PROJECT METEOR OXIDIZER SYSTEM AND STRUCTURE DETAIL DESIGN REVIEW Friday November 9, 2007 MAGGIE ANDERSON NATHAN CONFER TONY NIMEH TIM SEIBERT CHRIS WERGIN 4/9/2019

CONTENTS METEOR Overview Team Organization Deliverables Hybrid Rocket Concept Strategy Detail Design Overall Hybrid Rocket Structure and O.D.S Oxidizer Tank Oxidizer Delivery System Structure Finite Element Analysis Deliverables Revisited SDII Project Plan Questions/Discussion *Please feel free to ask questions or make comments during the presentation* 4/9/2019

Introductions Tim Seibert Maggie Anderson Chris Wergin Tony Nimeh Nathan Confer Tim Seibert Maggie Anderson Chris Wergin Tony Nimeh 4/9/2019

Project METEOR strives to create a lower-cost Project Background Project METEOR strives to create a lower-cost alternative to current low-Earth orbit launch solutions for "Picosatellites", a class of satellites weighing approximately 1 kg. The purpose of the Rocket Integration Team is to accept the hybrid engine while incorporating the remainder of the major rocket subsystems. 4/9/2019

Project Overview 4/9/2019

Benchmarking and Brainstorming Chalice Design Embedded Design After investigating the previous team’s work and looking into other hybrid rocket designs it became obvious that the project has three major components. These components are the frame, the tank, and the oxidizer delivery system. 4/9/2019

Team Organization Project Manager Technical Lead Frame Oxidizer Tank Nathan Confer Technical Lead Tony Nimeh Tank Design -sizing dimensions -material considerations Manufacturing -composite capabilities Frame Tony Nimeh (focal) Tim Seibert Super Structure -assembly rods -support plates Oxidizer Tank Chris Wergin (focal) Tony Nimeh Delivery System Maggie Anderson (focal) Nathan Confer Components -piping -valves Safety -burst prevention -pressure regulators 4/9/2019

Constraints and Objectives Tank Importance N20 tank needs to sustain pressure of 2500 psi 9 Incorporate safeguards with respect to burst pressure Oxidizer Delivery System Maintain pressure of 1500 psi at the injector plate Controllable (steady) flow rate Safe fuel delivery system Tank refilling mechanism 3 Fuselage Accept and support delivery system, tank, motor Withstand heat transfer from combustion Accommodate payload integration Power source for pressure regulator 4/9/2019

Hybrid Rocket Concept 4/9/2019

From Concept to Reality… Engineering the Future Tank Design 4/9/2019

Oxidizer Tank 4/9/2019

N20 Pressurization Oxidizer Tank Single-tank configuration with Helium gas used to pressurize the liquid nitrous oxide. Goal: Deliver 1500 psi to injector plate Helium (gas) Nitrous Oxide (liquid) 4/9/2019

Equations Used to Size Oxidizer Tank 1st Law of Thermodynamics (N2O) Ideal Gas Law Isentropic Assumption (Helium) 4/9/2019

MATLAB Program Results – End Pressure Tank Volume 4/9/2019

MATLAB Program Results – End Pressure Initial Temperature 4/9/2019

MATLAB Tank Evacuation Solution 4/9/2019

Final Oxidizer Sizing Prefab composite Tank produced by SCI composites Aluminum liner with carbon/glass reinforcement 1212 cubic inch volume 3259psi rated service pressure Pressure tested to 5000psi 18.7lbs empty weight Tank already purchased by P07109 4/9/2019

From Concept to Reality… Engineering the Future Oxidizer Delivery System 4/9/2019

Oxidizer Delivery System 4/9/2019

Head Loss Calculations Pressure at a given point: Reaction from Momentum Flux: 4/9/2019

Head Loss Calculations Mass Flow Rate: Velocity: 4/9/2019

Head Loss Calculations Continued Head Loss Term: Reynolds Number: Friction Coefficient: Relative Roughness: 4/9/2019

Head Loss Values Component Description Head Loss (in) A N2O Tank 0.00 1 N2O Tank Connection Port 16.48 2 N2O tank Fitting 0.19 3 Cross Fitting 73.36 4 Connection Nipple 0.06 5 Remote Ball Valve 1.39 6 7 Pressure Regulator / Flow Switch 0.28 8 9 Flexible Hose + Connectors 5.61 10 11 Check Valve 244.23 12 13 14 15 Injector Plate Connection Port 0.05 B Injector Plate TOTAL 415 4/9/2019

Feed System: Part Selection Aaaaaaaahhhhhhhhhhhh that’s a lot of money! With a regulator in there, I just spent about 4/5 of our budget! Well, at least the feed system will be pretty sweet. 4/9/2019

Feed System: Part Details Relief Valve Desired range: 3000-3600 psi Proof pressure: 4500 psi Stainless steel construction ½” Pipe Size 250°F max temperature ~$450 each 4/9/2019

Feed System: Part Details Ball Valve 316 Stainless Steel ball 17-4 PH SS stem Delrin seats PTFE body seals & packing ½” Pipe Size 4500 psi max at 120°F $126.45 each Check Valve 303 Stainless Steel 440 SS ball 5000 psi max at 400°F $86.40 4/9/2019

Feed System: Part Details Metal Hose and JIC Swivel Female Fittings T361L SS heavy-weight hose T321 SS double braid 1500°F max temperature ½” Pipe Size Minimum length for vibration = 6 in 4/9/2019

Feed System: Part Details Circle Seal Pressure Regulator 303 Stainless Steel body Orifice = 0.145” Cv = 0.37 Inlet/Outlet: 0-6000 psig 160°F max temp ~$2000 (approximation based on P07105 Emerson Quote) 4/9/2019

From Concept to Reality… Engineering the Future Structure 4/9/2019

Structure 4/9/2019

Rods Rings Structural Skeleton Continuous-length distributes thrust and weight Lightweight & strong Excess length for future add-ons Rings Anchored to rods Spaced so as to avoid buckling Chamfered in order to support tank 4/9/2019

Structural Skeleton Rod analysis Worst-Case (Axial Stress): Vert. Test Stand Fixed at top, Axial load Worst-Case (Bending Stress): Balloon Ascent TBD depending on carriage 4/9/2019

Sourcing Rods Structural Skeleton Online Metal Store – round bar stock Grade 5 more difficult to machine than 2 4/9/2019

Sourcing Rings Structural Skeleton McMaster-Carr – Aluminum plate stock 6061 Al is reasonable to machine in-house 4/9/2019

From Concept to Reality… Engineering the Future Finite Element Analysis 4/9/2019

Boundary Conditions At the nozzle end there are 75 pounds force per rod in the negative Z direction At the payload end all displacement degrees of freedom are fixed at 0 4/9/2019

Displacement Maximum deflection is 0.074623 inches in the direction of the force loading which is located at the nozzle end of the assembly 4/9/2019

Maximum Stress Maximum stress is 6280 psi which is located at the payload end of the assembly 4/9/2019

Vibration – Modal Analysis 4/9/2019

Vibration – Modal Analysis 4/9/2019

From Concept to Reality… Engineering the Future Concluding Remarks 4/9/2019

Constraints and Objectives Revisited Tank Importance N20 tank needs to sustain pressure of 2500 psi 9 Incorporate safeguards with respect to burst pressure Oxidizer Delivery System Maintain pressure of 1500 psi at the injector plate Controllable (steady) flow rate Safe fuel delivery system Tank refilling mechanism 3 Fuselage Accept and support delivery system, tank, motor Withstand heat transfer from combustion Accommodate payload integration Power source for pressure regulator in progress to be determined 4/9/2019

Senior Design II Outlook Review finalized design, milestones, and lessons learned from SDI Establish part delivery dates Resolve any shipping delays or unexpected setbacks during transition from SDI to SDII Finalize manufacturing schedule Setup manufacturing and assembly completion date(s) Correlate with P08105 for date to assemble entire rocket (tank with engine) Test entire rocket assembly (if time allows) Write up design, manufacturing, and testing, reports and conclusions (and poster) 4/9/2019

Senior Design Two Schedule Senior Design One Update edge Finalize pressure regulator selection Finalize SDII Testing Plans Order parts Week 1 Review Senior Design One deliverables, calculations, and design criteria Determine locations and delivery dates of all parts Begin assembly of rocket body Begin assembly of testing mechanisms Week 2 – 4 Validate design Completely assemble all subsystems Place subsystems into entire assembly Complete assembly on testing mechanisms 4/9/2019

Senior Design Two Schedule Week 5 - 7 Analyze data from testing Re-evaluate testing mechanisms and scheduling Coordinate testing with P08105 Week 8 – 11 Retest proper conditions based on conclusions from weeks 5-7 Make project poster Write up technical paper Present Senior Design Two Deliverables Ensure proper documentation of all paperwork and procedures 4/9/2019

questions comments concerns 4/9/2019

thank you 4/9/2019