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Thermo-Structural Analysis of a Rocket Engine Thrust Chamber

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Thermo-Structural Analysis of a Rocket Engine Thrust Chamber Thermo-Structural Analysis of a Rocket Engine Thrust Chamber Chethan Madhu Suryavanshi SUPERVISED BY Dr. Jose Ignacio Rojas Gregorio Dr. Luca d’ Agostino Universitat Politècnica de Catalunya & University of Pisa Master in Aerospace Science & Technology December 2018 This Page Intentionally Left Blank Thermo-Structural Analysis of a Rocket Engine Thrust Chamber BY Chethan Madhu Suryavanshi DIPLOMA THESIS FOR DEGREE Master in Aerospace Science and Technology AT Universitat Politècnica de Catalunya & University of Pisa SUPERVISED BY: Dr. Jose Ignacio Rojas Gregorio Dr. Luca d’ Agostino Department of Aerospace Science and Engineering MASTER THESIS Dedicated to my family and my inspiration « Dr B.R Ambedkar » Thermo-structural analysis of a rocket engine thrust chamber i ABSTRACT The rocket engine market today presents several new trends that will substantially change the current technological scenario. Apart from the imminent applications to the mega constellations and the advancement of electric propulsion, some aspects such as environmental protection require a conceptual redefinition of rocket propulsion systems with chemical propellants. One of the best technological options to contribute to the protection of the environment and personnel is to use "green" propellants to replace current toxic and / or ecologically harmful propellants. Thermal and mechanical loads represent the most stringent operating limits for liquid propellant rocket combustion devices (chamber, injectors, expansion nozzle). This report describes the two-dimensional model developed for the evaluation of the temperature distribution across the wall of the thrust chamber and the extension of a typical rocket motor. In the model the thrust chamber and the nozzle extension are divided into several stations using ANSYS APDL 16.0 and are subjected to a steady state and a transient analysis to study the characteristics of heat transfer and to understand the thermal response and structural of the model. The results obtained help to study the thermo-structural feasibility and to identify the most critical operating conditions and their impact on the design of the combustion devices of rocket engines with chemical propellants. The analysis developed in this paper includes the selection of the most suitable materials and the subsequent modeling of the rocket thrust chamber and the nozzle extension using the ANSYS APDL 16.0 software and the SolidWorks software. Loads and constraints on the structure are applied after the combination of the thermal and structural models. Key words: Rocket Propulsion, Liquid Propellant Rocket Engines, Structural Analysis, Thermal Analysis, R-4D. ACKNOWLEDGEMENTS I owe my gratitude to my supervisor Dr Luca d’ Agostino, Department of Aerospace Engineering who offered invaluable assistance, guidance and support throughout my completion of master thesis at the University of Pisa. Deepest thanks to Eng. Riccardo Simi and Dr Mario Rosario Chiarelli, Department of Aerospace Engineering, without whose knowledge and assistance this thesis would not have been successful. I would like to thank Dr. Jose Ignacio Rojas Gregorio, Dept. of Physics - Division of Aerospace Engineering, for providing guidance and support throughout my master thesis. Their constant support in term of technical and scientific has laid an immense foundation for my master thesis. I am very thankful to my mother, father and brother for always believing in me and allowing me to realize my potential. All the support I got from them over the years was the greatest gift anyone has ever given to me. I would like to thank sincerely to my friends and colleagues Guru, Abhilash, Ankit, Akash, Prasenjit, Siddharth, Basavaraj, David, Naveen, Arjun and Gabriel from bottom of my heart for constant support, love and encouragement. Very special thanks to my girlfriend Ivette Fernandez for her support and assistance throughout thesis. She encouraged and inspired me which has given me a lot of courage and energy to complete my master thesis. A special thanks to Universitat Politecnica de Catalunya for providing me an opportunity to pursue my master thesis in University of Pisa, Italy. “Life should be great rather than long” Dr B.R.Ambedkar. Thermo-structural analysis of a rocket engine thrust chamber iii MOTIVATION Rocket engines' thrust chambers operate at high temperatures and pressures. From a structural point of view, this is fundamental for two reasons. Some properties of the material, such as yield strength, are negatively affected by an increase in temperature. The second reason is that during transient operation (startup and shutdowns) there may be strong temperature gradients which produce strong stresses in the chamber wall material. The thermo-structural analysis allows to estimate these two effects. The success of the Apollo mission and the lunar missions have attracted great attention. In particular, the rocket propellant engines used in these missions have aroused much interest because they made the mission possible and operated accordingly. The R-4D engine, used as reference in this work is a liquid propellant rocket engine produced by Marquardt, which is now part of Aerojet Rocketdyne. This engine is used for attitude control, for docking maneuvers and in general for those missions requiring small or moderate spacecraft velocity changes. The R-4D engine uses radiative and film cooling and have the option to shutoff when the heat flux to the combustion devices it's too high. Heat removal plays an important role in rocket engines, since the temperature field affects the structure. The combustion temperature depends on the propellants used, which influence the thrust and performance of the liquid propellant rocket engine and represent a key parameter in rocket engines. To study the structural behavior of the thrust chamber it is necessary to perform a 2D axisymmetric analysis which is a quick and reliable way to obtain representative results for the preliminary design and for the verification of more elaborate numerical simulations. Table of contents 1 Introduction ..................................................................................... 1 1.1 Characteristic of liquid rocket engine ....................................................... 3 1.1.1 Specific impulse (푰풔) ....................................................................................................... 3 1.1.2 Thrust .............................................................................................................................. 4 1.1.3 Characteristic velocity (풄 ∗) ............................................................................................. 6 1.2 Major components of the combustion chamber ...................................... 6 1.2.1 Combustion chamber ...................................................................................................... 6 1.2.2 Injectors ........................................................................................................................... 6 1.2.3 Propellant feed system .................................................................................................... 7 1.2.4 Valves .............................................................................................................................. 7 1.2.5 Regulators ....................................................................................................................... 7 1.2.6 Propellant tank ................................................................................................................ 7 1.2.7 Nozzle ............................................................................................................................. 7 1.3 Material selection of combustion chamber and nozzle extension .......... 7 1.4 Cooling channel analysis ........................................................................... 8 1.4.1 Cooling with steady state ................................................................................................ 9 1.5 Thesis structure ........................................................................................ 10 2 A new liquid rocket engine .......................................................... 11 2.1 Green propellants ..................................................................................... 11 2.2 Green propellants and their standards ................................................... 11 2.3 Types of green propellants ...................................................................... 12 2.3.1 LOX (Liquid oxygen) ..................................................................................................... 12 2.3.2 LOX/Kerosene ............................................................................................................... 12 2.3.3 LOX/LCH4 (Liquid methane) ......................................................................................... 12 2.3.4 LOX/LH2 (Liquid hydrogen) .......................................................................................... 13 2.4 Types of green propellant engines .......................................................... 13 2.4.1 RD-58MF ....................................................................................................................... 13 2.4.2 HM7-B ........................................................................................................................... 13 2.5 Hypergolic propellants ............................................................................
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