Professional Documents
Culture Documents
Compression
Panel
E10E
Delft University of Technology
This page is intentionally left blank.
iii
i
Contents ii
ρ Density kg/m3
A Cross-sectional area m2
b Stringer pitch mm
n st r Number of stringers -
s Rivet spacing mm
t Sheet thickness mm
V Shear force kN
These panels are basically the rocket’s skeleton and carry most of the loads during launch and flight.
Just like how a human would not be able to walk without a skeleton, a rocket would not be able to
fly without its compression panels. That is why a properly engineered compression panel is very
important.
The purpose of this report is to explain the function of the side panels of a launcher and the purpose
of the project described in this report is to design the panel itself whilst making sure it complies with
the requirements given by the IAC. When creating a launch vehicle to transport payload to space,
some of the parts that seem simple to manufacture are usually crucial to the success of the mission.
Without the outside panels of the launcher, the interior components would be crushed under the
forces generated when taking off. To design the panels for launch, three parts will be taken into
account:
• The panel;
Each part must be designed carefully so none of them fails during a mission. This panel is designed
specifically for the G.E.O.R.G.E. launcher from DELTA, i.e. this design process is unique for this ap-
plication as the loads and requirements may differ from company to company or from mission to
mission. However, the method used to determine the panel measurements can be used to design
compression panels for other launchers and missions.
This report will first cover a literature study on the topic at hand in Chapter 2, which will then lead
on to discussing the design results, the choices made for the design and the justifications for those
choices in Chapter 3. Chapter 4 will outline the manufacturing process and compares and evaluates
the produced panel with regard to the manufacturing plans. Chapter 5 describes the test procedure
and the results obtained from it. In Chapter 6, the data from Chapter 5 will discussed more in-
depth. Finally, the report will be closed off by Chapter 7, in which the final conclusions will be
given, together with recommendations for similar projects in the future.
1
2
Literature study
The literature study clarifies the main theory that is crucial to consider and understand in designing
a compression panel. This theory provokes allows for a deeper understanding of how a compression
panel is properly designed, tested, and used. Each section in this chapter covers a part of this theory.
The fast increase in thrust and the combustion in the engines causes vibrations in the launcher.
These vibrations introduce very high levels of low-frequency acceleration in the whole rocket.
Besides, rocket engines are very loud. So loud even that they introduce acoustic loads in the rocket
in the form of high frequency vibration. Next to the noise of the engines, acoustic loads are also
caused by the separation of the airflow along the rocket and the aerodynamic noise [2].
2
2.5. Panel as a Part of the Cryogenic Fuel Tank Structure 3
Also, if the temperature of the testing environment changed drastically, the thermal expansion of
the material could influence the compression load capabilities of the panel. If the stringer shrinks
more than the panel itself due to lower temperatures, for example, this will generate extra loads in
the panel on top of the compressive loads. This would make the panel fail at lower loads than it
would have if the panel and stringers extended equally.
Most deviations in manufacturing and testing could influence the compression load of the panel,
as to make a reliable test the conditions must be very controlled and precise so any minor change
could influence the results.
• Material: the panel and stringer material is aluminium. For the material properties of alu-
minium, please refer to Table C.1 in Appendix C;
• Outer dimensions: the plate has the following fixed outer dimensions: 495[mm] x 400[mm]
(±0.5[mm]);
• Plate type: although the plate choice is a free variable, there can only be a plate type chosen
from two pre-defined plates, see also Table 3.1, from [5];
• Stringers: although the stringer choice is a free variable, there can only be a stringer type
chosen from four pre-defined, L-shaped, stringers. For these stringer types, please refer to
Table 3.2, from [5];
• Stringer orientation: the stringers must be orientated in the longitudinal plate direction. There-
fore, the stringers are 495[mm] long;
• Rivet type: although the rivet choice is a free variable, there are only two rivet options avail-
able: one with a grip length of 1.5 − 3.0[mm] (short rivet) and one with a grip length of 3.0 −
4.8[mm] (long rivet). The properties of the rivets can be found in Table D.1, Appendix D;
4
3.2. Panel Design Description 5
• Rivet positioning: due to clamping, a zone of 35[mm] measured perpendicular from the short
panel end (the 400[mm] end) must be free of rivets.
• The section of the panel between two stringers considered to be clamped on all four sides;
• The rivet constant for the pop rivets used is assumed to be 2.1.
Each stringer has 12 holes (Ø3.2[mm]) of which the midpoints are spaced 38[mm] apart. There is
a 38.5[mm] distance from the top and bottom edges of the stringer to the midpoint of the first and
last hole to make sure the panel can be clamped in the compression test machine. In total, 84 short
rivets are needed to connect all the stringers to the panel. An exploded view of the design can be
found in Figure 3.1 (own work).
3.3. Free Body Diagram of the Panel 6
Figure 3.2: Free Body Diagram of the compressive load on the panel (own work)
The FBD, Figure 3.2, shows the forces acting on the panel. Using Static equilibrium in the y-direction,
we can find that the distributed loads are equal magnitude with opposite direction.
3.4. Determination of Design Parameters 7
Figure 3.3: Buckling concentration coefficient for a buckling plate [7, 458]
Note that for all the panel-stringer combinations, case 1 will be considered, which means that the
panel is clamped on all sides as stated in the assumptions. This has been chosen since the panel
part between two stringers will be clamped by the clamping machine at the short sides and by the
stringers at the long sides. Then, the critical buckling load can be calculated using Equation 3.2:
F cr = σcr A (3.2)
"σcr " being the critical buckling stress calculated using Equation 3.1, and "A" being the cross-
sectional area of the plate including the stringers.
3.4. Determination of Design Parameters 8
In order to fulfill the buckling requirement, the value calculated in Equation 3.2 for each panel-
stringer combination should be at least 34.5[kN ]. This value can be reached by changing the amount
of stringers, which changes both the stringer pitch "b" and the cross-sectional area "A". Note that an
increase of amount of stringers increases the stringer pitch "b", which decreases the critical buck-
ling load, but also increases the cross-sectional area "A", which increases the critical buckling load.
As the effect of increasing cross-sectional area is higher than the effect of increasing stringer pitch,
the critical buckling load will increase when the amount of stringers increases. The results from the
critical buckling calculations for eight different panel iterations can be found in Tables 3.3 and 3.4.
Table 3.3: Critical buckling calculations for face sheet type F-1
Stringer type Number of stringers b [m] Kc A [m 2 ] σcr [MPa] F cr [kN] Mass [kg]
L-1 7 0.05714 6.3 0.000724 78.4 56.8 0.876
L-2 6 0.06667 6.3 0.000776 57.6 44.7 0.938
L-3 7 0.05174 6.3 0.000523 78.4 41.0 0.632
L-4 7 0.05174 6.3 0.000619 78.4 48.6 0.749
Table 3.4: Critical buckling calculations for face sheet type F-2
As can be seen in Tables 3.3 and 3.4, all panel-stringer combinations adhere to the minimum re-
quired critical buckling load of 34.5[kN ]. Note that some of these critical buckling load values are
considerably higher than the required value. This is due to the fact that reducing the number of
stringers would lower the critical buckling load to such a value that the panel-stringer combination
does not meet the required value anymore.
cπ2 E I
F cr = (3.3)
L2
"c" is a constant, in this load case it is 0.25 [5, pg. 21]. "E " is young’s modulus, "I " is the area
moment of inertia and "L" is the free length of the column. To ensure the desired buckling of all
design permutations shown in Tables 3.3 and 3.4 is above 34.5[kN ] we check for all of these designs.
The area moment of inertia of the panel in the xz-plane can be calculated by reducing the shape
into rectangles, calculation of a centroid and using the parallel axis theorem to calculate the new
"I ". The centroid is given by :
Σx i A i
x̄ = (3.4)
ΣA i
where "x̄" is the centroid measured from the axis in the Figure 3.4 and "A" is the area of each rect-
angle.
3.4. Determination of Design Parameters 9
Figure 3.4: Cross section view of compression panel, showing the axis system used
1
I r ect ang l e = bh 3 + Ad 2 (3.5)
12
"b" is the base length, "h" is the height, "A" is the area and "d " is the distance between the average
centroid and the centroid of the whole body. By using Equation 3.3, 3.4 and 3.5, we obtain the values
in the Tables 3.5 and 3.6.
Table 3.5: Critical force for column buckling, face sheet type F-1
Table 3.6: Critical force for column buckling, face sheet type F-2
As is shown in the tables 3.5 and 3.6, column buckling occurs above sheet buckling for all designs
considered. Therefore column buckling will not be a failure mode.
Since the same material is used for the stringer and the plate, "σi r " can be calculated using Equation
3.7:
F · A pl at e
σi r = (3.7)
A 2t ot al
3.4. Determination of Design Parameters 10
A t ot al [m 2 ] A pl at e [m 2 ]
0.000523 0.000320
"A" being the corresponding area on the face the load is applied to, given in Table 3.7.
Using this data, "σi r " calculates to 46.35[M P a]. Rearranging Equation 3.6 for "s" allows the relevant
values to be inputted:
t
s=q (3.8)
σi r
0.9cE
Symbol Value
σi r [M P a] 46.35
t [mm] 0.8
c [−] 2.1
E [GP a] 63.5
This results in a rivet spacing of 40.71[mm]. However, due to the constraints (3.1.3) there is only a
possible length of 425[mm] to place rivets on the panel. Therefore to ensure no buckling occurs, the
calculated value is the maximum rivet spacing. To find the actual rivet spacing the amount of rivets
needs to be known. To find this, Equation 3.9 is used:
L
n r i vet = +1 (3.9)
s max
"L" being the available length and "s max " being the maximum rivet spacing. This equation gives
a number of rivets to be 11.44. This result is rounded up to 12, ensuring we have more rivets than
required.
To calculate the new rivet spacing, Equation 3.10 is used:
L
s= (3.10)
n r i vet − 1
This gives a new rivet spacing of 38.64[mm], which is lower than the previous calculation of "s". This
means that the calculations are correct and buckling should not be observed between the rivets at a
load of 40kN . To ensure this is correct, the value can be substituted back in Equation 3.6, and then
Equation 3.7 can be used to calculate the new force required for buckling. This value is 43.98[kN ],
which is above the requirements stated in subsection 3.1.2
out that the ultimate failure load requirement is more restrictive, hence different design parameters
would need to be decided based on the ultimate failure load requirement in a next iteration.
The failure mode of the panel will first be considered. The material used for the panel is aluminium,
which has the properties shown in Table 3.9, obtained from [5]. To ensure that the panel does not fail
below the ultimate load, the compressive stress in the panel at the ultimate load should stay below
the ultimate strength of the aluminium. This compressive stress can be calculated using Equation
3.11:
F ul t
σ= (3.11)
A
where "F ul t " is the ultimate load and "A" is the cross-section of the panel on which the load is
applied. The cross-section of the panel is calculated using Equation 3.12:
A = A panel + A st r i ng er ∗ n st r (3.12)
where "A panel " and "A st r i ng er " are the cross-section of the panel and the stringer, respectively and
"n st r " is the number of stringers. The number of stringers, the cross-section of the selected stringer,
type L-3, and the cross-section of the selected sheet, type F-1, can be found in Table 3.10. The di-
mensions of these components can be found in Table 3.2 and 3.1.
A panel [m 2 ] A st r i ng er [m 2 ] n st r [−]
2.9 · 10−5 3.2 · 10−4 7
Using Equation 3.12, and the values from Table 3.10, the total cross-section of the panel is calcu-
lated, which gives a value of 5.23 · 10−4 [m 2 ]. Now using Equation 3.11, the compressive stress in
the panel at the ultimate load of 40[kN ] can be calculated, which gives a compressive stress of
76.5[M P a]. This is below the ultimate strength of the aluminium and even below the yield strength.
Hence, it turns out that the requirements set on buckling were more restrictive than the failure re-
quirements. A new iteration will thus not be necessary. Furthermore, this means that there is a
safety factor of 1.66 and that the load at which the panel will fail is 66.4[kN ]. The load at which the
panel will start to yield is 52.3[kN ]. Hence, under compression, the panel will go through a sequence
of buckling, then yielding and finally failure.
Lastly, the failure of the rivets will be treated. The way in which rivets lead to failure of the whole
panel is when one of the rivets breaks off due to a shear stress or a tensile stress in the rivet. This
would cause one of the stringers to be locally weakened at the place where the rivet broke off. Since
this rivet break-off causes a larger rivet spacing between its neighbouring rivets, the load at which
inter-rivet buckling occurs will be reached sooner. This would lead to a higher deformation than
anticipated at a given load, which could cause other rivets to break off. This chain reaction would
lead to a rapid collapse, hence a failure of the panel.
3.4. Determination of Design Parameters 12
Since the rivets are not loaded directly, the situation in which the rivets fail is when the panel has al-
ready deformed significantly. This would impose a significantly higher load on the rivets. However,
since the panel has been designed such that it buckles at a load higher than 40[kN ], the rivets will
not experience high enough loads which causes them to fail, hence the failure of the rivets will not
be the cause of panel failure.
Having covered all the failure modes of the panel, it can now be determined how the panel will fail.
The applied compressive force will run up to the force at which inter-rivet, stringer and sheet buck-
ling will occur.
The buckling shifts the center of gravity in the z-direction, according to the coordinate system in
Figure 3.2. This causes a small moment arm to form between the applied compressive force and
the center of gravity. This imposes a bending moment on the panel. As the panel keeps bending
slightly due to the moment, the center of gravity shifts more and more, increasing the moment arm,
hence increasing the bending moment. At this point, the bending moment will have lowered the
compressive force at which yielding occurs since there is now not only a normal stress due to the
compression, but also due to the bending moment.
When the normal stress at which yielding occurs is reached, the sheet and stringers deform plasti-
cally. When this happens, the forces on the rivets might be high enough that would cause some of
the rivets to break off. This would weaken the panel significantly, as the stringers detach from the
panel. If the load continues being applied, the panel would simply fold in half.
Additionally, the theoretical compressive load at which inter-rivet buckling, thin sheet buckling,
column buckling, panel yielding and panel failure occur are given in Table 3.12
The tools list is followed by a new chapter which is the step-by-step guide on how to manufacture
the panel. This chapter starts with describing the necessary safety precautions both for general work
safety and for the current COVID regulations.
The first section in the actual manufacturing process describes the measuring and marking of all
the dimensions on the panel and the stringers. The section illustrates where to mark the lines and
points that will eventually become the outer dimensions of the panel and the holes for the rivets.
This section also contains some figures which help in portraying the dimensions. This should take
about 20 minutes.
After marking all the dimensions the layout of the parts should be checked. The section for layout in
the production plan gives the layout for the finished panel again providing dimensions and a figure.
Going over these steps should take about 5 minutes.
Now the holes in preparation for the rivets need to be made and all edges need to be finished. In
this section it is outlined in detail how to finish the edges using a hand reamer; how to drill the holes
and how to finish these holes using deburring tools. Figures are also included showing the best way
to fix parts together for precise drilling. Overall this should take up around 55 minutes
Lastly the parts of the panel should be riveted together. In the last section of this chapter and conse-
quently of the production plan, the steps for clamping and riveting the plate and stringers together
are described. Following these steps should take about 30 minutes. A detailed description of how to
use the riveting equipment is also provided.
13
4.2. Post Manufacturing Analysis 14
• The material for the L-stringers was missing and should have been given in Section 2.1 of the
production plan, see Appendix B.
• The manufacturer was instructed to band saw the aluminium sheet to size. This is not neces-
sary because the sheet was already cut to size. Also, using a band saw to cut aluminium sheet
is not appropriate due to the difficulty in obtaining accurate cuts.
• In Subsection 3.2.2 of Appendix B (the Production plan), it should have been specified which
long side of the L-stringer is meant, because an L-stringer has two long sides.
• The orientation of the rivets was missing. It should have been specified at which side of the
plate the heads of the rivets are visible.
• The manufacturer was instructed to drill the holes in the plate and the stringers separately.
This is not the preferred method, as drilling the holes in the plate and the stiffeners at once is
much more accurate.
• In Section 3.2 of Appendix B (the Production Plan), the tolerances during manufacturing were
taken into account. This was very convenient for the manufacturer.
In the case of a compression panel, the test will display data describing the failure modes and the
strength limits of the panel. This data can then be used to eliminate errors and further improve the
design of the panel to ensure the success of the mission. The testing process can be iterated as many
times as necessary until there is certainty that it will not fail under any expected circumstances.
15
5.3. Description of Test Events 16
During the actual test, no signs of failure showed until around a 28[kN ] compression. At this point,
the skin shows signs of inter-rivet buckling and at the maximum load the panel is subjected to
45[kN ] compression. This creates a sharp edge running perpendicular to the stringers and bulging
outward. Apart from the phenomena mentioned above, no signs of failure could be seen and all
rivets survived the test.
Figure 5.2: Laser Displacement Sensors measurements vs. time (a) and Difference in measurements from LDS number 1 / 2
(b) (own work).
5.4. Plots of Received Test Data 18
Figure 5.3: Compression force versus displacement (own work). The insert on the top right is Figure 5.1 from [5].
6
Analysis of the Panel Test
The purpose of this test analysis is to give an insight into what can be improved in the compression
panel design. Data analysis allows the responsible researchers to draw conclusions from the data
by representing the data in different ways: table, graphs et cetera. Using this analysis, the design
of the panel can be iterated to better fit the requirements of the mission. This chapter starts off by
describing where the panel failed (Section 6.1), then goes on to explaining how and why the panel
failed (Section 6.2). Next, the test data is compared to the calculations performed previous to the
testing (Section 6.3). Lastly, the production quality of the panel is reviewed with the aim of explain-
ing why the panel failed and what factors possibly influenced the panel failure (Section 6.4).
If the test shows that the panel has not reached the required strength, we can then analyse the lo-
cation and type of failure of the panel. This information allows for the strengthening of the panel
in appropriate areas. Once this is implemented, the panel is retested until there is absolute confi-
dence that the panel will not fail under the given loads. In addition if the panel over-performs some
corrections can be made to the design with the goal of saving weight.
The expected outcome was that the middle of the panel would fail, as the middle point on the panel
is the furthest away from the clamps. When the load is not applied perfectly through the center of
mass of the panel, a moment will be created. This moment, is what makes the panel buckle, and the
region of maximum moment is at the maximum distance from the region of loading; in this case this
region is the the middle of the panel. The moment thus led to column buckling. As the whole panel
was bending, it contracted one side of the panel, leading to the inter-rivet buckling. As a result, the
strips experienced plastic deformation as seen in Figure 6.1.
Secondary buckling locations at the top and the bottom near the clamping sites were also visible, as
seen in Figure 6.1. Those were most probably, a result of the secondary bending that happens at the
ends of a clamped plate once it buckles. Once the free middle part of the panel has deformed to an
arc shape, a reaction bending moment is created near the clamped area, due to the inability of the
clamped ends to follow the curve.
19
6.2. Description and Explanation of Failure Type 20
Figure 6.2: The panel at the beginning of the test, it is not yet deformed. On the left side the side view of the panel can be
seen, on the right the front view of the panel. From: [8]
6.2. Description and Explanation of Failure Type 21
Figure 6.3: The panel at 28 [kN] loading, the first column buckling of the stringers has already taken place, now thin sheet
buckling of the top panel starts. On the left side the side view of the panel can be seen, on the right the front view of the
panel. Note the −28.7[kN ] indication on the bottom left. From: [8]
Then, at approximately 44[kN ], the whole panel fails to withstand the applied loads. The thin sheet
buckling of the top plate and the column buckling are at their maximum, see Figure 6.4 [8].
When the machine stops compressing at the end of the test, the stringers have a "spring-back" ten-
dency and partially regain their original shape, whereas the top plate remains deformed, see Figure
6.5 [8]. This means that the stringers have not failed entirely, as it does not show complete plastic
deformation after the compression test. Therefore, it is likely that the panel could not withstand the
loads anymore due to top plate failure. It is thus concluded that the panel failed due to thin sheet
buckling of the top plate.
Figure 6.4: The panel at 44 kN (see bottom left indication): the thin sheet buckling is permanent and is visible on the right
side of the image. The stringer column buckling also reached its maximum (left side of the image). From: [8]
6.3. Comparison of Test Data with Failure Load/Mode Calculation 22
Figure 6.5: The panel after testing. Notice how the thin sheet buckling of the top plate (right side of the image) is
permanent and how the stringers experienced partial spring back (left side of the image) and have therefore not failed.
From: [8]
As we can see in Table 6.1 the buckling occurred at a force of about 13[kN ] less than expected or
about 70% of the calculated buckling load. This does not satisfy the requirements given by the IAC,
as the requirements asked for buckling only after 34.5[kN ] [5]. This means that our safety factor
was not big enough to account for all the errors created by the assumptions made during the de-
sign process and the aforementioned real life conditions. According to our calculations, the stress
in the plate will reach the ultimate strength of the material at loading of around 61.5[kN ] which is
well above the maximum load achieved during the test and thus we have no information to confirm
neither deny this claim.
The failure mode for our compression panel was excessive buckling (mainly thin sheet and column
buckling), which was expected by the team. With calculated failure load just 1[kN ] off the predicted
one (well within the margin of error), it can safely be argued that the prognosis made before the
test was accurate to a quite high degree, at least concerning the failure load. An increase in the
thickness of some of the stringers should be able to combat the bucking load problems that the
panel encountered.
internal shear flow distribution and thus leading to an uneven shear concentration in the panel.
This can lead to the compression panel failing earlier than expected. An ideal compression panel
would fail in a straight horizontal line in the middle of the panel. As can be seen from the formula
for shear flow:
VQ
q= (6.1)
I
Since Q is largest in the middle of the panel and the other variables do not change the shear flow will
be largest there and it is expected to fail at that location. Additionally during bending and buckling
normal stresses are created in the panel.
My
σ= (6.2)
I
In this equation "y" and "I " stay constant, but "M " changes and is greatest in the middle of the
panel. From this it follows that normal stresses are most severe at the middle of the panel, which is
the other reason for an ideal plate to be failing there.
In Figure 6.6 and Figure E.1, the analysis of the whole panel is visible. A more detailed view of the
buckled section can be seen in Figure 6.7. In Figure 6.6, each horizontal row was given a letter from
top to bottom (A to L), and each vertical row a number from left to right (1 to 7). This gives each
rivet an unique letter-number combination. Next to that, the vertical green lines are the reference
lines. These lines start in the midpoint of the rivets in row "A" and end in the midpoint of the rivets
in row "L". The orange lines are also reference lines. These start at the lower edge of each rivet in
row 1 and end at the lower edge of each rivet in row 7. Like this, the deviation from the orange lines
is marked in yellow and the deviation from the green lines in blue. For a more detailed view of the
panel analysis and the locations of deviation see Appendix E.
The following limitations might have an influence on the outcome of the results:
• The visual analysis is done on the panel after the compression test, which permanently de-
formed the panel locally and thus might caused for particular dislocations of some rivets;
• The image used has a HD quality which has its limitations in accurately depicting the possible
dislocations;
• The picture was taken without a proper camera stand. This introduces a slight angle into the
picture influencing the accuracy of the grid;
• The boundary reference rivets could also have been placed in inaccurately, which results in
inaccurate reference lines;
• The grid was made by hand. This means that there could exist some imperfections in it.
As seen in Table 7.2, rivets G3 and E3 have the greatest imperfections. Coincidentally rivet G3 is also
in the middle section of the panel. This section experiences the most internal forces as stated in the
introduction of Section 6.4. Since the internal forces are highest here, this is also where the effects
of a imperfection are expected to be noticed first. There are also several other large imperfections in
the region left to rivet G3. The effect of the imperfections can be clearly seen in the pictures of the
tested panel. The panel yields in a horizontal line until rivet G3. After G3 the yield line moves down
a row.
6.4. Assessment of the Production Quality in Relation to Testing Outcome 25
• The measurements were taken after the panel test, meaning the panel had been deformed
and the measurements are thus a bit inaccurate;
• A coordinate system has been set up to describe the position of one rivet relative to another.
These distances were measured with the "E10E"-inscription above and the "-0.95"-inscription
down (as in Figure 6.6). These distances are defined as follows: positive y (distance of rivet
relative to the rivet above), negative y (distance of rivet relative to the rivet below), positive x
(distance of rivet to the rivet on the left or the panel side, whichever is applicable) and nega-
tive x (distance of rivet to the rivet on the right side or the panel side, whichever is applicable).
A positive y value of for example 2 would indicate that the distance between the indicate rivet
and the rivet above is 2 percent larger than what it should have been according to the produc-
tion plan (37[mm]).
Most likely, the small relative placement errors of especially rivets F2, G2 and G3 led to the charac-
teristic horizontal S-shaped buckle between rows F, G and H, see Figure 6.6.
7
Conclusion and Recommendations
This project investigated the purpose and design process of a Launcher Compression Panel for the
G.E.O.R.G.E launcher from DELTA. The purpose of this project is to explain the function of the side
panels of a launcher and to design the panel itself. The ideal configuration for the panel involved
meeting desired strength at minimum weight possible.
The compression panels of a launcher experience compression forces due to the high amount of
thrust during lift-off. The function of the compression panels is to withstand these high compres-
sion forces without failing. For this project, a compression panel has been designed that was re-
quired to meet the following requirements:
By strengthening the panel with stiffeners riveted to the thin plate the design parameters in Table
7.1 have been concluded.
After the design was made, the compression panel needed to be manufactured. For this, a produc-
tion plan was written to instruct the manufacturer how the panel needed to be made. The manufac-
tured panel was made mostly identical to the designed panel. However, small production mistakes
led to slightly different panel behaviour.
To check if the manufactured panel would meet the requirements, it was tested using a MTS 311.51
test system. This test system operates by clamping the compression panel and applying a compres-
sion force up to the point when the panel has compressed 30 mm or when the test system measures
a reaction force equal to 20% of the maximum compression the panel can support after it has failed.
The test has led to results which are compared to the calculated values for the design in Table 7.2.
26
27
The test results imply that the panel was capable of resisting column buckling at the stringers until a
load of approximately 28[kN ]. This is lower than the first requirement provided by the IAC. Further-
more, the panel failed to withstand the applied loads at a load of approximately 45[kN ]. This means
that the designed compression panel was almost successful in meeting the requirements provided
by the IAC as it did not quite meet the buckling load of 34.5[kN ].
By analyzing the obtained test results, it was pointed out that the panel failed due to thin sheet
buckling of the top plate, combined with a deteriorated load-carrying capacity of the stringers due
to column buckling. A possible cause for the earlier-than-expected buckling of the panel could lie
in the fact that small manufacturing errors were made, which was the case for a few rivets.
Recommendations
Due to the ultimate strength of the design not being reached in testing, further optimisations for
lower ultimate strength could be considered to allow a weight saving. Furthermore, different ma-
terials for the compression panel including the stringers can be investigated to determine whether
these materials will be more optimal for the design.
Bibliography
[1] T. Woinowsky-Krieger, Theory of Plates and Shells. McGraw-Hill, 2 ed., 1959.
[3] L. Abbas, X. Rui, and P. Marzocca, “Aerothermoelastic analysis of panel flutter based on the ab-
solute nodal coordinate formulation,” Multibody system dynamics, vol. 33, pp. 163–178, 2015.
[4] V. Dawson and M. Bowels, Taming Liquid Hydrogen: The Centaur Upper Stage Rocket 1958-2002.
NASA, 1 ed., 2004.
[7] M. Niu, Airframe Stress Analysis and Sizing. Hong Kong Conmilit Press LTD, 2 ed., 1999.
28
A
Gantt Chart
29
30
1 2 2.5 3 4 5 6 7 8
Describing test
Time
Activity People spent
(min)
Writing introduction of production plan Theophile, Lucas 25
Writing tools and materials list Aleksei, Bart 240
Writing safety precautions Aleksei 15
Writing steps for measuring and marking Aleksei, Ewan 75
Writing steps for layout and sizing Mike, Theophile 75
Writing steps for drilling and finishing Didier, Dragomir, Robin 180
Writing steps for clamping and riveting Aleksei, Lucas, Morris 240
Making CATIA model Dragomir, Bart, Aleksei 240
Making relevant technical drawings and ren-
Dragomir, Aleksei 200
ders
Checking production plan Bart, Aleksei 105
Handing in production plan Robin 15
Writing introduction of report Theophile, Lucas 35
Doing literature search Lucas, Morris, Robin, Theophile 240
Making first design Didier, Ewan, Mike, Dragomir 240
Writing chapter on design Didier, Ewan, Mike, Bart 240
Writing description of production plan Robin 60
Doing post manufacture analysis Mike, Didier, Ewan 60
Updating production plan based on feedback Mike, Didier, Ewan, Dragomir 180
Describing test procedure Lucas, Theophile 15
Describing test events Lucas, Morris, Robin 60
Plotting Received Data Lucas, Morris, Dragomir, Robin 180
Writing test analysis method Lucas, Morris, Aleksei 200
Analyzing test and data Aleksei, Bart, Dragomir, Theophile, Lucas 200
Analyzing production quality Aleksei, Bart, Lucas 180
Writing conclusion and recommendations Didier, Ewan, Mike 90
Editing and finishing Bart, Morris, Robin 120
General formatting overleaf Robin 240
Handing in design report and drawings Dragomir, Robin 15
Table A.1: The task division and time spent on each task
Session 2.5 in the Gantt chart indicates when we all worked on the production plan outside of
project hours for about an hour. For the rest every block corresponds to a planned session.
The time spent in Table A.1 is the time people spent on this task on average.
B
Production Plan
32
"This is the Production Plan in Appendix B"
Summary
For the manufacturing of components it is important to know what parts and tools are required and how
these parts must be assembled. This is the purpose of this production plan; to describe in clear steps
what the method of manufacturing is for a compression panel used in a rocket by the DELTA Company.
Without this clear description it is hard for a manufacturer to know the exacts of a manufacture. Other
wise, the component might not end up as required. Calculations and technical drawings are made in
this report to ’freeze’ the design of the compression panel. Also, a list of materials, a list of tools and a
stepbystep procedure are given for the manufacturing of the panel.
i
"This is the Production Plan in Appendix B"
Contents
Summary i
1 Introduction 1
2 Tools and Materials needed for Compression Panel Assembly 2
2.1 List of required Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.2 List of required Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.2.1 Tools for Measuring and Marking . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.2.2 Tools for Punching, Drilling and Finishing . . . . . . . . . . . . . . . . . . . . . . . 4
2.2.3 Tools for Clamping and Riveting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3 Manufacturing Steps needed for Compression Panel Assembly 5
3.1 Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.2 Steps for Measuring and Marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.2.1 Marking the Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.2.2 Marking of the LStringer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.3 Steps for Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.4 Steps for Punching, Drilling and Finishing. . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.4.1 Deburring the Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.4.2 Drilling the Plate and the Stringers . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.4.3 Finishing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.5 Steps for Clamping and Riveting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Bibliography 10
A Technical Drawings 12
ii
"This is the Production Plan in Appendix B"
1
Introduction
In this report, a detailed production plan is given on how to manufacture a rocket side panel for the new
launch vehicle designed by DELTA: the GEOspace Rocket for Gravity (GEORGE). A launch vehicle
essentially is a tube with an engine and a fuel tank inside of it. To make sure the launcher is aerody
namically shaped and protects its interior components, it needs a shell which maintains the cylindrical
shape of the rocket. This shell is composed of many smaller, reinforced panels. This report gives the
production plan of these panels.
The panels are composed of three main parts:
• The panel;
• The stringers;
• The rivets.
The panel is a relatively thin sheet of metal, in this case aluminium. The aluminium stringers act as
reinforcement to the panel, as the panel on its own cannot support all compression loads during use.
The stringers are long, Lshaped pieces of metal which are there to give extra support by increasing
the average thickness of the panel without increasing the weight of the panel as much as when the
thickness of the panel itself would be doubled or tripled, for example. The rivet is a headed bolt which
is passed through holes in two pieces of metal and is then deformed, keeping the two pieces together
firmly. In this case, rivets are used to assemble the plate and the stringers.
This plan will first detail the tools and materials used to build the panel as well as the manufacturing
methods to build the sample panel in Chapters 2 and 3 respectively. To finish off the plan, 2D drawings
of the panel will be displayed. This is done throughout the chapters and in Appendix A.
"When in doubt about the interpretation of the assembly procedure in Chapter 3, please refer
to the drawings in Appendix A!
1
"This is the Production Plan in Appendix B"
The dimensions and material for the sheet and stringers are as specified in Table 2.1. Additionally,
table 2.1 contains specifications for the rivets. The specifications for the sheet, stinger and rivets were
obtained from [1, pg. 56]. The dimensions for the stringers are visually presented in Figure 2.1 (own
work). The dimensions for the metal sheet are shown in Figure 2.2 (own work).
Table 2.1: Dimensions of the required materials. From [1, pg. 5-6].
2
"This is the Production Plan in Appendix B"
• Steel ruler;
• Tape measure .
"This is the Production Plan in Appendix B"
• Safety glasses.
• Centre punch;
• Hammer;
• Drill bit Ø=2.5 [mm] (for the predrilling pilothole);
• Hand riveter.
"This is the Production Plan in Appendix B"
1. Put the precut F1 aluminium panel (0.8 [mm] thickness) horizontally on a workbench;
2. To mark the locations of the centre lines for the lines of rivets for the stringers on the aluminium
panel, mark a point on the short edge of the panel 29 [mm] from the long edge. Continue marking
points at a spacing of 57 [mm] until there are 7 points. Use a set square to mark lines from these
points to the opposite edge of the panel;
3. Repeat Step 2 for the opposite end of the panel.
5
"This is the Production Plan in Appendix B"
Figure 3.1: Dimensions for rivet holes on sheet F-1 (own work)
3. Along the centre line mark a point 44 [mm] from the bottom from the stringer. Repeat the point
with spacing 37 [mm] until there is 12 marks, no marks should be present closer than 35 [mm] to
the upper or lower edge;
4. Repeat this procedure for the other six stringers;
Figure 3.2: Dimensions for rivet holes on the Stringer (own work)
"This is the Production Plan in Appendix B"
1. Place the Stringer centre line aligned with the two marked points on the opposite ends of the
panel;
2. Repeat Step 1 for each of the 7 stringers;
3. The edge stringers should be 29 [mm] ±1 [mm] away from the nearest long side of the aluminum
sheet;
4. Ensure that the Ldirection of the stringers is consistent, i.e. the Lsides of the stringers are
oriented the same way.
5. Clamp all the stringers in place in preparation for drilling. To do that you need to use the clamp
screws to fix the stringer and the plate together at both ends of the stringer as shown in Figure
3.4. Place them together in the position that they will eventually be secured in;
The final layout of the panel (ignoring the rivets) should be as depicted in 3.3
(a) Clamping Method front view (b) Clamping Method side view
1. Remove the burrs on the edges of the plate using a hand reamer. This is done by first positioning
the hookend of the hand reamer against the plate edge;
2. Pull the hand reamer along the plate edge with one firm motion;
3. Repeat this process for every burred plate edge.
Now the holes for the rivets need to be drilled. This will be done by drilling the holes through the
stringers and the plate at the same time.
Now that the holes are made, the burrs created during the process need to be removed.
3.4.3. Finishing
(Time Estimate: 20 min.)
1. Use the counter sink tool to remove the burrs from the holes in the plate and the stringers. To do
this, start by putting the sharp end of counter sink tool into the hole on each burred side;
2. Turn the counter sink tool clockwise around its own axis while pushing it into the hole until the
burr is removed;
3. Repeat Step 1 and Step 2 for every hole made in the plate and the stringers;
4. Remove the remaining burrs on the edges of the stringers using a file by holding the file against
the edge and move it back and forth using long strokes until the edge is smooth;
4. Connect the pneumatic rivet gun to an air supply unit and turn the unit on;
5. Insert a blind rivet into every hole, from the stringer side, that does not have a rivet clamp in it
from the side of the panel. Make sure the mandrel of the rivet sticks out like in Figure 3.5;
6. Put the rivet gun on one of the rivets, squeeze the gun down tightly and push the trigger to rivet
it;
7. Repeat this for the other rivets;
8. Remove the rivet clamps and rivet the nonriveted holes;
"This is the Production Plan in Appendix B"
9. When all the holes without rivet clamps have been riveted, take out a rivet clamp and rivet that
hole. Repeat this until all the rivet clamps are gone and all the holes have been riveted;
10. Now repeat Step 1 through 9 of this Section 3.5 until all 7 Lstringers have been riveted to the
panel. The compression panel is now ready for further assembly into the launch vehicle.
"This is the Production Plan in Appendix B"
Bibliography
[1] TU Delft. “AE1222-I Design and Construction Project Manual Part II-Launcher Compression Panel
Design”. 2020.
[2] TU Delft. AE1222-II Design and Construction: How to Use a Drill. Film. TU Delft. URL: https:
//brightspace.tudelft.nl/d2l/le/content/292963/fullscreen/2089219/View.
[3] TU Delft. AE1222-II Design and Construction: Tools and Assembly Tips. Film. TU Delft. URL:
https://brightspace.tudelft.nl/d2l/le/content/292963/fullscreen/2089204/
View.
11
"This is the Production Plan in Appendix B"
A
Technical Drawings
12
"This is the Production Plan in Appendix B"
13
14
15
σul t [M P a] σ y [M P a] E [M P a] ρ [g /cm 3 ]
127 100 63500 2.78
50
D
Rivet properties
In the following table from the project reader [5] the rivet properties can be found.
Parameter Value
Diameter [mm] 3.2
Length [mm] 6
Grip range [mm] 3.0-4.6
Head shape Mushroom head
Material body/mandrel Steel
Shear load [N] 1060
Tensile load [N] 1285
51
E
Panel Analysis Image
52
53