Shuttle solid rocket booster bolted field joint shape optimization

A structural optimization procedure is used to determine the shape of an alternate design for the Shuttle's solid rocket booster field joint. In contrast to the tang and clevis design of the existing joint, this design consists of two flanges bolted together. Configurations with 150 studs of l| in. diam and 135 studs of 1^ in. diam are considered. Using a nonlinear programming procedure, the joint weight is minimized under constraints on either von Mises or maximum normal stresses, joint opening, and geometry. The procedure solves the design problem by replacing it with a sequence of approximate (convex) subproblems; the pattern of contact between the joint halves is determined every few cycles by a nonlinear displacement analysis. The minimum weight design has 135 studs of 1 ^ in. diam and is designed under constraints on normal stresses. It weighs 1144 Ib per joint more than the current tang and clevis design.

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