Design of Mechanical Loading Device

DESIGN OF A DESIGN OF A MECHANICAL LOADING MECHANICAL LOADING DEVICE FOR A GENERIC DEVICE FOR A GENERIC

INTERSTAGE OF A INTERSTAGE OF A MULTISTAGE ROCKETMULTISTAGE ROCKET

PRESENTED BY:PRESENTED BY: GUIDED BY:GUIDED BY: CYRIL JOSE 7411 Prof.(Dr) K. S. RAMAKRISHNANCYRIL JOSE 7411 Prof.(Dr) K. S. RAMAKRISHNAN ROY ROSHAN CHANDY 7442 HEAD OF THE DEPARTMENTROY ROSHAN CHANDY 7442 HEAD OF THE DEPARTMENT SHINU JERONE 7444 DEPT. OF MECHANICAL ENGG.SHINU JERONE 7444 DEPT. OF MECHANICAL ENGG. SHYAM STALIN 7445 MARIAN ENGG. COLLEGESHYAM STALIN 7445 MARIAN ENGG. COLLEGE

CONTENTSCONTENTS INTRODUCTIONINTRODUCTION INTERSTAGEINTERSTAGE TYPES OF INTERSTAGETYPES OF INTERSTAGE AEROSPACE VEHICLE DEVELOPMENTAEROSPACE VEHICLE DEVELOPMENT NEED FOR MECHANICAL LOADING DEVICESNEED FOR MECHANICAL LOADING DEVICES DESIGN FLOW CHARTDESIGN FLOW CHART PROJECT DEFINITIONPROJECT DEFINITION SCHEMATIC DIAGRAMSCHEMATIC DIAGRAM LOAD PATH DIAGRAMLOAD PATH DIAGRAM DESIGN OF ADAPTERSDESIGN OF ADAPTERS DESIGN OF CONNECTORDESIGN OF CONNECTOR DESIGN OF TOP & BASE BEAMDESIGN OF TOP & BASE BEAM DESIGN OF SHEAR PINDESIGN OF SHEAR PIN DESIGN OF EYEDESIGN OF EYE SELECTION OF HYDRAULIC JACKSELECTION OF HYDRAULIC JACK SELECTION OF LOAD CELLSELECTION OF LOAD CELL DESIGN OF REACTION LINEDESIGN OF REACTION LINE DESIGN OF FASTENERSDESIGN OF FASTENERS CONCLUSIONCONCLUSION REFERENCEREFERENCE

INTRODUCTIONINTRODUCTION

A SATELLITE LAUNCH VEHICLE IS A COMPLEX A SATELLITE LAUNCH VEHICLE IS A COMPLEX TRANSPORTATION SYSTEM.TRANSPORTATION SYSTEM.

THEY ARE BUILT AS AN ASSEMBLAGE OF SEVERAL THEY ARE BUILT AS AN ASSEMBLAGE OF SEVERAL STAGESSTAGES SOLID PROPULSIONSOLID PROPULSION LIQUID PROPULSIONLIQUID PROPULSION CRYO/SEMICRYO PROPULSIONCRYO/SEMICRYO PROPULSION

INTERSTAGE STRUCTURES NOT ONLY INTERCONNECT INTERSTAGE STRUCTURES NOT ONLY INTERCONNECT THE TWO STAGES , BUT ALSO HOUSE VARIOUS THE TWO STAGES , BUT ALSO HOUSE VARIOUS AVIONICS/PROPULSION PACKAGES & MECHANISMS AVIONICS/PROPULSION PACKAGES & MECHANISMS REQUIRED FOR PROPER FUNCTIONING OF VARIOUS REQUIRED FOR PROPER FUNCTIONING OF VARIOUS STAGES & LAUNCH VEHICLE AS A WHOLESTAGES & LAUNCH VEHICLE AS A WHOLE

INTERSTAGEINTERSTAGE

TYPES OF INTERSTAGETYPES OF INTERSTAGE

AEROSPACE VEHICLE AEROSPACE VEHICLE DEVELOPMENTDEVELOPMENT

MISSION

TRAJECTORY DESIGN

AERODYNAMIC CONFIGURATION

CFD & WTT

LOAD ANALYSIS

GEOMETRY MATERIAL

STRUCTURAL ANALYSIS

FABRICATION STRUCTURAL TESTING

ASSEMBLY

FLIGHT

NEED FOR A NEED FOR A MECHANICAL MECHANICAL

LOADING DEVICELOADING DEVICE

ONE TEST IS WORTH A THOUSAND OPINIONS ...

-AESOP

SO……

TEST IT………..

COST OF A MISSION IS SO EXPENSIVE THAT COST OF A MISSION IS SO EXPENSIVE THAT IT IS NECESSARY TO TEST, EVALUATE AND IT IS NECESSARY TO TEST, EVALUATE AND ENSURE ITS PERFORMANCE BEFORE LAUNCH.ENSURE ITS PERFORMANCE BEFORE LAUNCH.

FOR STRUCTURES WITH COMPLEX LOADING FOR STRUCTURES WITH COMPLEX LOADING & COMPLICATED BOUNDARY CONDITIONS, IS & COMPLICATED BOUNDARY CONDITIONS, IS DIFFICULT TO SIMULATE IN FEM THE EXACT DIFFICULT TO SIMULATE IN FEM THE EXACT BEHAVIOR OF JOINTS AS IT CANNOT BEHAVIOR OF JOINTS AS IT CANNOT ACCOUNT FOR BOUNDARY CONDITIONS, ACCOUNT FOR BOUNDARY CONDITIONS, IMPERFECTIONS, ASSEMBLY AND MACHINING IMPERFECTIONS, ASSEMBLY AND MACHINING STRESSES SATISFACTORILY.STRESSES SATISFACTORILY.

WHEREAS MECHANICAL LOADING DEVICES WHEREAS MECHANICAL LOADING DEVICES TESTIFIES THE ADEQUACY OF DESIGN, TESTIFIES THE ADEQUACY OF DESIGN, ASSUMPTIONS IN DESIGN & PERFORMANCE ASSUMPTIONS IN DESIGN & PERFORMANCE OF STRUCTURES DESPITE VARIOUS CUTOUTS OF STRUCTURES DESPITE VARIOUS CUTOUTS & DISCONTINUITIES.& DISCONTINUITIES.

DESIGN FLOW DESIGN FLOW CHARTCHART

DESIGN CONSIDERATIONSDESIGN CONSIDERATIONS

STRENGTH STRENGTH LOADLOAD

STIFFNESS STABILITY GEOMETRY MATERIAL

STRENGTH AND EXTRA RESERVE STRENGTH AND EXTRA RESERVE STRENGTHSTRENGTH

RESERVE STRENGTH

EXTRA RESERVE STRENGTH

STR

ES

S

STRAIN

PROJECT DEFINITIONPROJECT 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 TONNEAXIAL COMPRESSIVE LOAD OF 12 TONNE– AXIAL TENSILE LOAD LESS THAN 12 TONNEAXIAL TENSILE LOAD LESS THAN 12 TONNE– PURE CONSTANT BENDING MOMENT OF 4.2 TONNE-METREPURE 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 LENGTH OF THE HAT STIFFENED INTERSTAGE IS 1.5 METREMETRE

– DIAMETER OF THE INTERSTAGE IS 1 METREDIAMETER OF THE INTERSTAGE IS 1 METRE– DEPTH OF INTERFACING FLANGES 0.01 METREDEPTH OF INTERFACING FLANGES 0.01 METRE– WIDTH OF INTERFACING FLANGES 0.030 METRE.WIDTH OF INTERFACING FLANGES 0.030 METRE.– 60 EQUALLY SPACED HOLES OF M6 PROVIDED ON 60 EQUALLY SPACED HOLES OF M6 PROVIDED ON

THE FLANGES.THE FLANGES.

IIIIND ND CLASS LEVERCLASS LEVER

NUT (INTERST

AGE)

NUT CRACKER

(MECHANICAL LOADING DEVICE)

SCHEMATIC DIAGRAMSCHEMATIC DIAGRAM

COMPRESSIVE LOADING

OF 12 T

TENSILE LOADING

OF 12 T

PURE BENDING

OF 4.2 T-m

LOAD PATH DIAGRAM

TOP BEAMTOP BEAM

EYE EYE

CONNECTOR REACTION LINECONNECTOR REACTION LINE

BOTTOM BEAMBOTTOM BEAM

TOP ADAPTERTOP ADAPTER

INTERSTAGEINTERSTAGE

PLATE

BOTTOM ADAPTERBOTTOM ADAPTERHYDRAULIC JACK

SHEARPIN 1

SHEARPIN 2

60 M6 BOLTS

60 M6 BOLTS

4 BOLTS

EYE

LOADCELL

M16X1.5 BOLT

EYE

SHEAR PIN3

EYE

SHEAR PIN 4SHEAR PIN 5

4 M6 BOLTS

DESIGNED MECHANICAL DESIGNED MECHANICAL LOADING DEVICELOADING DEVICE

DESIGNED MECHANICAL DESIGNED MECHANICAL LOADING DEVICELOADING DEVICE

DESIGNED MECHANICAL DESIGNED MECHANICAL LOADING DEVICELOADING DEVICE

DESIGN OF MECHANICAL LOADING DEVICE FOR AXIAL LOADING & PURE BENDING

DESIGN OF TOP & BOTTOM DESIGN OF TOP & BOTTOM ADAPTERADAPTER

ADAPTERS ARE USED TO DIFFUSE THE CONCENTRATED LOADS UNIFORMLY THROUGHOUT THE INTERSTAGE.

THE ADAPTER HEIGHT IS DESIGNED AS FOLLOWS…HL

OW

HHIGH

OVERLAP

•HEIGHT OF ADAPTER SELECTED IS 400 mm

•THICKNESS OF ADAPTER IS SELECTED AS 5 mm

DESIGN OF CONNECTORDESIGN OF CONNECTOR LENGTH OF CONNECTOR : LENGTH OF CONNECTOR :

2100.5 mm2100.5 mm CONNECTOR IS MADE USING CONNECTOR IS MADE USING

ISRO 50 ISRO 50 INTERNAL THREAD OF M36X3 INTERNAL THREAD OF M36X3

CUT ON HYDRAULIC SIDE OF CUT ON HYDRAULIC SIDE OF THE CONNECTORTHE CONNECTOR

INTERNAL THREAD OF M16X1.5 INTERNAL THREAD OF M16X1.5 CUT ON THE EYE SIDE OF CUT ON THE EYE SIDE OF CONNECTOR.CONNECTOR.

CRIPPLINGCRIPPLING = 279.62 N/mm = 279.62 N/mm22

crushing crushing = 4.99 N/mm= 4.99 N/mm22

allowable allowable = 240 N/mm= 240 N/mm22

MOS = 47.09MOS = 47.09

DESIGN OF TOP & BASE BEAMDESIGN 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 OF FLANGE : 50mm

DESIGN PARAMETERSDESIGN PARAMETERS

MODES MODES OF OF FAILUREFAILURE

designeddesigned

N/mmN/mm22))

BENDINGBENDING 78.9 78.9

SHEARSHEAR 12.5712.57

allowableallowable

N/mmN/mm22))

MOSMOS

240240 2.0412.041

120120 8.548.54

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 PINDESIGN OF SHEAR PIN

MAXIMUM LOAD APPLIED: 3TONNEMAXIMUM LOAD APPLIED: 3TONNE DIAMETER OF SHEAR PIN SELECTED BASED ON DIAMETER OF SHEAR PIN SELECTED BASED ON

INTERFACING DIMENSIONS OF HYDRAULIC JACK : INTERFACING DIMENSIONS OF HYDRAULIC JACK : mm. mm.

DESIGN PARAMETERSDESIGN PARAMETERS

MODES OF MODES OF FAILUREFAILURE

designeddesigned

N/mmN/mm22))

allowableallowable

N/mmN/mm22))

MOSMOS

CRUSHING CRUSHING 89.4589.45 240240 1.681.68

BENDINGBENDING 51.9151.91 240240 3.623.62

SHEARSHEAR 15.2915.29 120120 6.846.84

DESIGN OF REACTION LINEDESIGN OF REACTION LINE IT IS MADE OF TWO DOUBLE IT IS MADE OF TWO DOUBLE

CHANNELS ISMC 150X150CHANNELS ISMC 150X150 HAVING THEIR FLANGES HAVING THEIR FLANGES

BUTTING & WELDED TOE TO TOE BUTTING & WELDED TOE TO TOE & BATTENS PLACED ON & BATTENS PLACED ON OPPOSITE ENDS AND PLACED OPPOSITE ENDS AND PLACED UNIFORMLY THROUGHOUT THE UNIFORMLY THROUGHOUT THE LENGTH.LENGTH.

LOAD : 2 TONNELOAD : 2 TONNE CRIPPLINGCRIPPLING = 4734 N/mm = 4734 N/mm22

crushing crushing = 4.69 N/mm= 4.69 N/mm22

allowableallowable = 240 MPa = 240 MPa

MOS = 50.17MOS = 50.17

DESIGN OF EYEDESIGN OF EYE

LENGTH OF EYE DESIGNED LENGTH OF EYE DESIGNED CONSIDERING TEAR FAILURE : CONSIDERING TEAR FAILURE : 105 mm105 mm

THICKNESS OF EYE :25 mmTHICKNESS OF EYE :25 mm HEIGHT OF EYE : 106 mmHEIGHT OF EYE : 106 mm MAXIMUM LOAD APPLIED : 3 MAXIMUM LOAD APPLIED : 3

TONNETONNE

SHEAR PIN HOLE :SHEAR PIN HOLE : mm. mm. SIZE OF FLAT WELDED : 65 SIZE OF FLAT WELDED : 65

mmX10 mm.mmX10 mm. SIZE OF EN24 HEAT TREATED SIZE OF EN24 HEAT TREATED

ROUND BAR WELDED TO ROUND BAR WELDED TO

FLAT : FLAT : 16 mm. & LENGTH 16 mm. & LENGTH 30 mm.30 mm.

TO PREVENT EDGE TEAR A TO PREVENT EDGE TEAR A

LENGTH OF 1.5XLENGTH OF 1.5Xi.e 1.5x35=53 i.e 1.5x35=53 mm IS PROVIDED.mm IS PROVIDED.

DESIGN PARAMETERSDESIGN PARAMETERS

MODES OF MODES OF FAILUREFAILURE

designeddesigned

N/mmN/mm22))

allowableallowable

N/mmN/mm22))

MOSMOS

CRUSHINGCRUSHING 11.21111.211 240240 20.40620.406

EDGE SHEAREDGE SHEAR 3.7013.701 120120 31.4131.41

TENSILE TENSILE 5.65.6 240240 41.8541.85

WELD WELD 5.335.33 100100 17.7617.76

DESIGN PARAMETERSDESIGN PARAMETERSMODES OF MODES OF THREAD THREAD FAILUREFAILURE

designeddesigned

N/mmN/mm22))

allowableallowable

N/mmN/mm22))

MOSMOS

THREAD THREAD SHEARSHEAR

67.8567.85 440440 5.485.48

TENSILE/ TENSILE/ COMPRESSIVE COMPRESSIVE

186.916186.916 880880 3.7073.707

BEARINGBEARING 51.951.9 880880 15.9515.95

SELECTION OF HYDRAULIC JACKSELECTION OF HYDRAULIC JACK

PISTON 80 mm

BOSCH REXROTH HYDRAULIC BOSCH REXROTH HYDRAULIC JACK (tie rod type)JACK (tie rod type)

SELECTION OF LOAD CELLSELECTION 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 6.5mm

DESIGN OF FASTENERSDESIGN OF FASTENERS

LOAD APPLIED : 3TLOAD APPLIED : 3T BOLT MADE OF : HSFG STEEL BOLT 12.9 GRADEBOLT MADE OF : HSFG STEEL BOLT 12.9 GRADE M6x1 BOLT OF M6x1 BOLT OF uu=1200 N/mm=1200 N/mm22YY= 1080 N/mm= 1080 N/mm22 & LENGTH 50 mm & LENGTH 50 mm

HEIGHT OF NUT : 7 mmHEIGHT OF NUT : 7 mm

DESIGN PARAMETERSDESIGN PARAMETERSMODES OF MODES OF THREAD THREAD FAILUREFAILURE

designeddesigned

N/mmN/mm22))

allowableallowable

N/mmN/mm22))

MOSMOS

THREAD THREAD SHEARSHEAR

140140 540540 2.82.8

TENSILE/ TENSILE/ COMPRESSIVE COMPRESSIVE

411.72411.72 10801080 1.621.62

BEARINGBEARING 101.02101.02 10801080 9.699.69

CONCLUSIONCONCLUSION A MECHANICAL LOADING DEVICE TO SIMULATE A MECHANICAL LOADING DEVICE TO SIMULATE

AXIAL LOADING FORCES & PURE BENDING FORCES AXIAL LOADING FORCES & PURE BENDING FORCES IS THUS CREATED.IS THUS CREATED.

THIS IS A MODULAR DESIGN AND CAN FURTHER BE THIS IS A MODULAR DESIGN AND CAN FURTHER BE MODIFIED TO TEST FOR SHEAR FORCES AND MODIFIED TO TEST FOR SHEAR FORCES AND TORSIONAL FORCES ACTING ON THE INTERSTAGE.TORSIONAL FORCES ACTING ON THE INTERSTAGE.

THE DESIGN WAS MADE KEEPING IN MIND THE THE DESIGN WAS MADE KEEPING IN MIND THE VARIOUS FUTURE REQUIREMENTSVARIOUS FUTURE REQUIREMENTS

ALL THE ELEMENTS IN THIS DEVICE WERE CHECKED ALL THE ELEMENTS IN THIS DEVICE WERE CHECKED FOR FAILURE AND SATISFACTORY MOS ARE GIVEN.FOR FAILURE AND SATISFACTORY MOS ARE GIVEN.

THERE IS EASY REPLACEMENT OF THE THERE IS EASY REPLACEMENT OF THE COMPONENTS IN EVENTS OF THEIR FAILURE AND COMPONENTS IN EVENTS OF THEIR FAILURE AND PERMANENT JOINTS ARE AVOIDED AS FAR AS PERMANENT JOINTS ARE AVOIDED AS FAR AS POSSIBLE TO GIVE MOBILITYPOSSIBLE TO GIVE MOBILITY

IF SUFFICIENT FINANCIAL ASSISTANCE IS PROVIDED IF SUFFICIENT FINANCIAL ASSISTANCE IS PROVIDED THE DEVICE CAN BE MADE IN A SHORT TIME.THE DEVICE CAN BE MADE IN A SHORT TIME.

REFERENCESREFERENCES

S. RAMAMRUTHAM, STEEL TABLESS. RAMAMRUTHAM, STEEL TABLES K. MAHADEVAN, DESIGN DATA HAND BOOKK. MAHADEVAN, DESIGN DATA HAND BOOK P. DAYARATNAM, DESIGN OF STEEL STRUCTURESP. DAYARATNAM, DESIGN OF STEEL STRUCTURES ABDULLA SHARIFF, A TEXT BOOK OF MACHINE DESIGNABDULLA SHARIFF, A TEXT BOOK OF MACHINE DESIGN H. ESCHENAUER, APPLIEDNSTRUCTURAL MECHANICSH. ESCHENAUER, APPLIEDNSTRUCTURAL MECHANICS BHAVIKKATTI, STRENGTH OF MATERIALSBHAVIKKATTI, STRENGTH OF MATERIALS NASA SP 8022, STAGING LOADSNASA SP 8022, STAGING LOADS S K D RACHEL, AEROSPACE STRUCTURES-PRESENT S K D RACHEL, AEROSPACE STRUCTURES-PRESENT

PRACTICES & FUTURE ASPIRATIONS IN LAUNCH VEHICLESPRACTICES & FUTURE ASPIRATIONS IN LAUNCH VEHICLES STEPHEN MAYERS, ARES1 STAGE SEPARATION SYSTEM STEPHEN MAYERS, ARES1 STAGE SEPARATION SYSTEM

DESIGN CERTIFICATION TESTINGDESIGN CERTIFICATION TESTING

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

CYRIL JOSE

SHYAM STALIN

ROY ROSHAN CHANDY

SHINU JERONE

A PROJECT BY

INSPIRED BYINSPIRED BY