Project M.E.T.E.O.R. P07109: Flying Rocket Team Andrew Scarlata,
Geoff Cassell, Zack Mott, Garett Pickett, Brian Whitbeck, Luke
Cadin, David Hall Slide 2 Inner and Outer Shell ANSYS Stress
Modeling ( Chalice Design) HTPB Fuel Grain Nitrous Oxide Tank
Pre-Combustion Chamber Post-Combustion Chamber Graphite Nozzle
Electronics Payload Composite-Honeycomb End Cap Composite Outer
Shell Micro IMU (Inertial Measurement Unit) Slide 3 Inner and Outer
Shell ANSYS Stress Modeling ( Embedded Design) Combustion Chamber
Inside Nitrous Oxide Tank Titanium Inner Shell 2x Outer Ring 2x
Aluminum End Cap Composite Outer Shell (Aluminum Inner Reinforced)
Siphon Tube Slide 4 Customer Specifications Spec. Number Design
SpecificationImportanceUnits Expected Value Current Value
1Containment of Nitrous Oxide5psi750-10001000 2Safety5P/FPP
3Operate within Material Temperature Range5K4700?TBD 4Max Allowable
Acceleration (with respect to design)4G10-50TBD 5 Nozzle Stress
Testing (to determine if the graphite will rip away from
body)5psiTBD 6Cost1USD10000TBD 7Structure to propellant ratio4
2:101:2 8Manufacturing feasibility4P/FPP 9Reliable Ignition
Method2s3-5 10Tank Pressure Regulation4psi750TBD 11Satellite
Implementation (diameter of top of rocket)1cm1018 + 12Accommodating
thrust vectoring equipment3P/FPTBD Slide 5 Bill of Materials Slide
6 Mass Budget Chalice ConceptEmbedded Concept: Electronics/Guidance
System: 1kgSiphon Tube: 0.03kg Composite Body: 0.85kgInner
Shell:.56kg Pre & Post Combustion Chambers: 0.15kg eachOuter
Shell: 1.64kg Injector Plate: 0.31kgOuter Bands: 0.11kg each Exit
Nozzle: 0.71kg Pre & Post Combustion Chambers: 0.15kg each
Pressure Vessel: 0.6-1.3kgInjector Plate: 0.31kg Aluminium Shell:
0.76kgExit Nozzle: 0.71kg Electronics/Guidance System: 1kg Total:
3.8 4.5kg End Caps: 0.52kg each Total: 5.9kg Slide 7 Identified
Company (CompositeX) to manufacture Custom Composite Pressure
Vessel Working pressure 1000psi Holds 8 kg Nitrous Oxide 700 cubic
inch volume HDPE lined 1.4 lbs Composite Pressure Vessel (Chalice
Concept) Liquid Nitrous Oxide Nitrous Oxide Vapor Slide 8 Composite
Pressure Vessel (Chalice Concept) Helium Gas Liquid Nitrous Oxide
Slide 9 Composite Pressure Vessel (Chalice Concept) Ideal gas law
used to model helium pressure p=m*R*T/V Verified from pressure/
temperature data that Helium will remain gaseous Compressibility
factor ~1, so ideal gas assumption valid Tank weights listed
estimated from quote of 700ci=1.4 lbs Also includes weight of
Helium (case dependent) Slide 10 Aluminum/Titanium Comparison Slide
11 Mass Calculation Slide 12 Mass Calculation Chalice Design,
7075-T6 Al 240mm OD, 1.75mm Thickness, FS 1.25 Slide 13 Mass
Calculation Embedded Outer Shell Design, 7075-T6 Al 180mm OD, 61mm
ID, 1.3mm Thickness, FS 1.25 Slide 14 Inner Shell (fuel grain
housing) Inner and Outer Shell ANSYS Stress Modeling ( Embedded
Fuel Grain Concept ) Outer radius: 2.40 (~61mm) Inner radius: 2.36
(~60mm) Height: 21.46 (~545 m) Matl: Aluminum 7075 T6 Outer radius:
1.75 + 0.5 mm (0.03225 m) Inner radius: 1.25 (0.03175 m) Height:
1.5 (0.0381 m) Matl: Al 7075 T6 with Composite over-wrap Composite:
IM7 Carbon (fiber) / PEEK (matrix) Model Geometry Outer Shell
(NOS/rocket housing) Slide 15 Material Properties Al 7075-T6
(Modeled as Isotropic) Density: 2810 kg/m 3 Longitudinal Mod., E1:
71.7e9 Pa Poissons Ratio, v12: 0.33 PEEK (matrix) Density: 1376
kg/m 3 IM7 Carbon Fiber (12,000 filaments) (Modeled as Orthotropic)
Density: 1780 kg/m 3 Longitudinal Mod., E1: 278e9 Pa Poissons
Ratio, v12: 0.20 Carbon/PEEK Composite (Modeled as Orthotropic)
Density: 1600 kg/m 3 Longitudinal Mod., E1: 71.7e9 Pa Transverse
Mod., E2: 10.2e9 Pa Poissons Ratio, v12: 0.30 Shear Modulus, G12:
5.7e9 Inner and Outer Shell ANSYS Stress Modeling ( Embedded Fuel
Grain Concept ) Slide 16 Outer Shell (w/ composite) Inner and Outer
Shell ANSYS Stress Modeling ( Embedded Fuel Grain Concept ) Figure
1: Outer Shell of Imbedded Fuel Grain Design (Meshed Elements
8node93) Slide 17 Inner and Outer Shell ANSYS Stress Modeling (
Embedded Fuel Grain Concept ) Outer Shell (w/ composite) Figure 2:
Outer Shell of Imbedded Fuel Grain Design: Plot Results Contour
Plot Element Solution Stresses von Mises stress Slide 18 Outer
Shell (w/ composite) Inner and Outer Shell ANSYS Stress Modeling (
Embedded Fuel Grain Concept ) Figure 3: Outer Shell of Imbedded
Fuel Grain Design: Plot Results Deformed Shape Def + undeformed
Slide 19 Outer Shell (w/ composite) Inner and Outer Shell ANSYS
Stress Modeling ( Embedded Fuel Grain Concept ) Figure 4: Outer
Shell of Imbedded Fuel Grain Design: (Pressure & Constraints
Rotated view) Slide 20 Outer Shell (w/ composite) Inner and Outer
Shell ANSYS Stress Modeling ( Embedded Fuel Grain Concept ) Figure
5: Outer Shell of Imbedded Fuel Grain Design: (Pressure &
Constraints - Front View) Slide 21 Outer Shell (w/ composite) Inner
and Outer Shell ANSYS Stress Modeling ( Embedded Fuel Grain Concept
) Figure 6: Outer Shell of Imbedded Fuel Grain Design: (Pressure
& Constraints - Side View) Slide 22 Inner Shell (All Aluminum)
Inner and Outer Shell ANSYS Stress Modeling ( Embedded Fuel Grain
Concept ) Figure 7: Inner Shell of Imbedded Fuel Grain Design
(Meshed Elements 8node93) Slide 23 Inner Shell (All Aluminum) Inner
and Outer Shell ANSYS Stress Modeling ( Embedded Fuel Grain Concept
) Figure 8: Inner Shell of Imbedded Fuel Grain Design: Plot Results
Contour Plot Element Solution Stresses von Mises stress Slide 24
Inner Shell (All Aluminum) Inner and Outer Shell ANSYS Stress
Modeling ( Embedded Fuel Grain Concept ) Figure 9: Inner Shell of
Imbedded Fuel Grain Design: Plot Results Deformed Shape Def +
undeformed Slide 25 Inner Shell (All Aluminum) Inner and Outer
Shell ANSYS Stress Modeling ( Embedded Fuel Grain Concept ) Figure
10: Inner Shell of Imbedded Fuel Grain Design: (Pressure &
Constraints Rotated view) Slide 26 Inner Shell (All Aluminum) Inner
and Outer Shell ANSYS Stress Modeling ( Embedded Fuel Grain Concept
) Figure 11: Inner Shell of Imbedded Fuel Grain Design: (Pressure
& Constraints Front view) Slide 27 Inner Shell (All Aluminum)
Inner and Outer Shell ANSYS Stress Modeling ( Embedded Fuel Grain
Concept ) Figure 12: Inner Shell of Imbedded Fuel Grain Design:
(Pressure & Constraints Side view) Slide 28 Outer Shell
(Aluminum only) Inner and Outer Shell ANSYS Stress Modeling (
Embedded Fuel Grain Concept ) Figure 13: Outer Shell of Imbedded
Fuel Grain Design (Meshed Elements 8node93) Slide 29 Outer Shell
(Aluminum only) Inner and Outer Shell ANSYS Stress Modeling (
Embedded Fuel Grain Concept ) Figure 14: Outer Shell of Imbedded
Fuel Grain Design: Plot Results Contour Plot Element Solution
Stresses von Mises stress Slide 30 Outer Shell (Aluminum only)
Inner and Outer Shell ANSYS Stress Modeling ( Embedded Fuel Grain
Concept ) Figure 15: Outer Shell of Imbedded Fuel Grain Design:
Plot Results Deformed Shape Def + undeformed Slide 31 Inner and
Outer Shell ANSYS Stress Modeling ( Embedded Fuel Grain Concept )
Outer Shell (Aluminum only) Figure 16: Outer Shell of Imbedded Fuel
Grain Design: (Pressure & Constraints Rotated view) Slide 32
Inner and Outer Shell ANSYS Stress Modeling ( Embedded Fuel Grain
Concept ) Outer Shell (Aluminum only) Figure 17: Outer Shell of
Imbedded Fuel Grain Design: (Pressure & Constraints - Front
View) Slide 33 Inner and Outer Shell ANSYS Stress Modeling (
Embedded Fuel Grain Concept ) Outer Shell (Aluminum only) Figure
18: Outer Shell of Imbedded Fuel Grain Design: (Pressure &
Constraints - Side View) Slide 34 Inner and Outer Shell ANSYS
Stress Modeling ( Embedded Fuel Grain Concept ) Figure 19: ELEMENT
LAYERS Slide 35 Inner and Outer Shell ANSYS Stress Modeling (
Embedded Fuel Grain Concept ) Figure 20: LAYER ORIENTATION AND
THICKNESS Slide 36 Inner and Outer Shell ANSYS Stress Modeling (
Embedded Fuel Grain Concept ) Figure 21: LAYER ORIENTATION AND
THICKNESS continued Slide 37 Inner and Outer Shell ANSYS Stress
Modeling ( Embedded Fuel Grain Concept ) Figure 22: COMPOSITE
PROPERTIES Slide 38 Inner and Outer Shell ANSYS Stress Modeling (
Embedded Fuel Grain Concept ) Figure 23: ALUMINUM PROPERTIES Slide
39 Inner and Outer Shell ANSYS Stress Modeling ( Embedded Fuel
Grain Concept ) Figure 24: FAILURE CRITERIA FOR COMPOSITES Slide 40
Inner and Outer Shell ANSYS Stress Modeling ( Embedded Fuel Grain
Concept ) Figure 25: INVERSE TSAI-WU STRENGTH RATIO INDEX Slide 41
Inner and Outer Shell ANSYS Stress Modeling ( Embedded Fuel Grain
Concept ) Figure 26: X-COMP OF STRESS Slide 42 Inner and Outer
Shell ANSYS Stress Modeling ( Embedded Fuel Grain Concept ) Figure
27: Y-COMP OF STRESS Slide 43 Inner and Outer Shell ANSYS Stress
Modeling ( Embedded Fuel Grain Concept ) Figure 28: X-COMP OF
STRESS Slide 44 Inner and Outer Shell ANSYS Stress Modeling (
Embedded Fuel Grain Concept ) Figure 29: SHEAR XY-DIR Slide 45
Inner and Outer Shell ANSYS Stress Modeling ( Embedded Fuel Grain
Concept ) Figure 30: SHEAR YZ-DIR Slide 46 Inner and Outer Shell
ANSYS Stress Modeling ( Embedded Fuel Grain Concept ) Figure 31:
SHEAR XZ-DIR Slide 47 Top and Bottom Fixture Solidworks Stress
Model (Embedded Fuel Grain Concept) Model Geometry Mass = 0.520526
kg % Allowable Mass(2.31kg) = 22.5% Volume = 0.00018 m 3 Geometry
is the same for both the top and bottom fixture Slide 48 Material
Properties, Loading, and Meshing Al 7075-T6 Density: 2810 kg/m 3
Modulus of Elasticity: 71.7 GPa Shear Modulus: 28 GPa Top and
Bottom Fixture Solidworks Stress Model (Embedded Fuel Grain
Concept) 1000 psi Meshing done with Solidworks and Cosmos finite
element analysis Elements: 25306 Nodes:49277 Slide 49 Factor of
Safety Results Top and Bottom Fixture Solidworks Stress Model
(Embedded Fuel Grain Concept) Slide 50 External Shell Solidworks
Stress Model (Embedded Fuel Grain Concept) Model Geometry Mass =
1.63918 kg % Allowable Mass(2.31kg) = 71.0% Volume = 0.00058 m 3
Slide 51 Material Properties, Loading, and Meshing Meshing done
with Solidworks and Cosmos finite element analysis Elements: 43804
Nodes:87448 External Shell Solidworks Stress Model (Embedded Fuel
Grain Concept) 1000 psi Al 7075-T6 Density: 2810 kg/m 3 Modulus of
Elasticity: 71.7 GPa Shear Modulus: 28 GPa Slide 52 Factor of
Safety Results External Shell Solidworks Stress Model (Embedded
Fuel Grain Concept) Slide 53 Internal Shell Solidworks Stress Model
(Embedded Fuel Grain Concept) Model Geometry Mass = 5.64597 kg %
Allowable Mass(2.31kg) = 244% Volume = 0.002 m 3 Slide 54 Material
Properties, Loading, and Meshing Al 2024 Density: 2780 kg/m 3
Modulus of Elasticity: 73.1 GPa Shear Modulus: 28 GPa Meshing done
with Solidworks and Cosmos finite element analysis Elements: 34919
Nodes:68256 Internal Shell Solidworks Stress Model (Embedded Fuel
Grain Concept) 1000 psi Slide 55 Factor of Safety Results Internal
Shell Solidworks Stress Model (Embedded Fuel Grain Concept) Slide
56 External Shell Composite Design (Embedded Fuel Grain Concept)
Slide 57 External Shell Composite Design (Chalice Concept) Slide 58
Al 2 O 3 Post Combustion Chamber Post Combustion Chamber ANSYS
Thermal Model (Embedded Fuel Grain Concept) Outer radius: 1.25
(0.03175 m) Inner radius: 1 (0.0254 m) Height: 1.5 (0.0381 m) Outer
radius: 1.75 + 0.5 mm (0.03225 m) Inner radius: 1.25 (0.03175 m)
Height: 1.5 (0.0381 m) Al 7075-T6 Housing (0.5 mm) Model Geometry
Slide 59 Post Combustion Chamber ANSYS Thermal Model (Embedded Fuel
Grain Concept) Material Properties Al 2 O 3 Density: 3970 kg/m 3
Specific Heat: 774.977 J/(kg- K) Thermal Conductivity: variable Al
7075-T6 Density: 2810 kg/m 3 Specific Heat: 960 J/(kg-K) Thermal
Conductivity: 130 W/(m-K) Assumptions Constant Aluminum properties
Chamber ends are adiabatic Constant film coefficients Constant bulk
temperatures Slide 60 Post Combustion Chamber ANSYS Thermal Model
(Embedded Fuel Grain Concept) Meshed Model Nodes: 9,589 Elements:
5,602 Volumes meshed using ANSYS SmartSize 1 with tetrahedral
elements Slide 61 Post Combustion Chamber ANSYS Thermal Model
(Embedded Fuel Grain Concept) Boundary Conditions Outer Surface
Film coefficient, h = 5 W/(m-K) Bulk temperature, T = 298 K
Simulates free convection of N 2 0 on Al housing Inner Surface Film
coefficient, h = 300 W/(m-K) Bulk temperature, T = 3000 K Simulates
convection of the propellant gas inside the combustion chamber All
nodes initially set to 298 K Slide 62 Post Combustion Chamber ANSYS
Thermal Model (Embedded Fuel Grain Concept) Transient Results Slide
63 Post Combustion Chamber ANSYS Thermal Model (Embedded Fuel Grain
Concept) Discussion of Results This model demonstrates heat
transfer across multiple ANSYS volumes, which will be necessary to
derive a film coefficient from thermocouple data A transient
analysis was also performed by hand using ANSYS input conditions
with results matching ANSYS output to within 100 Kelvin. The
transient model is considered validated for this test case. Slide
64 Post Combustion Chamber ANSYS Thermal Model (Engine Core) Future
Models A model of the post combustion chamber and nozzle is being
developed to utilize data that will be collected by the test stand
team. The model will be used to back out an average film
coefficient and to determine if the engine structure will meet the
Guidance burn time of 50 seconds. Slide 65 Flying Rocket Ignition
System (Darlington configure transistors) R3 Igniter load (Nicrome
Wire) Fc = 90 hz V2 = PWM from MSP430 F1-69 Slide 66 Transistor
Characteristics 2SC7401S Slide 67 2SC5001 Slide 68 Output
Characteristics Duty Cycle Current Slide 69 Ground Ignition System
Slide 70 Output Characteristics Time Current 3.3 A Slide 71 Power
Source 7.4 volt - 700mAh 20C Li-Poly Pack Discharge rate of 14 amps
6mm x 36mm x 55mm 50 grams Slide 72 Discharge Characteristics Max =
20.09 Avg = 18.9 Run Time = 2:32 min Slide 73 Questions?
