Marginal Stability Mounting Plate
Background
The mounting plate is located at the top of the internal structure, directly under the nose cone. It is the component that the main and drogue parachutes are attached to, and is therefore the primary chute load-bearing component. Like the nose cone ring, it needed to be lightweight, affordable, easy to manufacture, and easy to implement. Unlike the nose cone ring, the component already existed and did not have to be designed from scratch.
Design
The original design was a cross-shaped plate which bolted onto each of the structural C-channels. It had axially-oriented cutouts which would allow the parachute lines the be attached, and would no have any edges that were rounded or not right angles post-waterjet. Due to its thickness, my primary concern was the mass of the component. My next biggest concern was the huge reaction force on the face adjacent to the inside of the C-channels caused by the moment from the parachute. Finally, I was concerned that the current orientation of the cutouts would inhibit the parachute lines from freely rotating, and that the lines would be held in tension against a sharp edge. The first change I made was angling the face adjacent to the inside of the C-channels such that and rotation upward would not cause interference between the mounting plate and C-channel. Next, I rotated he cutouts to be oriented circumferentially and added fillets to the edges such that the parachute lines could rotate freely, eliminating the stress concentration caused by the sharp edge.
Analysis
The primary analysis done on the mounting plate was a static simulation. Like the nose cone ring, I added the structural C-channels as fixed, rigid bodies, and interfaced them with the mounting plate using pin connectors. I applied an upwards load on the mounting plate on the bottom face of each of the parachute mounting points. This was not the most accurate representation of the actual parachute load, which would be distributed over an area and at an angle; however, the perpendicular load case represents a more conservative estimate for the moments present in the component, which was of greatest interest. I iterated through analysis and redesign while decreasing geometries in the highest-FoS areas in order to minimize mass while maintaining a minimum FoS of 1.5.
Conclusions
Ultimately, I was able to reduce mass by around 50% while maintaining a minimum FoS of 1.5. I started drafting testing procedures and a PDR for this component, but this was cut short by the cancellation of Marginal Stability.
A Look Back
If I were to tackle the same design problem today with my more advanced skillset, I would consider a few more things:
Additional load cases
Dynamic response to parachute load, considering the response factor
Dynamic vibration loads from both the engine and aerodynamic effects
Buckling caused by potentially inward-facing reaction forces from parachute lines
Use of topology-optimizing software such as Altair Inspire to quickly determine a 2D geometry that would be mass-optimized for the parachute loads, while remaining possible to water jet