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Aug 17, 2022 103 likes •454 views

Characterization of a Clamp Band Fastening System MID/BCS Characterization of a Clamp Band Fastening System, Forum CADFEM 08/09/2015 Content Description & Applications of a Clamp Band Load Cases Classical Dimensioning Procedure

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MID/BCS – Characterization of a Clamp Band Fastening System, Forum CADFEM 08/09/2015

Characterization

  • f a

Clamp Band Fastening System

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MID/BCS – Characterization of a Clamp Band Fastening System, Forum CADFEM 08/09/2015

Content

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Classical Dimensioning Procedure FE-Models (2D & 3D) Conclusions for Design + Dimensioning Description & Applications of a Clamp Band Load Cases Sensitivity Analyses

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MID/BCS – Characterization of a Clamp Band Fastening System, Forum CADFEM 08/09/2015

What is a Clamp Band (CB)?

CB = commonly used fastening mechanism between: spacecraft (S/C) and launch vehicle (LV)

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Ariane 5 with James Webb Space Telescope (pict. ESA) CB Solar Orbiter

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MID/BCS – Characterization of a Clamp Band Fastening System, Forum CADFEM 08/09/2015

What is a Clamp Band (CB)?

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S/C Ring Adapter Ring Clamp Band

Tightening Bolt Band Saddles

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MID/BCS – Characterization of a Clamp Band Fastening System, Forum CADFEM 08/09/2015

CB Applications

Mechanical Ground Support Equipment

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Flight Equipment

Fixation Separation Fixation

Galileo (OHB)

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MID/BCS – Characterization of a Clamp Band Fastening System, Forum CADFEM 08/09/2015

Aim of the study

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Spacecraft + Load Cases

Classical Dimensioning Procedure Mathematical Formula Clamp Band Preload Clamp Band Design Limitations FE-Analysis Characterization Clamp Band Preload Updated Dimensioning Procedure

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MID/BCS – Characterization of a Clamp Band Fastening System, Forum CADFEM 08/09/2015

Working Principle

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Section View

S/C Ring LV Adapter Ring Saddles

Top View

F N MTG ! GAP !

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MID/BCS – Characterization of a Clamp Band Fastening System, Forum CADFEM 08/09/2015

Content

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Classical Dimensioning Procedure FE-Models (2D & 3D) Conclusions for Design + Dimensioning Description & Applications of a Clamp Band Load Cases Sensitivity Analyses

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MID/BCS – Characterization of a Clamp Band Fastening System, Forum CADFEM 08/09/2015

Loading Configurations

Horizontal

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Vertical

Fixation System:

  • Transport + Handling
  • Thermal Tests
  • Vibrations Tests

CB CB CB

Hoisting

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MID/BCS – Characterization of a Clamp Band Fastening System, Forum CADFEM 08/09/2015

Load Cases in CB joint

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Clamp Band S/C COG S/C ring Payload adapter ring m h

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MID/BCS – Characterization of a Clamp Band Fastening System, Forum CADFEM 08/09/2015

Content

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Classical Dimensioning Procedure FE-Models (2D & 3D) Conclusions for Design + Dimensioning Description & Applications of a Clamp Band Load Cases Sensitivity Analyses

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MID/BCS – Characterization of a Clamp Band Fastening System, Forum CADFEM 08/09/2015

ECSS - Dimensioning Procedure

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Flux from axial force [N/m] Flux from bending moment [N/m]

+ =

Maximal axial Flux:

Conservative !?

Critical load cases Equivalent line force Criterion: No Gaping Band Preload Stress Analysis

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MID/BCS – Characterization of a Clamp Band Fastening System, Forum CADFEM 08/09/2015

ECSS - Dimensioning Procedure

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T T r z Critical load cases Equivalent line force Criterion: No Gaping Band Preload

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MID/BCS – Characterization of a Clamp Band Fastening System, Forum CADFEM 08/09/2015

ECSS - Dimensioning Procedure

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Limitations

1- Shear loading 2- Stiffness of the assembled parts 3- Friction between S/C rings 4- Friction between band and saddles FE-MODEL T T

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MID/BCS – Characterization of a Clamp Band Fastening System, Forum CADFEM 08/09/2015

Content

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Classical Dimensioning Procedure FE-Models (2D & 3D) Conclusions for Design + Dimensioning Description & Applications of a Clamp Band Load Cases Sensitivity Analyses

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MID/BCS – Characterization of a Clamp Band Fastening System, Forum CADFEM 08/09/2015

FE-Models

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2D Axisymmetric 3D – 180°

+ Solution Time + Implementation + Visualization + Shear + Bending

  • Model size
  • Complexity
  • Simplified geometry
  • Only axial loading

50000 nodes 38000 elements 25-33 contact surfaces

19020 nodes 6120 elements 4 contact surfaces

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MID/BCS – Characterization of a Clamp Band Fastening System, Forum CADFEM 08/09/2015

2D FE – Axial Loading

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FE Model

Contacts: Band – Clamp Clamp – Rings Between Rings Fixed Ux=0 Negligible tangential stiffness: E-module 0 UY-Coupled

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MID/BCS – Characterization of a Clamp Band Fastening System, Forum CADFEM 08/09/2015

2D FE – Axial Loading

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FE Post-processing

Averaged Band Hoop Stress Clamp Extension Gaping Edge Distance

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MID/BCS – Characterization of a Clamp Band Fastening System, Forum CADFEM 08/09/2015

2D FE – Axial Loading

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Kinematics

Comparison T S G U

Sticking Sliding

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MID/BCS – Characterization of a Clamp Band Fastening System, Forum CADFEM 08/09/2015

3D FE – Shear Loading

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FE Model: 180°

Rigid Beams 180° 0° 2 [m] Remote Point =COG Fixed Thermal Preload

Sentinel 1A (ESA) Planck (ESA)

UY coupled

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MID/BCS – Characterization of a Clamp Band Fastening System, Forum CADFEM 08/09/2015

2D-3D FEM-Correlation (Axial loading)

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MID/BCS – Characterization of a Clamp Band Fastening System, Forum CADFEM 08/09/2015

3D FE – Shear Loading

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FE Post-processing

Gaping angle UY Y X

Gap side 180° Compression side 0°

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MID/BCS – Characterization of a Clamp Band Fastening System, Forum CADFEM 08/09/2015

3D FE – Shear Loading

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S G

Sticking Sliding

180° 0°

Kinematics

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MID/BCS – Characterization of a Clamp Band Fastening System, Forum CADFEM 08/09/2015

3D FE – Shear Loading

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Comparison: Pure Bending – Shear Loading

Bending only:

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MID/BCS – Characterization of a Clamp Band Fastening System, Forum CADFEM 08/09/2015

Content

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Classical Dimensioning Procedure FE-Models (2D & 3D) Conclusions for Design + Dimensioning Description & Applications of a Clamp Band Load Cases Sensitivity Analyses

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MID/BCS – Characterization of a Clamp Band Fastening System, Forum CADFEM 08/09/2015

Clamp Band - Parameters

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Sensitivity Analyses

Controllable

Parameters

Modifiable – Limited Influence Fixed Band Preload Band Stiffness Clamp Stiffness Friction Coeff. Clamp/Rings Ring Stiffness Friction Coeff. S/C Rings Wedge Angle GAPING

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MID/BCS – Characterization of a Clamp Band Fastening System, Forum CADFEM 08/09/2015

Sensitivity Analysis: Clamps Friction

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Axial Loading Shear Loading High Friction improves the gaping capability

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MID/BCS – Characterization of a Clamp Band Fastening System, Forum CADFEM 08/09/2015

Sensitivity Analysis: Clamps Friction

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Wedging effect

Limit of disassembly: r z =0 =0

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MID/BCS – Characterization of a Clamp Band Fastening System, Forum CADFEM 08/09/2015

SA: Shear Loading

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Band Stiffness Clamp Stiffness Ring Stiffness Friction Clamp Preload [kN] Friction S/C Rings

[GPa]

Shear Load Capability [kN]

[GPa] [GPa]

Wedge Angle Friction Tests Preloading Graph

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MID/BCS – Characterization of a Clamp Band Fastening System, Forum CADFEM 08/09/2015

Content

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Classical Dimensioning Procedure FE-Models (2D & 3D) Conclusions for Design + Dimensioning Description & Applications of a Clamp Band Load Cases Sensitivity Analyses

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MID/BCS – Characterization of a Clamp Band Fastening System, Forum CADFEM 08/09/2015

Preloading Graph for Axial Loading

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2SWL =1040 KN 39 KN

Example: MTG SHTCB

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MID/BCS – Characterization of a Clamp Band Fastening System, Forum CADFEM 08/09/2015

Conclusion for CB Design

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Friction High between clamps and rings, but… High between S/C rings Low between band and clamps Stiffness Design the parts as stiff as possible, but:

  • Clamp stiffness is the important one
  • Band stiffness plays a minor role

Preload Tighten the band with high preloading force Wedge Angle Small to improve gaping, but… Model uncertainty which cannot be modelled with FEM!

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MID/BCS – Characterization of a Clamp Band Fastening System, Forum CADFEM 08/09/2015

Benefits of ANSYS

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 Non-linear FE analysis (ANSYS Mechanical)

  • Mesh size, element formulation
  • Material parameters
  • Contact Formulation
  • Contact detection method
  • Contact normal stiffness
  • Contact sphere radius

 Easy access to the main parameters, such as:  Convergence and Sensitivity Analyses

(ANSYS Remote Solver Manager) Reality representative FE Model

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MID/BCS – Characterization of a Clamp Band Fastening System, Forum CADFEM 08/09/2015

END

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Questions?

Alphabus, credit ESA