Launch vehicle structures, such as payload adapters and interstages, are increasingly designed and constructed using composite materials due to their high stiffness- and strength-to-weight ratios. Therefore, it is important to develop a validated finite element modeling methodology for designing and analyzing composite launch-vehicle shell structures. This can be achieved, in part, by correlating high-fidelity numerical models with test data. Buckling is often an important failure mode for cylindrical shells, and the buckling response of such structures is also often quite sensitive to imperfections in geometry and loading. Hence, it is crucial to understand the model parameters and details required to accurately predict the buckling load and behavior of composite cylindrical shells, especially if the shell is buckling critical. The inclusion of as-built features, such as radial imperfections, thickness variations, and loading imperfections can help improve the correlation between test and analysis. To demonstrate such an approach, a validated modeling methodology that was used to predict the buckling behavior of a scaled component for a launch-vehicle-like structure is presented, and results from the model are compared with experimental results. The modeling approach presented herein was used to successfully predict the buckling behavior.@en

Conical shells are commonly used as structural components for launch vehicles. The axial compression experienced during launch is one of the sizing load cases, because it can lead to loss of structural stability. Because experimentally testing these full-scale structures is cumbersome and expensive, it is expedient to understand how reduced-scale shells can be designed such that their buckling behavior is representative of the full-scale shell behavior. An analytical, sequential scaling methodology is developed based on the nondimensional governing equations for composite conical shells with a symmetric, balanced layup and negligible flexural anisotropy. Linear and nonlinear finite element analyses characterizing the buckling behavior of the different size shells yielded comparable results in terms of buckling load, meridional displacement, and buckling mode. The inclusion of geometric imperfections affects the prediction accuracy, but not to the extent that the methodology is no longer valid. @en

Traditionally, launch vehicles are constructed with a series of buckling-prone thin-walled cylindrical and conical shells, in which the buckling behavior of these shells has been well studied and buckling design guidance exists. Conical-cylindrical shell geometry is now being utilized for launch-vehicle stage adapters and payload adapters due to advances in manufacturing and numerical techniques, but there is no available buckling design guidance for this nontraditional combined geometry. In order to provide design recommendations, the buckling behavior and imperfection sensitivity of conical-cylindrical shells and how it differs from the conical and cylindrical components needs to be better understood. From this premise, it is possible to investigate whether or not the buckling knockdown factor guidelines for conical and cylindrical shells outlined in NASA SP-8019 and NASA SP-8007, respectively, are still applicable. The results in this paper will show that the current recommendations are not appropriate in some cases. In addition, it was observed that the large rotations and displacements near the transition between the cone and cylinder can have a larger effect on the buckling load than the presence of radial imperfections for conical-cylindrical shells, which is different than for conical or cylindrical shells. More interesting is the fact that design modifications to increase the buckling capability of a conical-cylindrical shell such as adding reinforcement, which may add mass, will make the shell more sensitive to imperfections. The increased imperfection sensitivity may negate the increase in buckling capability that was thought to be achievable. In the end, it may be more beneficial to design a conical-cylindrical shell in which the buckling behavior is dominated by the more predictable geometric nonlinearity, which may lead to an overall lower buckling load, but a lower knockdown factor may be possible since it will not be as sensitive to the lessknown radial imperfections.@en