1. Outer Shell (fuel grain housing) Inner Shell (NOS/rocket housing)
Inner and Outer Shell ANSYS Stress Modeling (Embedded Fuel Grain Concept)
Model Geometry
Outer Shell (fuel grain housing)
Outer radius: 2.40” (~61mm)
Inner radius: 2.36” (~60mm)
Height: ” (~545 m)
Mat’l: Aluminum 7075 T6
Inner Shell (NOS/rocket housing)
Outer radius: 1.75” mm ( m)
Inner radius: 1.25” ( m)
Height: 1.5” ( m)
Mat’l: Al 7075 T6 with Composite over-wrap
Composite: IM7 Carbon (fiber) / PEEK (matrix)

2. Inner and Outer Shell ANSYS Stress Modeling (Embedded Fuel Grain Concept)
Material Properties
Al 7075-T6
(Modeled as Isotropic)
Density: 2810 kg/m3
Longitudinal Mod., E1: 71.7e9 Pa
Poisson’s Ratio, v12: 0.33
Carbon/PEEK Composite
(Modeled as Isotropic)
Density: 1600 kg/m3
Longitudinal Mod., E1: 71.7e9 Pa
Transverse Mod., E2: 10.2e9 Pa
Poisson’s Ratio, v12: 0.30
Shear Modulus, G12: 5.7e9
PEEK (matrix)
Density: 1376 kg/m3
IM7 Carbon Fiber (12,000 filaments)
(Modeled as Orthotropic)
Density: 1780 kg/m3
Longitudinal Mod., E1: 278e9 Pa
Poisson’s Ratio, v12: 0.20

3. Outer Shell (w/ composite)
Inner and Outer Shell ANSYS Stress Modeling (Embedded Fuel Grain Concept)
Outer Shell (w/ composite)
Figure 1: Outer Shell of Imbedded Fuel Grain Design
(Meshed Elements – 8node93)

4. Outer Shell (w/ composite)
Inner and Outer Shell ANSYS Stress Modeling (Embedded Fuel Grain Concept)
Outer Shell (w/ composite)
Figure 2: Outer Shell of Imbedded Fuel Grain Design:
Plot Results  Contour Plot  Element Solution  Stresses  von Mises stress

5. Outer Shell (w/ composite)
Inner and Outer Shell ANSYS Stress Modeling (Embedded Fuel Grain Concept)
Outer Shell (w/ composite)
Figure 3: Outer Shell of Imbedded Fuel Grain Design:
Plot Results  Deformed Shape  Def + undeformed

6. Outer Shell (w/ composite)
Inner and Outer Shell ANSYS Stress Modeling (Embedded Fuel Grain Concept)
Outer Shell (w/ composite)
Figure 4: Outer Shell of Imbedded Fuel Grain Design:
(Pressure & Constraints – Rotated view)

7. Outer Shell (w/ composite)
Inner and Outer Shell ANSYS Stress Modeling (Embedded Fuel Grain Concept)
Outer Shell (w/ composite)
Figure 5: Outer Shell of Imbedded Fuel Grain Design:
(Pressure & Constraints - Front View)

8. Outer Shell (w/ composite)
Inner and Outer Shell ANSYS Stress Modeling (Embedded Fuel Grain Concept)
Outer Shell (w/ composite)
Figure 6: Outer Shell of Imbedded Fuel Grain Design:
(Pressure & Constraints - Side View)

9. Inner Shell (All Aluminum)
Inner and Outer Shell ANSYS Stress Modeling (Embedded Fuel Grain Concept)
Inner Shell (All Aluminum)
Figure 7: Inner Shell of Imbedded Fuel Grain Design
(Meshed Elements – 8node93)

10. Inner Shell (All Aluminum)
Inner and Outer Shell ANSYS Stress Modeling (Embedded Fuel Grain Concept)
Inner Shell (All Aluminum)
Figure 8: Inner Shell of Imbedded Fuel Grain Design:
Plot Results  Contour Plot  Element Solution  Stresses  von Mises stress

11. Inner Shell (All Aluminum)
Inner and Outer Shell ANSYS Stress Modeling (Embedded Fuel Grain Concept)
Inner Shell (All Aluminum)
Figure 9: Inner Shell of Imbedded Fuel Grain Design:
Plot Results  Deformed Shape  Def + undeformed

12. Inner Shell (All Aluminum)
Inner and Outer Shell ANSYS Stress Modeling (Embedded Fuel Grain Concept)
Inner Shell (All Aluminum)
Figure 10: Inner Shell of Imbedded Fuel Grain Design:
(Pressure & Constraints – Rotated view)

13. Inner Shell (All Aluminum)
Inner and Outer Shell ANSYS Stress Modeling (Embedded Fuel Grain Concept)
Inner Shell (All Aluminum)
Figure 11: Inner Shell of Imbedded Fuel Grain Design:
(Pressure & Constraints – Front view)

14. Inner Shell (All Aluminum)
Inner and Outer Shell ANSYS Stress Modeling (Embedded Fuel Grain Concept)
Inner Shell (All Aluminum)
Figure 12: Inner Shell of Imbedded Fuel Grain Design:
(Pressure & Constraints – Side view)

15. Outer Shell (Aluminum only)
Inner and Outer Shell ANSYS Stress Modeling (Embedded Fuel Grain Concept)
Outer Shell (Aluminum only)
Figure 13: Outer Shell of Imbedded Fuel Grain Design
(Meshed Elements – 8node93)

16. Outer Shell (Aluminum only)
Inner and Outer Shell ANSYS Stress Modeling (Embedded Fuel Grain Concept)
Outer Shell (Aluminum only)
Figure 14: Outer Shell of Imbedded Fuel Grain Design:
Plot Results  Contour Plot  Element Solution  Stresses  von Mises stress

17. Outer Shell (Aluminum only)
Inner and Outer Shell ANSYS Stress Modeling (Embedded Fuel Grain Concept)
Outer Shell (Aluminum only)
Figure 15: Outer Shell of Imbedded Fuel Grain Design:
Plot Results  Deformed Shape  Def + undeformed

18. Inner and Outer Shell ANSYS Stress Modeling (Embedded Fuel Grain Concept)
Outer Shell (Aluminum only)
Figure 16: Outer Shell of Imbedded Fuel Grain Design:
(Pressure & Constraints – Rotated view)

19. Inner and Outer Shell ANSYS Stress Modeling (Embedded Fuel Grain Concept)
Outer Shell (Aluminum only)
Figure 17: Outer Shell of Imbedded Fuel Grain Design:
(Pressure & Constraints - Front View)

20. Inner and Outer Shell ANSYS Stress Modeling (Embedded Fuel Grain Concept)
Outer Shell (Aluminum only)
Figure 18: Outer Shell of Imbedded Fuel Grain Design:
(Pressure & Constraints - Side View)

21. Inner and Outer Shell ANSYS Stress Modeling (Embedded Fuel Grain Concept)
Figure 19: ELEMENT LAYERS

22. Inner and Outer Shell ANSYS Stress Modeling (Embedded Fuel Grain Concept)
Figure 20: LAYER ORIENTATION AND THICKNESS

23. Inner and Outer Shell ANSYS Stress Modeling (Embedded Fuel Grain Concept)
Figure 21: LAYER ORIENTATION AND THICKNESS continued…

24. Inner and Outer Shell ANSYS Stress Modeling (Embedded Fuel Grain Concept)
Figure 22: COMPOSITE PROPERTIES

25. Inner and Outer Shell ANSYS Stress Modeling (Embedded Fuel Grain Concept)
Figure 23: ALUMINUM PROPERTIES

26. Inner and Outer Shell ANSYS Stress Modeling (Embedded Fuel Grain Concept)
Figure 24: FAILURE CRITERIA FOR COMPOSITES

27. Inner and Outer Shell ANSYS Stress Modeling (Embedded Fuel Grain Concept)
Figure 25: INVERSE TSAI-WU STRENGTH RATIO INDEX

28. Inner and Outer Shell ANSYS Stress Modeling (Embedded Fuel Grain Concept)
Figure 26: X-COMP OF STRESS

29. Inner and Outer Shell ANSYS Stress Modeling (Embedded Fuel Grain Concept)
Figure 27: Y-COMP OF STRESS

30. Inner and Outer Shell ANSYS Stress Modeling (Embedded Fuel Grain Concept)
Figure 28: X-COMP OF STRESS

31. Inner and Outer Shell ANSYS Stress Modeling (Embedded Fuel Grain Concept)
Figure 29: SHEAR XY-DIR

32. Inner and Outer Shell ANSYS Stress Modeling (Embedded Fuel Grain Concept)
Figure 30: SHEAR YZ-DIR

33. Inner and Outer Shell ANSYS Stress Modeling (Embedded Fuel Grain Concept)
Figure 31: SHEAR XZ-DIR