2020-2021 Launch 2 Learn Introductory Rocket Workshop Handbook Brought to you by Wisconsin Space Grant Consortium, Tripoli Rocketry Association and AIAA Funded through NASA Cooperative Agreement #80NSSC20M0123 and #80NSSC19M0036 Revised 2/17/21 2 Table of Contents Table of Contents 3 1. Launch 2 Learn Contacts 7 2. Workshop Supply List 8 2a. Virtual Workshop 8 2b. In-Person Workshop 8 2c. Workshop Supply Check-List 9 3. Workshop Objectives 10 4. High-Power Rocketry Overview 11 4a. Rocketry History and Organizations 11 4b. Rocketry Launch Operations 11 4c. Launch Profile Overview 11 4d. Rocketry Resources 12 4e. High-Power Rocketry Overview Notes 14 5. Structures 15 5a. Parts and Subassemblies (Build Reference 13.b.iv) 15 5b. Nosecone (Build references 13.a.vi; 13.b.vi) 16 5c. Airframe (Build reference 13.a.iv) 16 5d. Coupler (Build references 13.a.iii; 13.b.iii, iv) 16 5e. Centering Rings / Bulkplates (Build references 13.a.i, ii, iii; 13.b.ii, iii, x) 17 5f. Motor Tube (Build references 13.a.ii, iii; 13.b.ii, v) 18 5g. Motor Retention (Build reference 13.b.x) 18 5h. Rail Buttons (Build references 13.b, vii, xi) 19 5i. Fins (Build references 13.a.v; 13.b.ix) 20 5j. Structures Notes 21 6. Propulsion Systems 22 6a. HPR Definition and Classifications 22 6b. Commercial Motors 23 6c. E-Matches / Motor Ignitor 24 6d. Thrust to Weight Ratio 24 6e. Trajectory Analysis 24 3 6f. Commercial Software Packages 25 6g. Propulsion System Notes 26 7. Stability 27 7a. Center of Gravity 27 7b. Center of Pressure (Build reference 13.b.viii) 28 7c. Static Margin 28 7d. Stability Notes 30 8. Recovery Hardware (Build references 13.b.v, xii) 31 8a. Single Event Recovery System (SERS) 31 8b. Dual Event Recovery System (DERS) 32 8c. Parachutes 33 8d. Parachute Selection 34 8e. Parachute Protectors 34 8f. Recovery Hardware 34 8g. Quicklinks / Eyebolts 35 8j. Recovery Notes 36 9. Avionics System 37 9a. Avionics Bay 37 9b. Avionics Bay Housing / Coupler 37 9c. End Caps 37 9d. Avionics Sled 38 9e. Recovery Electronics 38 9f. Batteries 40 9g. Switches 40 9h. Tracking 41 i. Audible 41 ii. RF Tracking 41 iii. GPS Tracking 41 9i. Ejection Charges 41 9j. Avionics Notes 44 10. Recovery Exercise: Ejection Charge Sizing 45 4 10a. Ejection Charge Calculation Worksheet 46 11. RockSim Overview 47 11a. Creating a Model 47 11b. Importing a Model 47 11c. Running a Flight Simulation 47 11d. Interpreting Results 47 11e. Simulation Tips 47 11f. RockSim Notes 48 12. Designing and Acquiring Your Rocket 49 12a. Rocket Selection / Rocket Simulation 49 12b. Simulations 49 12c. Weight (Simulation vs. Stock Kit vs. Modified Kit with Payload) 49 12d. Recovery 50 12e. Miscellaneous Design Tips 50 12f. Design & Acquisition Notes 51 13. Rocket Build 52 13a. Pre-Fit Check 52 i. Centering Ring 53 ii. Bulkplate 54 iii. Centering Ring Alignment 55 iv. Airframe 57 v. Fins 57 vi. Nosecone 57 13b. Assembly 58 i. Epoxy Overview 58 ii. Motor Mount Assembly 59 iii. Coupler Assembly 60 iv. Coupler/Sustainer 61 v. Motor Mount 62 vi. Nosecone 63 vii. Rail Button Alignment 64 5 viii. Vent Holes 65 ix. Fin Installation 66 x. Aft Centering Ring Installation 72 xi. Rail Button Installation 73 xii. Recovery Installation 74 xiii. Parachute Preparation 75 14. Certification Launch Requirements 78 14a. Airframe 78 14b. Recovery 78 14c. Motor 78 14d. Electronics 78 14e. Certification Flight 78 14f. Post-Flight Inspection 79 14g. Non-Certification 79 14h. Certification Launch Notes 80 15. Rocket Teams – Project Management 81 15a. Suggested Team Structure 81 15b. Project Management 83 16. Reference Sheet 84 16a. WSGC Resources 84 16b. NASA Resources 84 16c. Collegiate Rocket Launch (CRL) Resources 84 16d. First Nations Launch (FNL) Resources 84 16e. Apogee Resources 84 16f. Tripoli Rocketry Association (TRA) Resources 85 16g. National Association of Rocketry (NAR) Resources 85 6 1. Launch 2 Learn Contacts WSGC Collegiate Rocket Launch Christine Bolz Dr. William Farrow WSGC Assistant Director WSGC Associate Director for Student FNL Program Director Satellite Initiatives [email protected] [email protected] 262-551-5915 First Nations Launch Danielle Weiland Aaron Ashley WSGC Space Grant Project FNL Project Assistant Coordinator [email protected] [email protected] 262-551-6237 Mark Abotossaway FNL Advisor Liaison Connie Engberg [email protected] WSGC Project Support Assistant [email protected] AIAA 262-551-6548 Trent Cybela WSGC CRL Alumni Tripoli Rocketry Assocation [email protected] Frank Nobile Wisconsin Tripoli Association Jane Denali CRL & FNL Technical Advisor WSGC CRL Alumni [email protected] [email protected] Bob Justus Illinois Tripoli Association Tripoli Assistant [email protected] Kevin Harnack Wisconsin Tripoli Association Tripoli Assistant [email protected] 7 2. Workshop Supply List 2a. Virtual Workshop If you are attending a virtual weeklong or weekend workshop, you have received a supply box with the all the items required to build your rocket. IT IS YOUR RESPONSIBILITY TO FULLY CHECK YOUR SUPPLY KIT AT LEAST 7 DAYS PRIOR TO THE WORKSHOP YOU ARE ATTENDING. A check- list is provided on the next page. If you are missing any items, email us as soon as possible at [email protected] with the subject line: “Launch 2 Learn Workshop – Missing Supplies”. In addition to the supplies we provided, you will also need to secure a quiet workspace Figure 2-1: Parts included with the LOC Precision – 3.10” Caliber ISP Rocket Kit (not including parts supplied by WSGC) with ample table space, a computer with a camera and microphone, and reliable internet. If you have concerns about your ability to participate in the workshop, please contact us as soon as possible at [email protected]. 2b. In-Person Workshop If you are attending an in-person workshop, the WSGC workshop leader will coordinate delivery of the supplies to your Institution and/or bring the materials and supplies listed below with an asterisk(*). You/Your Team will be responsible for providing all other materials and supplies: • Classroom/Workspace • Yard Stick • Computers • Ruler(s) • RockSim (1-2 licenses) • Drill(s) • Table coverings • Screw Driver Set(s) • Internet Access • Paper Towel • Projector 2c. Workshop Supply Check-List ITEM DESCRIPTION: QUANTITY: RECEIVED: Launch 2 Learn Handbook* 1 Epoxy* 1 Wooden Craft Sticks* 10 Sandpaper* 1 Pencil* 1 Wooden dowel* 1 X-Acto Knife* 1 Masking Tape* 1 Plastic Cups and Paper Plates* 5 ea. Nitrile Gloves* 5 Alcohol (wipes or bottle)* 15 or 1 Ruler 1 Drill 1 Screw Driver Set 1 Paper Towel 1 Paper or Plastic Table Runner 1 LOC Precision – 3.10” Caliber ISP Rocket Kit*: 1 Booster Airframe 1 Nose Cone 1 Coupler 1 Payload Section 1 38mm Motor Mount Tube 1 Recovery Strap 1 Parachute 1 Parachute Protector 1 Fin 4 Quick Link 2 Centering Ring Bag: Centering Ring with 2 Small Holes 1 Centering Ring with 1 Small Hole 1 Centering Ring with 0 Small Holes 1 Eyebolt 1 Washer 2 T-Nut 2 Machine Screw 2 Z-Clip 2 Rail Button Bag: Rail Button 2 Nut 2 Machine Screw 2 Wood Screw 2 Bulk Plate Bag: Bulk Plate 1 Eyebolt 1 Nut 2 3. Workshop Objectives The Launch 2 Learn Introductory Rocket Workshop has multiple objectives: ● Introduce teams to the design, build, fly stages of high-power rocketry ● Build a Level 1 high-power rocket ● Present the difference between single and dual deploy rockets ● Develop basic understanding of RockSim ● Learn to analyze RockSim data ● Understand Tripoli Level 1 certification 4. High-Power Rocketry Overview 4a. Rocketry History and Organizations Amateur high-power rocketry (HPR) began in the 1950’s following on the launch of Sputnik and coinciding with the Space Race. There are two national organizations that govern high-power rocketry: Tripoli Rocketry Association (TRA) http://www.tripoli.org National Association of Rocketry (NAR) https://www.nar.org To launch an HPR safely and legally, you must belong to one of these clubs, and follow the necessary procedures as determined by the club. 4b. Rocketry Launch Operations Launch operations require a set of TRA or NAR personnel, to safely complete a launch. At a minimum, the personnel required are: ● Range Safety Officer ● Launchpad Safety Officer ● Launchpad Manager 4c. Launch Profile Overview The typical launch profiles for high-power rockets are: ● Powered flight from the launch pad ● Coast time after burn out ● Apogee ● Deployment and recovery time ● Descent Figure 4-1: Single Deploy Flight Profile Figure 4-2: Dual Deploy Flight Profile 4d. Rocketry Resources There are many resources to be found online for the new amateur rocket enthusiast. There are many manufacturers that make rocket kits to build your HPR. Some of these include: ● Aerotech ● LOC Precision ● Madcow Rocketry ● Public Missiles Limited (PML) There are many vendors that distribute many of the kits along with other necessary rocketry supplies (think one-stop shopping): ● Apogee Rockets ● Giant Leap Rocketry ● Wildman Rocketry The Tripoli website contains links to many rocket vendors at: http://www.tripoli.org/Vendors. Kits come in a range of materials for a range of skill levels and budgets. Paper, phenolic, blue tube, fiberglass and carbon fiber are all popular choices. Recovery hardware, electronics and motors can also be found at the vendors listed on the Tripoli website. At the end of this workshop, we will recap the procedures of how to design, build and fly an HPR. 4e. High-Power Rocketry Overview Notes 5. Structures The main component of a high-power rocket build is the airframe structure itself. Other systems include recovery and propulsion. The size and internal structure of an amateur high- power rocket is different than actual rockets which attain suborbital and orbital trajectories.