DOUBLE SUGAR SHOT NOSECONE DESIGN,STUDY AND CONSTRUCTION

REV. 2013/01/28

Author: Vicente Alvero

Mass and materials. As the SStS project generally uses low impuls rocket propellant, this fact implicates extremely high requirements on mass ratio of the whole vehicle. If propellants of higher specific impulse would be used, there would be no such critical need. Therefore, mass of all fairings and covers should be held as low as possible. Some mass calculated were provided, but there is always a lot of unconsidered bolts, nuts, wires, holders and brackets. Theirs mass may increase the final checksum significantly. Based on the DSS Mass Target, iteration #1 should be total mass of the NC kept below of 1.156 kg. For first approximation, the shape of the NC is considered to be true cone length of 0.93 m and 169 mm diameter at the base. NC surface is calculated to be: S = *r *s , where 2 = 2 + 2 When h>>r then h s and S = *0.169*0.93 = 0.496 0.5 [m, m, m2] Then outer surface of the NC (approximation for the true cone) is 0.496 sqm. If usual fiber glass cloth 160 g/ m2 ( thickness about 0.16mm) would be used, one full dry ply covering the whole surface of the NC weighs 160*0.496= 79,4 80 [g/m2, m2 , g] If resin/fiber glass mass ratio about 1:1 would be considered, one full ply including resin would take about 160g. If overlaps are considered, lets increase this mass for 15%, 160*1.15 = 184 [g, %, g] for full cured ply ( what is lot more realistic number). If kevlar (170 gr/2 , thickness 1.7mm) would be used, the entire covering ply of the NC would weigh 170*0.496 = 84.32 [gr/m2, m2, gr] If resin/kevlar mass ratio about 1:1 would be considered, one full ply including resin would take about 170g. If overlaps are considered, lets increase this mass for 15%, 170*1.15 = 195 [g, %, g] Our main requirements for the monocoque are that no more than 1.5 mm thick and weighing no more than 1156 grams.

Author: Vicente Alvero

If entire NC structure doesn't have to be heavier than 1156 g at maximum, mass margin for the nylon tip should be at least 5%, this leaves 1156*0.95 = 1098.2 [g, %, g] (approx 1098g) As we can see, if monocoque design would be proposed, it could consist from 1098 : 195 = 5.63 6 [gr ,gr , -] That means 6 full plies of 160 g/ m2 fiber glass cloth (well saturated, because 50:50 cloth/resin ratio is usually considered for free hand-layup technologies). Therefore, the total number of folds that it used is 6. In which case the thickness is equal to: 6 * 0.2 = 1.2 [- ,mm , mm] Rigidity. In this particular situation, as much as we can for the NC, means to keep all structures as thick, as possible. As calculated above, small increasing of the kevlar thickness doesn't change mass fraction too much, but the gain of final rigidity is extreme. Remember that the value of the modulus of elasticity at room temperature is around 80 GPa (Kevlar29) and 120 (Kevlar49) . The value of a typical steel is 200 GPa. Higher rigidity also moves selfresonance frequencies higher and simultaneously decreases their maximum amplitude. However,increased rigidity of structural components imposes higher requirements on manufacturing tolerances. Unidirectional plies embeded into the NC structure may change the final stiffness significantly; using of the IM (Intermediate Modulus) kevlar/fiber glass filaments also provides higher strength than usual HT (High Tenacity) filament type. When line of bolts or rivets is considered as a part of structure, a softening strips may be used to keep local stresses under control and displaced over larger areas. There was a finite element study on the final design of the nose cone and requirements have been met, because the weakest area of the nose cone, the base can withstand loads of 220 N (50 lbf).

Author: Vicente Alvero

Deformations of the NC. Basically, the NC may be considered a long tube (his length >> his diameter) his aspect ratio is about 5.5. Exactly, this is valid only for total length and full diameter of the NC at the root; his structure however, may be considered also as a tube of smaller diameters of the extended length, as we travel from the root to the tip. In case of wobbling, the structure in fairing-NC adjacent areas is extremely stressed. Under extreme conditions, root of NC or upper part of adjacent fairing may crack, especially when vehicle moves by transsonic velocities. As result from experience, confirmed by calculations of pressure fields in Partial Heating Study (pressure fields and streamlines are by products of temperature results) values of local overpressures combined with interference and movements of shock waves may exceed steady conditions several times. Therefore, all joints and all weak points of the structure should be carefully tested and overrated as we are not capable to determine such a loads exactly. Flattening of the NC (change of round cross-section of the into the ellipse) may happened when structure of the tube in considered section is too thin and flexible and not rigid enough - as tube changes into the ellipse, it loses stability and may bend, subsequently crack. This sequence may be dangerous in highly stressed area. Therefore, the structure should so stiff as possible. Uncertainty here may be considered so high and dangerous, that adjacent fairing could be proposed and designed with the NC as a monocoque structure. Therefore, the structure should be designed and manufactured very carefully.

Author: Vicente Alvero

Construction Mold The first step in building the nosecone was making the mold. We used two panels of Galician oak with dimensions of 1 meter long, 20 cm wide and 10 in thickness, which were joined together by epoxy resin.

Once they were bonded, was given pressure and the resin was allowed to dry for one week.

Once dry, we draw the outline of the nosecone on the surface of the wood and cut everything out of the trace of the pencil, so that the lathe need to work least possible.

Author: Vicente Alvero

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Once the mold has been finished with the lathe, sanding and is used to get the surface as smooth and uniform as possible.

And thereby the mold is finished.

Author: Vicente Alvero

Nosecone Once the mold is ready to start with the fiberglass, you need to apply a few layers of primer to cover his posilbes pores, layers of wax release agent and polyvinyl alcohol.

Applies 4 layers of primer drying time between coats 1 hour and thoroughly sanded between coats with 600 grit sandpaper. Also applied 6 layers of wax release agent with a drying time between layers 1 hour. Once the wax 6 layers have dried properly apply 4 layers of polyvinyl alcohol, waiting 3 hours between layers for its proper drying. Once everything is dry, we cut the layers of fiberglass and Kevlar, we can begin. For the nosecone ,we determined the following configuration with layers: two layers of 200 gr/sqm fiberglass, two layers of 170 gr/sqm kevlar and two layers of 160 gr/sqm fiberglass. All dried in a room at a constant temperature of 30 C for 24 hours.

Author: Vicente Alvero

Once the resin is completely dry, we proceed to sanding. For this process, we use the lathe in which the mold we had made previously. This ensures uniform sanding the entire surface. To sandig, we use different sandpaper with different grains, to finish with a 800 grit sandpaper.

Once the nosecone is sanded, and the edges are cut, we proceed to demoulding. The weight of the nose cone, the absence of the tip, is 581 gr. An improvement of 47% with respect to calculated. Finally, once the tip made of nylon, the overall weight of the nosecone is 639 gr, 45% improvement with respect to the top marked.

Author: Vicente Alvero

Author: Vicente Alvero