AMAMS02-ACOP-STRUCTURE

ACOP preliminary structural analysis

for PDR (I)

Jih-Long Tsai, Meng Lung Liu

December 1, 2004

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 AMAMS02-ACOP-STRUCTURE

Outline
1. ACOP structure description
2. Finite element model
3. Model check
4. Dimensioning loads
5. Natural frequency analysis
6. Stress analysis
7. Margins of safety
8. Conclusion

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1. ACOP structure description

 The ACOP dimension is 460x535x273mm meeting the Mid Deck
Locker (MDL) form factor as modified for the EXPRESS Rack
Payloads.
 The ACOP structure includes two parts: the locker and a chassis.
This aluminium alloy chassis provide a 6U CompactPCI card cage
and 4 hard disk driver slots, and a lot of fins in two sides of chassis
as heat sinks. Due to the limited space the LCD is mounted to the
front panel of the locker.
 The cooling air comes from inlet duct and goes to outlet duct; these
ducts are directly connected to electronic backplane and locker
backplate at each end. At corners of locker, four sleeve bolt
receptacles are used to fasten ACOP structure and EXPRESS rack
backplate together.
 The 3D drawings of ACOP structure are as follows:

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ACOP structure views

Chassis assembly
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2. Finite element model

Air in/outlet

Chassis

Front panel ACOP FE model

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2. Finite element model(continued)

 Used software: MSC/NASTRAN for analysis,
EDS/I-DEAS for pre/post processing.
 Model units:
Mass: kilogram (kg)
Force: milli-Newton (mN)
Length: milli-meter (mm)
Strength (Stress): milli-Newton/mm2 (mN/mm2)
 Coordinate: These axis directions are same as ISPR
coordinate system used in EXPRESS rack payload.
Z

Z
Y
Y
X
X
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2. Finite element model(continued)

 Material strength: AL 7075-T6, Fty=4.55E+5 mN/mm2,
Ftu=5.17E+5 mN/mm2 (ref. MIL-HDBK-5G)
 Model descriptions:
(1) 77463 nodes and 48077 elements in FEM.
(2) Use a single layer element to simulate each electronic board,
and LCD module and connect to locker(or chassis) by
coincident nodes. Board mass considered by using assumed
material density and elastic modulus.
(3) Interface between chassis and locker, air in/outlet and
backplates use coincident nodes.
(4) Interface between electronic backplate and chassis use rigid
bar connections.
(5) Front panel two top corners and central region connect to
locker by coincident nodes, and bottom edge use rigid bar
connections to simulate friction hinge.

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2. Finite element model(continued)

 Boundary conditions: all d.o.f. of fastened points at 4
corners of locker backplane are fixed. The joint
analysis would be done from reaction forces.

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2. Finite element model(continued)

 Model mass budge: the mass and CG location from
NASTRAN.
REFERENCE POINT = 83941 (the origin of model coordinate)
MASS AXIS SYSTEM MASS X-C.G. Y-C.G. Z-C.G.
X 2.811882E+01 0.000000E+00 2.248420E+02 1.308052E+02
Y 2.811882E+01 -2.975965E-01 0.000000E+00 1.308052E+02
Z 2.811882E+01 -2.975965E-01 2.248420E+02 0.000000E+00

If add mass of some components neglected in model

(such as HDD, tray, cable) to NASTRAN predicted
mass value, the predicted total mass will be 33.52 kg.

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3. Model check & 4. Dimensioning loads

 Model check:
(1) model size and geometry: PASS
(2) free-free and hardmounted modes: PASS, (need to
discuss)
(3) 1 G check: PASS
(4) strain energy check: PASS (need to discuss)

 Dimensioning loads:
(1) Low frequency load factors defined in SSP-52000-IDD-
ERP section 4.1.2 and random vibration load spectrum list
in section 4.3.
(2) Use the methodology of load combination defined in SSP
52005C section 4.2. and SSP52000-IDD-ERP section
4.3.3.
(3) we choose some more severe load cases to check MOS of
ACOP structure.
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4. Dimensioning loads (continue)

 Combination of EXPRESS Rack loads

32 load cases(16 liftoff cases have done)

 Middeck emergency landing loads

6 load cases (not yet)

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4. Dimensioning loads (continue)

 Combination of SPACEHAB loads

144 load cases

(not yet)

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5. Natural frequency analysis

 Natural frequency for each axis:

 There are many electronic board modes due to assumed

material properties, and would not be considered for
structural safety.

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5. Natural frequency analysis(continue)

Y axis first primary structural

mode shape

X axis first primary structural

mode shape

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5. Natural frequency analysis(continue)

Z axis first primary structural mode shape

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6. Stress analysis
 Maximum stresses and displacements are listed as follows:
(only EXPRESS Rack 16 liftoff load cases done)

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6. Stress analysis(continue)

2
Max stress1.46E+5 mN/mm2 at location 2
Max displacement 0.183mm at LCD & I/O let
by loading case (25.309,-11.6,9.9) G

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6. Stress analysis(continue)

3
Max stress: 1.32E+5 mN/mm2 at location 3
Max displacement: 0.33mm at LCD
by loading case: (-7.7,-27.765,9.9) G

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6. Stress analysis(continue)

 The joint force results: fastener at location 2 take

more loading force. (from 16 EXPRESS load cases)

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7. Margins of safety
 The structural factors of safety applied to the EXPRESS Rack
load and SPACEHAB loads are 1.25 for yield and 2.0 for
ultimate.
 The tensile yield strength for aluminum (7075-T6) is
reduced by a factor of .97 when the reference temperature
is modified to 120 °F. suggested in SSP 52000-IDD-ERP
Table 5-I.
 MOS for structure: (ref. SSP 52005C)

 MOS for fastener: (ref. NASA reference pub. 1228)

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7. Margins of safety (continue)

 MOS of ACOP structure are positive.

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7. Margins of safety (continue)

 Use most conservative x=1,y=1 for

 Use bolt strength defined in SSP 52000-IDD-ERP sec. 3.4.3.6.2.1

 MOS of joints are positive.

 Preload of fastener is not considered in analysis. It should be careful

that avoid too large preload force to reduce the MOS of joint during
ACOP installation.

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8. Conclusion

 The first natural frequency of structure 146.15Hz and of electronic

board 71.06Hz (need to be verified by test) satisfy the requirement of
SSP-52000-IDD-ERP section 4.1.1, that require more than 35Hz for
EXPRESS, 30Hz for Middeck, 50Hz for SPACEHAB payload.

 The margin of safety of ACOP structure and joints under 16 EXPRESS

rack liftoff load cases are positive.

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