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Materials Today: Proceedings 4 (2017) 2290–2297 www.materialstoday.com/proceedings

5th International Conference on Materials Processing and Characterization

Effect of Material Mismatch on Static behavior of Flex Seal

Prakash D.a, Balakrishna Murthy V.b *, Chandra Mohan R.c, Karteek N.d
a,d
PG Scholar, bProfessor, Mech. Engg. Dept, V. R. Siddhartha Engineering College, Vijayawada, India
c
MD, Resin & Allied Products, Vijayawada, India.

Abstract

A flex seal in a rocket nozzle provides required flexibility for smooth functioning of directional change of the rocket and acts
as a pressure tight seal to prevent hot gases from the rocket motor. Flex seal consists of four different components, i) Elastomeric
pads , ii) shims, iii) fore end ring and iv) aft end ring. Elastomeric pads are made of hyper elastic material like rubber to provide
required flexibility in the system. Shims are made of either metals are composite materials to provides required stiffness to the
flex seal. Fore end and Aft end rings are connected to the flex nozzle system and motor respectively. The objective of present
work is to study the effect of mismatch in materials of shim and elastomeric pads. In the analysis, ground test conditions of flex
seal system are simulated using 2D finite element models. From the analysis it is observed that there is no influence of the
Poisson's ratio mismatch. Reduction in deflection and increase in stresses is observed with increase Young`s modulus mismatch,
which is varied by changing the Young`s modulus of shims.

© 2017 Elsevier Ltd. All rights reserved.

Selection and peer-review under responsibility of the conference committee members of the 5th International conference on
Materials Processing and Characterization (ICMPC 2016).

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1. Introduction

Many people observe the rocket launching process through online news, movies and internet. In those videos
during the take-off time, a large quantity of gasses releasing from the nozzle can be observed. These gases are
produced during combustion of fuel inside the rocket. The thrust produced by the gases will cause an opposite
momentum in the system that drives the rocket in the forward direction. A steering mechanism is required to

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E-mail address:vbkmpublications@gmail.com

2214-7853© 2017 Elsevier Ltd. All rights reserved.

Selection and peer-review under responsibility of the conference committee members of the 5th International conference on Materials Processing
and Characterization (ICMPC 2016).
 Prakash et al/ Materials Today: Proceedings 4 (2017) 2290–2297 2291

navigate the rocket in desired path. Flex nozzle system is usually employed for steering solid fuel rocket. The flex
nozzle system is also able to absorb flight disturbances during its motion. The Flex nozzle is equipped with a flex
seal which consists of alternate layers of elastomeric pads and metallic shims, permitting the nozzle to take the
desired orientation required to guide the rocket.

John T.Herbert [1] invented the flexible joint, which consists of alternative layers of resilient material and a rigid
reinforcing material. E.Y.Wong [2] implemented the concept to the solid rocket motors. Donat James [3] estimated
the core geometry required for rocket and analyzed its performance characteristics such as stress, weight and torque
required based on the constraints. Louis E Miltenberger [4] invented a system which providing a power to the rocket
by nozzle containing convergent- divergent parts. Nozzle attached to a rocket motor casing by a flexible joint
member. Stanley P Desjardins [5] invention represents a further advance in the art of incorporating flexible bearing
as a separate component. Woodberry [6, 7] conducted the experiments and developed empirical relations for
designing an elastomeric seal for Omni-axial movable nozzle. Bapiraju et al [12] said that linear analysis of the
structure yields results far from the reality, Fig. 1. To get better results nonlinear analysis will be needed. Suresh et
al [13] said that element size in finite element analysis plays major role in convergence and accuracy of the problem.
Higher number of elements may take more computational time. To overcome these difficulties adaptive meshing can
be used. Ajay Babu [8] has done the parametric studies on varying No. of shims, thickness of the elastomeric
materials. Eswar Kumar [9, 10] has done parametric studies on varying shim percentage within the volume and
number of shims to be there within the flex seal with constant shim percentage. The present work is regarding
mismatch in materials of shim and elastomeric pads, Fig. 2.

2. Problem Modeling

The following geometrical parameters are assumed for present analysis.

2.1 Geometry

Inner diameter : 330 mm Outside diameter : 400 mm Overall height : 204.5 mm

Inner joint angle : 42 degrees Outer joint angle : 54degrees Mean joint angle : 48 degrees
Pivot radius : 248 mm Throat diameter : 157 mm Shim geometry : Spherical
Number of shims : 11 Number of pads : 12 Thickness of shim : 4 mm
Thickness of Pad : 2.17 mm Shim percentage : 62.85%.

Fig. 1. Flex Seal Geometry Fig. 2. Parts of flex seal

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2.2 Finite element meshing

It is the process of converting the geometric entities to finite element entities such as nodes and elements. Rubber
areas are meshed with 4 node element having non-linear capability termed as PLANE182 in ANSYS. Remaining
areas are meshed with generalized 4 Node element termed as PLANE42 in ANSYS, Fig. 3.

Fig. 3. Meshed view of flex seal

2.3 Loads and boundary conditions

Following boundary conditions are applied on the model.

· All degrees of freedom are arrested on the bottom edge of aft end ring to resemble the real situation.
· X-direction (Radial) arrested on left extreme end of blank as shown in Fig 4.
· Pressure of 9MPa is applied on necessary lines as shown in Fig 4.

Fig. 4. Loads and Boundary conditions

2.4 Material properties

The materials used for the shims in the analysis are varied as per the case.
i. Effect of material mismatch with varying Young`s Modulus: In this case shim material Young`s modulus value
is changed from 100 to 500 GPa with a rise of 25GPa, by placing a constant Poisson's ratio i.e., 0.3.
ii. Effect of material mismatch with varying Poisson`s ratio: In this case shim material Young`s modulus value is
constant i.e., 200 GPa, by varying Poisson's ratio from 0.1 to 0.35 with a scale increase of 0.05 is done.
Mooney-rivlin two parameters are used to define the material properties of elastomeric pads. Steel is assigned for
throat housing, fore end ring and aft end ring. For elastomeric pads hyper-elastic rubber material is chosen. The
 Prakash et al/ Materials Today: Proceedings 4 (2017) 2290–2297 2293

properties of rubber can be defined by Mooney-rivlin two parameters (C01 = 1.0 MPa, C10 = 1.85 MPa, d = 0[11]).
The properties of steel are (Young`s modulus) E = 200 GPa, (Poisson’s ratio) ν = 0.3.

2.5 Verification

The present finite element model is verified by computing the radial stresses and shear stresses in combination
with radial direction at the Fore end ring and throat housing of Flex seal. The radial stresses at outer surface are
close to applied pressure.the parameters used for Verification of finite element model are shown in table 1.

Table 1. Verification of finite element model

Location Distance σR (MPa) σR𝜭 (MPa)

Fore end ring 54 mm -9.012 -0.1257

Throat housing 7 mm -8.978 -0.2236

2. Analysis results

The effects of mismatch between shim material and elastomeric pads are studied by changing the material
parameters of the shim.

3.1 Effect of material mismatch with varying Young`s Modulus

In this section a 2D axisymmetric models are analyzed by varying Young`s modulus from 100 GPa to 500 GPa
with a scale increase of 25 GPa, where the Poisson's ratio is kept constant for all models. And there results of axial
compression and stresses are discussed.

3.1.1 Axial Compression

From the fig 5 it is seen that with increase in Young`s modulus of shim from 100 GPa to 500 GPa there is a
gradual decrease in axial deformation from 8.608 mm to 4.77 mm. The stiffness of the flex seal is increased with
increase in Young`s modulus, so the deformation came down. But in all cases the axial deformation is within the
limit (i.e. 10 mm). Therefore the design of flex is safe in stability point of view for this case, but strength point of
view is to be verified by considering various stresses.

Fig. 5. Variation of axial deformation w.r.to Young`s modulus.

3.1.2 Radial Stress: In the fig 6 the radial stress is seems to be reducing with increase in Young`s modulus. This is
due to the free expansion of the material radial direction. But due to material stiffness a small amount of stress is
produced. Out of the stresses produced compressive stress is dominating, because of compressive pressure load
acting on it. When compared to remaining two normal stresses it is very negligible.
2294 Prakash et al/ Materials Today: Proceedings 4 (2017) 2290–2297

Fig. 6. Variation of Radial stress w.r.to Young`s modulus.

3.1.3 Hoop stress in θ Direction

From the fig 7 it is seen that the stress in θ hoop direction is gradually increased with respect to increase in
Young`s modulus. Due to the inter-laminar constraints the stress in θ hoop direction is increased with increase in
Young`s modulus of shims. The maximum is observed at the shims near to fixed support. As said earlier it is
spherical and material discontinuity at top portion it tries to move in that direction so stress is more at that top face
of shim.

Fig. 7. Variation of Hoop stress in θ Direction w.r.to Young`s modulus.

3.1.4 Hoop stress in ø direction

From the fig 8 it is observed the stress is increased gradually with increase in the Young`s modulus. In this
direction there are two reasons for more stress occurring in the shim. One of them is due to material continuity in its
shape, and the other one is due to material mismatch as said in the earlier cases. By the combination of these two
reasons stress produced is more in this direction, which is a major stress to be considered while considering the
material to be used for shims.

Fig. 8. Variation of Hoop stress in ø Direction w.r.to Young`s modulus.

 Prakash et al/ Materials Today: Proceedings 4 (2017) 2290–2297 2295

3.1.5 Shear stress in Rθ direction.

From the above graph it is clear that shear stress in Rθ direction is decreasing from 100 GPa to 375 GPa. And
from 375 GPa to 500GPa the value is increased with a small change, but it is seen stabilized. The maximum is
observed at inner face of the shim adjacent to the aft end ring as shown below fig 9.

Fig. 9. Variation of shear stress in Rθ direction w.r.to Young`s modulus.

3.2 Effect of material mismatch with varying Poisson`s ratio

In this section, a 2D axisymmetric model is used to for change in Poisson's ratio for shim material from 0.1 to
0.35 with a scale rise of 0.05 by placing constant Young`s modulus i.e. is 210 GPa. The results of flex seal is
analyzed and discussed in stability and strength point of view.

3.2.1 Axial compression

The fig 10 shows the variation of axial compression with respect to change in Poisson`s ratio for shim material at
constant Young`s modulus i.e. 210 GPa. The axial compression is decreased gradually with increase in Poisson's
ratio, but the actual change in axial compression is very negligible. So, it can be said that the effect of Poisson's ratio
on axial deformation is negligible.

Fig.10. Variation of axial deformation w.r.to Poisson`s Ratio.

3.2.2 Radial Stress

The fig 11 shows the variation of radial stress with respect to change in Poisson’s ratio for shim material at
constant Young`s modulus i.e. 210 GPa. The graph indicates that with increase in Poisson's ratio the radial stress
also increase. When Y axis is observed, it can be said that there is now much variation in stress.
2296 Prakash et al/ Materials Today: Proceedings 4 (2017) 2290–2297

Fig. 11. Variation of Radial stress w.r.to Poisson`s Ratio.

3.2.3 Hoop stress in θ Direction

The maximum hoop stress in θ direction are noted down for change in Poisson`s ratio and a graph is plotted as
shown in the fig 12. In this graph the stress increased with respect to increase in Poisson`s ratio of shim. The
percentage of variation is less than 1%.

Fig. 12. Variation of Hoop stress in θ direction w.r.to Poisson`s Ratio.

3.2.4 Hoop stress in ø Direction

The maximum hoop stress in ø direction are noted down for change in Poisson`s ratio and a graph is plotted as shown in
the fig 13. In this graph the stress are having same value with a small change i.e. is negligible when compared to its original
value. So it can be said that there is no effect of Poisson`s ratio change on stress in this direction.

Fig.13. Variation of Hoop stress in ø direction w.r.to Poisson`s Ratio.

3.2.5 Shear stress in Rθ direction

The graph in fig14 shows the change in shear stress in Rθ direction for an Young`s modulus of 210 GPa with
varying Poisson`s ratio. And it is seen that the variation is very small.
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Fig. 14: Variation of Shear stress in Rθ direction w.r.to Poisson`s Ratio.

4. Conclusions

The following conclusions are drawn from the above analysis.

· With increasing the Young`s modulus of shims (increase of Young`s modulus mismatch), the stiffness of the
structure is increased. Due to this the axial compression is decreased.
· With increase in the Young`s modulus mismatch the major stresses (i.e. in hoop stresses in θ and Ø directions)
are increased.
· With increase in the Poisson's ratio of shims, there is no change (i.e. is <1%) in axial compression and stresses
produced in the structure.
· The material can be chosen based on its strength required to resist the stresses developed corresponding to its
Young`s modulus.

References

[1] John Herbert, Redlands, Frank J. Kovitch, Jr., River side, and Max McCorkle ‘Flexible Joint Means’, United States Patent no. 3,390,899, July
2, 1968.
[2] E.Y. Wong, "Design, Fabrication, and Test of Omni directional Flexible Seals for Thrust Vector Control of Large Solid Rocket Motors”,
NASA CR 72889, final report of Advanced Technical Operations, Sacramento, California. 10 June 1971.
[3] Donate James R, "Solid rocket motor nozzle design sensitivity', AIAA
[4] Louis E. Miltenberger, "Thrust Vectoring Control System for Rocket Nozzles", United States Patent no. 3,726,480, Apr. 10, 1973.
[5] Stanley P. Desjardins, Jonathan W, Wilson, Alan R.Canifield. "Movable Thrust Nozzle for rockets", United States Patent no. 3,696,999, Oct.
10, 1972.
[6] Woodberry, “Solid Rocket Thrust Vector Control”, NASA SP-8114, December, 1974
[7] Woodberry, "Flexible joints for thrust vector controls", AIAA-75- 1221, October, 1975
[8] Ajay, “Finite element analysis of flex nozzle system of solid rocket motor” IJERIA, Vol. 5, Nov-2012
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[10] Eswar Kumar A, Balakrishna Murthy V, Chandra Mohan R, Prakash D, "Study of Nonlinear Static Behavior of Flex seal of Rocket Nozzle
by Varying Number of Shims", 4th ICMPC, Organized by GRIET Hyderabad, during 2014-2015 March, page no.24.
[11] Ch. V. Ram Mohan, J. Ramanathan, Satish Kumar. "Characterisation of Materials Used in Flex Bearing of Large Solid Rocket Motors",
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[13] Suresh Kurra, srinivasa prakash Regalla, ''Effect of mesh parameters in finite element simulation of single point incremental sheet forming
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