FEA Analysis of a Thrust Structure, BURPG
FEA Analysis of a Thrust Structure, BURPG
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10/2023 - 12/2023
10/2023 - 12/2023
Project Description
Project Description
As a part of BURPG's structures team, I performed a comprehensive Finite Element Analysis (FEA) on our rocket Icarus's thrust structure—a critical component transferring engine thrust to the airframe. The primary goal was to validate structural integrity, with a specific focus on buckling resistance for compression members, under all anticipated flight loads.
Skills Used:
Software: SolidWorks (CAD & FEA Simulation)
Engineering Analysis: Hand Calculations, Conservative Load Case Design
Professional Skills: Technical Collaboration, Engineering Judgment, Risk Mitigation
Key Contributions
Key Contributions
Defining aerodynamic loads (drag, torque due to transition ring and fins) acting on the vehicle through conservative hand calculations.
Defining conservative load cases
Developing and running FEA simulations in SolidWorks to model structural response, with a specific focus on displacement and buckling.
FEA Analysis Setup and Results by Load Case
FEA Analysis Setup and Results by Load Case
Nominal Startup Transient Setup
Nominal Startup Transient Setup
3,000 lb compressive force distributed evenly over thrust plate
Asymmetric Startup Transient Setup
Asymmetric Startup Transient Setup
3,000 lb compressive force distributed over the weakest quarter of the thrust plate
Recovery Force Setup
Recovery Force Setup
3,850 lbf tensile force distributed around the edge of the ox dome
Flight Combined Loads Setup
Flight Combined Loads Setup
2,500 lb compressive force distributed evenly over thrust plate
90 lb drag force from fins applied to the outer edge of the thrust plate
847 lb drag force on transition ring
947 lb force from wind pressure on fins applied as torque about the outer edge of the thrust plate
Close-Up of Displacement Plot Under Flight Loads
Analysis Review and Findings
Analysis Review and Findings
The FEA results under combined loads revealed a significant 11.95 mm displacement. While our initial hypothesis was that we had overestimated the torsional loads and underestimated bolt preload, upon further review the simulation still clearly indicated a fundamental lack of torsional stiffness in the design.
Erring on the side of safety, we presented our findings to alumni in the aerospace industry for an external review. They confirmed that the displacement was unacceptable and represented a critical failure risk, validating the need for a redesign. At a consensus, the team quickly moved forward with a new design focused on increased torsional rigidity.
Results & Key Takeaway
Results & Key Takeaway
Prevented Structural Failure: The analysis identified a critical flaw that was not apparent from initial design reviews, preventing a potential failure during flight.
Catalyzed Design Improvement: The findings directly led to a total redesign of the thrust structure, resulting in a more robust and reliable vehicle.
Key Takeaway: This experience taught me the importance of thoroughly understanding and investigating simulation data. It highlighted that conservative design and external feedback are critical to responsible engineering, especially when facing uncertainty.
New Design With Increased Torsional Stiffness
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