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Weight optimization of the design parameters of launch vehicle payload fairing for space purpose
A. Boopathiraja, graduate student of Department 403 Supervisor of studies: A.V. Kondratyev, Cand. Tech. Science, Docent of Department 403 National Aerospace University
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Payload Fairing It is one of the main components of a launch vehicle that are located in the upper stage. The main function of fairing is to protect the payload during the ascent against the impact of the atmosphere (aerodynamic pressure, heating and acoustic loading). It maintains the cleanroom environment for precision instruments. Outside the atmosphere the fairing is jettisoned, exposing the payload.
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Geometry of the PF PF includes spherical tip, two conical and one cylindrical section Two half-shells connected by Horizontal and Vertical Separation system Length : 8.59 m Diameter : 4 m
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Statistical data
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Payload Fairing Construction
Honeycomb Sandwich Smooth shell Waffle shell Foam Sandwich
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Results
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Need of Verification Need to verify PF with FEM analysis because:
Analytical calculations were made only for the maximum load (excessive pressure force load). In real condition this structure may work with more than one load case (axial load, shear load, bending moment, etc.,). So FEA is very important to check our construction with more than one load case and to ensure the maximum strength of the design. It is necessary to perform finite element analysis of the obtained PF for verification of the results and preparing of the design engineering documentation.
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Creation of FEM Model Geometrical model of the PF FEM of the PF
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Boundary conditions and Loads
FEM with displacement FEM with excessive pressure FEM with forces and moments
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FEA Results The deformed state of the PF. The maximum deflection – fmax = 7,8mm. scale factor – Ksc = 50 Maximum Failure Index
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FEA Results Shear stresses XZ in layer 5 (aluminum honeycomb core)
Shear stresses YZ in layer 5 (aluminum honeycomb core)
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FEA Results Von Mises stresses in the frames
First Buckling mode (scale factor – Ksc = 10)
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FEA Result analysis
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Design Modification MFIND > 1 Identifying Maximum MFIND region
Increase the value of Design parameter > 1 Check for MFIND < 1 Final Design
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Design Modification + = The process of refining the design
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FEA Results The deformed state of the PF. The maximum deflection – fmax = 5,85mm. scale factor – Ksc = 50 Maximum Failure Index
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FEA Result analysis
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Behavioral constraints
Optimization Design Parameters (Thickness) Behavioral constraints (Mfind, δ, σ, τ & BLF) Objective Function (Weight)
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FEA Results The deformed state of the PF. The maximum deflection – fmax = 5,85mm. scale factor – Ksc = 50 Maximum Failure Index
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FEA Results Shear stresses YZ in layer 5 (aluminum honeycomb core)
Shear stresses XZ in layer 5 (aluminum honeycomb core) Shear stresses YZ in layer 5 (aluminum honeycomb core)
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FEA Results Von Mises stresses in the frames
First Buckling mode (scale factor – Ksc = 10)
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FEA Result analysis
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Comparison of Results
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Weight of each component in PF
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Ground Transportation Modes of Transportation
Manufacturing Unit Launch Pad Railway Road Air Sea Modes of Transportation Fixation with trailer FEM model
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Ground Transportation At maximum overloaded condition
Maximum failure Index Deformation
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Parameters of Thermal Insulation
Theoretical Calculation of Thermal loads Statistical data of flight parameters up to 40 km
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Parameters of Thermal Insulation
Experimental Calculation of Thermal loads Geometry Thermal Distribution over PF Altitude Surface temperature (meters) (K) 288.15 4105.3 285.87 10250 307.55 19080 454.92 31090 822.71 FEM model
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Parameters of Thermal Insulation Fourier similarity criterion
Material : Aerogel Melting point : > 1200 ᵒC Density : 2 to 350 Kg/m3 Specific Heat Capacity : 840 J/Kg/K Fourier similarity criterion
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Economic Analysis Total cost 14593.63 UAH Salary of Executive workers
Cost for Software Works UAH Salary of Executive workers UAH Single social contribution UAH Operation and Maintenance cost UAH Other Expenses UAH Profit 20 % of cost VAT UAH 20 % of cost and profit
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Labor Safety Measure Insufficient Light
Harmful Factors: Insufficient Light Increased or Decreased Air Temperature Humidity Increased noise level Increased vibration level Electromagnetic radiation Air ventilation Work Heaviness Uncomfortable working position Long term without movement Repeating movements Work Intensity Eye stress Emotional fatigue Metal fatigue Dangerous Factors: Electrical Hit
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Extreme Situation Analysis
Accidents and Dangers Fire or Unprovoked explosion (10200) Sudden destruction of building (10600) Accidents on electrical power supply networks ( 10700) Accidents on life supporting system (10800) Geological process (20100)
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Conclusion Analysis of the PF structural and force scheme showed that the using of a CFRP with Al honeycomb shell significantly reduces the weight compared with the “smooth shell”, “waffle shell type” and “foam sandwich” Optimization work helps to reduce 6 kg of mass, and ensures the maximum strength and stability to work proposed load cases. For ground transportations this PF have enough strength to overcome the action of load in all mode of transports. Thermal calculations helps to find the action maximum thermal loads, required material and thickness To complete this work it took UAH based on Ukrainian Labor pay scale standard. All the necessary Safety precautions for this work is studied.
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Thank You… Thank You… Thank You… Thank You… Thank You…
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