Orion Capsule Launch Abort System Analysis Assignment 2 AE 4802 Spring 2016 – Digital Design and Manufacturing Georgia Institute of Technology Authors: Tyler Scogin Michel Lacerda Jordan Marshall Table of Contents 1. Introduction ......................................................................................................................................... 4 1.1 Mission Profile ............................................................................................................................. 7 1.2 Literature Review ........................................................................................................................ 8 2. Conceptual Design ............................................................................................................................. 13 2.1 Design Process ........................................................................................................................... 13 2.2 Vehicle Performance Characteristics ......................................................................................... 15 2.3 Vehicle/Sub-Component Sizing ................................................................................................. 15 3. Vehicle 3D Model in CATIA ................................................................................................................ 22 3.1 3D Modeling Roles and Responsibilities: .................................................................................. 22 3.2 Design Parameters and Relations:............................................................................................. 22 3.3 3D Model: .................................................................................................................................. 24 4. Aerodynamic Analysis........................................................................................................................ 27 4.1 Team members and Associated Tasks ....................................................................................... 27 4.2 Geometry Snapshot (Mesh Scene) as Original Surface mesh in STAR-CCM+ and Surface Repair Threshold Statistics ............................................................................................................................... 27 4.2 Surface Mesh Regeneration, Surface Wrapper Snapshots, and Error Statistics ....................... 28 4.3 Volume Mesh Generation, Section Plane Snapshot, and Volume Mesh Diagnostics ............... 36 4.4 Physics Selection and Initial Conditions .................................................................................... 41 4.5 Surface Names, Boundary Types and BC Values ....................................................................... 42 4.6 Solver Information ..................................................................................................................... 43 4.7 Post-Processing ......................................................................................................................... 44 5. Structural Analysis ............................................................................................................................. 55 6. References ......................................................................................................................................... 64 Table of Figures Figure 1: Challenger disaster after launch and Columbia disaster upon reentry...................................... 5 Figure 2: Space Launch System evolvable capability.................................................................................. 6 Figure 3: Orion Launch Abort System mission profile artist depiction................................................ 8 Figure 4: United States capsule design diameter comparison............................................................. 9 Figure 5: Comparison of international capsule design parameters..................................................... 10 Figure 6: Launch abort towers are common practice in human spaceflight....................................... 11 i Figure 7: Blunt vehicle shapes are typically chosen............................................................................. 11 Figure 8: Ogive fairing of LAS fits over Orion, model image from NASA.............................................. 13 Figure 9: Design process flowchart for Orion LAS analysis................................................................... 14 Figure 10: LAS Integrated geometry………………………………………………………………………………………..…... 16 Figure 11: Orion Crew Module fundamental geometric relations....................................................... 18 Figure 12: Orion Crew Module fundamental geometric parameters and dimensions…...................... 18 Figure 13: Orion Crew Module fundamental geometric dimensions................................................... 19 Figure 14: Orion Crew Module fundamental geometric orientation.................................................... 20 Figure 15: Orion Crew Module fundamental geometric parameters................................................... 21 Figure 17: 3D isometric view of LAS and Orion model......................................................................... 24 Figure 18: Additional view of the LAS and Orion model...................................................................... 25 Figure 19: Exploded view of LAS and Orion.......................................................................................... 26 Figure 20: Original LAS and Orion surface model as imported from CATIA V6.................................... 27 Figure 21: Surface Repair Threshold statistics………………………………………………………………………..…....... 28 Figure 22: Automated mesh scene for two surface wrappers……........................................................ 32 Figure 23: Automated mesh scene wit view of Orion inside LAS…………………………………...................... 32 Figure 24: Mesh snapshot after Surface Wrapper and Automated Mesh Repair................................ 33 Figure 25: Mesh snapshot after Surface Wrapper and Automated Mesh Repair of abort motors...... 33 Figure 26: Mesh snapshot after Surface Wrapper and Automated Mesh Repair of Orion module..... 34 Figure 27: Surface repair threshold statistics chart after the repair for LAS only................................ 34 Figure 28: Output text for the surface repair for LAS only................................................................... 35 Figure 29: Surface repair threshold statistics chart after the repair for Orion only............................. 35 Figure 30: Output text for the surface repair for Orion only................................................................ 35 Figure 31: Mesh of the subtract block and LAS………………………………………………………………………..……… 38 Figure 32: LAS and Orion close up view inside the subtract block mesh ............................................. 38 Figure 33: Section Plane with wake………………………………………………………………………….…......................39 Figure 34: Section Plane view of upper section of LAS……………………................................................... 39 Figure 35: Section Plane view of Orion capsule and Ogive fairing…..................................................... 40 Figure 36: Volume mesh diagnostics report………………………………….................................................... 41 Figure 37: Plot of the residuals showing convergence…………………………………...................................... 43 Figure 38: Pressure scene for LAS and Orion………............................................................................... 44 Figure 39: Contour plot of pressure for LAS and Orion………………………................................................ 44 Figure 40: Vector scene for velocity magnitude for Orion and LAS .................................................... 45 Figure 41: Vector scene showing the wake behind Orion………………………………………………………..………. 45 Figure 42: Vector scene showing flow inside LAS………………………........................................................ 46 Figure 43: Vector scene showing flow at the nose cone and nose cone tip in detail..…...................... 47 Figure 44: Vector scene showing flow at the abort motors in detail................................................... 47 Figure 45: Streamline velocity for flow around and behind Orion, with semi-transparent LAS………… 48 Figure 46: Streamline velocity for flow around and behind Orion, semi-transparent LAS in detail..... 49 Figure 47: Streamline velocity showing flow around LAS and in the wake behind Orion.................... 49 Figure 48: Streamline velocity scene showing a detail of the vortices in the wake behind Orion....... 50 Figure 49: Streamline velocity for single abort motor with a progressively more detailed view.……… 51 Figure 50: CD report……………………………………………………………………………………………………………………..... 53 Figure 51: CL report generation…………………………………………………………………………………….................... 54 Figure 52: Drag report…………….…………………………………………………………………………………….................... 54 Figure 53: Mesh for three-dimensional wing in Abaqus……………………………………………………………..…… 55 Figure 54: Von Mises stress analysis for three-dimensional wing in Abaqus………………………………...... 55 Figure 55: Original shape of three-dimensional wing in Abaqus.......................................................... 56 ii Figure 56: Deformation of three-dimensional wing in Abaqus……………..…………………………………......... 56 Figure 57: Stress magnitude in the primary U1 direction………………………………………………………...……… 57 Figure 58: Stress magnitude in the primary U2 direction………………………………………………………...……… 57