Conceptual Design and Analysis of a Multilobe Dome Propellant Tank

Abstract

This paper is intended for the design and analysis of a novel second-stage rocket propellant tank for the RFA Two vehicle. A multi-lobe dome design is finalized, which will be manufactured using the sheet metal hydroforming technique. The fundamental concepts of pressure vessel, balloon tank, different bulkhead shapes and finally hydroforming techniques are discussed in this report. Material selection of propellant tank and sizing of various primary components are performed. FEM tool is used to model and verify the structural integrity of structure after comparing with material allowables. Furthermore, the manufacturing methods for dome hydroforming and mass budget is discussed. Finally a 3D CAD model of the whole upper stage with primary load-carrying is presented.