New NASA workflow improves shock and vibration analysis to spot spacecraft weak points before launch

A new modeling workflow

Rockets flex and shake during ascent, while spacecraft carry sensitive scientific instruments. Engineers at NASA’s Launch Services Program Office at Kennedy Space Center in Florida developed a standardized workflow to evaluate how launch forces could affect that hardware.

The process uses a commercial software tool for finite element modeling. This technique divides a complex structure into smaller components so computers can estimate how it may respond to particular forces and launch conditions.

The template guides engineers through vibration profiles and shock conditions, replacing older tools and reducing the need to rebuild complex modeling workflows each time. The team said the method can also support more thorough assessments.

Testing a commercial rocket

The Dynamic Environments Group first used the software while certifying a commercial provider’s rocket selected for a NASA mission. The provider supplied vibration tests but not shock tests, and NASA engineers concluded shock testing was needed.

Using their template, the team compared possible scenarios, visualized structural behavior and examined questions that previously required extensive manual modeling. NASA verified the provider’s test results for flight environments, and the work offered new insight into shock during transport. Brian Beaver, chief of the Flight Analysis Division, said the computer-based approach can help reveal weak spots and potential failure risks before hardware is built.

Why early analysis matters

Rockets and spacecraft are built to withstand vibration and shock, but those forces can still cause wear or contribute to flight failures. Once a rocket has left the launch pad, many problems cannot be fixed, making early identification important.

For decades, engineers estimated these environments using rules of thumb or by scaling data from earlier missions. The method worked, but depended substantially on engineering judgment and simplified estimates of how equipment would behave once assembled and flown.

Alex Hardt, an aerospace engineer at Kennedy, said the team defines the severity of random vibration and shock levels, then checks whether rocket parts have been tested to those levels. He said the goal includes maximizing component longevity.

Faster, more consistent assessments

Dynamic environments engineers may use finite element modeling tools infrequently, which can mean relearning complicated processes. The new workflow is intended to help the team work more quickly and consistently.

Hardt said the models have provided valuable insight into verifying a provider’s system, including information that would normally take considerable effort to obtain. He also said visualizing complex dynamics can support learning and efficiency.

The workflow can help engineers share knowledge, improve assessments as more flight data becomes available and build skill with modeling tools. NASA said the capability has already saved months by allowing the team to conduct analysis independently rather than request and wait for reports.