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Design, Development, and Testing of Research Payloads on Various Suborbital Flight-Test Platforms

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Design, Development, and Testing of Research Payloads on Various Suborbital Flight-Test Platforms PhD Dissertations and Master's Theses 8-2021 Design, Development, and Testing of Research Payloads on Various Suborbital Flight-Test Platforms Vijay Vishal Duraisamy Follow this and additional works at: https://commons.erau.edu/edt Part of the Mechanical Engineering Commons This Dissertation - Open Access is brought to you for free and open access by Scholarly Commons. It has been accepted for inclusion in PhD Dissertations and Master's Theses by an authorized administrator of Scholarly Commons. For more information, please contact [email protected]. DESIGN, DEVELOPMENT, AND TESTING OF RESEARCH PAYLOADS ON VARIOUS SUBORBITAL FLIGHT-TEST PLATFORMS by Vijay Vishal Duraisamy A Dissertation Submitted to the College of Engineering Department of Mechanical Engineering in Partial Fulfillment of the Requirements for the Degree of Doctor of Philosophy in Mechanical Engineering Embry-Riddle Aeronautical University Daytona Beach, Florida August 2021 DESIGN, DEVELOPMENT, AND TESTING OF RESEARCH PAYLOADS ON VARIOUS SUBORBITAL FLIGHT-TEST PLATFORMS by Vijay Vishal Duraisamy Committee Chair, Dr. Birce Dikici, Associate Professor, Daytona Beach Campus, and Dissertation Committee Co-Chair Dr. Pedro Llanos, Associate Professor, Daytona Beach Campus, and Dissertation Committee Members Dr. Sathya Gangadharan, Professor, Daytona Beach Campus, Dr. Fardin Khalili, Visiting Assistant Professor, Daytona Beach Campus, Dr. Victor Huayamave, Assistant Professor, Daytona Beach Campus, and Dr. Mandar Kulkarni, Assistant Professor, Daytona Beach Campus and has been approved by the Dissertation Committee. It was submitted to the Department of Mechanical Engineering in partial fulfillment of the requirements for the degree of Doctor of Philosophy in Mechanical Engineering. Dissertation Review Committee: __________________________________ __________________________________ Birce Dikici, Ph.D. Pedro Llanos, Ph.D. Committee Chair Committee Co-chair __________________________________ __________________________________ Sathya Gangadharan, Ph.D., P.E. Fardin Khalili, Ph.D. Committee Member Committee Member __________________________________ __________________________________ Victor Huayamave, Ph.D. Mandar Kulkarni, Ph.D. Committee Member Committee Member __________________________________ __________________________________ Eric Coyle, Ph.D. Eduardo Divo, Ph.D. Ph.D. Program Chair, Department Chair, Mechanical Engineering Mechanical Engineering __________________________________ __________________________________ Maj Mirmirani, Ph.D. Lon Moeller, J.D. Dean, College of Engineering Senior Vice President for Academic Affairs and Provost ii In loving memory of my dear father, Duraisamy, who went through immense sacrifices for our family and always believed in my abilities in academics; and my best friend, Syed, who has inspired me to enjoy every moment and face everything in life with a smile. iii Acknowledgments I want to dedicate this research work to my parents, Umaa Saivignesh and Saivignesh, who have always supported me and encouraged me. Special thanks to Prabashini, my awesome wife, who encouraged and supported me in pursuing my Ph.D. I would like to express my deepest gratitude to my advisor, Dr. Birce Dikici, for her extensive support, encouragement, and her willingness to assist me in every way she could throughout this research. I would like to thank you for your patience and your advice on navigating through my Ph.D. research and defense. I would like to mention my special thanks to Dr. Pedro Llanos for mentoring me and providing me opportunities that have brought immense value to my professional portfolio. I would like to express my sincere gratitude to Dr. Sathya Gangadharan for his support and guidance. You have been a guardian and a mentor for me since I joined Embry-Riddle, for which I am forever grateful. I take this opportunity to thank my committee members: Dr. Fardin Khalili, Dr. Victor Huaymave, and Dr. Mandar Kulkarni, for their valuable feedback and insights on my dissertation. I would like to acknowledge the Department of Mechanical Engineering and the Department of Applied Aviation Sciences for supporting my research. I would like to thank Bill Russo, Alvey Gary, and Mike Potash for their fabrication help. I would like to express my special gratitude to Leander Paul, Manikandan Vairamani, Nikita Amberkar, Justin Nafziger, Cynthia Stockton, Topolski Collin, and Morgan Shilling for their help with my research. Finally, and most importantly, I would like to thank my friends, Christable, Shruthi, Faizal, Lokesh, Deepak, and all my roommates for their moral support and the great times we have had together. iv Abstract Researcher: Vijay Vishal Duraisamy Title: Design, Development, and Testing of Research Payloads on Various Suborbital Flight-Test Platforms Institution: Embry-Riddle Aeronautical University Degree: Doctor of Philosophy in Mechanical Engineering Year: 2021 With recent advances in the commercial space industry, suborbital payload launches have become more common and accessible to researchers actively seeking solutions for problems involving prolonged space travel and future missions to Moon and Mars. Suborbital payload missions compared to orbital launches are less expensive and offer faster turnaround times; however, the novelty of this domain provides unique challenges. This multidisciplinary research effort aims to tackle some of these challenges by detailing the design, development, and testing techniques followed in the successful launch and recovery of payload experiments in currently active and upcoming suborbital launch vehicles. The research methodology involves collecting payload requirements, CAD design, computational analysis, mass optimization, 3D printing, vibration, and load testing, model rocketry development, simulation, and launch operations. Structural analysis using FEA and vibration testing on a shaker table shows the compliance of the payload prototypes in the maximum predicted flight environments. Multiphase CFD analysis is used as benchmarking technique to characterize the behavior of payloads containing liquids in microgravity. Hands-on model rocketry has proven as a valuable research platform for subsequent payload deliveries. v Table of Contents Page Dissertation Review Committee ......................................................................................... ii Acknowledgments.............................................................................................................. iv Abstract ............................................................................................................................... v Table of Contents ............................................................................................................... vi List of Tables ..................................................................................................................... xi List of Figures ................................................................................................................... xii 1. Introduction ................................................................................................................. 1 1.1. Significance of Study ............................................................................................... 4 1.2. Problem Statement ................................................................................................... 5 1.3. Research Facilities ................................................................................................... 9 1.4. Limitations and Assumptions ................................................................................ 11 2. Review of Relevant Literature .................................................................................. 17 2.1. Suborbital Reusable Vehicles ................................................................................ 17 2.2. Suborbital Space Vehicles as a Platform for Microgravity Research .................... 18 2.3. Payload User Guides .............................................................................................. 18 2.4. NASA’s Flight Experiment Onboard Blue Origin’s New Shepard Vehicle ......... 19 2.5. CubeSat Approach ................................................................................................. 19 2.6. Propellant Gauging in Microgravity ...................................................................... 20 vi 2.7. Investigation of MAPMD using Floating Membranes .......................................... 21 2.8. Vibration Testing of Small Satellites ..................................................................... 21 2.9. Model Rocket Projects ........................................................................................... 22 2.10. Summary .............................................................................................................. 22 2.11. Research Contribution ......................................................................................... 23 3. CRExIM Payload ...................................................................................................... 26 3.1. Payload Design ...................................................................................................... 27 3.2. FEA with Acceleration Loads ................................................................................ 30 3.3. Random Vibration Analysis ................................................................................... 33 3.4. Mass Optimization ................................................................................................
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