How NASA Uses Finite Element Analysis to Predict Rocket Vibration and Shock

Rockets vibrate, shake and bend violently as they ascend into space. Spacecraft carrying sensitive scientific equipment must withstand these forces, so NASA engineers are developing better ways to predict how launch stresses will affect every part of a vehicle before liftoff.

NASA Improves Rocket Shock and Vibration Analysis

Engineers in the Dynamic Environment Group at NASA’s Launch Services Program Office at Kennedy Space Center in Florida have streamlined the process for evaluating how spacecraft and rockets respond to severe vibrations, shocks, stresses and other physical forces. The work is designed to improve mission safety and hardware reliability.

Using commercially available digital software tools in new ways, the engineers developed a standardized finite element modeling workflow. The process strengthens shock and vibration analysis and helps ensure spacecraft hardware is prepared for the extreme environments of launch and ascent.

“This computer-based method helps predict how rockets and spacecraft will perform under extreme conditions before the hardware is built, helping to identify weaknesses and potential failure risks early so teams can address their consequences,” said Brian Beaver, chief of flight analysis at NASA’s Kennedy Launch Services Program Office.

Modeling Helps NASA Identify Launch Risks Earlier

The team recently used the software for the first time while certifying a commercial launch provider’s rocket selected for a NASA mission. The commercial partner supplied vibration testing but not shock testing.

The Dynamic Environment Group determined that impact testing was necessary. Using templates developed by the team, engineers compared different scenarios, visualized structural behavior and answered complex questions that previously would have required extensive manual modeling.

The team also reviewed the company’s test results for the flight environment. Its analysis provided new insights into how to address shock during transportation.

“We’re using tools that have been around for decades, but they aren’t typically used in the dynamic environment field,” said Alex Hardt, an aerospace engineer with NASA Kennedy’s Launch Services Program Office. “But we’re changing that. We’re using it in a relatively new area of dynamics.”

Why Rocket Vibration and Shock Testing Matter

Rockets and spacecraft are designed to absorb shock and vibration, but these forces can cause wear and tear and potentially lead to flight failure, particularly during launch and ascent.

“We define how severe random vibration and shock levels are and ensure that all parts used in future rockets are tested at those levels to maximize longevity,” Hurd said.

For decades, engineers estimated shock and vibration environments using rules of thumb and by scaling previous data. These methods helped predict how rocket components and spacecraft instruments would respond after assembly and during flight, but they relied heavily on engineering judgment and approximations based on earlier missions.

How Finite Element Modeling Supports Spacecraft Design

Many dynamic environment engineers do not regularly use finite element modeling tools and may have to relearn complex workflows. NASA’s new software process replaces older tools with standardized templates that guide engineers through vibration profiles and impact conditions more quickly and thoroughly.

Finite element analysis is a powerful simulation technique that divides complex structures into smaller components. Computers can then use those components to predict how rockets and spacecraft will respond to specific forces and launch environments.

This capability is important because engineers can address problems on the ground. Early identification is essential, since most issues cannot be repaired or corrected once a rocket has left the launch pad.

“We used this to very quickly gain invaluable insight into validating the provider’s systems,” Hart said. “We’re already getting pretty deep insights into things that normally require a lot of effort.”

NASA Workflow Saves Time and Improves Collaboration

Hardt said the ability to visualize nonintuitive mechanics problems with finite element models demonstrates the software’s value for learning, efficiency and NASA’s people-focused culture.

The standardized workflow helps engineers share knowledge, refine evaluations with additional flight data and improve their proficiency with modeling tools. It has already saved teams months by enabling them to conduct analyses independently instead of requesting and waiting for analysis reports and data.

The approach also helps engineers identify risks that may not previously have been considered.

Supporting NASA Missions From Earth Observation to Mars

NASA’s Launch Services Program Office is responsible for launching rockets that carry spacecraft to observe Earth, visit other planets and explore space. Its missions include weather satellites, space telescopes and Mars rovers.

The team continues to introduce new tools and processes, including advanced finite element modeling for shock and vibration analysis, to maximize the chance of success for every mission.