FEAT/Rail Button Bending Moments

CHANGELOG.md

@@ -31,6 +31,7 @@ and this project adheres to [Semantic Versioning](http://semver.org/).
 Attention: The newest changes should be on top -->
 
 ### Added
+- ENH: Rail button bending moments calculation in Flight class [#893](https://github.com/RocketPy-Team/RocketPy/pull/893)
 - ENH: Built-in flight comparison tool (`FlightComparator`) to validate simulations against external data [#888](https://github.com/RocketPy-Team/RocketPy/pull/888)
 - ENH: Add persistent caching for ThrustCurve API [#881](https://github.com/RocketPy-Team/RocketPy/pull/881)
 - ENH: Compatibility with MERRA-2 atmosphere reanalysis files [#825](https://github.com/RocketPy-Team/RocketPy/pull/825)

docs/user/flight.rst

@@ -266,6 +266,39 @@ The Flight object provides access to all forces and accelerations acting on the
     M2 = flight.M2                   # Pitch moment
     M3 = flight.M3                   # Yaw moment
 
+Rail Button Forces and Bending Moments
+~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~
+
+During the rail launch phase, RocketPy calculates reaction forces and internal bending moments at the rail button attachment points:
+
+**Rail Button Forces (N):**
+
+- ``rail_button1_normal_force`` : Normal reaction force at upper rail button
+- ``rail_button1_shear_force`` : Shear (tangential) reaction force at upper rail button  
+- ``rail_button2_normal_force`` : Normal reaction force at lower rail button
+- ``rail_button2_shear_force`` : Shear (tangential) reaction force at lower rail button
+
+**Rail Button Bending Moments (N⋅m):**
+
+- ``rail_button1_bending_moment`` : Time-dependent bending moment at upper rail button attachment
+- ``max_rail_button1_bending_moment`` : Maximum absolute bending moment at upper rail button
+- ``rail_button2_bending_moment`` : Time-dependent bending moment at lower rail button attachment  
+- ``max_rail_button2_bending_moment`` : Maximum absolute bending moment at lower rail button
+
+**Calculation Method:**
+
+Bending moments are calculated using beam theory assuming simple supports (rail buttons provide reaction forces but no moment reaction at rail contact). The total moment combines:
+
+1. Shear force × button height (cantilever moment from button standoff)
+2. Normal force × distance to center of dry mass (lever arm effect)
+
+Moments are zero after rail departure and represent internal structural loads for airframe and fastener stress analysis. Requires ``button_height`` to be defined when adding rail buttons via ``rocket.set_rail_buttons()``.
+
+.. note::
+   See Issue #893 for implementation details and validation approach.
+
+
+
 Attitude and Orientation
 ~~~~~~~~~~~~~~~~~~~~~~~~
 

rocketpy/plots/flight_plots.py

@@ -395,6 +395,70 @@ def angular_kinematics_data(self, *, filename=None):  # pylint: disable=too-many
         plt.subplots_adjust(hspace=0.5)
         show_or_save_plot(filename)
 
+    def rail_buttons_bending_moments(self, *, filename=None):
+        """Prints out Rail Buttons Bending Moments graphs.
+
+        Parameters
+        ----------
+        filename : str | None, optional
+            The path the plot should be saved to. By default None, in which case
+            the plot will be shown instead of saved. Supported file endings are:
+            eps, jpg, jpeg, pdf, pgf, png, ps, raw, rgba, svg, svgz, tif, tiff
+            and webp (these are the formats supported by matplotlib).
+
+        Returns
+        -------
+        None
+        """
+        if len(self.flight.rocket.rail_buttons) == 0:
+            print(
+                "No rail buttons were defined. Skipping rail button bending moment plots."
+            )
+        elif self.flight.out_of_rail_time_index == 0:
+            print("No rail phase was found. Skipping rail button bending moment plots.")
+        else:
+            # Check if button_height is defined
+            rail_buttons_tuple = self.flight.rocket.rail_buttons[0]
+            if rail_buttons_tuple.component.button_height is None:
+                print("Rail button height not defined. Skipping bending moment plots.")
+            else:
+                plt.figure(figsize=(9, 3))
+
+                ax1 = plt.subplot(111)
+                ax1.plot(
+                    self.flight.rail_button1_bending_moment[
+                        : self.flight.out_of_rail_time_index, 0
+                    ],
+                    self.flight.rail_button1_bending_moment[
+                        : self.flight.out_of_rail_time_index, 1
+                    ],
+                    label="Upper Rail Button",
+                )
+                ax1.plot(
+                    self.flight.rail_button2_bending_moment[
+                        : self.flight.out_of_rail_time_index, 0
+                    ],
+                    self.flight.rail_button2_bending_moment[
+                        : self.flight.out_of_rail_time_index, 1
+                    ],
+                    label="Lower Rail Button",
+                )
+                ax1.set_xlim(
+                    0,
+                    (
+                        self.flight.out_of_rail_time
+                        if self.flight.out_of_rail_time > 0
+                        else self.flight.tFinal
+                    ),
+                )
+                ax1.legend()
+                ax1.grid(True)
+                ax1.set_xlabel("Time (s)")
+                ax1.set_ylabel("Bending Moment (N·m)")
+                ax1.set_title("Rail Button Bending Moments")
+
+                show_or_save_plot(filename)
+
     def rail_buttons_forces(self, *, filename=None):  # pylint: disable=too-many-statements
         """Prints out all Rail Buttons Forces graphs available about the Flight.
 
@@ -959,6 +1023,9 @@ def all(self):  # pylint: disable=too-many-statements
         print("\n\nAerodynamic Forces Plots\n")
         self.aerodynamic_forces()
 
+        print("\n\nRail Buttons Bending Moments Plots\n")
+        self.rail_buttons_bending_moments()
+
         print("\n\nRail Buttons Forces Plots\n")
         self.rail_buttons_forces()
 

rocketpy/prints/flight_prints.py

@@ -358,6 +358,34 @@ def maximum_values(self):
                 f"{self.flight.max_rail_button2_shear_force:.3f} N"
             )
 
+    def rail_button_bending_moments(self):
+        """Prints rail button bending moment data.
+
+        Returns
+        -------
+        None
+        """
+        if (
+            len(self.flight.rocket.rail_buttons) == 0
+            or self.flight.out_of_rail_time_index == 0
+        ):
+            return
+
+        # Check if button_height is defined
+        rail_buttons_tuple = self.flight.rocket.rail_buttons[0]
+        if rail_buttons_tuple.component.button_height is None:
+            return
+
+        print("\nRail Button Bending Moments\n")
+        print(
+            "Maximum Upper Rail Button Bending Moment: "
+            f"{self.flight.max_rail_button1_bending_moment:.3f} N·m"
+        )
+        print(
+            "Maximum Lower Rail Button Bending Moment: "
+            f"{self.flight.max_rail_button2_bending_moment:.3f} N·m"
+        )
+
     def stability_margin(self):
         """Prints out the stability margins of the flight at different times.
 
@@ -429,5 +457,8 @@ def all(self):
         self.maximum_values()
         print()
 
+        self.rail_button_bending_moments()
+        print()
+
         self.numerical_integration_settings()
         print()

rocketpy/rocket/aero_surface/rail_buttons.py

@@ -19,12 +19,19 @@ class RailButtons(AeroSurface):
         relative to one of the other principal axis.
     RailButtons.angular_position_rad : float
         Angular position of the rail buttons in radians.
+    RailButtons.button_height : float, optional
+        Height (standoff distance) of the rail button from the rocket
+        body surface to the rail contact point, in meters. Used for
+        calculating bending moments at the attachment point.
+        Default is None. If not provided, bending moments cannot be
+        calculated but flight dynamics remain unaffected.
     """
 
     def __init__(
         self,
         buttons_distance,
         angular_position=45,
+        button_height=None,
         name="Rail Buttons",
         rocket_radius=None,
     ):
@@ -48,6 +55,7 @@ def __init__(
         super().__init__(name, None, None)
         self.buttons_distance = buttons_distance
         self.angular_position = angular_position
+        self.button_height = button_height
         self.name = name
         self.rocket_radius = rocket_radius
         self.evaluate_lift_coefficient()
@@ -104,6 +112,7 @@ def to_dict(self, **kwargs):  # pylint: disable=unused-argument
         return {
             "buttons_distance": self.buttons_distance,
             "angular_position": self.angular_position,
+            "button_height": self.button_height,
             "name": self.name,
             "rocket_radius": self.rocket_radius,
         }
@@ -113,6 +122,7 @@ def from_dict(cls, data):
         return cls(
             data["buttons_distance"],
             data["angular_position"],
+            data.get("button_height", None),
             data["name"],
             data["rocket_radius"],
         )

rocketpy/simulation/flight.py

@@ -470,6 +470,18 @@ class Flight:
         array.
     Flight.simulation_mode : str
         Simulation mode for the flight. Can be "6 DOF" or "3 DOF".
+    Flight.rail_button1_bending_moment : Function
+        Internal bending moment at upper rail button attachment point in N·m
+        as a function of time. Calculated using beam theory during rail phase.
+    Flight.max_rail_button1_bending_moment : float
+        Maximum internal bending moment experienced at upper rail button
+        attachment point during rail flight phase in N·m.
+    Flight.rail_button2_bending_moment : Function
+        Internal bending moment at lower rail button attachment point in N·m
+        as a function of time. Calculated using beam theory during rail phase.
+    Flight.max_rail_button2_bending_moment : float
+        Maximum internal bending moment experienced at lower rail button
+        attachment point during rail flight phase in N·m.
     """
 
     def __init__(  # pylint: disable=too-many-arguments,too-many-statements
@@ -3958,3 +3970,142 @@ def __lt__(self, other):
                     otherwise.
                 """
                 return self.t < other.t
+
+    @cached_property
+    def calculate_rail_button_bending_moments(self):
+        """
+          Calculate internal bending moments at rail button attachment points.
+
+          Uses beam theory to determine internal structural moments for stress
+          analysis of the rail button attachments (fasteners and airframe).
+
+          The bending moment at each button attachment consists of:
+          1. Bending from shear force at button contact point: M = S × h
+          where S is the shear (tangential) force and h is button height
+          2. Direct moment contribution from the button's reaction forces
+
+          Assumptions
+          -----------
+          - Rail buttons act as simple supports: provide reaction forces (normal
+        and shear) but no moment reaction at the rail contact point.
+          - The rocket acts as a beam supported at two points (rail buttons).
+          - Bending moments arise from the lever arm effect of reaction forces
+          and the cantilever moment from button standoff height.
+
+          The bending moment at each button attachment consists of:
+          1. Normal force moment: M = N x d, where N is normal reaction force
+         and d is distance from button to center of dry mass
+          2. Shear force cantilever moment: M = S x h, where S is shear force
+         and h is button standoff height
+
+          Notes
+          -----
+          - Calculated only during the rail phase of flight
+          - Maximum values use absolute values for worst-case stress analysis
+          - The bending moments represent internal stresses in the rocket
+          airframe at the rail button attachment points
+
+          Returns
+          -------
+          tuple
+              (rail_button1_bending_moment : Function,
+              max_rail_button1_bending_moment : float,
+              rail_button2_bending_moment : Function,
+              max_rail_button2_bending_moment : float)
+
+              Where rail_button1/2_bending_moment are Function objects of time
+              in N·m, and max values are floats in N·m.
+        """
+        # Check if rail buttons exist
+        null_moment = Function(0)
+        if len(self.rocket.rail_buttons) == 0:
+            warnings.warn(
+                "Trying to calculate rail button bending moments without "
+                "rail buttons defined. Setting moments to zero.",
+                UserWarning,
+            )
+            return (null_moment, 0.0, null_moment, 0.0)
+
+        # Get rail button geometry
+        rail_buttons_tuple = self.rocket.rail_buttons[0]
+        # Rail button standoff height
+        h_button = rail_buttons_tuple.component.button_height
+        if h_button is None:
+            warnings.warn(
+                "Rail button height not defined. Bending moments cannot be "
+                "calculated. Setting moments to zero.",
+                UserWarning,
+            )
+            return (null_moment, 0.0, null_moment, 0.0)
+        upper_button_position = (
+            rail_buttons_tuple.component.buttons_distance
+            + rail_buttons_tuple.position.z
+        )
+        lower_button_position = rail_buttons_tuple.position.z
+
+        # Get center of dry mass (handle both callable and property)
+        if callable(self.rocket.center_of_dry_mass_position):
+            cdm = self.rocket.center_of_dry_mass_position(self.rocket._csys)
+        else:
+            cdm = self.rocket.center_of_dry_mass_position
+
+        # Distances from buttons to center of dry mass
+        d1 = abs(upper_button_position - cdm)
+        d2 = abs(lower_button_position - cdm)
+
+        # forces
+        N1 = self.rail_button1_normal_force
+        N2 = self.rail_button2_normal_force
+        S1 = self.rail_button1_shear_force
+        S2 = self.rail_button2_shear_force
+        t = N1.source[:, 0]
+
+        # Calculate bending moments at attachment points
+        # Primary contribution from shear force acting at button height
+        # Secondary contribution from normal force creating moment about attachment
+        m1_values = N2.source[:, 1] * d2 + S1.source[:, 1] * h_button
+        m2_values = N1.source[:, 1] * d1 + S2.source[:, 1] * h_button
+
+        rail_button1_bending_moment = Function(
+            np.column_stack([t, m1_values]),
+            inputs="Time (s)",
+            outputs="Bending Moment (N·m)",
+            interpolation="linear",
+        )
+        rail_button2_bending_moment = Function(
+            np.column_stack([t, m2_values]),
+            inputs="Time (s)",
+            outputs="Bending Moment (N·m)",
+            interpolation="linear",
+        )
+
+        # Maximum bending moments (absolute value for stress calculations)
+        max_rail_button1_bending_moment = float(np.max(np.abs(m1_values)))
+        max_rail_button2_bending_moment = float(np.max(np.abs(m2_values)))
+
+        return (
+            rail_button1_bending_moment,
+            max_rail_button1_bending_moment,
+            rail_button2_bending_moment,
+            max_rail_button2_bending_moment,
+        )
+
+    @property
+    def rail_button1_bending_moment(self):
+        """Upper rail button bending moment as a Function of time."""
+        return self.calculate_rail_button_bending_moments[0]
+
+    @property
+    def max_rail_button1_bending_moment(self):
+        """Maximum upper rail button bending moment, in N·m."""
+        return self.calculate_rail_button_bending_moments[1]
+
+    @property
+    def rail_button2_bending_moment(self):
+        """Lower rail button bending moment as a Function of time."""
+        return self.calculate_rail_button_bending_moments[2]
+
+    @property
+    def max_rail_button2_bending_moment(self):
+        """Maximum lower rail button bending moment, in N·m."""
+        return self.calculate_rail_button_bending_moments[3]