1. PROJECT METEOR HYBRID ROCKET MOTOR
Marc Balaban
Ken Court
Chad Eberhart
Patrick Haus
Chris Natoli
Nohl Schluntz
DETAILED DESIGN REVIEW
Friday November 9, 2007
5/14/2019

2. CONTENTS METEOR Overview Hybrid Background Team Organization
Project Deliverables & Needs
Constraints/Risks
Specifications List
Hybrid Rocket Concept Strategy
Detail Design
Overall Hybrid Rocket Motor
Structure
Injection
Combustion/Exhaust
Nozzles
Ignition
P08104 Deliverables
SDII Project Plan
Projected Costs - BOM
Questions/Discussion
*Please feel free to ask questions or make comments during the presentation*
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3. PROJECT METEOR OVERVIEW
Multidisciplinary Senior Design
Purpose: Deliver Pico satellites into low-earth orbit at low cost
MICROSYSTEMS
ENGINEERING, SCIENCE, AND
TECHNOLOGIES FOR THE
EXPLORATION AND UTILIZATION OF
OUTER SPACE
REGIONS
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4. PROJECT METEOR OVERVIEW
~ 24 km
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5. Rocket Motor which combines:
HYBRID BACKGROUND
Rocket Motor which combines:
Liquid Oxidizer: Nitrous Oxide (NOX)
Solid Propellant: Hydroxyl Terminated Poly-Butadiene (HTPB)
Previous Accomplishments
Design of a Static Test Rocket Motor
Extensive Horizontal Ground Testing
50 second Burn Time
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6. P08105 ORGANIZATION Patrick Haus – Project Leader
Chris Natoli – Lead Engineer
Marc Balaban – Fluids/Combustion Specialist
Ken Court – Fuel Injection Specialist
Chad Eberhart – Fluids/Combustion Specialist
Nohl Schluntz – Fuel Injection Specialist
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7. Support a launchable test flight at 24 km (80,000 ft)
P08105 DELIVERABLES / NEEDS
Support a launchable test flight at 24 km (80,000 ft)
Specific Impulse: sec
Burn time: 20 sec
Thrust to Weight Ratio: ~ 3:1
Ensure Safety to all participants
Integration with P08106 (Flying Rocket Body)
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8. * IT’S ONLY ROCKET SCIENCE*
CONSTRAINTS - RISKS
Safety First
Scope of Work
METEOR is very challenging
Budget = $5000
Time = 22 Weeks (12 Remaining)
Integration to other METEOR Teams
Internal Temperature and Pressure
Titanium Shell (Process & Strength)
Lead Time
Machine Shop Availability
External Resources
* IT’S ONLY ROCKET SCIENCE*
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9. PROJECT SPECIFICATIONS
Design Specification
Importance
Units of Measure
Marginal Value
Ideal Value
Specific Impulse 4
sec
220
250
Thrust 5 N
490
500
Burn Time 25 60
Oxidizer/Fuel Ratio
(--) 6 8
Overall Mass Flow Rate
kg/s
0.35
0.3677
Pressure Loss Pa
2.76E+06
2.06E+06
Oxidizer Mass Flow Rate
0.25
0.3152
Regression Rate
m/s
0.0009
Chamber Pressure
6.89E+06
Exit Mach Number
Mach #
5.548
Ratio of Spec Heats 3 --
1.258
Nozzle Area Ratio
175
189
Scale: 1 Least Important - 5 Most Important
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10. HYBRID ROCKET DESIGN STRATEGY
Test Flight
Design Flying Rocket
- Structure
- Injector
- Combustion
- Ignition
- Nozzle
Test Steel Rocket
Design Iteration
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11. OVERALL HYBRID ROCKET MOTOR DESIGN
Supersonic Nozzle
Post-Combustion
HTPB Fuel Grain
Pre-Combustion
Titanium Shell (t = 1/8’’)
Brackets
Injector Plate
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12. STRUCTURE DETAILS Titanium Chamber & Welded Flanges
High Structural Strength → E = 16,800 ksi
Melting Point → 1604ºC
Bolt Hole Pattern Provides FOS = 2.7 (Plus FOS from Rods)
Dual O-Rings for sealing
Vibration Dampener
Advantages
Durability
Lightweight
Adaptability
Ease of Integration
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13. STRUCTURE EXPLODED VIEW
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14. COMBUSTION CHAMBER – HAND CALCULATIONS
Hoop Stress
σh,max
σh,max = 20,500 psi
Radial Deflection
δr,max
δr,max = in
Longitudinal Stress
σl,max
σl,max = 10,000 psi
Longitudinal Deflection
δr,max = in
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15. ANSYS RESULTS – HOOP STRESS & DEFLECTION
Boundary Conditions
Titanium Shell
P0 = 1000 psi
Thickness = 1/8 in
E = 16,800 ksi
Bisymmetric
Results
σh,max = 21,046 psi
δr,max = in
σallow = 25,000 psi
Yield FOS = 5.12
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16. ANSYS RESULTS – LONGITUDINAL STRESS & DEFLECTION
Boundary Conditions
Titanium Shell
F = 19,072 lbf
Thickness = 1/8 in
E = 16,800 ksi
Results
σL,max = 13,047 psi
δr,max = in
σallow = 15,000 psi
Yield FOS = 8.53
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17. STRUCTURE – THEORETICAL VS. SIMULATED
Parameter
Hand Calculations
ANSYS Results
% Deviation
Hoop Stress (psi)
σh,max
20,500
21,046
2.66
Radial Deflection (in)
δr,max in
1.31
Longitudinal Stress (psi)
σl,max
10,000 psi
13,047
30.47
Longitudinal Deflection (in) in
1.41
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18. Use a Composite Sleeve for added strength
CARBON FIBER SHELL
Plan of Action
Use a Composite Sleeve for added strength
Reduce Combustion Chamber Deflection
Lightweight Addition
Additional Considerations
High Temperature Epoxy
Fiber Orientation
Lay-up Process
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19. THERMAL CONSIDERATIONS
Attempted to model heat transfer through:
Combustion Chamber
Nozzle
Difficulties
Transient Heat Flow
Moving Boundary Condition
Do not have dQ/dt (Heat Generation)
Convection, h
Specific Gas Constant, R
Plan of Action
Combustion Analysis
Improve Convection Condition
3MTM NextelTM 440 Woven Fabric
Ceramic Insulator for Nozzle
High Temperature Epoxy
FOS for Thermal Stresses
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20. INJECTION BACKGROUND Assumptions
Fully Developed, Turbulent, Steady, Viscous Flow
Liquid Phase
Current test setup
Nine Hole Straight Injector (1-Piece)
Bolts to Steel Test Chamber
Improvements
Interchangeable Injector Inserts
Geometry of Inserts (Flow Characteristics)
Working with DELPHI (Bill Humphrey)
Atomization
Relocation of Pressure Transducer
Weight Reduction
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21. TEST INJECTOR DESIGN Base Injector Pressure Gasket Insert Test Piece
Snap Ring
Insert Test Piece
Base Injector
Pressure Gasket
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22. INJECTION – EXPECTED RESULTS
Improve Atomization
Increase Combustion Stability
Reduce Pressure Loss
From George P. Sutton’s Rocket Propulsion Elements
∆P ≈ 30% Po
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23. INJECTOR – PRESSURE LOSSø Z L2 L1 L3 1 2 D1 D2 1 2
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24. INJECTION TESTING In House Testing Delphi Testing (Possibility)
Volumetric Flow Rate
Visualization of Flow Geometry
Delphi Testing (Possibility)
High Speed Video
High Speed Photography
Electro sensing plate
Test Stand
Clear Acrylic Tubing
Injector
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25. COMBUSTION / EXHAUST DETAILS
Assumptions
Locally Isentropic
Compressible Flow
Ratio of Specific Heats (γ) = 1.258
Complete Combustion
Current test setup
HTPB (Hydroxyl-Terminated Polybutadiene) as the solid fuel grain
Nitrous Oxide (NOX) as the oxidizer
Cylindrical fuel grain geometry
Linear (Laval) Convergent-Divergent Supersonic Nozzle
Improvements
Fuel Grain Type (Paraffin Wax, HTPB)
Geometry
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26. THRUST – NOZZLE CALCULATIONS
Equation
Projected
Thrust:
R ~ 200 lbf
Area Ratio:
Mach Number:
Ae/At ~
Me ~
Isentropic:
Po/Pe ~ 177
PROGRAMS USED
MATLAB
MICROSOFT EXCEL
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27. Demonstration Isentropic_Nozzle.m
MATLAB DEMO
Demonstration Isentropic_Nozzle.m
MATLAB Program used to determine isentropic flow properties
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28. SUPERSONIC NOZZLE DESIGN
Annular - Mach 4
Annular - Mach 3
8° Conical - Mach 4
12° Conical - Mach 4
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29. Nozzle cost-performance analysis Resolution of data acquisition system
DELIVERABLES FOR P08104
Nozzle cost-performance analysis
Resolution of data acquisition system
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30. FUEL GRAIN Geometry Fuel Composition Regression Rate
Currently cylindrical design
Investigate use of star-pattern
Fuel Composition
Currently HTPB
Investigate Paraffin wax
Regression Rate
Optimize fuel consumption through experimentation
Cylindrical (Current)
6-Point Star
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31. VELCRO© PLUG Purpose Provide back pressure during ignition Equipment
Velcro will be used to hold the plug in place.
The pull strength for which the plug should be released will determine which Velcro will be selected
Velcro can be purchased based on pull strength criteria
Procedures
Tensile test to determine yield
Simulate Temperature conditions
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32. IGNITION - IGNITERS Pyromix Igniter Ultra-Low Current Igniter
Materials
1.2 V, 20mA light bulb
Black powder
Advantages
requires only 25mA to fire
highly shock proof
Disadvantages
very rapid burn rate
Pyromix Igniter
Materials
Nichrome bridgewire-30 AWG
Pyromix
potassium perchlorate
sulfur
high grade epoxy
Advantages
requires very low voltage to fire
epoxy offers hotter and more sustained burn rates
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33. IGNITION – IGNITERS (Cont)
Thermex Igniter
Materials
1.2V, 20mA light bulb
Thermex powder
65% potassium perchlorate
20% charcoal
10% aluminum powder
5% red Ferric Oxide
Advantages
Requires very low voltage to fire
Thermex offers much hotter and
more sustained burn rates
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34. IGNITION – TESTING PROCEDURES
Determine most efficient battery under various
amperage
voltage
temperature
Heat gun will be used to record temperature of fuel.
Test “Blow Out” condition
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35. > 50% Reduction in Weight Operational at 80,000 ft
SUMMARY
~ 100% Increase in Thrust
> 50% Reduction in Weight
Operational at 80,000 ft
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36. SENIOR DESIGN II PROJECT PLAN
Week 11
Order Materials
Paper / Binder
Edge Update
Revisions / Suggestions
Senior Design II
Week 1
Inventory
Fabrication
Injector Plate Test Fixture Fabrication
Injector Insert Fabrication
Fuel Grain Fabrication
Week 2 & 3
Combustion Chamber & Nozzles
Testing
Fuel Grain Regression
Ignition
Week 4
Horizontal Test Fire
Combustion Chamber Materials
Week 5
Data Analysis
Design Modifications
Week 6
Horizontal Test Fire 2
Week 7
Horizontal Test Fire 3
Week 8
Fabrication
Modification
…. Vertical Test 1
Week 9
Vertical Test Stand (2)
Week 10
Project Paper
Week 11
Delivery
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37. EXPECTED COSTS - BOM
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38. SPECIAL THANKS TO: Dr. Jeffrey Kozak Dr. Dorin Patru
Dr. Steve Weinstein
Dr. Amitabah Ghosh
Dr. Lawrence Agbezuge
Bill Humphrey (Delphi)
Thomas Fountain (RIT)
Harris Corporation
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39. QUESTIONS / COMMENTS Please feel free give suggestions and critiques
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