SIST-TP CEN/TR 17603-32-22:2022

Space engineering - Insert design handbook

This handbook recommends engineering inserts and practices for European programs and projects. It may be cited in contracts and program documents as a reference for guidance to meet specific program/project needs.
The target users of this handbook are engineers involved in the design, analysis and verification of launchers and spacecraft in relation to insert usage. The current know‐how is documented in this handbook in order to make expertise to all European developers of space systems.
It is a guidelines document, therefore it includes advisory information rather than requirements.

Raumfahrttechnik - Handbuch zu Einsätzen

Ingénierie spatiale - Manuel de conception d’inserts

Vesoljska tehnika - Priročnik za oblikovanje vstavkov

Ta priročnik priporoča inženirske vstavke in prakse za evropske programe in projekte. Lahko se navaja v pogodbah in programskih dokumentih kot referenca za smernice glede izpolnjevanja posebnih potreb v okviru programa/projekta.
Ciljni uporabniki tega priročnika so inženirji, ki se ukvarjajo s projektiranjem, analiziranjem in preverjanjem lansirnikov ter vesoljskih plovil v povezavi z uporabo vstavkov. Ta priročnik dokumentira dosedanje strokovno znanje, da se dostop do njega omogoči vsem evropskim razvijalcem vesoljskih sistemov.
Ker gre za dokument s smernicami, ne podaja zahtev, temveč vsebuje informacije svetovalne narave.

General Information

• Status: Published
• Publication Date: 29-Jun-2022
• ICS: 49.140 - Space systems and operations
• Technical Committee: I13 - Imaginarni 13
• Current Stage: 6060 - National Implementation/Publication (Adopted Project)
• Start Date: 20-Jun-2022
• Due Date: 25-Aug-2022
• Completion Date: 30-Jun-2022
• Mandate: M/496 - Mandate addressed to CEN, CENELEC and ETSI to develop standardisation regarding space industry (Phase 3 of the process)
• Ref Project: CEN/TR 17603-32-22:2022 - Space engineering - Insert design handbook

Standards Content (Sample)

SLOVENSKI STANDARD
SIST-TP CEN/TR 17603-32-22:2022
01-september-2022
Vesoljska tehnika - Priročnik za oblikovanje vstavkov
Space engineering - Insert design handbook
Raumfahrttechnik - Handbuch zu Einsätzen
Ingénierie spatiale - Manuel de conception d’inserts
Ta slovenski standard je istoveten z: CEN/TR 17603-32-22:2022
ICS:
49.140 Vesoljski sistemi in operacije Space systems and
operations
SIST-TP CEN/TR 17603-32-22:2022 en,fr,de
2003-01.Slovenski inštitut za standardizacijo. Razmnoževanje celote ali delov tega standarda ni dovoljeno.

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SIST-TP CEN/TR 17603-32-22:2022


TECHNICAL REPORT CEN/TR 17603-32-22

RAPPORT TECHNIQUE

TECHNISCHER BERICHT
June 2022
ICS 49.030.99; 49.140

English version

Space engineering - Insert design handbook
Ingénierie spatiale - Manuel de conception d'inserts Raumfahrttechnik - Handbuch zu Einsätzen


This Technical Report was approved by CEN on 17 May 2022. It has been drawn up by the Technical Committee CEN/CLC/JTC 5.

CEN and CENELEC members are the national standards bodies and national electrotechnical committees of Austria, Belgium,
Bulgaria, Croatia, Cyprus, Czech Republic, Denmark, Estonia, Finland, France, Germany, Greece, Hungary, Iceland, Ireland, Italy,
Latvia, Lithuania, Luxembourg, Malta, Netherlands, Norway, Poland, Portugal, Republic of North Macedonia, Romania, Serbia,
Slovakia, Slovenia, Spain, Sweden, Switzerland, Turkey and United Kingdom.
























CEN-CENELEC Management Centre:
Rue de la Science 23, B-1040 Brussels
© 2022 CEN/CENELEC All rights of exploitation in any form and by any means
Ref. No. CEN/TR 17603-32-22:2022 E
reserved worldwide for CEN national Members and for
CENELEC Members.

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Table of contents
European Foreword . 27
1 Scope . 28
2 References . 29
3 Terms, definitions and abbreviated terms . 30
4 Insert system . 67
4.1 Insert systems and components . 67
4.1.1 Inserts . 67
4.1.2 Insert system components . 69
4.1.3 Loading modes . 70
5 Insert . 71
5.1 General . 71
5.2 Types. 71
5.2.1 General . 71
5.2.2 Group A . 71
5.2.3 Group B . 73
5.2.4 Group C . 73
5.2.5 Potting methods . 74
5.2.6 Injection . 74
5.3 Sizes. 75
5.3.1 General . 75
5.3.2 Standards . 75
5.3.3 Strength . 76
5.3.4 Standardised diameters . 77
5.3.5 Standardised heights . 78
5.4 Materials . 79
5.4.1 General . 79
5.4.2 Aluminium alloys . 80
5.4.3 Titanium alloys . 80
5.4.4 Steels . 81
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5.4.5 Material selection . 81
5.5 Surface protection. 81
5.5.1 General . 81
5.5.2 Aluminium alloy . 82
5.6 References . 83
5.6.1 General . 83
5.6.2 ECSS standards . 83
6 Sandwich panels . 84
6.1 Sandwich properties . 84
6.1.1 Insert load-bearing capability . 84
6.1.2 Sandwich dimensions . 85
6.2 Face sheet properties . 85
6.2.1 Tensile and compressive loading . 85
6.2.2 Shear loading . 87
6.2.3 Other loads . 89
6.3 Core properties . 90
6.3.1 Types of cores . 90
6.3.2 Hexagonal core . 90
6.4 Core shear modulus . 94
6.4.1 Data sources . 94
6.5 Core shear strength . 94
6.5.1 Data sources . 95
6.6 Core tensile strength . 95
6.6.1 Data sources . 95
6.6.2 Aluminium core . 95
6.6.3 Non-metallic cores . 95
6.7 Core compressive strength . 96
6.8 Core to face sheet bond . 96
6.9 References . 96
7 Embedding of inserts . 97
7.1 Potting compounds . 97
7.1.1 Commercial products . 97
7.1.2 Modification of properties . 99
7.2 Potting and equivalent dimensions . 99
7.2.1 Insert load capability . 99
7.2.2 Increasing insert tensile capability . 101
7.3 Effective potting radius, or equivalent dimension . 101
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7.3.1 Minimum value . 102
7.3.2 Average value . 102
7.3.3 Relationship of minimum and average values . 103
7.4 Real potting radius, or equivalent dimension . 104
7.4.1 Minimum value . 104
7.4.2 Average value . 104
7.4.3 Relationship between minimum and average values . 104
7.5 Potting height . 105
7.5.1 Full potting . 105
7.5.2 Partial potting . 106
7.5.3 Minimum value . 106
7.5.4 Average value . 106
7.5.5 Relationship of minimum and average values . 106
7.6 Potting mass . 108
7.6.1 Effect of core and insert characteristics . 108
7.6.2 Total mass of insert system . 110
7.7 References . 110
7.7.1 General . 110
7.7.2 ECSS standards . 110
8 Mechanics of sandwich structures . 111
8.1 Structural sandwich concept . 111
8.1.1 Properties of constituent materials . 112
8.1.2 Fundamentals of classical ‘antiplane’ sandwich theory . 113
8.2 Structural failure modes . 116
8.2.1 Global failure modes . 117
8.2.2 Local failure modes . 118
8.3 Load introduction aspects and discontinuities . 118
8.3.1 General . 118
8.3.2 Local bending response . 119
8.3.3 Antiplane-type theory . 120
8.3.4 Finite element analysis . 120
8.3.5 Elastic foundation model . 120
8.3.6 Transverse flexibility . 120
8.3.7 Higher-order sandwich beam theory . 120
8.4 Sandwich plates with potted inserts . 121
8.4.1 Classification of potted insert types . 121
8.4.2 Load transfer . 122
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8.4.3 External load cases . 122
8.4.4 Example . 124
8.4.5 Purpose of the potting compound . 129
8.4.6 Design guidelines . 129
8.5 Remarks . 130
8.5.1 General . 130
8.5.2 Antiplane theories . 130
8.5.3 Higher-order theories . 131
®
8.5.4 ESAComp . 131
8.6 References . 132
8.6.1 General . 132
8.6.2 ECSS standards . 134
9 Design aspects . 135
9.1 Design parameters . 135
9.1.1 Metal face sheets . 137
9.1.2 Composite face sheets . 137
9.2 Main load directions . 138
9.2.1 Out-of-plane load . 138
9.2.2 In-plane load . 139
9.3 References . 139
9.3.1 General . 139
9.3.2 ECSS standards . 139
10 Design considerations . 140
10.1 Insert arrangement . 140
10.1.1 Load capability . 141
10.2 Load conditions . 142
10.2.1 General . 142
10.2.2 Design guide . 144
10.3 Mounting modes . 148
10.3.1 General . 148
10.3.2 Flush-mounted insert . 148
10.3.3 Recessed insert . 148
10.3.4 Protruding insert . 149
10.3.5 Bonded flange . 150
10.4 Junction of components . 150
10.4.1 General . 150
10.4.2 Minimum value . 151
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10.5 Adequate insert design . 152
10.5.1 Insert arrangement . 152
10.5.2 Typical spacecraft design . 152
10.5.3 Examples . 153
10.6 Selection of inserts . 153
10.6.1 General . 153
10.6.2 Sufficient static strength . 154
10.6.3 Safety factor . 155
10.7 Minimum and average insert capability . 155
10.7.1 Minimum . 155
10.7.2 Average . 156
10.8 Pre-design . 156
10.8.1 Load path for in-plane forces . 157
10.8.2 Load path for transverse forces . 159
10.8.3 Transverse and in-plane load interaction . 160
10.8.4 Proximity and edge effects . 160
10.9 Failure modes . 160
10.9.1 General . 160
10.9.2 Failures under out-of-plane loads . 161
10.9.3 Failures under in-plane loads . 166
10.10 References . 168
10.10.1 General . 168
11 Design flow chart . 169
11.1 Introduction . 169
11.2 Flow chart: Predefined sandwich and loads . 169
11.3 Flow chart: Variable main parameters . 171
11.4 References . 172
11.4.1 General . 172
12 Tensile strength . 173
12.1 Normal tensile load . 173
12.1.1 General . 173
12.1.2 Failure modes . 173
12.1.3 Shear rupture: core surrounding the potting . 174
12.1.4 Tensile rupture: core underneath the potting . 175
12.1.5 Tensile rupture: potting underneath the insert . 176
12.2 Basic parameters . 176
12.2.1 Out-of-plane loads: Insert strength . 179
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12.3 Minimum and average design values . 181
12.3.1 Overview . 181
12.3.2 Minimum insert design values . 181
12.3.3 Average insert values . 182
12.4 Safety factors . 183
12.4.1 Load capability . 183
12.4.2 Failure modes . 184
12.5 Permissible tensile loads . 184
12.5.1 General . 184
12.5.2 Insert capability graphs . 184
12.5.3 Design values . 184
12.6 Influence of insert height . 185
12.6.1 Insert capability graphs . 185
12.6.2 Different insert heights . 185
12.7 Composite face sheet . 187
12.7.1 Effect of anisotropy . 187
12.7.2 Loading by moments . 187
12.8 References . 187
12.8.1 General . 187
13 Compressive strength . 188
13.1 Normal compressive load . 188
13.1.1 General . 188
13.1.2 Partially-potted inserts . 188
13.1.3 Potting strength . 188
13.1.4 Increased face sheet thickness . 188
13.1.5 Insert capabilities . 189
13.2 Permissible compressive loads . 189
13.2.1 Graphs of permissible static insert loads . 189
13.3 Composite face sheet . 189
14 Shear strength . 191
14.1 Shear (in-plane) load . 191
14.1.1 Effect of in-plane load . 191
14.1.2 Effect of face sheet material . 192
14.1.3 Effect of partial clamping . 192
14.2 Permissible shear load . 192
14.3 Composite face sheet . 193
14.3.1 Strength . 193
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14.3.2 Face sheets . 196
14.3.3 CFRP face sheets . 196
14.3.4 Effect of panel layout . 201
14.3.5 Sensitivity of insert strength in face sheets . 202
14.3.6 Effect of thin CFRP face sheet . 203
14.4 References . 204
14.4.1 General . 204
15 Bending strength . 205
15.1 Bending load . 205
15.2 Permissible bending load . 206
15.3 Composite face sheet . 207
15.4 References . 208
15.4.1 General . 208
16 Torsional strength . 209
16.1 Torsional load . 209
16.2 Permissible torsion load . 209
16.2.1 General . 209
16.2.2 Metallic core . 209
16.2.3 Non-metallic core .
...