REVISION HISTORY

REV DESCRIPTION OF CHANGE AS RELEASED DATE 12/22/2009 APPROVED

NATIONAL AERONAUTICS AND SPACE ADMINISTRATION

LYNDON B. JOHNSON SPACE CENTER HOUSTON, TEXAS

SIZE

PREPARATION OF STRESS ANALYSIS REPORTS CAGE CODE DWG NO 8594001 21356

AOD, CC3 SHEET:

REV

SCALE: NONE

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8594001, Rev -

Preparation of Stress Analysis Reports

Rev-, December 2009

-1.'*t
David McMahon

Aircraft Engineering

Approved

By

74"rq
Son Nguyen

Lead, Aircraft Engineering

Chief, Aircraft Engineering Branch

Poge 2 of

t4

8594001,Rev

1.0 Introduction
ThisdocumentestablishesrequirementsforformalstressanalysisreportspreparedfortheNASA JohnsonSpaceCenter,AircraftOperationsDivision(AOD).Itplacesspecialemphasisontheimportance ofwritingaccurate,concise,andreadablereportsthatstandaloneandcanserveasformal documentationforthestrengthofthestructure.Awelldocumentedstressanalysisisonethatcanbe readandunderstoodbyanyonethatisknowledgeableinthefieldofstructuresbutisnotfamiliarwith thestructurebeinganalyzed.

2.0 Scope
ThisdocumentisapplicabletostressanalysisreportspreparedfortheJohnsonSpaceCenterAircraft OperationsDivision.Thisdocumentappliestotheanalysisofaircraftstructures,installedequipment, payloads,andgroundsupportequipment.

3.0 Analysis
3.1Coverage
Allloadcarryingstructureswhosefailurecouldresultindamagetotheaircraftorinjurytopersonnel shallbesubstantiatedbyastressanalysis.Theanalysisshallcoverthehardwareinanasbuiltandas installedconfiguration.Includedinthisanalysisshallbeallstructures,fasteners,welds,orbondsinthe primaryloadpath.

3.2Details
Eachpartshallbeanalyzedbasedonthedesignintentandloadenvironmentofthestructure.The analystshallensurethatallfailuremodesandworstcasecombinedstresseshavebeenexamined. Thefollowingisalistofexamplestressanalysiscategories.Note,thislistisprovidedforreferenceonly; itistheresponsibilityofthestressanalysttodeterminewhattypesofanalysesshouldbeperformedfor agivenstructure a) Bending,flexuralshearand/ortorsionanalysisofabeam,frame,rib,shaft,orringofvarious openorclosedsections b) Plateandshellanalysis c) Beamonanelasticfoundation d) Pressurevesselanalysis(Note:pressurevesselanalysisrequiresreviewandapprovalbythe NASAFractureControlTeam.ContactNASAAircraftEngineeringforpressurevesselanalysis requirements) e) Alltypesofstabilityanalysisincludinggeneralandlocalstabilityofplates,skins,webs,shells, webshearbucklingordiagonaltension,localbucklingorcripplingofcompositeshapes,column stability,andbeamcolumnstability f) Analysisofcomposite,honeycomb,andreinforcedmaterials g) Largeelasticdeformations,geometricalnonlinearity,andgappinganalysis

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 h) i) j) k) l) m)

8594001,Rev

Nonlinearanalysisbeyondtheelasticrangeofthematerial Vibration/flutteranalysis Dynamic,impact,andfatigueanalysis Stressconcentrationandfractureanalysis Crackgrowthanalysis Machinecomponents(spring,gear,shaft,clutch,brake,ropes,belts,chains,cables,etc.) analysis n) Thermalstructuralandotheranalysis

Forfasteners,fittings,andconnections,thestressanalysismayfallintoanyofthefollowingcategories: a) b) c) d) e) f) g) h) Boltedjoint,fitting,spliceplate,andboltgroupanalysis Rivetedjointandconnectionanalysis Lug,pin,andbushinganalysis Boltpreloadandinstallationtorqueanalysis Weldedjointanalysis Bonding,adhesive,andfrictionanalysis Linearandnonlinearresidualstressanalysis Tolerance,interference,mismatch,thermalandotherstructuralanalysis

4.0 ReportFormat
ThestressanalysisreportshallcontainthesectionsshowninFigure1.Allsectionsshallbeclearly labeledandallreportpagesnumbered.Anexplanationofthecontentofthesesectionsfollows. TITLEPAGE TABLEOFCONTENTS LISTOFSYMBOLSANDACRONYMS 1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0 EXECUTIVESUMMARY MINIMUMMARGINOFSAFETYSUMMARYTABLE INTRODUCTION MATERIALPROPERTIES&ALLOWABLESSUMMARY COORDINATESYSTEMS LOADSSUMMARY CALCULATIONS REFERENCES APPENDIX

Figure1:StressReportOutline

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8594001,Rev

TITLEPAGE Thetitlepageofthereportshallincludeareportnumberandtitle.Itshallbespecific,unique,and concise.Acronymsshallnotbeusedinthetitlewithoutdefinition.Thetitlepageshallincludearevision blockforreportrevisions.AnexampletitlepageisshowninFigure4. TABLEOFCONTENTS Atableofcontentsshallbeincludedinthereportlistingeachreportsectionandapplicablepage number.Itisacceptabletoomitthetableofcontentsforreportsshorterthanten(10)pages. LISTOFSYMBOLSANDACRONYMS Allsymbolsandacronymsusedinthereportmustbedefinedandshowdimensionalunitsifapplicable. Groupthesymbolsandacronymsseparatelyandarrangetheentriesinalphabeticalorderinthe followingpriority. a) b) c) d) Englishletters Greekletters Subscripts Superscripts

EXECUTIVESUMMARY Theexecutivesummaryshallsummarizethemajorresultsandconclusionsinthereportsothatthe readermaydeterminethesubstanceofthematerialanddecidewhethertoreadthereportfrom beginningtoend.Thissectionshallclearlystatewhetherornotthestructuremeetsthedesign requirements.Theexecutivesummaryshallalsoincludeanyrecommendationsbasedontheanalysis. Thissectionshallcontainapictorialoverviewofthesystembeinganalyzedalongwithfiguresor diagramsshowingasummaryofloadingandresults.Thisisprobablythemostreadsectionofthe report. MINIMUMMARGINOFSAFETYSUMMARYTABLE Thissectionshallincludeatableshowingthecalculatedminimummarginsofsafetysummarizedina tabularformat.Thistablegivesthereaderaquickreviewoftheresults.Exampletablesshowingthe datathatshallbeprovidedisshowninFigure2andFigure3.Thesetablesmaybecustomizedtoadd additionalrelevantdatabutshall,ataminimum,containthedatashown.Notethateachpartnumber shallonlybelistedonceeventhoughtheremayhavebeenseveralmarginsofsafetycalculatedforeach part.Therefore,thislistisaminimummarginofsafetysummaryandsignifiesthedesigncritical condition. INTRODUCTION Theintroductionshallexplainthepurposeorobjectiveofthereport.Theintroductionshouldcontaina listofthepartsbeinganalyzedandshouldalsoincludeanyhistoricalinformationthatwouldhelpthe readerfurtherunderstandthecontextoftheanalysis.Ifthestructureisacomponentofalarger assembly,thissectionshallindicatehowthecomponentbeinganalyzedfitsintotherestofthe assembly.Otherrelatedanalysisreportsshallbereferencedinthissectiontoprovidethereaderwithan

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8594001,Rev

overallpictureofthecompleteanalysispackage.Thelengthoftheintroductionshouldbekeptasshort aspossibleyetstillconveythenecessaryinformation. MATERIALPROPERTIESANDALLOWABLESSUMMARY Thissectioncontainsallthematerialallowablesthatareusedintheanalysistocalculatethestructure marginsofsafety.Allmaterialsusedintheanalysisshallbeclearlyidentified(alloy,heattreat, compositetype,etc.)alongwiththeapplicablematerialproperties.Thisisareferencesectionforthe readersothathecaneasilydetermineifthecorrectallowablewasusedintheanalysistoobtainthe marginofsafety.Thesourceoftheseallowableswillbeclearlyreferencedandreadilyobtainablebythe reader.Reproducedpagesofmaterialmanualsandreferencesshowingtheallowableswillbe acceptableprovidedthesepagesalsoshowthesource. COORDINATESYSTEMS Thecoordinatesystem(s)usedforloadsapplicationandcalculationsshallbedefinedinthissection.A diagramshowingthecoordinatesystemorientationrelativetostructurebeinganalyzedandhowit relatestotheaircraftcoordinatesystemshallbeprovided. LOADSSUMMARY Thissectionshallincludeasummaryofthecriticalloadsappliedtothecomponentbeinganalyzed. Componentweightsandcentersofgravityshallalsobelisted.Dependingonthecomplexityofthe structurebeinganalyzed,thissectionmayormaynotincludeadetailedloadsanalysis.Ifthestructureis ofsubstantialcomplexityasdeterminedbytheanalyst,thedetailedloadsanalysisshallbeinaseparate reportorintheappendix.Theloadsshallbelistedbyloadcaseinatabularformatshowingload magnitudeanddirectionbasedonthespecifiedcoordinatesystem.Highlevelfreebodydiagrams showingtheappliedloadsandreactionsforthegoverningloadconditionsshallbeprovidedinthis section.Moredetailedfreebodydiagrams,ifapplicable,specifictoindepthanalysesshallbeprovided inthecalculationssection. CALCULATIONS Thissectioncontainsthedetailedanalysisofthestructuralcomponents.Allassumptionsusedinthe analysisshallbeclearlydescribed.Inaddition,allcalculationunitsshallbeclearlyshown.Finalresults shallshowmaximumstresses,deflectionsandotherpertinentdatalistedbyloadcase. Sketches,Figures,andDiagrams Thecalculationssectionshallincludesketches,figures,ordiagramstoillustratethepartsbeing analyzed.Theanalysisshallbereadablewithoutreferencetodrawings.Thefollowinginformation shallbeincluded: a) b) c) d) Whatpartsarebeinganalyzedidentifyallpartsbypartnumber Wheretheyareintheaircraftorpayload Wheretheexternalloadsare Wherethereactionsare.Ifpractical,showafreebodydiagraminbalancewithappliedloads andreactions e) Showthepartdimensionsthatarereferencedintheanalysis

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 f)

8594001,Rev

Locatethesectionsanalyzedandreferenceaxesusingaconsistentcoordinatesystem

AllAnalyses Thefollowinginformationshallbeincludedforallanalyses: a) Loadsandboundaryconditionsshallbeclearlydefined.Theloadpathasittravelsfromthe aircrafttothestructurebeinganalyzedshallbeclearlyidentified. b) Allsketches,figures,diagrams,andplotsshallbeclearlydrawnandlabeled. c) Allcalculatedmarginsofsafetyshallbeclearlynoted(e.g.underlined,bold,boxed,etc.)All resultsshallbepresentedusingaconsistentcoordinatesystem.Thecoordinatesystemshallbe clearlyshownonallmodelandresultplots. HandCalculations Thefollowinginformationshallbeincludedforhandcalculations: a) Everyequationshallbereferencedtoitssourcebysection/pagenumberandthesourcelistedin thereferencesectionofthereport.Itisacceptabletoomitreferencesforverybasicequations thatwouldbecommonknowledgetoawideaudienceknowledgeableinstressanalysis.See Figures5&6forexamplehandcalculations. b) Componentloadsmaybeobtainedfromafiniteelementmodelandthenusedinhand calculationstocomputestresses.Printoutsoftheinternalforcesobtainedfromthefinite elementmodelshallbeprovidedintheappendix. ComputerAnalyses Thefollowinginformationshallbeincludedforcomputeranalyses: a) ForFiniteElementAnalyses(FEA),thissectionshallincludeadescriptionofthemeshstrategy, boundaryconditions,loadapplication,andconvergencecriteria. b) WhereFEAresultsareusedtocomputemarginsofsafety,astressplotshallbeprovidedwith themaximumstresslocationandvaluenotedonthefigure. c) FEAresultsshallbecrosscheckedviahandbookcalculationstoverifyFEAresultsare reasonable.ComponenttestingtoverifyFEAresultsisalsohighlydesirable.Thecrosscheck processshallbeclearlydescribedinthereport.Thefollowingprovidesarecommendedchecklist foritemstobereviewed: a. Reactions(vs.handcalculatedfreebodydiagramvalues) b. Results(vs.handcalculatedstressesanddeflections) Allrepetitiousandsimplecalculationsshouldbeomitted.Onesamplecalculationshallbeshownand theremainingresultssummarizedbytabularorgraphicalform(suchcalculationsshouldbestatedas typical).

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8594001,Rev

Acompletefileofunsubmittedbackupornotebookanalysesshallbemaintainedbythe responsiblestressanalysispersonnelwithintheoriginatingorganization.Theseunsubmittedsupporting analysesshallbesaveduntilthehardwarehascompleteditsdesignlife. REFERENCES Alistofallreferencescitedinthereportshallbeincludedinordertodocumentthesourceof informationusedintheanalysis.Alldocumentsreferencedshallbereadilyobtainablebythereaderso thattheycanbestudiedifadditionalinformationisrequired.ItcanbeassumedthattheNASAhas accesstoallgovernmentspecifications,publishedtechnicalarticles,andpublishedbooks.However,it shouldnotbeassumedthatNASAhasaccesstoContractors'internalletters,reports,orstressmanuals sincetheseitemsareusuallyContractors'proprietaryinformation.Whenitemsofthistypeare referencedinthestressanalysis,thepertinentdatashallbeincludedinthestressreport.Ifthisdata cannotbeinsertedattheplaceinthereportwhereitisneeded(duetobulk)thenitshallbemadean appendixtothereport.AsimplecurvetakenfromaContractors'stressmanualtoshowwherea particularfactorcamefromisnotsufficientdocumentationtovalidatethefactorunlessthereis sufficientinformationwrittendirectlyonthecurvetoshowhowitwasgenerated;i.e.,boundary conditions,assumptions,etc. APPENDIX Examplesofitemsthatmaybeincludedintheappendix: Drawingsandtechnicalinformation Technicalcorrespondence Finiteelementanalysismodelplots&results Stressmanualreferences Multiplecalculationresults Computerfiletable

5.0Checking
Thestressanalysisreportshallbecheckedbyanapprovedrepresentativefromtheoriginating organizationindependentofthereportauthor.Verificationofthefollowingshallbecompleted: a) b) c) d) e) f) Numericalcalculations(equations,unitconversions,etc.) Methodofanalysis(analysistechniques,assumptions,etc.) Materialproperties(tensilestrength,yieldstrength,modulusofelasticity,etc.) Completenessofcoverage(allfailuremodesandloadconditionsinvestigated) FiniteElementAnalysis(analysisstrategy,geometry,mesh,mass,boundaryconditions,load selection,loadapplication,reactions,&results) Legibilityandreadabilityofanalysis

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8594001,Rev

6.0ReportSignatures
Thereporttitlepageorsignaturepageshallinclude,ataminimum,thesignaturesbelow.Notethatthe requiredsignaturesaredifferentforreportsgeneratedinternaltoNASAAircraftOperationsDivisionand forreportsgeneratedbyorganizationsexternaltoNASAAircraftOperationsDivision. RequiredSignaturesforNASAAircraftOperationsGeneratedReports a) Author/Engineer(personwhopreparedreport) b) Stress(personwhocheckedstressanalysis) c) Authorization(personauthorizedtoapprovereportreleaseintoNASAconfigurationcontrol system) RequiredSignaturesforReportsGeneratedbyOrganizationsExternaltoNASAAircraftOperations a) Author/Engineer(personwhopreparedreportfromoriginatingorganization) b) Checker/Stress(personwhocheckedstressanalysisfromoriginatingorganization) c) Approver(personauthorizedbyoriginatingorganizationtoapprovereportrelease) d) AODStress(NASAAircraftOperationsDivisionpersonwhoreviewedstressanalysis) e) AODAuthorization(NASAAircraftOperationsDivisionpersonauthorizedtoreleasereportinto NASAconfigurationcontrolsystem) ForreportsgeneratedbyorganizationsexternaltoNASA,theoriginatingorganizationshallsubmit thereportwiththeAuthor,Checker,andApproverboxessigned.NASAshallthenreviewthereport andsigntheNASAStressandNASAAuthorizationboxesforreleaseintoNASAsconfiguration controlsystem.

7.0References
Thefollowingreferenceswereusedinthepreparationofthisdocument: 1. InstructionsforthePreparationofStressAnalysisReports,JSC19652A,NASAJohnsonSpace Center,1987 2. CriteriaForPreloadedBolts,NSTS08307,NASAJohnsonSpaceCenter 3. E.F.Bruhn,AnalysisandDesignofFlightVehicleStructures,1973 4. ThomasP.Sarafin,SpacecraftStructuresandMechanisms,FromConcepttoLaunch,2003

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8594001,Rev

Figure2:MinimumMarginofSafetySummaryTable
Description Analysis MinimumMargin ofSafety
Yld. 1 Ult.2

Reference

PartNumber

Name

Material

FailureTheory

AppliedLoad (LoadCase)
Fx=125lbs, Tx=6000inlbs (LoadCase1)

FEA Filenames
widget.db widget.rst

Report Page#(s)
1012

MSCZZD001001

Widget

Ti6AL4V

VonMises

+.05

+.01

M.S. yield =

yield strength 1 limit

ultimate strength 1 limit F.S.

ExampleChoices: VonMises MaximumNormalStress Buckling Fatigue TsaiWu Other(describe)

M.S.ultimate =

limit : thestresslimitiscalculatedbasedontheflightvehiclelimit
loads.Limitloadsarethemaximumloadsanticipatedontheflight vehicleduringitslifetimeofservice.

F.S.: theFactorofSafetyvariesbasedonthetypeofaircraft,installed
location,material,andotherconditions.PleasecontactNASAAircraft Engineeringfortheapplicablefactorofsafetytouseinyourapplication.

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8594001,Rev

Figure3:FastenerMinimumMarginofSafetySummaryTable
Fastener
# Fastener Location FastenerPart Number Description Material

Analysis
AppliedLoad

FastenerForces
Max Tensile (lbs) Max. Comb. Shear (lbs)
1830

MinimumMarginofSafety
Tension Shear Interaction1

Reference
FEA Report Filenames Page#(s)

XXXXXXX001

NAS670710

7/1620 UNFX1.3L

A286

Fx=125lbs, Tx=6000inlbs (LoadCase1)

868

+.36

+.79

+.16

widget.db widget.rst

1012

RearFlange
1

SeeNSTS08307,CriteriaForPreloadedBoltsandAnalysis&DesignofFlightVehicleStructures,ChapterD1.8,byBruhnforexampleinteraction calculations. Y 1 Fastener Number 8 2

3 X Component Coordinate System

6 5 ExampleFastenerPattern

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REVISION HISTORY
DESCRIPTION OF CHANGE DATE

2292208,Rev
APPROVED

Figure4:ExampleTitlePage
Formatmaybedifferentbasedonoriginatingorganizationstandards buttitlepageshallcontainrequiredinformationoutlinedinSection4.0

SIGNATURES
ENG CH APP STRESS AUTH (AUTHOR) (CHECKER) (APPROVER) (NASA) (NASA)

DATE

NATIONAL AERONAUTICS AND SPACE ADMINISTRATION

LYNDON B. JOHNSON SPACE CENTER HOUSTON, TEXAS

TITLE
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SIZE

CAGE CODE

XXXXX

REPORT NO

XXXXXX
SHEET: X OF X

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SCALE: NONE

ORG

8594001,Rev

Figure5:ExampleHandCalculationLocker

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8594001,Rev

Figure6:ExampleHandCalculationFlap

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