

= ki = !m' d2zdt 2

48

Fundamental Vibrational Frequencies of Circular Plates

f = natural frequency of first mode, Hz

49Pisacane, 2005

Vibrational Mode Shapes for the X-30 (NASP)

Vehicle Computational Grid for Finite-

Element Model

Body elastic deflection distorts the shape of scramjet inlet and exhaust ramps

Aeroelastic-propulsive interactionsImpact on flight dynamics

Shapes of the First Seven Modes

50

Raney, J. Aircraft, 1995

Pogo Oscillation!! Longitudinal resonance of launch vehicle structure

!! Flexing of the propellant-feed pipes induces thrust variation in liquid-propellant rocket

!! Gas-filled cavities added to the pipes, damping oscillation

!! “Organ-pipe” oscillation in Space Shuttle Solid Rocket Booster!! 15-Hz resonance in 4-segment motor!! 12-Hz resonance in 5-segment motor

51Pogo oscillation http://history.nasa.gov/SP-4205/ch10-6.html

Fuel Slosh!! Lateral motion of liquid propellant in partially empty

tank induces inertial forces!! Resonance with flight motions!! Problem reduced by baffling

52http://en.wikipedia.org/wiki/Space_Shuttle_external_tank

Space Shuttle External Tank

Thermal Stresses•! Direct weakening of

material by high temperature, e.g., effect of aerodynamic heating

•! Embrittlement of metals at low temperature

•! Internal stress caused by differential temperatures, e.g., on common bulkhead between hydrogen and oxygen tanks

53

Temperature ofLiquid Hydrogen: 20.3 K (–253°C)Liquid Oxygen: 50.5 K (–223°C)

Fracture and Fatigue Failure from Repeated/Oscillatory Loading

54

!! Cyclic loading produces cracks!! Fatigue life: # of loading cycles

before failure occurs

Miner’s rule, Paris’s law, Goodman relation, …

Finite-Element Structural Model

55

!! Grid of elements, each with!! Mass, damping, and elastic properties!! 6 degrees of freedom at each node

!! Static and dynamic analysis

see Pisacane (Skullney), Sec 8.15

Types of Finite Element

56

Fortescue, 2011

Structural Modeling Using PTC CREO

57

Assemble Parts Using PTC CREO

58

Analyze Loads Using PTC CREO

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http://learningexchange.ptc.com/tutorial/799/creating-a-buckling-analysis

Next Time:!Spacecraft Configurations!

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