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FEMCI Workshop 2005 Poster Session Langley Research Center Exploration Concepts Branch La. RC/Exploration Concepts FEMCI Workshop 2005 Poster Session Langley Research Center Exploration Concepts Branch La. RC/Exploration Concepts Branch 3 D Finite Element Based Structures Tools May 4 -5, 2005 Goddard Space Flight Center Zoran N. Martinovic NASA/La. RC Jeffrey A. Cerro NASA/La. RC Lloyd B. Eldred / Swales Aerospace Philip Su / Raytheon Corp.

FEMCI Workshop 2005 Poster Session Langley Research Center Exploration Concepts Branch Objective: • To FEMCI Workshop 2005 Poster Session Langley Research Center Exploration Concepts Branch Objective: • To quickly create coarse vehicle 3 D models which are subject to typical structural design loads • To estimate Level 2 primary structure weights during conceptual design phase - Level 0 weight estimates are based on historical data - Level 1 weight estimates are line model subject to shear, moment and axial force estimates - Level 2 coarse FEM structural weight estimates - Level 3 detailed FEM structural weight estimates • To do structural trade studies

FEMCI Workshop 2005 Poster Session Tool Outline Langley Research Center Exploration Concepts Branch Semi-automated FEMCI Workshop 2005 Poster Session Tool Outline Langley Research Center Exploration Concepts Branch Semi-automated iterative procedure for structural weight estimation and trade studies of new vehicle design concepts • JAVA - Object Oriented process control language (original process was wrapped in Phoenix Integration/Model Center) • UGS / I-DEAS - CAD/CAE • Collier Research / Hyper. Sizer - Structural component sizing • LOFT - Swales code to quickly create FEMs with property assignment regions defined • EXCEL Solver - utility used for balancing of flight loads • HSLOAD - Swales code to automate the Hyper. Sizer design process • Multidisciplinary input from CONSIZ (Subsystem weights), POST (Trajectory), CBAERO (Aero) 3

FEMCI Workshop 2005 Poster Session Exploration Concepts Branch POST Flight Profile with Accelerations & FEMCI Workshop 2005 Poster Session Exploration Concepts Branch POST Flight Profile with Accelerations & CBAERO generated Aeroforces Process Outline Vehicle Geometry and Weights CONSIZ INPUT Geometry Langley Research Center LOFT Generated Mesh INPUT Gs & Fs INPUT Lump Mass INPUT I-DEAS FE FE Mesh Model [M], [K] Finite elements organized in groups/Panels Panel sizing in HYPERSIZER Load Balancing EXCEL Solver Loaded I-DEAS FE Model Running loads [Nx, Ny, Nxy ……] New [K] & Struct. [M] HSLoad / HYPERSIZER Model Assign: • Panel/beam Concept • Material • Limits on design variables • Failure Criteria Zoran N. Martinovic/VAB/NASA La. RC/ June 2004 4

FEMCI Workshop 2005 Poster Session Langley Research Center Exploration Concepts Branch Geometry, packaging and FEMCI Workshop 2005 Poster Session Langley Research Center Exploration Concepts Branch Geometry, packaging and sub-system weights received …. . 5

FEMCI Workshop 2005 Poster Session Langley Research Center Exploration Concepts Branch LOFT Automatic Finite FEMCI Workshop 2005 Poster Session Langley Research Center Exploration Concepts Branch LOFT Automatic Finite Element Mesh Generation For Aerospace Vehicles • Use supplied Geometric Dimensions • Generate Panels, Frames, Beams/Bars for a full or partial vehicle • Mark each element with User Specified component names and coordinates • Attach to commercial codes for FEA and sizing • Post process sizing results 6

FEMCI Workshop 2005 Poster Session Langley Research Center Exploration Concepts Branch LOFT Extrudes between FEMCI Workshop 2005 Poster Session Langley Research Center Exploration Concepts Branch LOFT Extrudes between arbitrary cross sections Builds objects using panels, beams and bars Merges objects to form a single FE model # ISAT Reference Mach 3. 4 TSTO Vehicle # Our nose object dome BST Nose curve 1 sc c 1_xscale 15. 589 c 1_yscale 15. 589 length -36 taper para nodes_circ 21 nodes_axial 20 droop line Portable C code with Text Input zdroop 8 7

FEMCI Workshop 2005 Poster Session Langley Research Center Exploration Concepts Branch Desired forms are FEMCI Workshop 2005 Poster Session Langley Research Center Exploration Concepts Branch Desired forms are programmed … Example of LOFT input file 8

FEMCI Workshop 2005 Poster Session Langley Research Center Exploration Concepts Branch Property Assignments Create FEMCI Workshop 2005 Poster Session Langley Research Center Exploration Concepts Branch Property Assignments Create Physical and Material Property Names to mark Engineering components Allows easy application of sizing parameters to different Vehicle sections and easy post processing LOX FW Dome LOX Barrel LOX Ring Frame LOX Aft Dome LOX Longeron Meaningful names allow different construction approaches across the vehicle 9

FEMCI Workshop 2005 Poster Session Langley Research Center Exploration Concepts Branch High fidelity tool FEMCI Workshop 2005 Poster Session Langley Research Center Exploration Concepts Branch High fidelity tool to estimate wing structural weights • Generates detailed FE mesh • Calls FEA solver • Calls and controls sizing program • Postprocesses results Proof of Concept: Wing. Sizer If only wing needs to be studied, user may use a standalone program: Wingsizer …. 10

FEMCI Workshop 2005 Poster Session Langley Research Center Exploration Concepts Branch Wing. Sizer Analysis FEMCI Workshop 2005 Poster Session Langley Research Center Exploration Concepts Branch Wing. Sizer Analysis Mesh FEA Size 11

FEMCI Workshop 2005 Poster Session Langley Research Center Exploration Concepts Branch Process Highlights Geometry FEMCI Workshop 2005 Poster Session Langley Research Center Exploration Concepts Branch Process Highlights Geometry Model LOFT FEM Mesh 12

FEMCI Workshop 2005 Poster Session Langley Research Center Exploration Concepts Branch Nose cone Nose FEMCI Workshop 2005 Poster Session Langley Research Center Exploration Concepts Branch Nose cone Nose gear bulkhead Nose skirt LOFT generated model is imported to UGS/I-DEAS for static analysis … Fin Wing center section LOX tank Inter-tank Aft transition skirt Wing Forward LH tank Aft LH tank Fwd. transition skirt Bay fwd. bulkhead Model consists of shells (panels) and … Payload bay Thrust structure Bay aft bulkhead Thrust structure bulkhead Zoran N. Martinovic/VAB/NASA La. RC/ June 2004 13

FEMCI Workshop 2005 Poster Session Langley Research Center Exploration Concepts Branch Nose Skirt … FEMCI Workshop 2005 Poster Session Langley Research Center Exploration Concepts Branch Nose Skirt … beams (frames and longerones) LOX Tank Bay Inter tank FWD LH Tank Transition Skirts Longerones around circumference AFT LH tank Thrust 14

FEMCI Workshop 2005 Poster Session Langley Research Center Exploration Concepts Branch Sub-system masses are FEMCI Workshop 2005 Poster Session Langley Research Center Exploration Concepts Branch Sub-system masses are mapped and lumped to FEM … CONSIZ output file Mapping template file Mapping file into FEM XB Component mapping x XE fofx mapping 15

FEMCI Workshop 2005 Poster Session Langley Research Center Exploration Concepts Branch Individual Unit Loads FEMCI Workshop 2005 Poster Session Langley Research Center Exploration Concepts Branch Individual Unit Loads are applied and model analyzed for each of them … 1 psi Unit load … propellant loads are applied for each flight point and model analyzed for each of them … 16

FEMCI Workshop 2005 Poster Session Langley Research Center Exploration Concepts Branch Scaling of unit FEMCI Workshop 2005 Poster Session Langley Research Center Exploration Concepts Branch Scaling of unit Loads And Loads and Balancing Aero Inertia Objective function: Pitch moment = 0 1 psi Unit load Scaling factors I-DEAS/EXCEL/Text/JAVA Fz. ORB Constraints on axial and normal force, and other flight constraints Sum of balanced forces and moment Fx. ORB Fz. SRB Fx. SRB • Unit load sets are scaled, combined and balanced to create actual design loads. • Inputs are vehicle accelerations from design conditions (POST) and aero loads mapped from CBAERO (or user input fields in FEA) 17

FEMCI Workshop 2005 Poster Session Langley Research Center Exploration Concepts Branch Propellant Tanks with FEMCI Workshop 2005 Poster Session Langley Research Center Exploration Concepts Branch Propellant Tanks with Head pressure and Ullage pressure Booster Wing Lift and Flap Lift Orbiter ½ Wing Drag Booster ½ Nose Drag Orbiter ½ Fin Drag Balanced flight loads are applied to the FEM in UGS / I-DEAS and static analysis is done … Booster ½ Wing Drag Booster ½ Fin Drag az Orbiter ½ Nose Drag T ax W Booster Body Lift 18

FEMCI Workshop 2005 Poster Session Langley Research Center Exploration Concepts Branch Model, subdivided into FEMCI Workshop 2005 Poster Session Langley Research Center Exploration Concepts Branch Model, subdivided into panels and beams, is imported to Collier Research / Hyper. Sizer … … with internal running loads … … and sized for minimum weight with different structural concepts and materials 19

FEMCI Workshop 2005 Poster Session Langley Research Center Exploration Concepts Branch Model with new FEMCI Workshop 2005 Poster Session Langley Research Center Exploration Concepts Branch Model with new structural mass and stiffness is imported to UGS /I-DEAS and process iterates until converges. 20

FEMCI Workshop 2005 Poster Session Summary Complex vehicle designs multiple body ground/ascent/entry loads Variety FEMCI Workshop 2005 Poster Session Summary Complex vehicle designs multiple body ground/ascent/entry loads Variety of panel and beam designs metallic composite Langley Research Center Exploration Concepts Branch Integral panels Frame Stiffened Semi-monocoque shell 21

FEMCI Workshop 2005 Poster Session Langley Research Center Exploration Concepts Branch Reference configurations in FEMCI Workshop 2005 Poster Session Langley Research Center Exploration Concepts Branch Reference configurations in development Atlas 5 Heavy Space Shuttle RLV – TSTO and OSP RLV - SSTO Shuttle Derived Lifting Body 22

FEMCI Workshop 2005 Poster Session Langley Research Center Exploration Concepts Branch Other applications under FEMCI Workshop 2005 Poster Session Langley Research Center Exploration Concepts Branch Other applications under considerations Launch vehicle payload fairings Capsules 23