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Critical Design Review (CDR)

Critical Design Review (CDR). Charger Rocket Works University of Alabama in Huntsville NASA Student Launch 2013-14. Kenneth LeBlanc (Project Lead) Brian Roy (Safety Officer) Chris Spalding (Design Lead) Chad O’Brien (Analysis Lead) Wesley Cobb (Payload Lead).

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Critical Design Review (CDR)

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  1. Critical Design Review (CDR) Charger Rocket Works University of Alabama in Huntsville NASA Student Launch 2013-14 Kenneth LeBlanc (Project Lead) Brian Roy (Safety Officer) Chris Spalding (Design Lead) Chad O’Brien (Analysis Lead) Wesley Cobb (Payload Lead)

  2. Prometheus Flight Overview Payloads Here

  3. Technology Readiness Level http://web.archive.org/web/20051206035043/http://as.nasa.gov/aboutus/trl-introduction.html

  4. Outreach • Adaptable for different ages and lengths • Beginning outreach packet with Elementary School • Building the program from the ground up with school advisers • Supporting activity • Water Rockets • Completed • Science Olympiad • 102 Middle School • 54 High School • Scheduled • Challenger Elementary

  5. On Pad Cost

  6. Analysis

  7. Analysis Responsibilities • Fin Flutter Analysis • RockSim/Open Rocket Trajectory Simulations • MATLAB 3DOF Simulations • Monte Carlo Simulations • FEA Analysis using MSC PATRAN and NASTRAN • CFD Analysis using CFD-ACE+

  8. Flight Trajectory • Max Altitude: 15800 ft • Max Velocity: 1600 ft/s, Mach: 1.45 • Acceleration: 40 G

  9. Flight Trajectory

  10. Flight Trajectory

  11. Vehicle Aerodynamics – M4770 • Static Margin – 1.61 • CP – 92 in • CG– 84.4in • Thrust To Weight • Max Thrust – 1316 lbf T2W: 40 • Average Thrust – 1073 lbf T2W: 33.5 • Exit Rail Velocity – 122 fps

  12. Final Motor Selection - CTI M4770-P • ISP – 208.3s • Loaded Weight: 14.337 lb • Propellant Weight: 7.3 lb • Max Thrust: 1362 lbf

  13. Monte Carlo Analysis

  14. Proof of Randomization in Inputs • Shows output consistency overmultiple sets of simulations.

  15. Drift Analysis

  16. Variation in Flight Time • Time variance directlyaffects the radial landingdistance.

  17. CFD - Critical Mach Number *Steady state values Indicated by color maps

  18. CFD – AerothermalHeating *Steady state values Indicated by color maps

  19. CFD - Drag vs Mach Plot • Uncertainty with Mach < 0.5 • Inadequate convergence in low Mach Regime

  20. Plan B Motor: CTI-L890

  21. Recovery System • Single Separation Point • Main Parachute • Hemispherical • 12 ft • Cd 1.2 • Nylon • Drogue Parachute • Conic • 2.5 ft • Cd 0.71 (experimentally determined) • Nylon

  22. Recovery System Deployment Process • Stage 1 • 2 seconds after apogee • nose cone separates • release the drogue • Stage 2 • 2.1 • Drogue attached via tethers. • 2.2 • A black powder charge separates the tethers • Stage 3 • Main parachute pulled from deployment bag Eye bolt Drogue L.H.D.S Main Parachute InDeployment bag Tethers Black Powder Charge

  23. Deployment Process Stage 2.1 Stage 1: Drogue Deployment Stage 3 Stage 2.2

  24. Energy and Velocity at Key Points

  25. Sewing Technique • Seam Type: French Fell • Vent Hole supported with double stitched bias tapes • The bottom edge hemmed • Prevent fraying • Increase durability Stich Seam Cross Section

  26. Subscale Drogue • Flight Test • Built by team • First attempt • Subscale Data • Perfect flight Altimeter • Cd of 0.71 • 27.5” Diameter

  27. Construction Materials • Swivel ultimate load:1045 lbs • The nylon line anchor points ultimate load: 120 lbs per strap • The eyebolt ultimate load: 500 lbs

  28. Design

  29. Hardware Team responsibilities: • Vehicle design • Testing and verification of materials and components • Vehicle construction • Interfaces • Design Details: • 34lbs • 40Gs acceleration • Geometric similarity to NASA Nanolaunchprotoype • Nanolaunch team requested maximum use of SLS printed titanium

  30. Interfaces (1)

  31. Interfaces (2)

  32. Thrust Ring • Printed titanium • Analyzed with FEA • Significantly stronger than required

  33. Fin Assemblies • Modified significantly since PDR due to updated geometry from Nanolaunch team (bolted instead of epoxied) • Easier to inspect and verify • Fin replacement in the field now possible • Moderate weight penalty compared to original design.

  34. Body Tube • Carbon composite • FEA, destructive testing and hand calculations done to assess strength • Large margin of safety and low weight

  35. Payload Shaft • 7075-T6 Aluminum threaded shaft • Preloaded in tension • FEA and hand calculations show significantly over strength requirements

  36. Payload Shaft Load Paths • Carries thrust loads into payloads and recovery forces into lower rocket, as well as providing assembly method for payloads, body tubes and recovery harness • Red Arrow indicates motor loads from thrust ring through body tube • Green arrow indicates motor loads passed through payloads • Blue arrow indicates recovery forces passed through payload shaft • Orange arrow indicates motor case retention force

  37. Coupler Rings • Machined aluminum • Aft coupler retained by payload shaft preload • Fore coupler retained by nose cone shaft and shear pins

  38. Nose Cone Assembly • All components retained by shaft similar to payload shaft • Carbon fiber nose cone shroud and bulkhead • Contains pitot pressure and accelerometer/ gyro data package

  39. Pitot Probe • Allows measurement of static pressure along with supersonic AND subsonic total pressure • Unique and original design which could only be made with 3D printing techniques • Helps fulfill our Nanolaunchrequest to explore selective laser sintering in original ways.

  40. Carbon fiber dog bones • Loaded in tension • Verify tensile strength of materials • Tubes • Loaded in compression • Verify compressive strength of representative structures of body tube • 45/45 Sleeve • 0/90 Wrapped • Parachute Material • Loaded in tension • Verify parachute material and seam strength Structure Testing

  41. Tension Results Fractures Dog bones • Verified Strength Requirements • Fractures showed uniformity in the angle of the fibers • Calculated Young Modulus to be 309 ksi Fractures

  42. Tubes • Wrapped tube holds the most force • Fractures showed uniformity in the angle of the fibers • Failure Load: 8094.5 (lbf) Compression Results Fractures

  43. Parachute Results Seam Test • Seam failed before material • Breaking of seam occurred at 35 lbf • Narrow sample failed at seam due to edge effects

  44. Structure Testing Conclusions Verified Requirements • Strength • Thickness • Fiber Angle • Fabrication Future Testing • Recovery system • Electronic payload • Verification of flight hardware • Flight testing completed rocket

  45. Vehicle Requirements

  46. Procedures

  47. Testing Procedures

  48. Subscale Testing and Results

  49. Recovery Hardware Testing CRW Built Parachute Deployment Bag Failure Point Separation Charges • Problems with deployment bag. • Successful proof of concept flight for parachute design. • Successful test of separation charges.

  50. Subscale Flight Data • Apogee: 1,573 feet AGL. • Max Velocity: 279 ft/s. • Time of Flight: 63.9 seconds. • Motor: CTI I-205. • Recorded Using a PerfectFlite SL100 • Apogee: 4,156 feet AGL. • Max Velocity: 597 ft/s. • Time of Flight: 128.6 seconds. • Motor: Aerotech I-600. • Recorded Using a PerfectFliteSL100

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