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NATIONAL UNIVERSITY OF SCIENCES AND TECHNOLOGY (NUST)

School of Mechanical and Manufacturing Engineering (SMME)

Design and Analysis of Lunar Electric Rover


(Mechanics of Materials II Class Project – Fall 2019)
(Dr Aamir Mubashar and Dr Sana Waheed)
Submission Date: 16 Dec 2019

NASA is celebrating 50 years of human landing on moon. The exploration range on the moon
was greatly enhanced by using a rover for travel of astronauts on the moon surface. Since NASA
is planning to land humans on moon again in near future, development of new rover concepts
and technologies is an ongoing exercise. The Lunar Electric Rover (LER) is a conceptual lunar
rover that was developed by NASA’s Johnson Space Centre and showcased in 2010, as seen in
the following figure.

NASA’s Lunar Electric Rover (LER) vehicle (https://science.howstuffworks.com/lunar-


rover5.htm)

Problem Description
The LER is a modular vehicle where the two main structural modules include a pressurized
container mounted on a chassis. The main specifications of the LER are as follows;
Weight: 3000 kg
Payload: 1000 kg
Length: 4.5 m
Wheelbase: 4m
Height: 3m
Wheels: 12 x 99 cm in diameter, 30.5 cm wide

Mechanics of Materials II Class Project 1


NATIONAL UNIVERSITY OF SCIENCES AND TECHNOLOGY (NUST)
School of Mechanical and Manufacturing Engineering (SMME)

The main specifications of the chassis are as follows;


Weight: 1000 kg
Payload: 3000 kg
Length: 4.5 m
Wheelbase: 4m
Height: 1.3 m
Wheels: 12 x 99 cm in diameter, 30.5 cm wide

Safety of the astronauts is of prime concern in this design. The other important factor is the
weight of the LER. Your goal as design and analysis engineer is to ensure the safety of
astronauts while developing a vehicle of minimum weight. Use appropriate safety factors in your
design calculations and provide a justification. Perform the structural design and analysis of the
LER for the following conditions.
1. The pressurized cabin should provide atmospheric pressure to astronauts so they can
work without space suits. By choosing an appropriate material or combination of
materials, design the pressurized cabin so that it can sustain the moon environment.
Include mechanical as well as thermal stresses in your design. Structural members may
be used to stiffen the structure.
2. The pressurized cabin should be safe against buckling loads.
3. In case the LER is dropped to lunar surface using a parachute, check your design against
impact loading.
4. Design and analyze the chassis of the LER using standard beam sections. Calculate
stresses, draw bending moment and shear force diagrams and justify your selection of
cross-section. Determine torsional stresses in each member induced during movement
over an obstacle.
5. Assume an appropriate load cycle and calculate fatigue loading in the suspension links.
6. All calculations must be performed using at least three different materials and the best
design should be clearly mentioned at the end.
7. All strength calculations must be done using analytical methods. Use of finite element
method is not allowed.

Design Objective
The objective is to design LER with lowest possible weight and cost that is able to ensure safety
of astronauts. Structural integrity of the rover is of prime concern. Safe delivery of LER to lunar
surface must also be ensured.

Mechanics of Materials II Class Project 2


NATIONAL UNIVERSITY OF SCIENCES AND TECHNOLOGY (NUST)
School of Mechanical and Manufacturing Engineering (SMME)

Project Report Format


General Requirements
The project report should be clear and neat with correct grammar and spelling. Adequate margins
should be used. It should be concise and well-illustrated. Body text should be typed in 12 pt.
Times New Roman font. Use one side of 8.5 x 11or A4 size paper only. The report should be
assembled in the order of the sections given below, pages numbered and bound by a report cover.
Submit the report on or before the deadline.

Cover Sheet
The report must have a cover sheet with names of all group members.

Report Organisation
The report should have following elements:

1. Introduction
A section providing brief introduction to the design problem and explaining what is
covered in the following sections of the report.

2. Methods
This section summarizes in narrative form your design process: your plan or strategy,
approach to solving problems or overcoming obstacles, considerations to achieve
function as well as form, technical research done, engineering methods used, and
in particular, creative ideas and significant ideas discarded. It addresses key design
issues such as safety, standards, material selection, and environmental impact. Keep it
less than a page and tie it to other sections, Section 3 in particular.

3. Drawings, Parts List and Bill of Materials


These communicate and summarizes the design. Drawings must be to scale and must
include (a) rendering of your design (b) an isometric assembly view with components
called out and correlated by number or part name with the part list (c) details to clarify
components connections and joints and (d) any other details as necessary. Use
professional conventions. Include all dimensions. Don’t draw details of standard off-the-
shelf parts like nuts, bolts, rivets, washers, etc. Just specify the off-the-shelf parts in the
bill of material and call them out in the drawings. The bill of materials lists (a) structural
parts/sub-assemblies/assemblies and their material, sizes and amounts and (b) off-the-
shelf parts. It may include weight and cost or they can be given in a separate table.

4. Assumptions
Provide a list of numbered assumptions made during the design process and justify each
assumption. Cite the assumptions where used by number. Assumptions should be used
sparingly and when absolutely necessary for the design.

Mechanics of Materials II Class Project 3


NATIONAL UNIVERSITY OF SCIENCES AND TECHNOLOGY (NUST)
School of Mechanical and Manufacturing Engineering (SMME)

5. Data Section
This section provides a single place to put basic data that is applicable throughout the
report. It should include the following

a. Materials Data Table


Displays properties, their allowable values and sources. Below the table, provide
sample calculations for the allowable values

b. Loads Data
This includes loads that the structure must bear. If applicable, calculate dynamic load
factors.

c. Other Data
Any other data e.g. loads given in standards, etc.

6. Calculations
For each component, show its location within the structure and consider possible loading
scenarios, which may include but are not limited to the following;
a. Loading due to internal pressurization
b. Buckling of the module walls
c. Static loading on the module due to the payload
d. Impact loads upon landing
e. Fatigue analysis
f. Thermal loads
g. Loading due to acceleration/deceleration during take-off and re-entry
h. Stresses due to possible rotations of the spacecraft
Construct a model for each loading scenario. For each model, draw a free-body diagram
and do analysis. Then make a decision. The model displays either the component
removed from the structure or the structure itself, with boundary supports. Free-body
diagrams must be drawn even in simple circumstances. Analysis is used to determine
dimensions or check critical stresses and deformations. The decision sets final nominal
dimensions and other conclusions; if it is not obvious, give reasons for it. Sets of
calculations should follow a logical sequence. Avoid over-design. Seek a “tight” design
near the feasibility limit. Design formulas transformed from conventional analysis
formulas should be developed.
All design calculations should be done using MathCAD. MathCAD is an engineering
notebook software by PTC. A 30-day trial version of the software can be downloaded
from PTC website. Calculations can be copy / pasted from MathCAD worksheet in the
MS Word report.

Mechanics of Materials II Class Project 4


NATIONAL UNIVERSITY OF SCIENCES AND TECHNOLOGY (NUST)
School of Mechanical and Manufacturing Engineering (SMME)

7. References
This section provides a bibliography of books, papers, websites, etc. sources. Cite each
where used in the body of the report and list its details in this section. Use a “Numbered”
format. You are encouraged to use a citation software such as Mendeley or Zotero which
are freely available. A trial version of endnote can also be used for 30 days.

Example of book reference [1]:


1. Da Silva, L.F.M. and R.D.S.G. Campilho, Advances in Numerical Modelling of Adhesive
Joints. 2012: Springer.

Example of journal paper reference [2]

2. Mubashar, A., I.A. Ashcroft, and A.D. Crocombe, Modelling Damage and Failure in
Adhesive Joints Using A Combined XFEM-Cohesive Element Methodology. The Journal
of Adhesion, 2014. 90(8): p. 682-697.
8. Plagiarism Report
Attach plagiarism report obtained from “Turnitin” that can be accessed from your LMS
account. Overall match percentage should be less than 15% and matching percentage of a
single source should not be more than 5%. A project report without the plagiarism report
would not be considered.

Resources
Following may be useful during the analysis and design phase.
1. Mechanics of Materials by R. C. Hibbeler.
2. Roark's formulas for stress and strain by Warren C. Young & Richard G. Budynas
3. Peterson's stress concentration factors by Walter D. Pilkey & Deborah F. Pilkey
4. Formulas for stress, strain, and structural matrices by Walter D. Pilkey
5. ASM Handbook Vol 2 - Properties and selection: Nonferrous alloys and special purpose
materials
6. Materials selection in mechanical design by Michael F. Ashby
7. Metallic Materials and Elements for Aerospace Vehicle Structures MIL-HDBK-5J

Mechanics of Materials II Class Project 5


NATIONAL UNIVERSITY OF SCIENCES AND TECHNOLOGY (NUST)
School of Mechanical and Manufacturing Engineering (SMME)

Submission Requirement
Submit the following before the project end date:
1. Hardcopy of the project report prepared according to the requirements laid out in the
previous section. Turnitin report must be attached with the report.
2. Softcopy of the project report on LMS.
3. Turnitin report of the project on LMS.
4. MathCAD worksheet with all calculations on LMS.

Mechanics of Materials II Class Project 6

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