navy lighterage replacement program
TRANSCRIPT
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Navy Lighterage Replacement ProgramNavy Lighterage Replacement Program
Lightweight Composite Lighter Module Prototype Development Program
Paul Coffin
NSWCCD Code 65539500 Macarthur Blvd
West Bethesda, MD 20817-5700301-227-5127
Deputy Program Manager: Dan McCluskeyNaval Facilities Engineering Command, (NAVFAC)
Project Manager: Himat GaralaCode 6551, NSWCCD
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Navy Lighterage Replacement ProgramNavy Lighterage Replacement Program
• The Naval Facilities Command (NAVFAC) Sealift Support Program Office is evaluating alternatives to improve the current lighterage system by
– Reducing platform weight– Increasing load carrying capacity– Increasing throughput requirements
• One option for achieving these goals is use lightweight composite 40’ x 24’ x 8’ modules. This effort is investigating that option.
• This, and other prototypes, will be compared by at sea testing.
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Navy Lighterage Replacement ProgramNavy Lighterage Replacement Program
Program Outline
• Program established to rapidly design and build a prototype– Establish loads– Concept development– Initial Design– Analysis– Prototype Contract– Fabricate Prototype– Test Prototype
• Activities– Naval Facilities Engineering Command (NAVFAC)………..Program Management– Naval Surface Warfare Center, Carderock Division (NSWCCD)……...Engineering– Northup Grumman Ship Systems..……………………………Prototype fabrication
All this to be completed in 18 months !
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Navy Lighterage Replacement ProgramNavy Lighterage Replacement Program
Loads Definition
• Survive Sea State 5 (SS5)• High deck loads
– Vehicle loads• RCHT Vehicle
– Tire patch 31”x31” with 81 kips, equivalent to 84 psi
– RORO Ramp– Weight of Ramp and 2 vehicles ~
700 kips– Ramp load distributed by dunnage– Load assumed to be reacted by one
module• Load only 11 psi
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Hydrodynamic Loads
• Sea State 5 Loads– Modeled using WAMIT code (Wave Analysis, MIT).– Loads depend on
• module assembly geometry• position of hinged joints• Wave height, frequency and direction
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Design
24’
40’
8’
• Ballasting requirements and damage stability necessitated internal bulkheads
• Many concepts considered, but schedule drove a conservative design
• Rough scantlings calculated based on first principals
• End connection attachment major challenge
ConceptsConcepts
Final DesignFinal Design
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Fabrication Concept
• If concept selected, possible purchase of large numbers of modules.– Fabrication process must be adaptable to large scale production.
• Prismatic shapes (pultrudable, continuous lamination,…)• Self aligning parts
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Analysis
• Models built in FEMAP and analyzed in NASTRAN.• Global modeling of seaway loads on worst case assemblies
– Longitudinal Vertical Bending– Lateral Bending– Torsional Bending– Wave Slap: 1500 psf – Vertical Bending w/ RTCH Loading– Buckling Analysis
• Global results generated boundary conditions for detailed analysis of joints.
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Analysis
• Longitudinal Vertical Bending with RTCH loads
Top deck y stresses x stressesHull bottom 1st buckling mode
Max stress 24 ksiFS Buckling 2.1
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Analysis
• Lateral Bending
Max stress 7 ksi
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Analysis
• Torsional Bending
• Wave Slap
Max stress 14 ksi
Max stress 5 ksi
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Detailed/Joint Analysis
• Loads from global analysis fed into subsection detailed analysis.
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Material Testing
• Rapid schedule required material testing to occur after most analysis and during the prototype fabrication
• Northrup Grumman fabricated 24 oz. woven roving/VE panels for evaluation– VARTM– Vacuum bagged hand layup– Hand layup
• Material tests (ASTM standard tests)– Volume fractions– Tension– Compression– Inplane shear (“V” notched specimen)– Short Beam Shear (Apparent Interlaminar Shear Strength)– Bolt Bearing
• Tests validated material property assumptions used in the design and analysis.• Specimens are being conditioned at 120F, 80% Rh, for follow on tests.
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Outfitting/Deck Jewelry
• Module decks are populated with a diverse array of fittings
– Tie downs– De-watering holes– Hatches– Lifting eyes– Post Bitts
• Deck Jewelry placement used to assist structural attachment
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Alignment Feature
• Modules must be joined together in up to Sea State 3 conditions.
• Relative motion of ends can make joining difficult.
• Alignment feature designed to bring ends in phase to assist joining.
• Feasibility demonstrated in wave tank testing at the US Naval Academy.
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Prototype Fabrication
Fabricated by Northup Grumman Ship Systems, Gulfport, MS.
Materials: 24 oz/yd2 E-glass woven roving/Vinylester Resin, 9 and 15 lb/ft3 balsa core.
Process: Combination VARTM and hand layup.
Fabricated by Northup Grumman Ship Systems, Gulfport, MS.
Materials: 24 oz/yd2 E-glass woven roving/Vinylester Resin, 9 and 15 lb/ft3 balsa core.
Process: Combination VARTM and hand layup.
Contract Awarded October 2001Picture taken January 2002
Contract Awarded October 2001Picture taken January 2002
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Prototype Connector Testing
Load Arm
Transition
End Connector
Section
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Contact Information
• Please direct any questions relating to the US Navy’s Lighter systems to:
Mr. Dan McCluskey
Sealift Support Program OfficeNaval Facilities Engineering Command, (NAVFAC)
Washington Navy Yard, Washington, D.C.202-685-6012