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Mellis.matt
1.
2. Lessons from Columbia
Ballistic Impact Dynamics
Project Management Challenge 2009
Daytona Beach, Florida
Matt Melis
NASA Glenn Research Center
Cleveland Ohio
3. Contributions of Ballistic Impact Research in
The Columbia Accident Investigation
&
NASA’s Return to Flight
Project Management Challenge 2009
Daytona Beach, Florida
Matt Melis
NASA Glenn Research Center
Cleveland Ohio
11. On January 16 2003, Columbia’s leading edge
was impacted by a piece of foam suspected to
have separated from the external tank bipod
ramp at 81 seconds into its launch.
Columbia was traveling at Mach 2.46, at an
altitude of 65,860 feet. The foam was calculated
to have hit the Orbiter at 700 – 800 feet per
second
34. The NASA Impact Analysis Development Effort
With the Explicit Finite Element Code LS DYNA
Boeing, NASA GRC, JSC, LaRC
Extensive impact dynamics experience at Glenn & Langley
35. Impact Analysis Development Effort
For the Accident Investigation
• Demonstrate valid impact analysis capability with LS DYNA
• BX-250 External Tank foam characterization
• Reinforced Carbon-Carbon characterization
• Develop finite element mesh of panels and T-seals
43. Ballistic Research Supporting the Accident Investigation
BX-250 External Tank Foam Characterization
High Speed Video of 90
Degree Impacts
No Vacuum
708 ft/sec
Vacuum
693 ft/sec
44. Ballistic Research Supporting the Accident Investigation
LS DYNA - explicit finite element impact analysis
LS DYNA Predicts 90 Degree
Foam Impact on Load Cell
LS Dyna is an industry
standard commercial finite
element analysis code
typically used to model
impact events
45. Ballistic Research Supporting the Accident Investigation
LS DYNA - explicit finite element impact analysis
LS DYNA Predicts 23 Degree
Foam Impact on Load Cell
49. Ballistic Research Supporting the Accident Investigation
Ballistic Impact Tests on RCC Coupons
RCC Coupon Shows No Damage After 397 ft/sec Foam Impact
50. Ballistic Research Supporting the Accident Investigation
Ballistic Impact Tests on RCC Coupons
Foam Fractures RCC coupon in half at 695 ft/sec
51. Ballistic Research Supporting the Accident Investigation
Ballistic Impact Tests on RCC Coupons
700 ft/second Impact
400 ft/second Impact
53. Ballistic Research Supporting the Accident Investigation
Dyna - explicit finite element impact analysis
Full Scale Panel Analysis
54. Ballistic Research Supporting the Accident Investigation
Dyna - explicit finite element impact analysis
43,000 Panel Shell Elements
147,000 Foam Brick Elements
74. Impact Analysis Development Effort
For Return to Flight
• Full development of analysis capability with LS DYNA
• Additional foams, ice, ablator material characterization
• Begin advance RCC model development (coating)
75. Ballistic Impact Research Supporting Return to Flight
Impact Studies on RCC for Model Validation
2 grams foam 2 grams foam
2054 ft/sec 2054 ft/sec
8 grams ice 8 grams ice
650 ft/sec 650 ft/sec
76. Ballistic Impact Research Supporting Return to Flight
Impact Studies on RCC for Model Validation
2 grams foam 2 grams foam
2371 ft/sec 2371 ft/sec
8 grams ice 8 grams ice
858 ft/sec 858 ft/sec
79. Aramis Displacement Measurement System
Photogrametric Technique Determines Full 3-D displacements
Point Displacement vs Time Displacement Contour Plot
149. Additional Reading
- The Columbia Accident - The Challenger Launch
Investigation Board Decision
Final Report by Diane Vaughan
- To Engineer is Human
by Henry Petroski - Organization at the Limit
by William Starbuck and
Moshe Farjoun
- Lessons from Everest: The Interaction of Cognitive Bias,
Psychological Safety, and System Complexity by
Michael Roberto. Obtain from Harvard Bussiness Online