Post on 23-Oct-2014
DESIGN OF A DESIGN OF A MECHANICAL LOADING MECHANICAL LOADING DEVICE FOR A GENERIC DEVICE FOR A GENERIC
INTERSTAGE OF A INTERSTAGE OF A MULTISTAGE ROCKETMULTISTAGE ROCKET
PRESENTED BY:PRESENTED BY: GUIDED BY:GUIDED BY: CYRIL JOSE 7411 Prof.(Dr) K. S. RAMAKRISHNANCYRIL JOSE 7411 Prof.(Dr) K. S. RAMAKRISHNAN ROY ROSHAN CHANDY 7442 HEAD OF THE DEPARTMENTROY ROSHAN CHANDY 7442 HEAD OF THE DEPARTMENT SHINU JERONE 7444 DEPT. OF MECHANICAL ENGG.SHINU JERONE 7444 DEPT. OF MECHANICAL ENGG. SHYAM STALIN 7445 MARIAN ENGG. COLLEGESHYAM STALIN 7445 MARIAN ENGG. COLLEGE
CONTENTSCONTENTS INTRODUCTIONINTRODUCTION INTERSTAGEINTERSTAGE TYPES OF INTERSTAGETYPES OF INTERSTAGE AEROSPACE VEHICLE DEVELOPMENTAEROSPACE VEHICLE DEVELOPMENT NEED FOR MECHANICAL LOADING DEVICESNEED FOR MECHANICAL LOADING DEVICES DESIGN FLOW CHARTDESIGN FLOW CHART PROJECT DEFINITIONPROJECT DEFINITION SCHEMATIC DIAGRAMSCHEMATIC DIAGRAM LOAD PATH DIAGRAMLOAD PATH DIAGRAM DESIGN OF ADAPTERSDESIGN OF ADAPTERS DESIGN OF CONNECTORDESIGN OF CONNECTOR DESIGN OF TOP & BASE BEAMDESIGN OF TOP & BASE BEAM DESIGN OF SHEAR PINDESIGN OF SHEAR PIN DESIGN OF EYEDESIGN OF EYE SELECTION OF HYDRAULIC JACKSELECTION OF HYDRAULIC JACK SELECTION OF LOAD CELLSELECTION OF LOAD CELL DESIGN OF REACTION LINEDESIGN OF REACTION LINE DESIGN OF FASTENERSDESIGN OF FASTENERS CONCLUSIONCONCLUSION REFERENCEREFERENCE
INTRODUCTIONINTRODUCTION
A SATELLITE LAUNCH VEHICLE IS A COMPLEX A SATELLITE LAUNCH VEHICLE IS A COMPLEX TRANSPORTATION SYSTEM.TRANSPORTATION SYSTEM.
THEY ARE BUILT AS AN ASSEMBLAGE OF SEVERAL THEY ARE BUILT AS AN ASSEMBLAGE OF SEVERAL STAGESSTAGES SOLID PROPULSIONSOLID PROPULSION LIQUID PROPULSIONLIQUID PROPULSION CRYO/SEMICRYO PROPULSIONCRYO/SEMICRYO PROPULSION
INTERSTAGE STRUCTURES NOT ONLY INTERCONNECT INTERSTAGE STRUCTURES NOT ONLY INTERCONNECT THE TWO STAGES , BUT ALSO HOUSE VARIOUS THE TWO STAGES , BUT ALSO HOUSE VARIOUS AVIONICS/PROPULSION PACKAGES & MECHANISMS AVIONICS/PROPULSION PACKAGES & MECHANISMS REQUIRED FOR PROPER FUNCTIONING OF VARIOUS REQUIRED FOR PROPER FUNCTIONING OF VARIOUS STAGES & LAUNCH VEHICLE AS A WHOLESTAGES & LAUNCH VEHICLE AS A WHOLE
INTERSTAGEINTERSTAGE
TYPES OF INTERSTAGETYPES OF INTERSTAGE
AEROSPACE VEHICLE AEROSPACE VEHICLE DEVELOPMENTDEVELOPMENT
MISSION
TRAJECTORY DESIGN
AERODYNAMIC CONFIGURATION
CFD & WTT
LOAD ANALYSIS
GEOMETRY MATERIAL
STRUCTURAL ANALYSIS
FABRICATION STRUCTURAL TESTING
ASSEMBLY
FLIGHT
NEED FOR A NEED FOR A MECHANICAL MECHANICAL
LOADING DEVICELOADING DEVICE
ONE TEST IS WORTH A THOUSAND OPINIONS ...
-AESOP
SO……
TEST IT………..
COST OF A MISSION IS SO EXPENSIVE THAT COST OF A MISSION IS SO EXPENSIVE THAT IT IS NECESSARY TO TEST, EVALUATE AND IT IS NECESSARY TO TEST, EVALUATE AND ENSURE ITS PERFORMANCE BEFORE LAUNCH.ENSURE ITS PERFORMANCE BEFORE LAUNCH.
FOR STRUCTURES WITH COMPLEX LOADING FOR STRUCTURES WITH COMPLEX LOADING & COMPLICATED BOUNDARY CONDITIONS, IS & COMPLICATED BOUNDARY CONDITIONS, IS DIFFICULT TO SIMULATE IN FEM THE EXACT DIFFICULT TO SIMULATE IN FEM THE EXACT BEHAVIOR OF JOINTS AS IT CANNOT BEHAVIOR OF JOINTS AS IT CANNOT ACCOUNT FOR BOUNDARY CONDITIONS, ACCOUNT FOR BOUNDARY CONDITIONS, IMPERFECTIONS, ASSEMBLY AND MACHINING IMPERFECTIONS, ASSEMBLY AND MACHINING STRESSES SATISFACTORILY.STRESSES SATISFACTORILY.
WHEREAS MECHANICAL LOADING DEVICES WHEREAS MECHANICAL LOADING DEVICES TESTIFIES THE ADEQUACY OF DESIGN, TESTIFIES THE ADEQUACY OF DESIGN, ASSUMPTIONS IN DESIGN & PERFORMANCE ASSUMPTIONS IN DESIGN & PERFORMANCE OF STRUCTURES DESPITE VARIOUS CUTOUTS OF STRUCTURES DESPITE VARIOUS CUTOUTS & DISCONTINUITIES.& DISCONTINUITIES.
DESIGN FLOW DESIGN FLOW CHARTCHART
DESIGN CONSIDERATIONSDESIGN CONSIDERATIONS
STRENGTH STRENGTH LOADLOAD
STIFFNESS STABILITY GEOMETRY MATERIAL
STRENGTH AND EXTRA RESERVE STRENGTH AND EXTRA RESERVE STRENGTHSTRENGTH
RESERVE STRENGTH
EXTRA RESERVE STRENGTH
STR
ES
S
STRAIN
PROJECT DEFINITIONPROJECT DEFINITION TO DEVELOP A MECHANICAL LOADING DEVICE THAT CAN
MECHANICALLY SIMULATE THE FOLLOWING LOADS ON A GENERIC INTERSTAGE OF A ROCKET:
– AXIAL COMPRESSIVE LOAD OF 12 TONNEAXIAL COMPRESSIVE LOAD OF 12 TONNE– AXIAL TENSILE LOAD LESS THAN 12 TONNEAXIAL TENSILE LOAD LESS THAN 12 TONNE– PURE CONSTANT BENDING MOMENT OF 4.2 TONNE-METREPURE CONSTANT BENDING MOMENT OF 4.2 TONNE-METRE
DIMENSIONS OF INTERSTAGE AS GIVEN BY THE DESIGNER:
– LENGTH OF THE HAT STIFFENED INTERSTAGE IS 1.5 LENGTH OF THE HAT STIFFENED INTERSTAGE IS 1.5 METREMETRE
– DIAMETER OF THE INTERSTAGE IS 1 METREDIAMETER OF THE INTERSTAGE IS 1 METRE– DEPTH OF INTERFACING FLANGES 0.01 METREDEPTH OF INTERFACING FLANGES 0.01 METRE– WIDTH OF INTERFACING FLANGES 0.030 METRE.WIDTH OF INTERFACING FLANGES 0.030 METRE.– 60 EQUALLY SPACED HOLES OF M6 PROVIDED ON 60 EQUALLY SPACED HOLES OF M6 PROVIDED ON
THE FLANGES.THE FLANGES.
IIIIND ND CLASS LEVERCLASS LEVER
NUT (INTERST
AGE)
NUT CRACKER
(MECHANICAL LOADING DEVICE)
SCHEMATIC DIAGRAMSCHEMATIC DIAGRAM
COMPRESSIVE LOADING
OF 12 T
TENSILE LOADING
OF 12 T
PURE BENDING
OF 4.2 T-m
LOAD PATH DIAGRAM
TOP BEAMTOP BEAM
EYE EYE
CONNECTOR REACTION LINECONNECTOR REACTION LINE
BOTTOM BEAMBOTTOM BEAM
TOP ADAPTERTOP ADAPTER
INTERSTAGEINTERSTAGE
PLATE
BOTTOM ADAPTERBOTTOM ADAPTERHYDRAULIC JACK
SHEARPIN 1
SHEARPIN 2
60 M6 BOLTS
60 M6 BOLTS
4 BOLTS
EYE
LOADCELL
M16X1.5 BOLT
EYE
SHEAR PIN3
EYE
SHEAR PIN 4SHEAR PIN 5
4 M6 BOLTS
DESIGNED MECHANICAL DESIGNED MECHANICAL LOADING DEVICELOADING DEVICE
DESIGNED MECHANICAL DESIGNED MECHANICAL LOADING DEVICELOADING DEVICE
DESIGNED MECHANICAL DESIGNED MECHANICAL LOADING DEVICELOADING DEVICE
DESIGN OF MECHANICAL LOADING DEVICE FOR AXIAL LOADING & PURE BENDING
DESIGN OF TOP & BOTTOM DESIGN OF TOP & BOTTOM ADAPTERADAPTER
ADAPTERS ARE USED TO DIFFUSE THE CONCENTRATED LOADS UNIFORMLY THROUGHOUT THE INTERSTAGE.
THE ADAPTER HEIGHT IS DESIGNED AS FOLLOWS…HL
OW
HHIGH
OVERLAP
•HEIGHT OF ADAPTER SELECTED IS 400 mm
•THICKNESS OF ADAPTER IS SELECTED AS 5 mm
DESIGN OF CONNECTORDESIGN OF CONNECTOR LENGTH OF CONNECTOR : LENGTH OF CONNECTOR :
2100.5 mm2100.5 mm CONNECTOR IS MADE USING CONNECTOR IS MADE USING
ISRO 50 ISRO 50 INTERNAL THREAD OF M36X3 INTERNAL THREAD OF M36X3
CUT ON HYDRAULIC SIDE OF CUT ON HYDRAULIC SIDE OF THE CONNECTORTHE CONNECTOR
INTERNAL THREAD OF M16X1.5 INTERNAL THREAD OF M16X1.5 CUT ON THE EYE SIDE OF CUT ON THE EYE SIDE OF CONNECTOR.CONNECTOR.
CRIPPLINGCRIPPLING = 279.62 N/mm = 279.62 N/mm22
crushing crushing = 4.99 N/mm= 4.99 N/mm22
allowable allowable = 240 N/mm= 240 N/mm22
MOS = 47.09MOS = 47.09
DESIGN OF TOP & BASE BEAMDESIGN OF TOP & BASE BEAM
•THE TOP & BASE BEAM ARE MADE OF TWO ROLLED STEEL C-CHANNELS PLACED BACK TO BACK & HAVE DISTANCE OF 25 mm
TWO ROLLED C CHANNELS OF ISMC 100 ARE SELECTED.
llowable = 240 MPa
OVERALL LENGTH OF BEAM : 1000 mm.
DEPTH OF SECTION : 100mm
THICKNESS OF FLANGE : 50mm
DESIGN PARAMETERSDESIGN PARAMETERS
MODES MODES OF OF FAILUREFAILURE
designeddesigned
N/mmN/mm22))
BENDINGBENDING 78.9 78.9
SHEARSHEAR 12.5712.57
allowableallowable
N/mmN/mm22))
MOSMOS
240240 2.0412.041
120120 8.548.54
POINT OF MAXIMUM DEFLECTION : 489 mm from centre of shear pin on reaction line side.
VALUE OF MAXIMUM DEFLECTION: 1.2 mm
DESIGN OF SHEAR PINDESIGN OF SHEAR PIN
MAXIMUM LOAD APPLIED: 3TONNEMAXIMUM LOAD APPLIED: 3TONNE DIAMETER OF SHEAR PIN SELECTED BASED ON DIAMETER OF SHEAR PIN SELECTED BASED ON
INTERFACING DIMENSIONS OF HYDRAULIC JACK : INTERFACING DIMENSIONS OF HYDRAULIC JACK : mm. mm.
DESIGN PARAMETERSDESIGN PARAMETERS
MODES OF MODES OF FAILUREFAILURE
designeddesigned
N/mmN/mm22))
allowableallowable
N/mmN/mm22))
MOSMOS
CRUSHING CRUSHING 89.4589.45 240240 1.681.68
BENDINGBENDING 51.9151.91 240240 3.623.62
SHEARSHEAR 15.2915.29 120120 6.846.84
DESIGN OF REACTION LINEDESIGN OF REACTION LINE IT IS MADE OF TWO DOUBLE IT IS MADE OF TWO DOUBLE
CHANNELS ISMC 150X150CHANNELS ISMC 150X150 HAVING THEIR FLANGES HAVING THEIR FLANGES
BUTTING & WELDED TOE TO TOE BUTTING & WELDED TOE TO TOE & BATTENS PLACED ON & BATTENS PLACED ON OPPOSITE ENDS AND PLACED OPPOSITE ENDS AND PLACED UNIFORMLY THROUGHOUT THE UNIFORMLY THROUGHOUT THE LENGTH.LENGTH.
LOAD : 2 TONNELOAD : 2 TONNE CRIPPLINGCRIPPLING = 4734 N/mm = 4734 N/mm22
crushing crushing = 4.69 N/mm= 4.69 N/mm22
allowableallowable = 240 MPa = 240 MPa
MOS = 50.17MOS = 50.17
DESIGN OF EYEDESIGN OF EYE
LENGTH OF EYE DESIGNED LENGTH OF EYE DESIGNED CONSIDERING TEAR FAILURE : CONSIDERING TEAR FAILURE : 105 mm105 mm
THICKNESS OF EYE :25 mmTHICKNESS OF EYE :25 mm HEIGHT OF EYE : 106 mmHEIGHT OF EYE : 106 mm MAXIMUM LOAD APPLIED : 3 MAXIMUM LOAD APPLIED : 3
TONNETONNE
SHEAR PIN HOLE :SHEAR PIN HOLE : mm. mm. SIZE OF FLAT WELDED : 65 SIZE OF FLAT WELDED : 65
mmX10 mm.mmX10 mm. SIZE OF EN24 HEAT TREATED SIZE OF EN24 HEAT TREATED
ROUND BAR WELDED TO ROUND BAR WELDED TO
FLAT : FLAT : 16 mm. & LENGTH 16 mm. & LENGTH 30 mm.30 mm.
TO PREVENT EDGE TEAR A TO PREVENT EDGE TEAR A
LENGTH OF 1.5XLENGTH OF 1.5Xi.e 1.5x35=53 i.e 1.5x35=53 mm IS PROVIDED.mm IS PROVIDED.
DESIGN PARAMETERSDESIGN PARAMETERS
MODES OF MODES OF FAILUREFAILURE
designeddesigned
N/mmN/mm22))
allowableallowable
N/mmN/mm22))
MOSMOS
CRUSHINGCRUSHING 11.21111.211 240240 20.40620.406
EDGE SHEAREDGE SHEAR 3.7013.701 120120 31.4131.41
TENSILE TENSILE 5.65.6 240240 41.8541.85
WELD WELD 5.335.33 100100 17.7617.76
DESIGN PARAMETERSDESIGN PARAMETERSMODES OF MODES OF THREAD THREAD FAILUREFAILURE
designeddesigned
N/mmN/mm22))
allowableallowable
N/mmN/mm22))
MOSMOS
THREAD THREAD SHEARSHEAR
67.8567.85 440440 5.485.48
TENSILE/ TENSILE/ COMPRESSIVE COMPRESSIVE
186.916186.916 880880 3.7073.707
BEARINGBEARING 51.951.9 880880 15.9515.95
SELECTION OF HYDRAULIC JACKSELECTION OF HYDRAULIC JACK
PISTON 80 mm
BOSCH REXROTH HYDRAULIC BOSCH REXROTH HYDRAULIC JACK (tie rod type)JACK (tie rod type)
SELECTION OF LOAD CELLSELECTION OF LOAD CELL
•SHERBORNE SENSORS
•SERIES U2000
•CAPACITY 1-50 kN
•STAINLESS STEEL CONSTRUCTION
•WEIGHT 0.15 KG
•INTERNAL THREAD M16X1.5
•4 MOUNTING HOLES OF 6.5mm
DESIGN OF FASTENERSDESIGN OF FASTENERS
LOAD APPLIED : 3TLOAD APPLIED : 3T BOLT MADE OF : HSFG STEEL BOLT 12.9 GRADEBOLT MADE OF : HSFG STEEL BOLT 12.9 GRADE M6x1 BOLT OF M6x1 BOLT OF uu=1200 N/mm=1200 N/mm22YY= 1080 N/mm= 1080 N/mm22 & LENGTH 50 mm & LENGTH 50 mm
HEIGHT OF NUT : 7 mmHEIGHT OF NUT : 7 mm
DESIGN PARAMETERSDESIGN PARAMETERSMODES OF MODES OF THREAD THREAD FAILUREFAILURE
designeddesigned
N/mmN/mm22))
allowableallowable
N/mmN/mm22))
MOSMOS
THREAD THREAD SHEARSHEAR
140140 540540 2.82.8
TENSILE/ TENSILE/ COMPRESSIVE COMPRESSIVE
411.72411.72 10801080 1.621.62
BEARINGBEARING 101.02101.02 10801080 9.699.69
CONCLUSIONCONCLUSION A MECHANICAL LOADING DEVICE TO SIMULATE A MECHANICAL LOADING DEVICE TO SIMULATE
AXIAL LOADING FORCES & PURE BENDING FORCES AXIAL LOADING FORCES & PURE BENDING FORCES IS THUS CREATED.IS THUS CREATED.
THIS IS A MODULAR DESIGN AND CAN FURTHER BE THIS IS A MODULAR DESIGN AND CAN FURTHER BE MODIFIED TO TEST FOR SHEAR FORCES AND MODIFIED TO TEST FOR SHEAR FORCES AND TORSIONAL FORCES ACTING ON THE INTERSTAGE.TORSIONAL FORCES ACTING ON THE INTERSTAGE.
THE DESIGN WAS MADE KEEPING IN MIND THE THE DESIGN WAS MADE KEEPING IN MIND THE VARIOUS FUTURE REQUIREMENTSVARIOUS FUTURE REQUIREMENTS
ALL THE ELEMENTS IN THIS DEVICE WERE CHECKED ALL THE ELEMENTS IN THIS DEVICE WERE CHECKED FOR FAILURE AND SATISFACTORY MOS ARE GIVEN.FOR FAILURE AND SATISFACTORY MOS ARE GIVEN.
THERE IS EASY REPLACEMENT OF THE THERE IS EASY REPLACEMENT OF THE COMPONENTS IN EVENTS OF THEIR FAILURE AND COMPONENTS IN EVENTS OF THEIR FAILURE AND PERMANENT JOINTS ARE AVOIDED AS FAR AS PERMANENT JOINTS ARE AVOIDED AS FAR AS POSSIBLE TO GIVE MOBILITYPOSSIBLE TO GIVE MOBILITY
IF SUFFICIENT FINANCIAL ASSISTANCE IS PROVIDED IF SUFFICIENT FINANCIAL ASSISTANCE IS PROVIDED THE DEVICE CAN BE MADE IN A SHORT TIME.THE DEVICE CAN BE MADE IN A SHORT TIME.
REFERENCESREFERENCES
S. RAMAMRUTHAM, STEEL TABLESS. RAMAMRUTHAM, STEEL TABLES K. MAHADEVAN, DESIGN DATA HAND BOOKK. MAHADEVAN, DESIGN DATA HAND BOOK P. DAYARATNAM, DESIGN OF STEEL STRUCTURESP. DAYARATNAM, DESIGN OF STEEL STRUCTURES ABDULLA SHARIFF, A TEXT BOOK OF MACHINE DESIGNABDULLA SHARIFF, A TEXT BOOK OF MACHINE DESIGN H. ESCHENAUER, APPLIEDNSTRUCTURAL MECHANICSH. ESCHENAUER, APPLIEDNSTRUCTURAL MECHANICS BHAVIKKATTI, STRENGTH OF MATERIALSBHAVIKKATTI, STRENGTH OF MATERIALS NASA SP 8022, STAGING LOADSNASA SP 8022, STAGING LOADS S K D RACHEL, AEROSPACE STRUCTURES-PRESENT S K D RACHEL, AEROSPACE STRUCTURES-PRESENT
PRACTICES & FUTURE ASPIRATIONS IN LAUNCH VEHICLESPRACTICES & FUTURE ASPIRATIONS IN LAUNCH VEHICLES STEPHEN MAYERS, ARES1 STAGE SEPARATION SYSTEM STEPHEN MAYERS, ARES1 STAGE SEPARATION SYSTEM
DESIGN CERTIFICATION TESTINGDESIGN CERTIFICATION TESTING
WE THANK OUR GUIDES , TEACHERS & OUR COLLEAGUES FOR HELPING US IN OUR JOURNEY
CYRIL JOSE
SHYAM STALIN
ROY ROSHAN CHANDY
SHINU JERONE
A PROJECT BY
INSPIRED BYINSPIRED BY