NONLINEAR SOLUTIONS LLC, Material Modeling

Problem: Will the Space Shuttle External Tank Barry-mount cushion be crushed down to the bracket when exposed to launch environments?

Solution:

Developed a finite element model to calculate the deformations including:

Modeling of the Barry-mount cushion material nonlinear behaviour
Below top: simulation plastic deformation after 780 Lbf static load removal
Below bottom: test deformation after 780 Lbf static load removal
Inner radius deformation similar between simulation and test
Calculations indicate cushion will be crushed to the bracket, recommended bracket redesign to reduce bracket thickness

Modeling Bearing Steel nonlinear material behavior/fatigue:

Modeling 52100 Bearing Steel kinematic hardening behavior
a. Stress amplitude versus plastic strain range material model comparison with test
b. Ratchetting (continued plastic deformation) decay material model comparison with test

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mike.howell@nonlinear-solution.com