Undue Conservatisim in Structural Designs

Assuming that dynamic (transient/vibratory) loads are static in the design of structures is a long-standing engineering practice. The assumption is conservative for hardware that will have limited exposure to the specified dynamic environment and fatigue is not a concern. This is the case for most space flight hardware. Once out of the Earth’s atmosphere, significant vibrations are non-existent for most hardware and vibration cycles are limited. Mass is, and has always been, a concern with respect to flight hardware design. How much unnecessary mass due to the subject assumption may be in structural designs was questioned and numerous tests have been performed to qualitatively address that. Tests have been performed on simple aluminum beams, beams with bolted joints and beams with welded joints. Results of those tests are reported in this paper. The objective of these efforts was to demonstrate the order of magnitude of conservatism associated with this engineering process via comparing static to dynamic tests and the longer term endgame is to develop a new or modified quick turnaround structural design process that circumvents assuming dynamic loads are static and results in lighter structural designs. Test results qualitatively demonstrate notable conservatism. Activities to devise the new method are underway.