MECHANICAL LOADING DEVICE FOR A GENERIC INTERSTAGE OF A MULTISTAGE ROCKET

PRESENTED BY: GUIDED BY: CYRIL JOSE 7411 K. S. RAMAKRISHNAN ROY ROSHAN CHANDY 7442 THE DEPARTMENT SHINU JERONE 7444

Prof.(Dr) HEAD OF DEPT. OF

CONTENTS
INTRODUCTION INTERSTAGE TYPES OF INTERSTAGE AEROSPACE VEHICLE DEVELOPMENT NEED FOR MECHANICAL LOADING DEVICES DESIGN FLOW CHART PROJECT DEFINITION SCHEMATIC DIAGRAM LOAD PATH DIAGRAM DESIGN OF ADAPTERS DESIGN OF CONNECTOR DESIGN OF TOP & BASE BEAM DESIGN OF SHEAR PIN DESIGN OF EYE SELECTION OF HYDRAULIC JACK SELECTION OF LOAD CELL DESIGN OF REACTION LINE DESIGN OF FASTENERS CONCLUSION REFERENCE

INTRODUCTION
A SATELLITE LAUNCH VEHICLE IS A COMPLEX TRANSPORTATION SYSTEM. THEY ARE BUILT AS AN ASSEMBLAGE OF SEVERAL STAGES SOLID PROPULSION LIQUID PROPULSION CRYO/SEMICRYO PROPULSION INTERSTAGE STRUCTURES NOT ONLY INTERCONNECT THE TWO STAGES , BUT ALSO HOUSE VARIOUS AVIONICS/PROPULSION PACKAGES &

INTERSTAGE

TYPES OF INTERSTAGE

AEROSPACE VEHICLE DEVELOPMENT

MISSION TRAJECTORY DESIGN AERODYNAMIC CONFIGURATION CFD & WTT LOAD ANALYSIS GEOMETRY STRUCTURAL ANALYSIS FABRICATION STRUCTURAL TESTING ASSEMBLY FLIGHT MATERIAL

NEED FOR A MECHANICAL LOADING DEVICE

ONE TEST IS WORTH A THOUSAND OPINIONS ... -AESOP

SO TEST IT..

 COST OF A MISSION IS SO EXPENSIVE THAT IT IS NECESSARY TO TEST, EVALUATE AND ENSURE ITS PERFORMANCE BEFORE LAUNCH. FOR STRUCTURES WITH COMPLEX LOADING & COMPLICATED BOUNDARY CONDITIONS, IS DIFFICULT TO SIMULATE IN FEM THE EXACT BEHAVIOR OF JOINTS AS IT CANNOT ACCOUNT FOR BOUNDARY CONDITIONS, IMPERFECTIONS, ASSEMBLY AND

DESIGN FLOW CHART

DESIGN CONSIDERATIONS

STRENGTH

LOAD

STIFFNESS

STABILITY

GEOMETRY

MATERIAL

STRENGTH AND EXTRA RESERVE STRENGTH

EXTRA RESERVE STRENGTH

STRE SS

RESERVE STRENGTH

STR AIN

PROJECT DEFINITION
TO DEVELOP A MECHANICAL LOADING DEVICE THAT CAN MECHANICALLY SIMULATE THE FOLLOWING LOADS ON A GENERIC INTERSTAGE OF A ROCKET:
AXIAL COMPRESSIVE LOAD OF 12 TONNE AXIAL TENSILE LOAD LESS THAN 12 TONNE PURE CONSTANT BENDING MOMENT OF 4.2 TONNE-METRE

DIMENSIONS OF INTERSTAGE AS GIVEN BY THE DESIGNER: LENGTH OF THE HAT STIFFENED INTERSTAGE IS 1.5 METRE DIAMETER OF THE INTERSTAGE IS 1 METRE DEPTH OF INTERFACING FLANGES 0.01 METRE WIDTH OF INTERFACING FLANGES 0.030 METRE. 60 EQUALLY SPACED HOLES OF M6 PROVIDED ON THE FLANGES.

IIND CLASS LEVER

NUT (INTERSTA GE) NUT CRACKER (MECHANICAL LOADING DEVICE)

COMPRESSIVE LOADING OF 12 T

TENSILE LOADING OF 12 T

PURE BENDING OF 4.2 T-m

SCHEMATIC DIAGRAM

LOAD PATH DIAGRAM

TOP BEAM
SHEAR PIN 5

SHEAR PIN 1
EYE

EYE M16X1.5 BOLT LOADCELL 4 M6 BOLTS TOP ADAPTER PLATE 60 M6 BOLTS EYE

SHEAR PIN 4

CONNECTOR

INTERSTAGE
60 M6 BOLTS

REACTION LINE

HYDRAULIC JACK SHEAR PIN 2

BOTTOM ADAPTER EYE 4 BOLTS SHEAR PIN3 BOTTOM BEAM

DESIGNED MECHANICAL LOADING DEVICE

DESIGNED MECHANICAL LOADING DEVICE

DESIGNED MECHANICAL LOADING DEVICE

DESIGN OF MECHANICAL LOADING DEVICE FOR AXIAL LOADING & PURE BENDING

DESIGN OF TOP & BOTTOM ADAPTER

ADAPTERS ARE USED TO DIFFUSE THE CONCENTRATED LOADS UNIFORMLY THROUGHOUT THE INTERSTAGE. THE ADAPTER HEIGHT IS DESIGNED AS FOLLOWS
HLO
W

HHIGH

OVERLAP

HEIGHT OF ADAPTER SELECTED IS 400 mm THICKNESS OF ADAPTER IS SELECTED AS 5 mm

DESIGN OF CONNECTOR
LENGTH OF CONNECTOR : 2100.5 mm CONNECTOR IS MADE USING ISRO 50 INTERNAL THREAD OF M36X3 CUT ON HYDRAULIC SIDE OF THE CONNECTOR INTERNAL THREAD OF M16X1.5 CUT ON THE EYE SIDE OF CONNECTOR.

CRIPPLING = 279.62 N/mm2 crushing = 4.99 N/mm2 allowable = 240 N/mm2 MOS = 47.09

DESIGN OF TOP & BASE BEAM

THE TOP & BASE BEAM ARE MADE OF TWO ROLLED STEEL C-CHANNELS PLACED BACK TO BACK & HAVE DISTANCE OF 25 mm TWO ROLLED C CHANNELS OF ISMC 100 ARE SELECTED. llowable =

240 MPa

OVERALL LENGTH OF BEAM : 1000 mm. DEPTH OF SECTION : 100mm THICKNESS 50mm OF FLANGE :

DESIGN PARAMETERS
MODES OF FAILURE
BENDING SHEAR

designed ( N/mm2)
78.9 12.57

allowable ( N/mm2)
240 120

MOS

2.041 8.54

POINT OF MAXIMUM DEFLECTION : 489 mm from centre of shear pin on reaction line side. VALUE OF MAXIMUM DEFLECTION: 1.2 mm

DESIGN OF SHEAR PIN

MAXIMUM LOAD APPLIED: 3TONNE DIAMETER OF SHEAR PIN SELECTED BASED ON INTERFACING DIMENSIONS OF HYDRAULIC JACK : = 35 mm.

DESIGN PARAMETERS
MODES OF FAILURE

designed allowable ( N/mm2) ( N/mm2)

89.45 51.91 15.29 240 240 120

MOS

CRUSHING

1.68 3.62 6.84

BENDING

SHEAR

DESIGN OF REACTION LINE

IT IS MADE OF TWO DOUBLE CHANNELS ISMC 150X150 HAVING THEIR FLANGES BUTTING & WELDED TOE TO TOE & BATTENS PLACED ON OPPOSITE ENDS AND PLACED UNIFORMLY THROUGHOUT THE LENGTH. LOAD : 2 TONNE CRIPPLING = 4734 N/mm2 crushing = 4.69 N/mm2 allowable = 240 MPa MOS = 50.17

DESIGN OF EYE
LENGTH OF EYE DESIGNED CONSIDERING TEAR FAILURE : 105 mm THICKNESS OF EYE :25 mm HEIGHT OF EYE : 106 mm MAXIMUM LOAD APPLIED : 3 TONNE SHEAR PIN HOLE := 35 mm. SIZE OF FLAT WELDED : 65 mmX10 mm. SIZE OF EN24 HEAT TREATED ROUND BAR WELDED TO FLAT : = 16 mm. & LENGTH 30 mm. TO PREVENT EDGE TEAR A LENGTH OF 1.5X i.e 1.5x35=53 mm IS PROVIDED.

DESIGN PARAMETERS
MODES OF FAILURE

designed allowable ( N/mm2) ( N/mm2)

11.211 3.701 5.6 5.33 240 120 240 100

MOS

CRUSHING

20.406 31.41 41.85 17.76

EDGE SHEAR

TENSILE

WELD

DESIGN PARAMETERS
MODES OF THREAD FAILURE

designed allowable ( N/mm2) ( N/mm2)

67.85 186.916 51.9 440 880 880

MOS

THREAD SHEAR

5.48 3.707 15.95

TENSILE/ COMPRESSIVE BEARING

SELECTION OF HYDRAULIC JACK

PISTON = 80 mm

BOSCH REXROTH HYDRAULIC JACK (tie rod type)

SELECTION OF LOAD CELL

SHERBORNE SENSORS SERIES U2000
CAPACITY 1-50 kN STAINLESS STEEL CONSTRUCTION WEIGHT 0.15 KG INTERNAL THREAD M16X1.5 4 MOUNTING HOLES OF

DESIGN OF FASTENERS
LOAD APPLIED : 3T BOLT MADE OF : HSFG STEEL BOLT 12.9 GRADE M6x1 BOLT OF u=1200 N/mm2 Y= 1080 N/mm2 & LENGTH 50 mm HEIGHT OF NUT : 7 mm

DESIGN PARAMETERS
MODES OF THREAD FAILURE

designed allowable ( N/mm2) ( N/mm2)

140 411.72 101.02 540 1080 1080

MOS

THREAD SHEAR

2.8 1.62 9.69

TENSILE/ COMPRESSIVE BEARING

CONCLUSION
A MECHANICAL LOADING DEVICE TO SIMULATE AXIAL LOADING FORCES & PURE BENDING FORCES IS THUS CREATED. THIS IS A MODULAR DESIGN AND CAN FURTHER BE MODIFIED TO TEST FOR SHEAR FORCES AND TORSIONAL FORCES ACTING ON THE INTERSTAGE. THE DESIGN WAS MADE KEEPING IN MIND THE VARIOUS FUTURE REQUIREMENTS ALL THE ELEMENTS IN THIS DEVICE WERE CHECKED FOR FAILURE AND SATISFACTORY MOS ARE GIVEN. THERE IS EASY REPLACEMENT OF THE COMPONENTS IN EVENTS OF THEIR FAILURE AND PERMANENT JOINTS ARE AVOIDED AS FAR AS POSSIBLE TO GIVE MOBILITY IF SUFFICIENT FINANCIAL ASSISTANCE IS PROVIDED THE DEVICE CAN BE MADE IN A SHORT TIME.

REFERENCES
S. RAMAMRUTHAM, STEEL TABLES K. MAHADEVAN, DESIGN DATA HAND BOOK P. DAYARATNAM, DESIGN OF STEEL STRUCTURES ABDULLA SHARIFF, A TEXT BOOK OF MACHINE DESIGN H. ESCHENAUER, APPLIEDNSTRUCTURAL MECHANICS BHAVIKKATTI, STRENGTH OF MATERIALS NASA SP 8022, STAGING LOADS S K D RACHEL, AEROSPACE STRUCTURES-PRESENT PRACTICES & FUTURE ASPIRATIONS IN LAUNCH VEHICLES STEPHEN MAYERS, ARES1 STAGE SEPARATION SYSTEM DESIGN CERTIFICATION TESTING

WE THANK OUR GUIDES , TEACHERS & OUR COLLEAGUES FOR HELPING US IN OUR JOURNEY

A PROJECT BY

CYRIL JOSE

SHYAM STALIN ROY ROSHAN CHANDY

SHINU JERONE

INSPIRED BY