PROJECT METEOR OXIDIZER SYSTEM AND STRUCTURE DETAIL DESIGN

PROJECT METEOR OXIDIZER SYSTEM AND STRUCTURE DETAIL DESIGN REVIEW Friday November 9, 2007 12/14/2021 MAGGIE ANDERSON NATHAN CONFER TONY NIMEH TIM SEIBERT CHRIS WERGIN 1

CONTENTS q q q METEOR Overview Team Organization Deliverables Hybrid Rocket Concept Strategy Detail Design • Overall Hybrid Rocket Structure and O. D. S • Oxidizer Tank • Oxidizer Delivery System • Structure q q Finite Element Analysis Deliverables Revisited SDII Project Plan Questions/Discussion *Please feel free to ask questions or make comments during the presentation* 12/14/2021 2

Introductions Nathan Confer Tim Seibert Maggie Anderson Tony Nimeh 12/14/2021 Chris Wergin 3

Project Background q Project METEOR strives to create a lower-cost alternative to current low-Earth orbit launch solutions for "Picosatellites", a class of satellites weighing approximately 1 kg. q The purpose of the Rocket Integration Team is to accept the hybrid engine while incorporating the remainder of the major rocket subsystems. 12/14/2021 4

Project Overview 12/14/2021 5

Benchmarking and Brainstorming Chalice Design Embedded Design After investigating the previous team’s work and looking into other hybrid rocket designs it became obvious that the project has three major components. These components are the frame, the tank, and the oxidizer delivery system. 12/14/2021 6

Team Organization Project Manager Nathan Confer Technical Lead Tony Nimeh Frame Oxidizer Tank Delivery System Tony Nimeh (focal) Chris Wergin (focal) Maggie Anderson (focal) Tim Seibert Tony Nimeh Nathan Confer Super Structure Tank Design Components -assembly rods -sizing dimensions -piping -support plates -material considerations -valves Manufacturing Safety -composite capabilities -burst prevention -pressure regulators 12/14/2021 7

Constraints and Objectives Tank Importance N 20 tank needs to sustain pressure of 2500 psi 9 Incorporate safeguards with respect to burst pressure 9 Oxidizer Delivery System Importance Maintain pressure of 1500 psi at the injector plate 9 Controllable (steady) flow rate 9 Safe fuel delivery system 9 Tank refilling mechanism 3 Fuselage Importance Accept and support delivery system, tank, motor 9 Withstand heat transfer from combustion 9 Accommodate payload integration 3 Power source for pressure regulator 3 12/14/2021 8

Hybrid Rocket Concept 12/14/2021 9

From Concept to Reality… Engineering the Future Tank Design 12/14/2021 10

Oxidizer Tank 12/14/2021 11

N 20 Pressurization Oxidizer Tank q Single-tank configuration with Helium gas used to pressurize the liquid nitrous oxide. q Goal: Deliver 1500 psi to injector plate Helium (gas) Nitrous Oxide (liquid) 12/14/2021 12

Equations Used to Size Oxidizer Tank 1 st Law of Thermodynamics (N 2 O) Ideal Gas Law Isentropic Assumption (Helium) 12/14/2021 13

MATLAB Program Results – End Pressure Tank Volume 12/14/2021 14

MATLAB Program Results – End Pressure Initial Temperature 12/14/2021 15

MATLAB Tank Evacuation Solution 12/14/2021 16

Final Oxidizer Sizing q 12/14/2021 Prefab composite Tank produced by SCI composites ◊ Aluminum liner with carbon/glass reinforcement ◊ 1212 cubic inch volume ◊ 3259 psi rated service pressure ◊ Pressure tested to 5000 psi ◊ 18. 7 lbs empty weight ◊ Tank already purchased by P 07109 17

From Concept to Reality… Engineering the Future Oxidizer Delivery System 12/14/2021 18

Oxidizer Delivery System 12/14/2021 19

Head Loss Calculations Pressure at a given point: Reaction from Momentum Flux: 12/14/2021 20

Head Loss Calculations Head Loss: Mass Flow Rate: 12/14/2021 Velocity: 21

Head Loss Calculations Continued Head Loss Term: Friction Coefficient: 12/14/2021 Reynolds Number: Relative Roughness: 22

Head Loss Values Component 12/14/2021 Description Head Loss (in) A N 2 O Tank 0. 00 1 N 2 O Tank Connection Port 16. 48 2 N 2 O tank Fitting 0. 19 3 Cross Fitting 73. 36 4 Connection Nipple 0. 06 5 Remote Ball Valve 1. 39 6 Connection Nipple 0. 06 7 Pressure Regulator / Flow Switch 0. 28 8 Connection Nipple 0. 06 9 Flexible Hose + Connectors 5. 61 10 Connection Nipple 0. 06 11 Check Valve 12 Connection Nipple 0. 06 13 Cross Fitting 73. 36 14 Connection Nipple 0. 06 15 Injector Plate Connection Port 0. 05 B Injector Plate 0. 00 TOTAL 415 244. 23 23

Feed System: Part Selection 12/14/2021 24

Feed System: Part Details q Relief Valve ◊ ◊ ◊ 12/14/2021 Desired range: 30003600 psi Proof pressure: 4500 psi Stainless steel construction ½” Pipe Size 250°F max temperature ~$450 each 25

Feed System: Part Details q Ball Valve ◊ ◊ ◊ ◊ q Check Valve ◊ ◊ ◊ 12/14/2021 316 Stainless Steel ball 17 -4 PH SS stem Delrin seats PTFE body seals & packing ½” Pipe Size 4500 psi max at 120°F $126. 45 each 303 Stainless Steel 440 SS ball ½” Pipe Size 5000 psi max at 400°F $86. 40 26

Feed System: Part Details q Metal Hose and JIC Swivel Female Fittings ◊ ◊ ◊ 12/14/2021 T 361 L SS heavyweight hose T 321 SS double braid 1500°F max temperature ½” Pipe Size Minimum length for vibration = 6 in 27

Feed System: Part Details q Circle Seal Pressure Regulator ◊ ◊ ◊ 12/14/2021 303 Stainless Steel body Orifice = 0. 145” Cv = 0. 37 Inlet/Outlet: 0 -6000 psig 160°F max temp ~$2000 (approximation based on P 07105 Emerson Quote) 28

From Concept to Reality… Engineering the Future Structure 12/14/2021 29

Structure 12/14/2021 30

Structural Skeleton q Rods Continuous-length distributes thrust and weight ◊ Lightweight & strong ◊ Excess length for future add-ons ◊ q Rings Anchored to rods ◊ Spaced so as to avoid buckling ◊ Chamfered in order to support tank ◊ 12/14/2021 31

Structural Skeleton q Rod analysis ◊ Worst-Case (Axial Stress): Vert. Test Stand • ◊ Worst-Case (Bending Stress): Balloon Ascent • 12/14/2021 Fixed at top, Axial load TBD depending on carriage 32

Structural Skeleton q Sourcing Rods Online Metal Store – round bar stock ◊ Grade 5 more difficult to machine than 2 ◊ 12/14/2021 33

Structural Skeleton q Sourcing Rings Mc. Master-Carr – Aluminum plate stock ◊ 6061 Al is reasonable to machine in-house ◊ 12/14/2021 34

From Concept to Reality… Engineering the Future Finite Element Analysis 12/14/2021 35

Boundary Conditions At the nozzle end there are 75 pounds force per rod in the negative Z direction At the payload end all displacement degrees of freedom are fixed at 0 12/14/2021 36

Displacement Maximum deflection is 0. 074623 inches in the direction of the force loading which is located at the nozzle end of the assembly 12/14/2021 37

Maximum Stress Maximum stress is 6280 psi which is located at the payload end of the assembly 12/14/2021 38

Vibration – Modal Analysis 12/14/2021 39

Vibration – Modal Analysis 12/14/2021 40

From Concept to Reality… Engineering the Future Concluding Remarks 12/14/2021 41

Constraints and Objectives Revisited Tank Importance N 20 tank needs to sustain pressure of 2500 psi 9 Incorporate safeguards with respect to burst pressure 9 Oxidizer Delivery System Importance Maintain pressure of 1500 psi at the injector plate 9 Controllable (steady) flow rate 9 Safe fuel delivery system 9 Tank refilling mechanism 3 Fuselage Importance Accept and support delivery system, tank, motor 9 Withstand heat transfer from combustion 9 Accommodate payload integration 3 Power source for pressure regulator 3 12/14/2021 in progress to be determined 42

Senior Design II Outlook q q q q 12/14/2021 Review finalized design, milestones, and lessons learned from SDI Establish part delivery dates Resolve any shipping delays or unexpected setbacks during transition from SDI to SDII Finalize manufacturing schedule Setup manufacturing and assembly completion date(s) Correlate with P 08105 for date to assemble entire rocket (tank with engine) Test entire rocket assembly (if time allows) Write up design, manufacturing, and testing, reports and conclusions (and poster) 43

Senior Design Two Schedule q Senior Design One ◊ ◊ q Update edge Finalize pressure regulator selection Finalize SDII Testing Plans Order parts Week 1 Review Senior Design One deliverables, calculations, and design criteria ◊ Determine locations and delivery dates of all parts ◊ Begin assembly of rocket body ◊ Begin assembly of testing mechanisms ◊ q Week 2 – 4 ◊ ◊ 12/14/2021 Validate design Completely assemble all subsystems Place subsystems into entire assembly Complete assembly on testing mechanisms 44

Senior Design Two Schedule q Week 5 - 7 Analyze data from testing ◊ Re-evaluate testing mechanisms and scheduling ◊ Coordinate testing with P 08105 ◊ q Week 8 – 11 ◊ ◊ ◊ 12/14/2021 Retest proper conditions based on conclusions from weeks 5 -7 Make project poster Write up technical paper Present Senior Design Two Deliverables Ensure proper documentation of all paperwork and procedures 45

questions comments concerns 12/14/2021 46

thank you 12/14/2021 47