Jesii Doyle 1312008 Internal Structure Mounting Materials Bulkhead

Jesii Doyle 1/31/2008 Internal Structure, Mounting Materials Bulkhead Weight and Cost AAE 450 Spring 2008

Bulkhead Weight and Cost § Assumptions – Max G-loading: 2 G’s – Bulkhead position as shown in Figure 1 – Bulkhead loading as shown in Figure 1 External Skin Engine Nozzle Dia. § Propulsion Options – LOX/LH 2 – H 2 O 2/RP-1 – HTPB/AP/Al *Dimensions and weights for each option provided by Dana Lattibeaudiere Bulkhead Tank Bulkhead Inner Radius Figure 1: Bulkhead Configuration AAE 450 Spring 2008 Structures

Bulkhead Weight and Cost Future Work § Internal support structure § CAD models - Internal structure AAE 450 Spring 2008 Structures

Backup Slides § Prop. Specifications AAE 450 Spring 2008 Structures

Backup Slides § Prop. Specifications (Cont. ) AAE 450 Spring 2008

Backup Slides § MATLAB Code Results – Config. 2 H 2 O 2/RP-1 LOX/LH 2 Material Weight (kg) Cost (USD) 2. 3 $6. 35 Al 7075 -T 6 2. 4 $6. 50 Ti 6 Al-4 V 3. 2 $684. 48 Steel 4. 7 $2. 09 $250, 520. 00 Fiberglass 2. 3 $5, 269. 20 $151, 670. 00 Carbon Fiber 2. 1 $2, 305. 80 160. 2 $442. 20 Al 7075 -T 6 121. 2 $334. 45 Ti 6 Al-4 V 137. 6 $29, 353. 00 Steel 453. 7 $200. 35 Fiberglass 109. 5 138. 6 Cost (USD) Al 6061 -T 6 Carbon Fiber Material Weight (kg) AAE 450 Spring 2008

Backup Slides § MATLAB Code Results – Config. 2 (Cont. ) HTPB/AP/Al Material Weight (kg) Cost (USD) Al 6061 -T 6 1. 1 $3. 04 Al 7075 -T 6 1. 1 $3. 12 Ti 6 Al-4 V 1. 5 $328. 02 Steel 2. 3 $1. 00 Fiberglass 1. 1 $2, 525. 20 Carbon Fiber 1. 0 $1, 105. 00 AAE 450 Spring 2008

Backup Slides § Global Governing Equations – Variables: • Gs = Max. G-loading • g = Gravitational constant = 9. 80665 m/s^2 • m = Weight applied to bulkhead (kg) • rnozzle = Nozzle radius (m) • w = Applied unit line load (Pa) • a = Rocket stage radius (m) • b = Inner bulkhead radius (m) • t = Bulkhead thickness (m) – Requirements: • Displacement <= Max. Displacement (y = -0. 01 m) • Applied Stress <= Yield Stress AAE 450 Spring 2008

Backup Slides § Governing Equations – Config. 2 – Calculation of Thickness • Maximum Displacement • E = Modulus of Elasticity (Pa) • ν = Poisson’s ratio AAE 450 Spring 2008

Backup Slides § Governing Equations - Config. 2 (Cont. ) – Applied Stress • Assume cantilever beam with square crosssection • F. S. = Factor of Safety AAE 450 Spring 2008

Backup Slides § Manufacturing Cost Estimations – Aluminum manufacturing: 1. 2 x Mat’l Cost – Steel manufacturing: 1. 6 x Aluminum – Titanium manufacturing: 2 x Aluminum – Fiberglass structure manufacturing: 1. 7 x Aluminum • Additional Safety Factor 3. 0 Required – Carbon fiber manufacturing: 2 x Aluminum AAE 450 Spring 2008

Backup Slides § Bulkhead Configuration 1 Tank F Nozzle Diameter External Skin Bulkhead Inner Radius Engine Nozzle Bulkhead Stage Diameter AAE 450 Spring 2008

Backup Slides § MATLAB Code Results – Config. 1 H 2 O 2/RP-1 LOX/LH 2 Material Weight (kg) Cost (USD) Al 6061 -T 6 257. 9 $729. 04 Al 6061 -T 6 62. 5 $180. 87 Al 7075 -T 6 202. 9 $602. 54 Al 7075 -T 6 47. 5 $146. 37 Ti 6 Al-4 V 233. 0 $20, 989. 00 Ti 6 Al-4 V 54. 6 $4, 926. 90 Steel 744. 3 $388. 69 177. 1 $100. 05 Fiberglass 177. 1 $198, 880. 00 Fiberglass 42. 1 $47, 328. 00 Carbon Fiber 227. 6 $104, 060. 00 Carbon Fiber 54. 0 $24, 678. 00 Steel AAE 450 Spring 2008

Backup Slides § MATLAB Code Results – Config. 1 (Cont. ) HTPB/AP/Al Material Weight (kg) Cost (USD) Al 6061 -T 6 21. 4 $86. 37 Al 7075 -T 6 15. 7 $73. 16 Ti 6 Al-4 V 21. 3 $1, 969. 90 Steel 60. 7 $73. 29 Fiberglass 16. 5 $18, 591. 00 Carbon Fiber 17. 8 $8, 189. 40 AAE 450 Spring 2008

Backup Slides § Governing Equations – Config. 1 – Calculation of Thickness • Maximum Displacement • E = Modulus of Elasticity (Pa) • ν = Poisson’s ratio AAE 450 Spring 2008

Backup Slides § Governing Equations - Config. 1 (Cont. ) – Applied Stress • Assume cantilever beam with square crosssection • F. S. = Factor of Safety AAE 450 Spring 2008

Backup Slides § Manufacturing Cost Estimations – Cost/Rivet: $0. 73/rivet – Labor hour/Rivet: 0. 049 hr/rivet – Cost/Labor Hour: $52. 00/hr – # Rivets = 6 * Circumference AAE 450 Spring 2008

Backup Slides § References Cyr, Kelley, “NASA New Start Index Inflation Calculator, ” Cost Estimating Web Site, NASA, May 2007. [http: //cost. jsc. nasa. gov/inflation/nasa /inflate. NASA. html. Accessed 1/28/08] Design Manual: Fiberglass Grating and Structural Products, Delta Composites, L. L. C. , Houston, TX, 2007. Green, E. A. , and Coulon, J. F. , “Cost Considerations in Using Titanium, ” AIAA Paper 67 -400, Jun. 1967. Noton, Bryan R. , “ICAM - Manufacturing Cost Design Guide, ” AIAA Paper 81 -0855, May 1981. AAE 450 Spring 2008

Backup Slides § References (Cont. ) Young, W. C. , and Budynas, R. G. , Roark’s Formulas for Stress and Strain (7 th Edition), Mc. Graw-Hill, 2002. AAE 450 Spring 2008