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SPACE STRUCTURES Prof. Alessandro Airoldi

SPACE STRUCTURES Prof. Alessandro Airoldi. INTRODUCTION TO THE COURSE. Introduction to the course. Objectives of the course Stressed skin constructions in aircraft structures Loads in space structures Examples of space structures Contents and organisation of the course.

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SPACE STRUCTURES Prof. Alessandro Airoldi

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  1. SPACE STRUCTURES Prof. Alessandro Airoldi INTRODUCTION TO THE COURSE

  2. Introduction to the course • Objectives of the course • Stressed skin constructions in aircraft structures • Loads in space structures • Examples of space structures • Contents and organisation of the course

  3. Introduction to the course Objectives of the course Approaches to the analysis of structures in aerospace constructions

  4. INERTIAL LOAD THRUST Introduction to the course Objectives of the course Aerospace constructions Aerospace structures AERODYNAMIC LOADS AERODYNAMIC LOADS Structure works to transfer the applied loads Force equilibrium (D’Alembert principle) INERTIAL LOAD Such considerations apply to all type of structures (not only aerospace structure)

  5. Introduction to the course Objectives of the course Requirements: Stiffness Limitation to the relative displacements due to functional requirements (e.g. aerodynamics) Avoid frequency coupling (resonance) AERODYNAMIC LOADS AERODYNAMIC LOADS Strength Avoid permanent deformation and the collapse of the structures under operative load INERTIAL LOAD Shape Constraints INERTIAL LOAD AERODYNAMICS, INTERNAL VOLUMES FOR PAYLOADS OBJECTIVE: perform structural functions, fullfilling requirements, respect constraints with MINIMUM WEIGHT THRUST

  6. Introduction to the course Objectives of the course Why analysis ? Analysis of existing structures helps understanding the functions of structural elements, critical issues in design, the available solution for design (synthesis) Design is an iterative process, which involve analysis of design hypothesis at different level of detail

  7. Introduction to the course Objectives of the course • Enhance the capability to apply the approaches of structural mechanics to the structural types that are employed in aerospace structure. Given the applied loads: • methods for the evaluation of internal stress and strain states • methods for the evaluation of stiffness, displacements, natural frequencies • Learn the main features of aerospace structures: comprehension of structural roles, capability to critically analyse a structure • Achieve the bases for a proper use of structural calculation software: knowledge of principles, technologies, limitations

  8. Introduction to the course Stressed skin constructions in aircraft structures The peculiar and severe requirements for aircraft structures led to the development of a very effective structural typology: Thin load bearing skin (stressed skin), reinforced by longitudinal stringers and internal frames SEMI-MONOCOQUE STRUCTURES They still represent the basic structural concept in aerospace structures, together with TRUSS STRUCTURES

  9. Introduction to the course Stressed skin constructions in aircraft structures FABRIC COVER TRUSS STRUCTURE INTERNAL FRAMES (RIBS) AND LONGITUDINAL REINFORCEMENT (SPARS) Biplane (1916) Motivations for the development of stressed skin constructions can be traced to the beginning of flight

  10. Introduction to the course Stressed skin constructions in aircraft structures Torsional stiffness: critical issue in wing design High pitch angle Low pitch angle WING TORSION

  11. Introduction to the course Stressed skin constructions in aircraft structures Torsional stiffness of biplane wings

  12. Introduction to the course Stressed skin constructions in aircraft structures Hurricane had originally a fabric cover (1935) All metal stressed skin provided in 1939 Load bearing skin provides a closed high-stiffness path for shear stress, contribute to bending stress and stiffness

  13. Introduction to the course Stressed skin constructions in aircraft structures Thin load bearing skin (stressed skin), reinforced by longitudinal stringers and internal frames Semi-monocoque structure (1943)

  14. Introduction to the course Stressed skin constructions in aircraft structures Modern airliner structure CLOSELY SPACED FRAME AND RIBS (internal diaphragm in fuselage and wing COMPOSITE VERTICAL TAIL WITH SEMI-MONOCOQUE MORPHOLOGY

  15. Introduction to the course Stressed skin constructions in aircraft structures Wing box and ribs REAR SPAR FWD SPAR Integrally stiffened composite skin

  16. Introduction to the course Stressed skin constructions in aircraft structures TRUSS STRUCTURES Type of diaphragms and instability C – SHAPED BEAMS WITH VARIABLE SECTION AND CUTOUTS CLOSED LOOP OF BEAMS WITH L, C, Z or other shape SECTIONS

  17. Introduction to the course Stressed skin constructions in aircraft structures Tail structure and bulkheads AIRBUS A 300 TAIL BULKHEAD WORKING UNDER PRESSURE LOADS A380 COMPOSITE BULKHEAD

  18. Introduction to the course Stressed skin constructions in aircraft structures Supersonic fighters FUSELAGE FRAMES ARE MORE SPACED DUE TO NEED OF LARGE CUT-OUTS (Cockpit, cut-out inspections of engines, air inlets) WINGS BECOME VERY THIN AND STRINGERS ARE MERGED IN A SERIES OF SPARS

  19. Introduction to the course Loads in space structures Natural environment: climatic, thermal, chemical and vacuum conditions, required cleanliness, levels of radiation and the meteoroid and space debris environment. Mechanical and thermal loads that are induced by operation of spacecraft: • ground handling • launch • manoeuvres and disturbances • re-entry • descent and landing • Additional induced loads, which include static pressure within the payload volume, temperature and thermal flux variations

  20. Introduction to the course Loads in space structures Ground handling and transportation loads

  21. Introduction to the course Loads in space structures Ground handling and transportation loads a • << Ra Rb Rc Rd -la

  22. INERTIAL LOAD THRUST Introduction to the course Loads in space structures Launch MODIFIED ICBM LAUNCHER SATURN V 7 g 3.7g 4.2 g Launch phase corresponds to the most severe loads Launcher structure is heavily compressed ARIANE V

  23. Introduction to the course Loads in space structures Loads are typically transient loads, vibration loads When load are applied for an extended period of time they can be considered static (g loading / steady state accelerations) The design load factors are represented by Quasi Static Loads, which are the most sever combination of dynamic and steady state acceleration COMPRESSIVE LOADS ARE THE HIGHEST LATERAL LOADS BEND THE STRUCTURE AND CAN NOT BE NEGLECTED Lateral g loads Axial g loads • << Ariane V QSL

  24. Introduction to the course Loads in space structures Internal forces in a launcher (first stage for the application of a beam model ) Generation of oscillatory axial tensile at engine shut down

  25. Introduction to the course Loads in space structures Launch loads also act on spacecraft, which represent the launcher payload. Spacecraft are constrained to launchers by means of structures called adapter (or dispenser). Ariane IV QSL AT PAYLOAD -ma THE TYPE OF LAUNCHER DEFINES THE LOAD CONDITIONS FOR THE SPACECRAFT QSL are the design loads for launcher structure, adapters and spacecrafts. Strength requirements imply a margin of safety > 1

  26. Introduction to the course Loads in space structures For spacecraft a fundamental (stiffness) requirement is avoiding resonant coupling with vibrations by launcher THE TYPE OF LAUNCHER DEFINES THE STIFFNESS REQUIREMENTS FOR THE SPACECRAFT Dynamic decoupling must be attained: spacecraft structure must exhibit natural frequency higher than the ones of launcher induced vibrations

  27. Introduction to the course Loads in space structures Other loads: • Pressure fluctuation due to engine operations and unsteady aeordynamic phenomena • Shock (e.g. during jettison of stages) • Thermo-elastic actions due to thermal flux • Collision with meteoroids and space debris

  28. Introduction to the course Examples of space structures: SPACE SHUTTLE Unique combination of semi-monocoque, pressure vessels, truss structures structural concepts Orbiter • Many different materials used: • Aluminium alloy • high strength steel • Titanium • Boron/aluminium composite • Carbon/epoxy composites • Fibreglass • Ceramics SRB External tank

  29. Introduction to the course Examples of space structures: SPACE SHUTTLE Solid busters MAIN STRUCTURE: SEGMENTED STRUCTURE (11 SEGMENT) HIGH STRENGTH STEEL 13 mm THICK JOINED BY STEEL PINS JUNCTIONS WRAPPED BY FIBERGLASS SEALED WITH RUBBER BANDS SUCH MAIN STRUCTURE IS CLOSED BY THE FWD AND AFT SEGMENT DOMES IT IS THE EXTERNAL STRUCTURE BETWEEN THE FORWARD AND THE AFT SKIRT EXTERNAL COVER, SUCH AS NOSE CAP AND SKIRTS ARE MADE OF WELDED ALUMINUN

  30. Introduction to the course Examples of space structures: SPACE SHUTTLE External Tank TWO TANKS: OXYGEN AND HYDROGEN PRE-FORMED ALUMINUM ELEMENTS (PANELS, MACHINED THICK ELEMENTS) PRESENCE OF INTEGRALLY MACHINED STRINGERS AND RING FRAMES RING FRAMES STABILIZE THE TANK AT HIGH COMPRESSIVE LOADS INTERTANK STRUCTURE IS A MORE CONVENTIONAL SEMIMONOCOQUE STRUCTURE (PANELS-SKIN-FRAMES MECHANICALLY JOINTED)

  31. Introduction to the course Examples of space structures: SPACE SHUTTLE Orbiter BASED ON SEMIMONOCOQUE PRINCIPLES LARGE PARTS MADE OF ALUMINUM ALLOY PECULIAR ASPECTS • CONVENTIONAL FORWARD FUSELAGE STRUCTURE HOSTS WELDED PRESSURISED CREW MODULE • CENTRAL SECTION FRAMES MADE OF BORON/ALUMINUM TRUSS STRUCTURE • THRUST BEARING TRUSS STRUCTURE WITH BORON/EPOXY REINFORCEMENTS • WINGS WITH HONEYCOMB SKIN COVER

  32. Introduction to the course Examples of space structures: SPACE SHUTTLE Orbiter FORWARD FUSELAGE: EXTERNAL SHELL STRUCTURE (SEMIMONOCOQUE CONCEPT) INTERNAL PRESSURIZED VESSEL

  33. Introduction to the course Examples of space structures: SPACE SHUTTLE Orbiter CENTRAL SECTION LONGHERON CARRY BENDING LOADS HIGH STIFFNESS- STRENGTH REQUIRMENT FOR FRAMES: TRUSS WITH BORON/ALUMINUM TUBES CONCEPTS OF STRESSED SKIN CONSTRUCTION LARGELY EMPLOYED

  34. Introduction to the course Examples of space structures: SPACE SHUTTLE Orbiter GRAPHITE\EPOXY PAYLOAD BAY DOORS REINFORCED BY FRAMES AND END TORQUE BOXES HIGH STRENGTH 3D TRUSS STRUCTURE TO SUSTAIN THE THRUST LOAD OF MAIN ENGINES

  35. Introduction to the course Examples of space structures: SPACE SHUTTLE Orbiter CONVENTIONAL ALUMINUM STRUCTURE WITH MULTI SPAR AND RIB ARRANGEMENT HONEYCOMB SKIN REINFORCED BY ALUMINUM HAT-SHAPED STRINGERS

  36. Introduction to the course Examples of space structures: SATURN V First Stage Separate serial tanks within semimonocque structure SEMI-MONOCOQUE AL 7075 INTERTANKS AND SKIRTS AL 2219 – T87 TANK WITH ANTI-SLOSH BAFFLES (diaphragms that reduces fuel movements)

  37. Introduction to the course Examples of space structures: SATURN V Second Stage Integral serial tanks with common bulkhead INTEGRALLY STIFFENED TANKS MADE OF DIFFUSION-WELDED AL 2014 PARTS COMMON BULKHEAD: AL 2014 SHEET + FIBERGLASS/ PHENOLIC HONEYCOMB CORE SKIRTS, INTERSTAGES, THRUST STRUCTURE: AL7075 SEMIMONOCOQUE

  38. Introduction to the course Examples of space structures: SATURN V Third Stage Serial tanks with common bulkhead VERY SIMILAR TO 2° STAGE STRUCTURE INTEGRALLY STIFFENED TANKS AND SEMIMONOCOQUE STRUCTURES

  39. Introduction to the course Examples of space structures: SPACECRAFTS Experimental spacecraft designed at John Hopkins University: multisensor platform including a Spatial Infrared Telescope IN SPACECRAFTS THE DISTINCTION BETWEEN PRIMARY AND SECONDARY STRUCTURES IS IMPORTANT: PRIMARY STRUCTURES • TRANSMIT LOADS TO THE BASE OF THE SATELLITE THROUGH SPECIFICALLY DESIGN COMPONENTS (CENTRAL TUBE, HONEYCOMB PLATFORM, BAR TRUSS, ETC.). • PROVIDE THE ATTACHEMENT POINTS FOR THE PAYLOAD AND THE ASSOCIATED EQUIPMENTS. • FAILURE OF THE PRIMARY STRUCTURE LEADS TO COLLAPSE OF SATELLITE SECONDARY STRUCTURES • BAFFLE, THERMAL BLANKET SUPPORT AND SOLAR PANELS • MUST ONLY SUPPORT THEMSELVES AND ARE ATTACHED TO THE PRIMARY STRUCTURE WHICH GUARANTEE THE OVERALL STRUCTURAL INTEGRITY.

  40. Introduction to the course Examples of space structures: SPACECRAFTS SEVERAL DIFFERENT STRUCTURAL TYPES: • TRUSS (ALSO IN HIGH STIFFNESS/STRENGTH COMPOSITE MATERIAL) • HONEYCOMB PANELS (OFTEN USED FOR ELECTRONIC SUPPORT AND SOLAR CELL SUPPORT) • MACHINED BEAMS AND PLATES

  41. Introduction to the course Examples of space structures: SPACECRAFTS MANNED SPACECRAF INCLUDES • TRUSS STRUCTURES • SEMI-MONOCOQUE CONCEPTS (THIN WALLED STRUCTURES WITH STIFFENERS AND FRAMES) • STIFFENED PRESSURE VESSELS

  42. Introductory lessons Examples of space structures: Structural concepts • Central role of two different but very effective structural types: semi-monocoque and truss structures • pressure vessels design concepts and honeycomb structures Basic structural elements (models) Beam models can be applied at level of the vehicle structure, for the analyses of truss systems, for the analyses of ribs and frames Plate theory is required to understand the behavior of panels and covers Required skills in aerospace structures • Extensive knowledge of • different structural typologies and engineering solutions • different theoretical models and analysis approaches to meet severe requirements in a multiplicity of conditions

  43. Introductory lessons Course Content and Organisation: Lectures (theory) • MECHANICS OF DEFORMABLE BODIES • BEAM MODELS AND BEAM SYSTEMS • SEMI-MONOCOQUE STRUCTURES • STIFFNESS APPROACHES AND RITZ METHOD • PLATES • FE METHOD • NON-LINEAR PROBLEMS AND INSTABILITY

  44. Introductory lessons Course Content and Organisation: Course Material & Textbooks Slides of the lectures will be provided during the course MALVERN, MECHANICS OF CONTINUOUS MEDIUM Continuum mechanics, general principles T.H. MEGSON, AIRCRAFT STRUCTURES FOR ENGINEERING STUDENTS, BUTTERWORTH-HEINEMANN, 1972 Semi-monocoque structures, force and displacement approach to beam systems J.N. REDDY, ENERGY PRINCIPLES AND VARIATIONAL METHODS IN APPLIED MECHANICS, WILEY 2002 Energy methods, Ritz Method, Plate Theory K.J. BATHE, FINITE ELEMENT PROCEDURES, PRENTICE HALL 1982 Finite elements V. GIAVOTTO, STRUTTURE AERONATICHE CITTA’ STUDI Covers several parts of the course

  45. Introductory lessons Course Content and Organisation: Exercise classes • STRESS AND STRAIN MEASURES • 3D BEAM SYSTEMS • SEMIMONOCOQUE STRUCTURES • STIFFNESS APPROACHES AND APPROXIMATE METHODS • MECHANICS OF DEFORMABLE BODIES • BEAM MODELS AND BEAM SYSTEMS • SEMIMONOCOQUE STRUCTURES • PLATES (THIN & THICK PLATES, LAMINATES, PRESSURE VESSELS HONEYCOMB) • STIFFNESS APPROACH AND APPROXIMATE METHODS • FE METHOD • NON-LINEAR PROBLEMS AND INSTABILITY The exercises that will be proposed during the classes will be all available on-line

  46. Introductory lessons Course Content and Organisation: Written Examination Based on the same type of exercises that have been presented, solved and discussed during classes Capability to critically apply concepts as well as to organize and carry out calculations Admission to oral examination is possible only if the written text will obtain a positive mark Oral Examination Comprehension of structural concepts, analytical and numerical approach Will include proofs of main theorems and formulation development

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