JEC COMPOSITES MAGAZINE - Issue #83 - August/September 2013 - 76

software
software’s database and incorporated
into the analysis.

Fig. 2: This screenshot from Collier Research
Corporation’s HyperSizer composite optimization
software shows the primary structure and its components (without solar panels) for the NASA Ames
Common Bus LADEE model. HyperSizer can be
used from preliminary design to flight certification
to perform extensive trade studies, determine
material allowables, and calculate margins of
safety.

vehicle using the software’s extensive
material property database (see Figure
2). Later on, as additional materials
from literature sources and empirical
in-house testing became available for
flight material systems, their properties were easily downloaded into the

Fig. 3: About one billion margins of safety were
calculated on an element-by-element basis as part
of a HyperSizer stress analysis for the LADEE satellite’s primary structure. The coloured legend on the
right displays the minimum margin from all failure
criteria, for all load cases, for each element.

Once the team arrived at a working design, the fidelity of the FEM was sharpened by using HyperSizer to calculate
detailed element-by-element margins
of safety for each of the many applicable failure modes (see Figure 3). The
structural portion of the LADEE FEM
contains approximately 500,000 shell
elements and was subjected to nearly
100 global load cases. On average about
20 failure modes – including core
shear, flatwise tension, face dimpling,
local buckling, and interactions – were
checked for each element, depending
on type (see Figure 4).
HyperSizer was used to verify the
performance of both the composite
structures and metal interfaces and
bracketry. In a full run, the software
calculated and sifted through about
one billion margins for the model.
HyperSizer was critically important and
comprehensive. It is extremely efficient
at organizing and presenting this staggering amount of data.
If all this work had been carried out
using a manual approach (as was the
case before HyperSizer was brought on
board), the engineering team would
have been forced to either simplify
the analysis or hire more analysts to
write in-house codes. Simplifying the
analysis means reducing the number
of load cases to some minimal amount
by including only critical structural
locations while ignoring the rest. Doing
things by hand would also be tedious.
Analysts would have to interrogate
stresses or strains at these critical
areas on a case-by-case basis and then
iterate several variations. When doing it
manually, the tendency can be to make
overstressed areas thicker, which runs
counter to strength/weight goals.
By using HyperSizer throughout the
design-test-build cycle, the engineering team was able to fully validate
their modular design for LADEE. The

76 jec composites magazine / No83 August - September 2013

Fig. 4: The controlling analysis of the LADEE
vehicle’s primary structure is illustrated in this
screenshot from HyperSizer structural sizing and
analysis software. The legend (top right) shows
which failure criteria produced the lowest margins
under all load cases on an element-by-element
basis: In general, red areas are metallic features
controlled by isotropic failure criteria, green are
composite structures controlled by composite criteria, and blue indicates elements governed by panel
shear criteria for both metallic and composite
panel areas.

software provided other benefits as
well. During critical design review
(CDR), for instance, graphical outputs that clearly illustrated structural
margins, critical load cases, and critical
failure modes could be produced. A
multitude of element properties ranging from input loads to material and
construction types were easily verified
and recorded. The tool generated a
stress report that became part of the
final Primary Structure Stress Substantiation Report. And during fabrication,
HyperSizer helped the team disposition non-conformances by allowing
engineers to quickly assess the impacts
of fabrication imperfections based on
margins in those areas.
The team used HyperSizer extensively
on LADEE. It increased their efficiency,
enabling them to complete the analysis
in far less time.

The changing spacecraft design
landscape
While the Ames Common Bus idea
was first born in 2006, HyperSizer was
introduced after many of the baseline



JEC COMPOSITES MAGAZINE - Issue #83 - August/September 2013

Table of Contents for the Digital Edition of JEC COMPOSITES MAGAZINE - Issue #83 - August/September 2013

Cover
Edito
Point of view > looking to the future
Contents
Agenda of Events
COMPANY & BUSINESS In Brief
APPLICATIONS
Elevator
Sport & leisure
Defense
E.V.
MARKET
Automotive
US market
SPECIAL JEC AMERICAS
9th I.C.S.
Awards
Canada: country guest of honor
RESEARCH & DEVELOPMENT
Graphene
Tow placement
TECHNOLOGY & INNOVATIONS
NDT
Software
Epoxy
Index
In the world
JEC COMPOSITES MAGAZINE - Issue #83 - August/September 2013 - Cover
JEC COMPOSITES MAGAZINE - Issue #83 - August/September 2013 - 2
JEC COMPOSITES MAGAZINE - Issue #83 - August/September 2013 - Edito
JEC COMPOSITES MAGAZINE - Issue #83 - August/September 2013 - Point of view > looking to the future
JEC COMPOSITES MAGAZINE - Issue #83 - August/September 2013 - 5
JEC COMPOSITES MAGAZINE - Issue #83 - August/September 2013 - Contents
JEC COMPOSITES MAGAZINE - Issue #83 - August/September 2013 - 7
JEC COMPOSITES MAGAZINE - Issue #83 - August/September 2013 - 8
JEC COMPOSITES MAGAZINE - Issue #83 - August/September 2013 - 9
JEC COMPOSITES MAGAZINE - Issue #83 - August/September 2013 - Agenda of Events
JEC COMPOSITES MAGAZINE - Issue #83 - August/September 2013 - 11
JEC COMPOSITES MAGAZINE - Issue #83 - August/September 2013 - Ad1
JEC COMPOSITES MAGAZINE - Issue #83 - August/September 2013 - Ad2
JEC COMPOSITES MAGAZINE - Issue #83 - August/September 2013 - COMPANY & BUSINESS In Brief
JEC COMPOSITES MAGAZINE - Issue #83 - August/September 2013 - 13
JEC COMPOSITES MAGAZINE - Issue #83 - August/September 2013 - Elevator
JEC COMPOSITES MAGAZINE - Issue #83 - August/September 2013 - 15
JEC COMPOSITES MAGAZINE - Issue #83 - August/September 2013 - Sport & leisure
JEC COMPOSITES MAGAZINE - Issue #83 - August/September 2013 - 17
JEC COMPOSITES MAGAZINE - Issue #83 - August/September 2013 - Defense
JEC COMPOSITES MAGAZINE - Issue #83 - August/September 2013 - 19
JEC COMPOSITES MAGAZINE - Issue #83 - August/September 2013 - E.V.
JEC COMPOSITES MAGAZINE - Issue #83 - August/September 2013 - 21
JEC COMPOSITES MAGAZINE - Issue #83 - August/September 2013 - Automotive
JEC COMPOSITES MAGAZINE - Issue #83 - August/September 2013 - 23
JEC COMPOSITES MAGAZINE - Issue #83 - August/September 2013 - 24
JEC COMPOSITES MAGAZINE - Issue #83 - August/September 2013 - 25
JEC COMPOSITES MAGAZINE - Issue #83 - August/September 2013 - US market
JEC COMPOSITES MAGAZINE - Issue #83 - August/September 2013 - 27
JEC COMPOSITES MAGAZINE - Issue #83 - August/September 2013 - 28
JEC COMPOSITES MAGAZINE - Issue #83 - August/September 2013 - 29
JEC COMPOSITES MAGAZINE - Issue #83 - August/September 2013 - 9th I.C.S.
JEC COMPOSITES MAGAZINE - Issue #83 - August/September 2013 - 31
JEC COMPOSITES MAGAZINE - Issue #83 - August/September 2013 - 32
JEC COMPOSITES MAGAZINE - Issue #83 - August/September 2013 - 33
JEC COMPOSITES MAGAZINE - Issue #83 - August/September 2013 - Awards
JEC COMPOSITES MAGAZINE - Issue #83 - August/September 2013 - 35
JEC COMPOSITES MAGAZINE - Issue #83 - August/September 2013 - 36
JEC COMPOSITES MAGAZINE - Issue #83 - August/September 2013 - 37
JEC COMPOSITES MAGAZINE - Issue #83 - August/September 2013 - 38
JEC COMPOSITES MAGAZINE - Issue #83 - August/September 2013 - 39
JEC COMPOSITES MAGAZINE - Issue #83 - August/September 2013 - Canada: country guest of honor
JEC COMPOSITES MAGAZINE - Issue #83 - August/September 2013 - 41
JEC COMPOSITES MAGAZINE - Issue #83 - August/September 2013 - 42
JEC COMPOSITES MAGAZINE - Issue #83 - August/September 2013 - 43
JEC COMPOSITES MAGAZINE - Issue #83 - August/September 2013 - 44
JEC COMPOSITES MAGAZINE - Issue #83 - August/September 2013 - 45
JEC COMPOSITES MAGAZINE - Issue #83 - August/September 2013 - 46
JEC COMPOSITES MAGAZINE - Issue #83 - August/September 2013 - 47
JEC COMPOSITES MAGAZINE - Issue #83 - August/September 2013 - 48
JEC COMPOSITES MAGAZINE - Issue #83 - August/September 2013 - 49
JEC COMPOSITES MAGAZINE - Issue #83 - August/September 2013 - 50
JEC COMPOSITES MAGAZINE - Issue #83 - August/September 2013 - 51
JEC COMPOSITES MAGAZINE - Issue #83 - August/September 2013 - 52
JEC COMPOSITES MAGAZINE - Issue #83 - August/September 2013 - 53
JEC COMPOSITES MAGAZINE - Issue #83 - August/September 2013 - 54
JEC COMPOSITES MAGAZINE - Issue #83 - August/September 2013 - 55
JEC COMPOSITES MAGAZINE - Issue #83 - August/September 2013 - 56
JEC COMPOSITES MAGAZINE - Issue #83 - August/September 2013 - 57
JEC COMPOSITES MAGAZINE - Issue #83 - August/September 2013 - 58
JEC COMPOSITES MAGAZINE - Issue #83 - August/September 2013 - 59
JEC COMPOSITES MAGAZINE - Issue #83 - August/September 2013 - 60
JEC COMPOSITES MAGAZINE - Issue #83 - August/September 2013 - 61
JEC COMPOSITES MAGAZINE - Issue #83 - August/September 2013 - Graphene
JEC COMPOSITES MAGAZINE - Issue #83 - August/September 2013 - 63
JEC COMPOSITES MAGAZINE - Issue #83 - August/September 2013 - Tow placement
JEC COMPOSITES MAGAZINE - Issue #83 - August/September 2013 - Index
JEC COMPOSITES MAGAZINE - Issue #83 - August/September 2013 - 66
JEC COMPOSITES MAGAZINE - Issue #83 - August/September 2013 - 67
JEC COMPOSITES MAGAZINE - Issue #83 - August/September 2013 - NDT
JEC COMPOSITES MAGAZINE - Issue #83 - August/September 2013 - 69
JEC COMPOSITES MAGAZINE - Issue #83 - August/September 2013 - 70
JEC COMPOSITES MAGAZINE - Issue #83 - August/September 2013 - 71
JEC COMPOSITES MAGAZINE - Issue #83 - August/September 2013 - 72
JEC COMPOSITES MAGAZINE - Issue #83 - August/September 2013 - 73
JEC COMPOSITES MAGAZINE - Issue #83 - August/September 2013 - Software
JEC COMPOSITES MAGAZINE - Issue #83 - August/September 2013 - 75
JEC COMPOSITES MAGAZINE - Issue #83 - August/September 2013 - 76
JEC COMPOSITES MAGAZINE - Issue #83 - August/September 2013 - 77
JEC COMPOSITES MAGAZINE - Issue #83 - August/September 2013 - Epoxy
JEC COMPOSITES MAGAZINE - Issue #83 - August/September 2013 - 79
JEC COMPOSITES MAGAZINE - Issue #83 - August/September 2013 - 80
JEC COMPOSITES MAGAZINE - Issue #83 - August/September 2013 - 81
JEC COMPOSITES MAGAZINE - Issue #83 - August/September 2013 - In the world
JEC COMPOSITES MAGAZINE - Issue #83 - August/September 2013 - 83
JEC COMPOSITES MAGAZINE - Issue #83 - August/September 2013 - 84
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