Project Description

What was the purpose of this project?

• Design a rocket end-ring that is optimized for manufacturing using directed energy deposition of titanium

What problem is this project trying to solve?

• Produce the end-ring in one solid part with limited post processing without sacrificing strength and stiffness

What are the requirements for this project?

• Mass Limit < 10 lbm
• Backup Stiffness > 400 kip/in
• Remain inside provided design space
• Limit amount of support material that will need to be machined away

Performance Review

• Using Ansys software, backup stiffness and Von Mises stress were calculated.
• The following loads were analyzed: Loads on lug holes, and line load.
• Worst load expected values: 312.5 kip/in backup stiffness, 43 ksistress
• Testing was performed to verify Finite Element Analysis (FEA)

Design Description

1. Lugs
2. Access slot
3. I-beam stiffener
4. Avionics box mounts

Conclusion

The design was a successful proof of concept that additive manufacturing can be used to replace the existing assembly. The ring exceed the weight requirement while achieving a sufficient stiffness.

Lessons Learned

• Release part to manufacturer as soon as possible to avoid delays
• Evaluate test fixture and dry run test protocol prior to live run
• Different part in the project can be worked in parallel

Future Work

• Testing other features on the ring
• Verify design is can be scaled to larger rings

Special thanks to Mikael Black, Dan Cowan, and Justin Wilding