PROJECT METEOR HYBRID ROCKET MOTOR SENIOR DESIGN PROJECT

PROJECT METEOR HYBRID ROCKET MOTOR SENIOR DESIGN PROJECT REVIEW Friday May 16, 2007 10/7/2020 Ken Court Chad Eberhart Patrick Haus Chris Natoli Nohl Schluntz 1

PROJECT METEOR OVERVIEW Multidisciplinary Senior Design q Purpose: Deliver Pico satellites into low-earth orbit at low cost q MICROSYSTEMS ENGINEERING, SCIENCE, AND TECHNOLOGIES FOR THE EXPLORATION AND UTILIZATION OF OUTER SPACE REGIONS 10/7/2020 2

P 08105 DELIVERABLES / NEEDS q Support a launchable test flight at 24 km (80, 000 ft) Specific Impulse: ◊ Burn time: ◊ Thrust to Weight Ratio: ◊ 220 sec ~ 3: 1 Ensure Safety to all participants q Integration with P 08106 (Flying Rocket Body) q 10/7/2020 3

OVERALL HYBRID ROCKET MOTOR DESIGN Post-Combustion HTPB Fuel Grain Supersonic Nozzle Injector Plate Titanium Shell (t = 1/8’’) Pre-Combustion Brackets 10/7/2020 4

STRUCTURE DETAILS q 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) q Dual O-Rings for sealing q Vibration Dampener q Advantages q Durability q Lightweight ◊ 24. 748 lbs Adaptability q Ease of Integration q 10/7/2020 5

STRUCTURE – THEORETICAL VS. SIMULATED 10/7/2020 Parameter Hand Calculations ANSYS Results % Deviation Hoop Stress (psi) σh, max 20, 500 21, 046 2. 66 Radial Deflection (in) δr, max 0. 0032 in 0. 003158 1. 31 Longitudinal Stress (psi) σl, max 10, 000 psi 13, 047 30. 47 Longitudinal Deflection (in) δr, max 0. 00987 in 0. 009731 1. 41 6

TEST INJECTOR DESIGN Injector Hub Gasket Orifice Insert Snap Ring 10/7/2020 7

INJECTOR – PRESSURE LOSS D 1 1 D 2 L 1 L 3 2 10/7/2020 ø L 2 Z 8

INJECTION TESTING q Increased holes decreased pressure and velocity q Fluid breakup 16 inches downstream q Need to maintain higher velocity q Devise method of building back pressure 10/7/2020 9

THRUST – NOZZLE CALCULATIONS Equation Thrust: Area Ratio: Mach Number: Isentropic: Projected R ~ 200 lbf Ae/At ~ 16 - 155 Me ~ 3 - 5. 5 Po/Pe ~ 177 PROGRAMS USED q q 10/7/2020 MATLAB MICROSOFT EXCEL 10

SUPERSONIC NOZZLE DESIGN 10/7/2020 Annular - Mach 4 Annular - Mach 3 12° Conical - Mach 4 8° Conical - Mach 4 11

IGNITION DEVICES q q q 10/7/2020 Mini bulb v Most miss fires • Filament burned up after a few seconds Epoxy v Acted as high insulator • Nichrome wire was unable to reach high temp. Nitrocellose / Pyrodex v Most effective • Nichrome wire was able to heat up and ignite Pyrodex is the most effective ignition component v Robust v Reliable v Sustainable burn times based on volume Nichrome wire v Best delivery source • Does not burn up • Works under low amperage and long lead wires 12

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Results q ~ 100% Theoretical Increase in Thrust q 58. 8% Theoretical Reduction in Weight q Designed and constructed 1: 1 scale model q Successfully tested new injector plate and orifice inserts q Validated P 07105’s current igniter configuration q Designed under budget 10/7/2020 14

Future Suggestions q Component research at graduate level q Undergraduate implementation q Improve manufacturing techniques q Improve testing procedures q Construct 10/7/2020 Titanium motor 15

SPECIAL THANKS TO: Dr. Jeffrey Kozak q Dr. Dorin Patru q q q Dr. Steve Weinstein Dr. Amitabah Ghosh Dr. Lawrence Agbezuge Paul Gaylo Mr. Natoli Harris Corporation q Global Machining q 10/7/2020 16

QUESTIONS / COMMENTS q 10/7/2020 Please feel free give suggestions and critiques 17