Test and Analysis of Full-Scale 27.5-Foot-Diameter Stiffened Metallic Launch Vehicle Cylinders

The Shell Buckling Knockdown Factor Project (SBKF) was established with the goal of developing improved (i.e., less-conservative, more robust) shell buckling knockdown factors (KDFs) for modern launch-vehicle structures. To this end, SBKF has engaged in several activities to support the development, validation, and implementation of the new design factors, including subscale and full-scale structural testing. Tests on eight different subscale, 8-foot-diameter, integrally stiffened aluminum-lithium 2195 (Al-Li 2195) cylinders were conducted in order to obtain the majority of the required validation data. In addition, two full-scale, 27.5-foot-diameter, Al-Li 2195, integrally stiffened cylinders were tested to provide additional validation data and to determine structural scaling trends. Presented herein are the details of a recent analysis model development and test and analysis correlation effort on the full-scale test articles. The effects of selected modeling assumptions and approaches are discussed, and results from a modeling sensitivity study are presented. It was found that simplified finite element models, that assume nominal test article geometry and material properties, can predict the overall response characteristics well. However, several discrepancies in the test and analysis results were observed. A sensitivity study was performed to determine the effects of several modeling assumptions and address the observed discrepancies. The results from the study indicated that the evolution of local skin pocket buckling and the presence of residual stresses due to the manufacturing process can have a significant influence on the predicted buckling response of the cylinders considered.