1. 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

2. 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.

3. 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

4. Statistical data

5. Payload Fairing Construction
Honeycomb Sandwich
Smooth shell
Waffle shell
Foam Sandwich

6. Results

7. 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.

8. Creation of FEM Model
Geometrical model of the PF
FEM of the PF

9. Boundary conditions and Loads
FEM with displacement
FEM with excessive pressure
FEM with forces and moments

10. FEA Results
The deformed state of the PF. The maximum deflection – fmax = 7,8mm. scale factor – Ksc = 50
Maximum Failure Index

11. FEA Results Shear stresses XZ in layer 5 (aluminum honeycomb core)
Shear stresses YZ in layer 5 (aluminum honeycomb core)

12. FEA Results Von Mises stresses in the frames
First Buckling mode (scale factor – Ksc = 10)

13. FEA Result analysis

14. Design Modification MFIND > 1 Identifying Maximum MFIND region
Increase the value of Design parameter
> 1
Check for MFIND
< 1
Final Design

15. Design Modification + =
The process of refining the design

16. FEA Results
The deformed state of the PF. The maximum deflection – fmax = 5,85mm. scale factor – Ksc = 50
Maximum Failure Index

17. FEA Result analysis

18. Behavioral constraints
Optimization
Design Parameters
(Thickness)
Behavioral constraints
(Mfind, δ, σ, τ & BLF)
Objective Function
(Weight)

19. FEA Results
The deformed state of the PF. The maximum deflection – fmax = 5,85mm. scale factor – Ksc = 50
Maximum Failure Index

20. 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)

21. FEA Results Von Mises stresses in the frames
First Buckling mode (scale factor – Ksc = 10)

22. FEA Result analysis

23. Comparison of Results

24. Weight of each component in PF

25. Ground Transportation Modes of Transportation
Manufacturing Unit
Launch Pad
Railway
Road
Air
Sea
Modes of Transportation
Fixation with trailer
FEM model

26. Ground Transportation At maximum overloaded condition
Maximum failure Index
Deformation

27. Parameters of Thermal Insulation
Theoretical Calculation
of Thermal loads
Statistical data of flight parameters up to 40 km

28. 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

29. 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

30. 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

31. 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

32. 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)

33. 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.

34. Thank You…
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