NASA Ares V Heavy Lift Vehicle Structural Analysis and Composite Material Weight Savings

摘要

For the NASA Heavy Launch Vehicle (HLV), substantial weight reduction is possible by designing the Payload Shroud, Interstage, and the Core Intertank structures with composite material. Previous trade studies reported included honeycomb and reinforced core sandwich panels and Hat, I, Tee, Blade, and PRSEUS stiffened panel concepts. The composite hat stiffened panel was reported as the lightest concept for each HLV structure. The honeycomb sandwich and hat stiffened concepts were down selected. This paper provides an update to the 2010 paper and focuses on the panel acreage, ring frames, and joints of the Interstage; a cylindrical barrel axially compressed that must withstand crushing and internal pressure causing compressive and tension hoop panel loads. For the Interstage, a composite honeycomb sandwich design is 33 percent heavier than a composite hat stiffened panel design. Likewise, the lightest metallic design is 54 percent heavier than the composite hat stiffened panel design. HyperSizer® commercial software is being used to further mature the hat design's composite laminates of hybrid fabric and tape and panel cross-sectional dimensions to achieve minimum weight, damage tolerance, producibility, and affordability.