Habitat for Space and Lunar

Environments - Light Weight

Structure Concept

AIAA SPACE 2008

Conference & Exposition

Paul Slysh
PS Associates
John Carsten, Dr. Peter J. Rohl, Andrew Jabola
Advatech Pacific

September 9, 2008
 Overview

• The Companies: PS Associates and Advatech Pacific

• The Habitat Concept
• Design Tool: Isogrid SST
• CAD Model
• Finite Element Analysis
• Conclusions

2
 The Companies

PS Associates:
• Small business, started 1988
• Invented habitat concept presented here
• Developed SST design software
• Based in San Diego, CA

Advatech Pacific:
• Small business, ~90 employees, started in 1995
• Design, analysis and software solution provider
• HQ in Redlands, CA, with branch offices in Palmdale, San Diego,
Huntsville, AL and Tempe, AZ
• Developed CAD and CAE model for habitat concept
• Performed FE structural analysis

3
The Habitat Concept

• Shown Deployed on the Lunar Surface

4
 The Habitat Concept

• Provides structural thermal and meteoroid protection

• Spokes join interior and exterior structures
• Consists of frustums and domes
• Deployed by EVA and robotics
• Stowed-to-deployed volume: 0.3 and lower
• Lighter and better stowed than inflatable structures
• Uses flanged isogrid
• Provides pegboards for mounting equipment

5
 Stowed Configuration

• Nested Inner Structures Stowed Within the Nested Outer Structures

• Interior Volume Available for Cargo

6
 Layout of an Inner Section

• Isogrid on the Inside Serves as Pegboard for Mounting Equipment

7
Flat Pattern of Isogrid Frustum

8
Bolted Deployed Structure

9
 Structural Design Tool “SST”

• SST “Shell Structures Tools”

• SST is a design and analysis tool for stiffened thin-walled structures
• SST has been developed and validated over the past 40 years
• SST facilitate rapid application to complex design objectives
• Initial verification by Advatech successful

SST designs the following structure types:

• Isogrid • Chemically milled

• Waffle • Skin frame
• Skin stringer • Fluted core sandwich
• Honeycomb • Monocoque
• Composites
10
 SST Input Categories

• Design Criteria • Frame Locations

• External Loads • Analytical Models
• Geometry • Knockdown Factors
• Interfaces • Mfg. Tolerances
• Material Selection • Clearance Envelopes
• Structure Type • Safety Factors
• Mfg. Methods • Cutout Requirements
• Kick Ring Requirements • Weight Bogie

11
 SST Capabilities

• Weight & Performance • Mass Properties

Optimization • Mfg. Planning
• Internal Loads • NC Program
• Section Properties • Rendering
• FEA Input • Reports
• Flat Patterns • Test Plans
• Performance Margins • Modal Response
• Trades • Body Stiffness

12
 SST Top-Level Program Flow

Design Algorithm:
• Select initial design
• Compute weight-to-
lowest-margin ratio
• Increment features to
raise margin floor
• Only decrease weight-
to-lowest-margin ratio.
• Continue until margins
are positive
• Use SST to create final
design definition

13
SST User Interface

14
 SST Output
• General instability
• Mass properties
• Skin buckling
• Web, flange buckling
• Bosses and cutouts
• Kick rings
• Frames
• Shell intersection sizing
• Internal line loads
• Bolted flanges
• Dimensioned geometry
• Modal response
• Unique NC tool paths
• High cycle fatigue
• Crack initiation, growth
• Margin summaries
15
SST Summary Output
SST ISOGRID STRUCTURES
CASE HABITAT LUNAR
DATE 4 May 2008
STRUCTURE FLANGED STD. ISOGRID
MATERIAL -423 F ALUM 2219-T851
ELEMENT 4 , 1 OPTION 1
UNITS ENGLISH UNITS
MODEL BODY, PRESSURE AND ACOUSTICALLY LOADED ISOGRID SHELL

GEOMETRY, WEIGHT STIFFNESS

SECTION LENGTH 15.5 in. EI BENDING 1.25E+11 lb-in^2
TOTAL LENGTH 62 in. AE AXIAL 1.18E+8 lbs
FRAME SPACING 62 in. KAG SHEAR 2.21E+7 lbs
SHELL MINIMUM RADIUS 40 in. GJ TORSION 9.4E+10 lb-in^2
SHELL MAXIMUM RADIUS 47 in.
MATERIAL
SECTION WEIGHT 18.2 lbs
ULTIMATE SRENGTH 81000 psi
TOTAL WEIGHT 77.5 lbs
YIELD SRENGTH 61000 psi
UNIT AREA WEIGHT .0045 lbs/sqin
SHEAR SRENGTH 46200 psi
WT. - EQUIV. THICKNESS .0441 in.
YOUNGS MODULUS 1.24E+7 psi
SECTIONS SHEAR MODULUS 4.65E+6 psi
NO. STATION RADIUS DENSITY .102 lbs/cuin
1 0 in. 40 in. POISSON'S RATIO .33
2 15.5 in. 41.75 in. RAMBERG OSGOOD 15
3 31 in. 43.5 in.
FACTORS, MARGINS
4 46.5 in. 45.25 in.
FAILURE ULT. YLD. INSTA. SP8007 SKIN
5 62 in. 47 in.
FACTOR 1.5 1.32 1.5 1.5 1.5
MARGINS 15.7 13.3 20.4 60.7 .303

16
Stiffener Detail Drawing

17
 SST and NX

• SST provides and excellent tool for designing ISOGRID

and similar structures
• We would like to combine SST with a state-of-the-art
CAD and CAE package for finite element analysis,
visualization, and manufacturing

18
 CAD Model

• Using the parameters from SST, a shell model and solid

model of the structure were created in Siemens NX6

Solid Model Full Structure Shell Model Panel

19
 CAD Model
• The shell model consists of 2D sheets that represent the
skin and stiffener webs
Inner Frustum Shell Model

20
 CAD Model
• The solid model creates a single panel with full detail of
the structure, which was then instanced circumferentially
• Both the solid and shell models are associative to the
underlying parametric geometry
Outer Frustum Panel Outer Frustum

21
 Solid Model Creation

• One of the issues with Siemens NX6 is rolling a flat-

pattern with varying thickness into a cylindrical shape
• Due to this difficulty, a 2D sketch of an instance of the
pattern was wrapped around the frustum
• Thicknesses were then applied to the 2D sketch to
create the skin, stiffener webs, and flanges
• Finally, the model was instanced, creating the full solid-
model structure

22
 Solid Model Creation

2D Sketch Before 2D Sketch Wrapped

Wrapping Around Cone Frustum

23
 Finite Element Model (FEM)

• A FEM using the CAD Associative shell model was

created
• 2D linear shell elements represented the skin,
top/bottom flanges, and stiffener webs while 1D beam
elements represented the stiffener flanges
• Lower and higher resolution FEMs were created

Lower Resolution Higher Resolution

Approx. DOF: 85680 Approx. DOF: 300600
Total number of elements: 21930 Total number of elements: 66360
Total number of nodes: 14430 Total number of nodes: 50100
Number of Beam elements: 7140 Number of Beam elements: 14280
Number of Quad4 elements: 14400 Number of Quad4 elements: 48840
Number of Tri3 elements: 390 Number of Tri3 elements: 3240
24
 Finite Element Model (FEM)

Full Finite Element Detail of Finite Element

Model Model

25
 Finite Element Analysis

• The FEM is solved using NX NASTRAN

• A modal analysis was performed on our FEM to test the
model
• Global stiffnesses of the FEM were calculated for
comparison against SST

Global Stiffness Comparison

Lower Res. Higher Res. SST
Axial AE 1.0189E+08 1.0223E+08 1.1800E+08
Torsion GJ 7.7000E+10 7.7549E+10 9.4000E+10
Shear KAG 1.8000E+07 1.8010E+07 2.2100E+07
Bending GJ 1.5376E+11 1.5651E+11 1.2500E+11

26
 Finite Element Analysis

Mode 5: 19.6 Hz Von-Mises Stress Plot

Averaged

27
 Where We Are

• SST Provides an excellent tool for quickly and efficiently

designing a preliminary ISOGRID structure
• We have shown that we can develop both a CAD model
for visualization and an analysis model using NX6 and
parameters from SST
• Analyses performed show corroboration with SST results

28
 Next Steps

• Detailed stress analysis on a repeating sub-section cut-

out of the solid model will be performed using ESRD
StressCheck

29
 Next Steps

• Perform a deeper study into buckling and instability

using FEA methods.

Preliminary Linear Buckling Test

30
 Next Steps

• Model and analyze the full habitat structure

• Create a direct integration between SST and NX6 to
create a single, seamless tool
PS Associates SST Siemens NX

31
 Conclusion

• SST provides a tool for quickly and efficiently developing an

ISOGRID Structure
• CAD and CAE methods provide a detailed analysis using finite
element methods along with providing models for CAE and
manufacturing
• ISOGRID structures provide an excellent concept for lunar habitats

32
 SST and NX

• SST provides and excellent tool for designing ISOGRID

and similar structures
• We would like to combine SST with a state-of-the-art
CAD and CAE package for finite element analysis,
visualization, and manufacturing

33
 CAD Model

• Using the parameters from SST, a shell model and solid

model of the structure were created in Siemens NX6

Solid Model Full Structure Shell Model Panel

34
 CAD Model
• The shell model consists of 2D sheets that represent the
skin and stiffener webs
Inner Frustum Shell Model

35
 CAD Model
• The solid model creates a single panel with full detail of
the structure, which was then instanced circumferentially
• Both the solid and shell models are associative to the
underlying parametric geometry
Outer Frustum Panel Outer Frustum

36
 Solid Model Creation

• One of the issues with Siemens NX6 is rolling a flat-

pattern with varying thickness into a cylindrical shape
• Due to this difficulty, a 2D sketch of an instance of the
pattern was wrapped around the frustum
• Thicknesses were then applied to the 2D sketch to
create the skin, stiffener webs, and flanges
• Finally, the model was instanced, creating the full solid-
model structure

37
 Solid Model Creation

2D Sketch Before 2D Sketch Wrapped

Wrapping Around Cone Frustum

38
 Finite Element Model (FEM)

• A FEM using the CAD Associative shell model was

created
• 2D linear shell elements represented the skin,
top/bottom flanges, and stiffener webs while 1D beam
elements represented the stiffener flanges
• Lower and higher resolution FEMs were created

Lower Resolution Higher Resolution

Approx. DOF: 85680 Approx. DOF: 300600
Total number of elements: 21930 Total number of elements: 66360
Total number of nodes: 14430 Total number of nodes: 50100
Number of Beam elements: 7140 Number of Beam elements: 14280
Number of Quad4 elements: 14400 Number of Quad4 elements: 48840
Number of Tri3 elements: 390 Number of Tri3 elements: 3240
39
 Finite Element Model (FEM)

Full Finite Element Detail of Finite Element

Model Model

40
 Finite Element Analysis

• The FEM is solved using NX NASTRAN

• A modal analysis was performed on our FEM to test the
model
• Global stiffnesses of the FEM were calculated for
comparison against SST

Global Stiffness Comparison

Lower Res. Higher Res. SST
Axial AE 1.0189E+08 1.0223E+08 1.1800E+08
Torsion GJ 7.7000E+10 7.7549E+10 9.4000E+10
Shear KAG 1.8000E+07 1.8010E+07 2.2100E+07
Bending GJ 1.5376E+11 1.5651E+11 1.2500E+11

41
 Finite Element Analysis

Mode 5: 19.6 Hz Von-Mises Stress Plot

Averaged

42
 Where We Are

• SST Provides an excellent tool for quickly and efficiently

designing a preliminary ISOGRID structure
• We have shown that we can develop both a CAD model
for visualization and an analysis model using NX6 and
parameters from SST
• Analyses performed show corroboration with SST results

43
 Next Steps

• Detailed stress analysis on a repeating sub-section cut-

out of the solid model will be performed using ESRD
StressCheck

44
 Next Steps

• Perform a deeper study into buckling and instability

using FEA methods.

Preliminary Linear Buckling Test

45
 Next Steps

• Model and analyze the full habitat structure

• Create a direct integration between SST and NX6 to
create a single, seamless tool
PS Associates SST Siemens NX

46
 Conclusion

• SST provides a tool for quickly and efficiently developing an

ISOGRID Structure
• CAD and CAE methods provide a detailed analysis using finite
element methods along with providing models for CAE and
manufacturing
• ISOGRID structures provide an excellent concept for lunar habitats

47