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ACD TSA Design –Status Report
15 April 2003Ken Segal
ACD Lead Mechanical Engineer
ACD Panel Procurement Readiness – Apr 15, 2003
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Outline
• Overall Description - Review• TSA Post CDR Updates
– Panel Design, Analyses and Testing– Panel Procurement
ACD Panel Procurement Readiness – Apr 15, 2003
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Shell Design Requirements• No Failure due to Launch & Thermal Loads• Minimum Frequency: 50 Hz, Goal• Shell Mass: 29.8 kg (Calculated)
– Shell w/ Corner inserts & Shell Flexures 37.5Kg• ACD Mass: 271 kg• Attachment to Aluminum BEA
– 4 Flexure Inserts @ Panel Mid-Spans– 4 Flexure Corner Inserts
• Temperatures– -40C to +45C Qualification
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Shell Design Drivers
• Adequate Real Estate & Suitable Configuration to Mount TDAs
• Sufficient Stiffness & Strength to Limit Vibro-Acoustic Loading and Deflection of TDA Elements
• Isolation of Thermal/Mechanical Loads and Deflections from the BEA
• Minimize Radiation Attenuation • Ascent Venting
ACD Panel Procurement Readiness – Apr 15, 2003
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ACD Panel Procurement Readiness – Apr 15, 2003
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Aluminum Inserts not Shown
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Tab & Slot FeaturesReview
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Construction / MaterialsReview
• Top & Side Panels– Facesheets: 20- mil M46J/EX1522-2, [0/45/90/-45]S– H/C Core 3.1 PCF, 5056, 1”-Thick Sides, 2”-Thick Top– Film Adhesive: FM 73M, 0.045 PSF– Core fill: EY3010, Syntactic Epoxy
• Panel-to-Panel Joints– Mortise & Tenon (Tab & Slot) Features on Mating Edges of Panels– 20-mil Internal & External Clips: Braided Tape Wetted with EA9396– Edge Bonds: EA 9394 Adhesive
• Flexure Inserts– 6061 External Channel/Block Post Bonded with EA9309
ACD Panel Procurement Readiness – Apr 15, 2003
GLAST-LAT-ACD ACD ShellPanel Design Update
• Status– Panel Designs are Complete– Shell Panels Drawings Complete– Panels Procurement Awarded
• Updates Since CDR – Changed from 1522 to 1522-2 Epoxy Matrix– Updated Shell Flexure Inserts to Panel Designs– Updated Tile Flexure to Designs– Analyses Updates Completed
• Facesheets and Doublers• Adhesive Bonds • Aluminum Inserts
ACD Panel Procurement Readiness – Apr 15, 2003
GLAST-LAT-ACD TSA Update -Material Characterization
• Material Changed from 1522 to 1522-2 Matrix. – Better Processing Characteristics on T300 Cloth Prepreg
• Material Being Tested– Flexure Laminate Mechanical Tests– Flexure Consolidation – new Material being tested
• Photomicrographs• Web Mini-Beam-Specimens• Fiber Volume/Void Content
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TSA Updates-Shell Flexure to Panel
• Shell Flexure Interfaces are Externally Bonded Aluminum Inserts – Panel Design Drivers
• Facesheet Interlaminar Strength• Adhesive Strength• Insert Strength
– Validation: Analyses Completed. • Test coupons to be fabricated and tested prior to Shell assembly.• Problem Mitigation (without impact on Shell Design):
– Facesheet Doublers can be thickened or extended– Corner inserts can be stiffened.
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•ACD Panel
•Panel Doubler
•Aluminum Insert
•Ti Flexure
Mid Span Insert
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GRID
Mid Span Design-Side View
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Corner Shell Insert -Analyses Model
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Corner Design Loads
• Static Forces from Flexure Blade– Weak Axis Force, 67.31 lbs.– Strong Axis Force, 488.34 lbs.– Axial Force, 344.20 lbs.
• Thermal Forces from Flexure Blade– Weak Axis Force, 147.18 lbs.– Strong Axis Force, 2.68 lbs.– Axial Force, -22.55 lbs.
Typical Results for Corner Doubler
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Corner Design Loads
Summary of Doubler Stresses– Max Shear (XY Component)
• 1.86E+03psi, Static Reverse– Component Stresses
• X component = 5.11E+03• Y component = 1.21E+04
Margins of Safety– F.S. = 1.5– M.S.(shear) =
– M.S. (compression) = 61.015.1*12100
29200+=−
13.415.1*1860
14300+=−
ACD Panel Procurement Readiness – Apr 15, 2003
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TSA Updates -Tile Flexures
• Flexure Interfaces Moved Away from Panel Edges
• Angled Shims Designed to Mount Angled Tiles.
• Bottom Row Tile is no longer slip stick, but thinned fixed/free flexure.– Repeating Flexure tests for
this design
ACD Panel Procurement Readiness – Apr 15, 2003
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• Panel to Panel Joints– Validation
• Test Coupons Made, tested to failure,– used with knockdown factors (per mil-handbook 5)
• Analyses show Positive Margins (lowest is 0.4)– Test Coupon Fabrication is part of Panel
Procurement• Mitigation in the case that vendor cutting looks
suspect during 1st Article procurement
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Bending Specimen
8.5”
5.5” 3”
4.5 PCF H/C•Moment Allowable
•Based on test results and Mil-HDBK-5 statistical reductions
• 324 in-lbs/in
•Transverse Shear
•87 lbs/in
•Edge Normal
•72 lbs/in
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In-Plane Shear Specimen
9”
4.5”
3”
•In-plane Shear Allowable
• 182 lbs/in
ACD Panel Procurement Readiness – Apr 15, 2003
GLAST-LAT-ACDPanel Procurement –Plan
• April 24th
– Schedule, Manufacturing Plan, and QA Plan Due• Phase 1
– Demonstrate 1st Article Manufacturing– Manufacturing Readiness Review
• Phase 2– Build Flight Panels and Spares– Perform Panel Fit Checks w/ GSFC– Deliver July 11th to GSFC