Within the European space programme, a new upper stage engine (Vinci) for the Ariane
5 launcher is being developed, and the Volvo Aero Corporation (VAC) is
contributing with tur-bines for the fuel turbopumps. This MSc thesis
investigates the possibility of designing the Turbine Exhaust Duct (TED)
of the Vinci-engine in a carbon fibre composite material with
adhesively attached titanium flanges. The focus of the project has been
on stress analyses of the adhesive joints using Finite Element Methods
(FEM), more specifically by using a cohe-sive zone material (CZM) to
model the adhesive layer. Analysing adhesive joints is complex and an
important part of the work has been to develop and concretise analysis methods for future use within VAC
To obtain
the specialised material parameters needed for a CZM analysis,
FE-models of ten-sile test specimens were analysed and the results
compared to those of equivalent experimen-tal tensile tests. These
parameters were then used when analysing the TED geometry with load
cases specified to simulate the actual operation conditions of the Vinci
engine. Both two-dimensional axisymmetric and fully three-dimensional
models were analysed and, addition-ally, a study was performed to
evaluate the effect of cryogenic temperatures on the strength of the
joint
The results show that the applied thermal and structural
loading causes local stress concentra-tions on the adhesive surface, but
the stresses are not high enough to cause damage to the joint if a
suitable joint design is used. Cryogenic temperatures (-150 °C) caused a
significant strength reduction in the tensile specimens, partially
through altered adhesive properties, but no such severe effects were
seen in the temperature-dependent FE-analyses of the TED. It should be
pointed out however, that some uncertainties about the material
parameters exist, since these were obtained in a rather unconventional
way. There are also several other impor-tant questions, beside the
strength of the adhesive joint, that need to be answered before a metal-composite TED can be realised.
پروژه
تحلیل اتصالات چسبی فلز به کامپوزیت در کاربردهای فضایی (Analysis of
Metal to Composite Adhesive Joints in Space Applications)، مشتمل بر 7 فصل، 115 صفحه، به زبان انگلیسی، تایپ شده، به همراه تصاویر، با فرمت pdf به ترتیب زیر گردآوری شده است:
Chapter 1: PROJECT BACKGROUND
- Volvo Aero Corporation
- The Vinci Engine Project
- The Turbine Exhaust Duct
- The KOMET Research Project
- Thesis Project Specifications
Chapter 2: THEORETIC BACKGROUND
- Adhesive Joint Theory
- Analytical methods
- Numerical Analysis in Solid Mechanics
- Introduction to Elastic FEA
- Thermal FEA
- Thermoelastic coupling
- Cohesive Zone Material Modelling
- Basic Concepts of Fracture Mechanics
- The Cohesive Zone Model
- CZM in ANSYS
Chapter 3: ANALYSIS METHODS
- Obtaining CZM Material Parameters
- Specimen modelling
- Testing Procedure
- 2D-axisymmetric TED Analysis
- Simplified Geometry from Preliminary Study
- Setup of the Finite Element Analysis
- Material Data
- Joint Geometry Concepts
- Three-Dimensional TED Analysis
- Load Extraction
- 3D Modelling
- Sub modelling
- Analysis of Cryogenic Properties
- Estimation of Cryogenic Material Parameters
Chapter 4: RESULTS
- Obtaining Material Parameters
- DOE 1 – Material Parameters
- DOE 2 – Modelling Parameters
- Typical Adhesive Stress Distribution
- Final Parameters Resulting From the DOE Tests
- 3D Validation Model
- Axisymmetric TED Analysis
- Preliminary Geometry – 40 mm Straight Overlap
- Straight End – 25 mm overlap
- Embedded Straight End Geometry
- Short Tapered End Geometry
- Fully Tapered End Geometry
- 3D TED analysis
- Static Structural Analysis
- Coarse Model Transient Analysis
- Submodel Result Plots
- Cryogenic Properties Analysis
Chapter 5: DISCUSSION
- Analysis of Tensile Test Specimens
- Comparison of FEA and Screening Test Results
- Conclusions of the DOE
- Analysis of the TED Inlet Flange
- Separate Load Analysis
- Analysis of New Geometry Concepts
- Analysis of the 3D Flange Model
- Analysis of Cryogenic Properties
- Potential Weight Savings
Chapter 6: CONCLUSIONS
- CZM Analysis of Adhesive Joints
- Review of the Analysis Procedure
- Feasibility of a CFRP/Metal TED Design
- Further Research Options
Chapter 7: REFERENCES
APPENDIX
- Cross section of the Vinci hydrogen turbo-pump
- Flow chart of the Vinci engine (only lower stages shown)
- ANSYS Code Sample – Tensile Test Specimen Analysis
- ANSYS Code Sample – 2D Axisymmetric Analysis
- ANSYS Code Sample – 3D Submodel Analysis
جهت دانلود
پروژه تحلیل اتصالات چسبی فلز به کامپوزیت در کاربردهای فضایی (Analysis
of Metal to Composite Adhesive Joints in Space Applications)، بر لینک زیر کلیک نمایید.
آموزش کتیا، طراحی و مدلسازی رینگ چرخ خودرو (Wheel Rims) در نرم افزار CATIA
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