Analysis and Testing of a Launch-Vehicle-Like Composite Conical–Cylindrical Shell

Launch-vehicle shell structures, which can be composed of both cylindrical and conical sections, are known to be susceptible to buckling due to their large radius-to-thickness ratios. Advancements in composite manufacturing and numerical methods have enabled designers to consider more nontraditional shapes, such as connecting the conical and cylindrical sections with a toroidal transition to create a single-piece conical–cylindrical shell. This single-piece construction eliminates the need for a stiff, heavy interface ring between sections and has the potential to reduce mass. To better understand the buckling behavior of a composite conical–cylindrical shell, a laboratory-scale article was designed, fabricated, and tested. Before the test, a finite element model that included thickness variations and radial imperfections was created. The test article buckled elastically at 251.8 kN, approximately 8.8% higher than the predicted buckling load of 231.4 kN. Because the test article buckled elastically, the buckling test was repeated. The buckling load measured from the second test was within 1% of that from the first test. Continued research on conical–cylindrical structures has the potential to expand the design space for launch-vehicle structures and lead to improved designs and reduced mass.