JB3-2001 Design, Analysis, and Test of a High-Powered Model Rocket A Major Qualifying Project Report Submitted to the Faculty of the WORCESTER POLYTECHNIC INSTITUTE in Partial Fulfillment of the Requirements for the Degree of Bachelor of Science in Aerospace Engineering by Nicolas Amato Zachary Huamán Alicea Hyland Jacob Koslow Jordan Pickunka Jack Procaccini Saiyab Ranjit William Roe Jarod Romankiw David Santamaria Jake Scarponi Braden St.Jacques Jake Tappen April 2020 Approved by: _________________________________ John J. Blandino, Advisor Professor, Aerospace Engineering Program Worcester Polytechnic Institute Abstract This paper describes the design, analysis, assembly and test of two High-Powered Model Rocket systems, one designed with traditional subsystems for recovery, separation, and flight stabilization while a second incorporated innovative subsystems. An analysis of the composite motor was completed using Cantera and COMSOL to model the chemical equilibrium reaction and evaluate the temperature distribution in the motor during flight. These results were used to provide chamber conditions in a MATLAB model for ideal rocket performance. For the separation system, a comparison of black powder separation charges and a spring-loaded ejection mechanism was investigated. Aerodynamic loads, spin stabilization, and rocket performance were evaluated using a combination of models created for this project in MATLAB and standard computational fluid dynamic (CFD) tools in ANSYS Fluent. Data from a successful test launch is presented. The design of a second rocket, incorporating a three-blade autorotation recovery system, dual stage motors, a spring separation system, and stabilized flight control surfaces is also presented. “Certain materials are included under the fair use exemption of the U.S. Copyright Law and have been prepared according to the fair use guideline and are restricted from further use." i Acknowledgements The MQP team would like to thank and recognize the following individuals and groups for their help and support throughout the project. • Project Advisor Professor Blandino for his support and guidance throughout the project • Barbara Furhman for purchasing materials used throughout the project • Professor Hera for supporting the team with training and special support in ANSYS, Fluent, MATLAB, etc. • Professor Jagannath Jayachandran for his assistance within Cantera, COMSOL, and thermal analysis • CMASS (Central Massachusetts Spacemodeling Society) for allowing the team to launch the baseline rocket • Nick Direda for providing an introductory lesson to Cantera ii Table of Contents Abstract...........................................................................................................................................................................i Acknowledgements ...................................................................................................................................................... ii Table of Contents......................................................................................................................................................... iii List of Figures ...............................................................................................................................................................vi List of Tables ................................................................................................................................................................xi Table of Authorship .................................................................................................................................................... xii 1 Introduction ........................................................................................................................................................... 1 1.1. Literature Review ......................................................................................................................................... 1 1.1.1 Airframe and Recovery System ............................................................................................................... 1 1.1.1.1 The Airframe of a Model Rocket .................................................................................................... 1 1.1.1.2 Payload Bay .................................................................................................................................... 3 1.1.1.3 Electronics Bay ............................................................................................................................... 4 1.1.1.4 Motor Bay ....................................................................................................................................... 6 1.1.1.5 Nose cone ........................................................................................................................................ 8 1.1.1.6 Recovery System ............................................................................................................................ 9 1.1.2 Propulsion, Thermal, and Separation Systems ....................................................................................... 18 1.1.2.1 Propulsion ..................................................................................................................................... 18 1.1.2.2 Ignition/Mounting Systems ........................................................................................................... 22 1.1.2.3 Staging .......................................................................................................................................... 26 1.1.2.4 Motor Performance Analysis ........................................................................................................ 28 1.1.2.5 Temperature Distribution Analysis ............................................................................................... 29 1.1.2.6 Existing Methods of Separation .................................................................................................... 31 1.1.2.7 Carbon Dioxide (CO2) Separation................................................................................................. 33 1.1.3 Flight Dynamic Analysis ....................................................................................................................... 34 1.1.3.1 Control Systems and Fin Design ................................................................................................... 34 1.1.3.2 Avionics ........................................................................................................................................ 37 1.1.3.3 Innovative Stabilization and Rocket Rotation ............................................................................... 38 1.1.3.4 Aerodynamic Analysis .................................................................................................................. 42 1.1.3.5 ANSYS Fluent Solvers and Models .............................................................................................. 45 1.1.3.6 Flight Dynamics and Performance ................................................................................................ 50 1.2. Overall Project Goals ................................................................................................................................. 52 1.3. Overall Project Design Requirements, Constraints and Other Considerations .......................................... 55 1.4. Tasks and Timetable .................................................................................................................................. 57 2 Airframe and Recovery Systems – Design and Analysis .................................................................................... 63 2.1. Methodology .............................................................................................................................................. 63 2.1.1 Airframe Mechanical Design ................................................................................................................. 64 2.1.2 Payload Bay ........................................................................................................................................... 67 2.1.3 Electronics Bay ...................................................................................................................................... 77 2.1.4 Motor Bay .............................................................................................................................................. 80 2.1.5 Nose cone............................................................................................................................................... 82 2.1.6 Autorotation ........................................................................................................................................... 83 2.2. Analysis ...................................................................................................................................................... 92 2.2.1 Airframe Stress Distribution (ARS Analysis Task 1) ............................................................................ 93 2.2.2 Fin Analysis (ARS Analysis Task 2) ..................................................................................................... 96 2.2.3 Stresses on U-Bolt Bulkhead Coupling (ARS Analysis Task 3)............................................................ 99 2.2.4 Parachute Sizing Model (ARS Analysis