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Project Report

Group Members:
Ahmad Nawab
ahmadnawab75@gmail.com

Arslan Saqib
arslansaqib68@gmail.com

Uzair Shakeel
uzairshakeel@rocketmail.com

Mohammad Ali
mohammadali19da@gmail.com
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Table of Contents
Turnitin Originality Report……………………………………………………………………………....3
Introduction ................................................................................................................................................. 3
Methods........................................................................................................................................................ 4
Drawings, Part Lists and Bill of Materials ............................................................................................... 5
Assumptions................................................................................................................................................. 7
Data Section ................................................................................................................................................. 8
Calculations ................................................................................................................................................. 8
References……………….……………………………………………………………………………..…20
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Turnitin Originality Report

 Processed on: 20-Dec-2019 23:47 PKT
 ID: 1237560216
 Word Count: 1348
 Submitted: 1

final report By Arsalan Saqib

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` Project Report Group Members: Ahmad Nawab ahmadnawab75@gmail.com
Arslan Saqib arslansaqib68@gmail.com Uzair Shakeel
uzairshakeel@rocketmail.com Mohammad Ali mohammadali19da@gmail.com

Introduction:
The goal of the project was to develop a lunar electric rover and perform a
complete stress analysis its body of the rover to ensure that the rover meets the safety
requirements and would not fail on its journey to the moon during its time there while keeping
the weight of the rover as minimum as possible. In the following sections, we will explain in
detail the assumptions that we made, the list of appropriate materials and their respective
properties, and the complete structural and design analysis of the rover. Reference for the data
and information pertaining to the report are mentioned at the end.

Method:

Approach:
We first modelled the craft that we were going to shape in SolidWorks which would
then be followed by calculations in Math-Cad. Much of the design specifications such as the
weight of Chassis and Payload was directly taken from the problem statement. As well as
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number of wheels (i.e. 12). Thus, it was ideal to first design the model then adjust and follow-up
with calculations.

Engineering Concepts Used:

For analyzing the model, we used a called-out assembly
approach in which we analyzed all the parts individually and applied various concepts on it. Our
first step was to analyze the cylinder that also carries our payload and astronauts for this we
implemented Thin-Walled Vessel analysis by calculating Hoop stresses, radial and
longitudinal stresses. This gave us internal and its comparison to the external pressure of the
vessel. This was then followed by static analysis of Chassis and its cross beams; this was done
by using section and truss analysis learned in the basics of Engineering Statics. These however
represent the constant stresses applied at all times, in order to test the limits of our material body
we calculated the maximum stress at the time of impact this was done by assuming that impact
occurs at h=0 to simplify the calculations however maximum possible Height (h) for which the
spring would be able to sustain the deformation was also calculated.

Technical Research:

Technical research was extensive and constrained by physical limitations such as the material
being able to sustain maximum load while having minimum weight. Thus, all possible
calculations were permuted on three distinct materials with different properties to decide what
the best material to use would be. The details of said materials is further discussed in Section 3.

Also, for the Chassis we used a standardized W-beam (------------) as per the requirement of the
problem statement.
In order to compensate for other stresses not anticipated we have chosen a factor of safety of 3
which means that all calculations are done with incorporating the factor of safety in the
calculations.
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Drawings, Parts List and Bill of Materials:

a) Rendered drawing
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b) Drawing:

c) Parts List:
The parts list is given as follows. The numbers indicated in the drawing symbolize
the respective elements on which they are written.
1. Pressure Vessel i.e. the container where the payload and the astronauts will be staying
2. Ribs: Ribs are used to create stability and to help uniformly distribute the load of the
cylinder on the chassis
3. Chassis: Chassis consists of W section beam
4. Wheels: There are 12 wheels in the drawing
5. Suspension
item no part number description quantity
1 1 W section
2 2 Cylinder 1
3 3 Rod 150mm diameter 6
4 4 Spring 6
5 5 Tire 12
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d) Bill of Materials:

Pressure Vessel:
The cylinder in the pressure vessel has a diameter of 1.7 meters, a length of 2.8 meters, and the
two semi-spheres at the end have a diameter of 1.7 meters.
Wheels:
The wheels have a diameter of 0.990 meters and a width of 0.35 meters. There are a total of
twelve wheels.
Chassis:
The chassis has a length of 4.65 meters and a width of 1.622 meters
Suspension:
Three different materials were used in case of suspension. There are six springs in the rover each
supporting two wheels. Three different springs used:
1. Music Wire ASTM A228
2. Hard Drawn ASTM A227
3. Stainless Steel ASTM A316

Assumptions:
We made a few assumptions in order to simplify the calculations during the
structural and design analysis of the material.
 To ensure that the rover exceeds the safety requirements even in the most extreme and
demanding cases, we performed the analysis with a safety factor of 3.0
 The load distribution of the cylinder i.e. the pressure vessel is assumed to be uniform
throughout the entire length of the chassis.
 No buckling occurs in the pressure vessel, as it is a cylinder
 In impact loading, the value of h i.e. the height from which it is dropped is assumed to be
0. However, we do calculate the height from above which if dropped the springs in the
suspension would not be able to sustain the impact
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Data Section
a) Materials Data Table

Material Allowable stress (MPa) Allowable temperature

(oC)

Aluminum alloy 420 350

Stainless steel 520 870
Carbon fiber 450 300
Music wire 500 120
Hard drawn 498 150

b) Load data
In our case the load which we require is 120000N, however the material cannot decide
the load, but the appropriate area and safety factor can lead us to the safe way against
failure.

Calculations:

c) Loading due to internal Pressurization:

The vessel has a thickness ratio i.e. r/t of 42.5 which means that the cylinder is a thin cylinder.
The calculations for internal pressurization are as follows
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d) Buckling of the Module Walls:

We assumed the buckling to be zero since the module is only a cylinder where the pressure of 1
atm is acting from inside out.

e) Static Loading on the module due to the payload:

We assume the loading is uniformly distributed over the entire cross-section of the chassis. First
we find the entire weight of the payload. Then we divide it by the total length of chassis to find
the distribution of the load per unit length on earth and further the area of the chassis to find the
average stress and then we find the bending moment and shear stress diagrams. We do this for all
three materials. We will include the diagrams of only aluminium alloy because we found it the
most suitable for our module. It is inexpensive when you compare it to carbon fibre and weighs
less than Stainless Steel.
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Now, the bending moment diagrams for the beams in the chassis where the material is
aluminium is given as belows. These are :
For Central Beam:
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For Beam 2:
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For Beam 3:
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For Beam 4:
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Impact Loads upon Landing:

As already mentioned, we have chosen three springs for suspension.
 Hard Draw
 Music Wire
 Stainless Steel
H is assumed as being 0
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Note: These calculations are performed with aluminium as the optimum material.

Fatigue Loads:

Figure: S-N curve for aluminum alloy

Figure: S-N curve for stainless steel

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Figure: S-N curve for carbon fiber

As observed in all of the graphs when 0.3 MPa is observed against number of cycles it almost tends to
infinity

Thermal Stresses:
The thermal stresses for all three materials at the day and night of moon are shown in the
following calculations. The MathCad screenshots for calculations for the thermal stresses are
attached below
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g) Loading due to acceleration/deceleration during take-off and re-entry

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The following calculations were performed to measure the shear stresses imparted due to launch of the
spacecraft that was carrying the rover.

References:
Data for springs taken from:
https://www.acxesspring.com/compression-spring-calculations.html

Escape velocities on average taken from:

https://www.sciencelearn.org.nz/resources/397-calculating-rocket-acceleration

Data Sections taken from:

https://www.unitedaluminum.com/chemical-composition-and-properties-of-aluminum-alloys/

Details of materials taken from:

Solid Works Libraries

Details of W-Beam and Other standard accessories:

Solid Works Libraries
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Equations and formulas

Mechanics of Materials Hibbler 6th edition