Post on 03-Jan-2016
AAE 450 Spring 2008
Jesii Doyle1/31/2008
Internal Structure, Mounting MaterialsBulkhead Weight and Cost
AAE 450 Spring 2008
Bulkhead Weight and Cost Assumptions
– Max G-loading: 2G’s– Bulkhead position as
shown in Figure 1– Bulkhead loading as
shown in Figure 1
Propulsion Options– LOX/LH2– H2O2/RP-1– HTPB/AP/Al*Dimensions and weights
for each option provided by Dana Lattibeaudiere
Structures
Figure 1: Bulkhead Configuration
Tank
Engine
External Skin
Nozzle
Bulkhead
Bulkhead Inner Radius
Nozzle Dia.
AAE 450 Spring 2008
Bulkhead Weight and Cost
Structures
Future Work Internal support structure CAD models - Internal structure
Bulkhead Cost vs Material
$2.09
$3.12
$6.35 $6.50
$1.00
$3.04
$0.00
$1.00
$2.00
$3.00
$4.00
$5.00
$6.00
$7.00
Al 6061-T6 Al 7075-T6 Steel
Material
Cost
(U
SD
)
H2O2/RP-1 HTPB/AP/Al
Bulkhead Weight vs Material
2.3 2.4
4.7
1.1 1.1
2.3
0.0
0.5
1.0
1.5
2.0
2.5
3.0
3.5
4.0
4.5
5.0
Al 6061-T6 Al 7075-T6 Steel
Material
Weig
ht
(kg
)
H2O2/RP-1 HTPB/AP/Al
AAE 450 Spring 2008
Backup Slides Prop. Specifications
Structures
LOX/LH2Engine: YF-73Nozzle Weight (kg): 116.0Engine Weight (kg): 236.0Tank Weight (kg): 116.0Propellant Mass (kg): 8500.0Stage Diameter (m): 2.3Nozzle Diameter (m): 2.2
Total Weight (kg): 8968.0Rocket Radius (m): 1.1Nozzle Radius (m): 1.1
* Values provided by Dana Lattibeaudiere
H2O2/RP-1Engine: RD-161-PNozzle Weight (kg): 55.0Engine Weight (kg): 105.0Tank Weight (kg): 55.0Propellant Mass (kg): 9000.0Stage Diameter (m): 1.0Nozzle Diameter (m): 0.6
Total Weight (kg): 9215.0Rocket Radius (m): 0.5Nozzle Radius (m): 0.3
* Values provided by Dana Lattibeaudiere
AAE 450 Spring 2008
Backup Slides Prop. Specifications (Cont.)
HTPB/AP/AlEngine: Star 37XFPNozzle Weight (kg): 31.8Engine Weight (kg): 72.4Tank Weight (kg): 26.4Propellant Mass (kg): 883.7Stage Diameter (m): 0.9Nozzle Diameter (m): 0.6
Total Weight (kg): 1014.2Rocket Radius (m): 0.5Nozzle Radius (m): 0.3
* Values provided by Dana Lattibeaudiere
AAE 450 Spring 2008
Backup Slides MATLAB Code Results – Config. 2
LOX/LH2
MaterialWeight
(kg) Cost (USD)
Al 6061-T6 160.2 $442.20
Al 7075-T6 121.2 $334.45
Ti 6Al-4V 137.6 $29,353.00
Steel 453.7 $200.35
Fiberglass 109.5 $250,520.00
Carbon Fiber 138.6 $151,670.00
H2O2/RP-1
MaterialWeight
(kg)Cost
(USD)
Al 6061-T6 2.3 $6.35
Al 7075-T6 2.4 $6.50
Ti 6Al-4V 3.2 $684.48
Steel 4.7 $2.09
Fiberglass 2.3 $5,269.20
Carbon Fiber 2.1 $2,305.80
AAE 450 Spring 2008
Backup Slides MATLAB Code Results – Config. 2 (Cont.)
HTPB/AP/Al
MaterialWeight
(kg)Cost
(USD)
Al 6061-T6 1.1 $3.04
Al 7075-T6 1.1 $3.12
Ti 6Al-4V 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 = -0.01m)• 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
2
2
22
3
123
14
1ln
2
19
12
17
1ln14
3
4
1ln
2
11
)1(123
3*9
9*
7
1
*2
**
a
b
b
a
a
bC
a
b
b
aC
a
b
b
a
a
b
a
bC
a
b
b
a
b
a
a
bC
EL
b
CrnozzleL
b
Crnozzle
C
C
y
wat
rnozzle
gGsmw
2
22
14
1ln
2
19
1ln14
3
a
rnozzle
rnozzle
a
a
rnozzleL
a
rnozzle
rnozzle
a
a
rnozzle
a
rnozzleL
AAE 450 Spring 2008
Backup Slides Governing Equations - Config. 2 (Cont.)
– Applied Stress• Assume cantilever beam with square cross-
section• F.S. = Factor of Safety
..*
*62
SFt
brnozzlewCirc
AAE 450 Spring 2008
Backup Slides Manufacturing Cost Estimations
– Aluminum manufacturing: 1.2x Mat’l Cost– Steel manufacturing: 1.6x Aluminum– Titanium manufacturing: 2x Aluminum– Fiberglass structure manufacturing:
1.7x Aluminum• Additional Safety Factor 3.0 Required
– Carbon fiber manufacturing: 2x Aluminum
AAE 450 Spring 2008
Backup Slides Bulkhead Configuration 1
Tank
Engine
External Skin
Nozzle
Bulkhead
Bulkhead Inner Radius
F Nozzle Diameter
Stage Diameter
AAE 450 Spring 2008
Backup Slides MATLAB Code Results – Config. 1LOX/LH2
MaterialWeight
(kg) Cost (USD)
Al 6061-T6 257.9 $729.04
Al 7075-T6 202.9 $602.54
Ti 6Al-4V 233.0 $20,989.00
Steel 744.3 $388.69
Fiberglass 177.1 $198,880.00
Carbon Fiber 227.6 $104,060.00
H2O2/RP-1
MaterialWeight
(kg)Cost
(USD)
Al 6061-T6 62.5 $180.87
Al 7075-T6 47.5 $146.37
Ti 6Al-4V 54.6 $4,926.90
Steel 177.1 $100.05
Fiberglass 42.1 $47,328.00
Carbon Fiber 54.0 $24,678.00
AAE 450 Spring 2008
Backup Slides MATLAB Code Results – Config. 1 (Cont.)
HTPB/AP/Al
Material Weight (kg) Cost (USD)
Al 6061-T6 21.4 $86.37
Al 7075-T6 15.7 $73.16
Ti 6Al-4V 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
rnozzle
a
a
rnozzle
a
rnozzleL
a
rnozzle
rnozzle
a
a
rnozzle
a
rnozzleL
b
a
a
bC
a
b
b
a
b
a
a
bC
EL
C
LC
y
wat
log214
6
1log14
3
)1()1(2
14
4
1log
2
11
)1(123
4
6*1
2
22
3
123
Circ
Pw
rnozzleCirc
gGsmP
*2
**
AAE 450 Spring 2008
Backup Slides Governing Equations - Config. 1 (Cont.)
– Applied Stress• Assume cantilever beam with square cross-
section• F.S. = Factor of Safety
..*
*62
SFt
rnozzleawCirc
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 /inflateNASA.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 (7th Edition), McGraw-Hill, 2002.