Critical Design Review University of Alabama in Huntsville January - PowerPoint PPT Presentation

NASA USLI 2020 Critical Design Review University of Alabama in Huntsville January 23rd, 2019 1

Presentation Agenda ● Introduction - Charger Rocket Works (CRW) Team, Project Overview ● Vehicle - CONOPs, Component Design Overview, Recovery System Overview, Mass Estimation, Flight Profile, Subscale Launch Report, Test Plans ● Payload - Design Overview, Mass Information, Electrical Information ● Safety - Test Safety Procedures, Hazard Analysis, Safety Verifications/Manual/Briefings ● Management - Schedule, Status of Requirements Verification, Budget Updates, Outreach Updates ● Questions 2 Introduction - Nick Roman

2019-2020 CRW Team Team Detail 20 Students participating as ● part of UAH Senior Rocket Design Course 8 Mechanical Engineers ○ 12 Aerospace Engineers ○ 3 Students with prior rocketry ● experience through NAR Level Certifications 2019-2020 CRW USLI Subscale Launch Mission Statement To give students an opportunity to gain experience with high-powered rocketry via the year-long system life cycle and share the knowledge gained with NASA and those in our communities through outreach programs. Introduction - Nick Roman 3

Project Overview CRW will complete the following mission objectives according to requirements set forth by NASA and CRW derived requirements. ● CRW has designed and will manufacture a launch vehicle capable of: ○ Launching and carrying payload safely to 4500 ft. Above Ground Level (AGL) ○ Descending via drogue parachute until 600 ft. AGL where main parachute and payload will leave body tube ○ Upon touchdown Payload will detach and complete mission ● CRW has designed and will manufacture a manually operated rover capable of: ○ Safely leaving body tube at 600 ft. AGL ○ Detaching from recovery harness after landing ○ Traversing the launch field to an objective zone ○ Gathering at least 10 ml of simulated ice ○ Retreating at least 10 ft. away from the objective zone after collection 4 Introduction - Nick Roman

Project Overview (Cont.) Vehicle: ● Length 135” Diameter 6.17” Weight 55.8 lbs. (loaded w/ payload) ○ Payload: ● Length 15.75” Width 4.5” Height 3.875” Weight 9 lbs. ○ Budget: ● Current Expenditures: $2,504.48 ○ Current Projected Cost: $5932.00 ○ Total Expected Funding: $8,448.83 ○ Schedule: ● Schedule is progressing as planned ○ Next Milestone is first Full Scale flight on Jan 18th, 2020 ○ Requirements & Verifications: ● CRW Derived Requirements are 14% Compliant ○ NASA Requirements are 19% Compliant ○ CDR Key Accomplishments: ● Final Design has been completed and modeled ○ Testing plans are in place for requirement verification ○ SOP’s are in place for Black Powder and Subscale and Full Scale ○ I ntroduction - Nick Roman 5

Vehicle Sub-Team Lead: Peter Martin Safety Deputy: Maggie Hockensmith 6

Concept of Operations Vehicle - Jacob Zilke 7

Vehicle Changes Since PDR Payload retention and deployment system entirely redesigned to include retention ● cage Main parachute increased in size from Fruity Chutes IFC-96 inch to Fruity Chutes ● IFC 144 inch so cut costs, with 144 inch chute already on hand. Drogue parachute downsized from Fruity Chutes CFC-24 inch to Fruity Chutes ● CFC-18 inch to increase descent velocity under drogue to meet flight time requirements with larger main parachute. Giant Leap Rocketry Slider added to main parachute to mitigate increased shock ● force from larger main parachute Thrust plate and aft centering ring combined into one unit that will be machined in ● house 8 Vehicle - Jacob Zilke

Vehicle Characteristics Vehicle CAD Model ● Total Vehicle Length ● Motor ○ 135 inch ○ AeroTech L2200G ● Body Diameter ● Static Stability ○ 6 inch ○ 2.4 caliber ● Nose Cone ● Velocity off rail ○ 24 inch ○ 73 ft/sec ● Upper Airframe ● Apogee ○ 60 inch ○ 4500 feet AGL ● Lower Airframe ● Drogue Parachute Deployment ○ 48 inch ○ at apogee ● Coupler with Cage Assembly ● Main Parachute Deployment ○ 32 inch ○ 600 feet AGL ● Launch weight ● Kinetic Energy at Landing ○ 55 lbm ○ 39.1 lbf 9 Vehicle - Jacob Zilke

Launch Vehicle Mass Budget Sub-Assembly Mass (lbm) Percentage of Mass Per Sub-Assembly Lower Airframe 17.2 Fin Assembly 3.5 Coupler and Avionics 5.9 Retention Cage and Upper 10.4 Airframe Nose Cone and Tracking 3.47 Assembly Drogue Parachute Assembly 1.52 Main Parachute Assembly 4.78 Payload 9 Total 55.8 Vehicle- Jacob Zilke 10

Upper Airframe Overview Overview: 24 inch 4:1 Ogive nose cone ● 60 inch upper airframe body tube length ● G12 Fiberglass ● Major inner diameter of 6 inch ● Houses main parachute and payload ● Tracker housed in nose cone ● 3.875 in Shock Cord Main Parachute Shoulder Tracker 4:1 Ogive Nose Nose Cone Coupler/Payload Cone Bulkhead Upper Airframe Diagram Vehicle - Jacob Zilke 11

Coupler/Payload Retention Overview Overview: 18 inch payload bay ● 14 inch coupler length ● Major outer diameter of 5.98 inch ● Houses payload bay and avionics sled ● ⅜ x 11/16-inch eye bolts ● ¼ -20 threaded rods ● Aft Coupler Forward Payload Bay Bulkhead Payload Coupler Forward Bulkhead Bulkhead Payload Switch Band AV Sled Retention 12 System Vehicle - Jacob Zilke

Coupler Overview • Four terminal blocks for redundant drogue and main parachute deployment charges • Key switches on switch band for redundant altimeters • Four 0.404 inch diameter static reference ports on switch band • Two ABS 3D printed charge wells on aft bulkhead for drogue deployment charges Terminal Block Switch Band Key Switch Charge Well Vehicle - Jacob Zilke 13

Lower Airframe Overview Overview: ● 48 inch lower airframe length ● Major inner diameter of 6 inch ● Houses drogue parachute and motor ● 4 fins mounted with individual 3D printed brackets ● Screw on aft motor retentainer with machined aluminum thrust plate Fin Bracket Rail Button Drogue Parachute Motor Case Motor Shock Cord Centering Bulkhead Retention Ring Lower Airframe Diagram Vehicle - Jacob Zilke 14

Lower Airframe Bulkhead Design: Lower airframe attachment point for ● recovery harness Machined from ⅜ inch thick 6061-T6 ● aluminum plate Attached to body tube with four #8-32 ● screws Lower Airframe Bulkhead Structural Analysis: 500 lb load applied at center eye bolt hole ● Constrained at airframe mount holes ● Yield stress of 40 ksi ● Maximum Von Mises Stress ● 24.7 ksi ○ Located at eye bolt hole ○ Lower Airframe Bulkhead FEA Vehicle - Jacob Zilke 15

Centering Ring Keeps motor case aligned parallel to ● airframe Machined from ⅜ inch thick ● aluminum plate Attached to body tube with four #8-32 ● screws Holes machined for weight reduction ● Centering Ring Vehicle - Jacob Zilke 16

Motor Retention Thrust Plate: Machined in-house ● Eliminates need for separate aft ● Thrust centering ring Plate Simplifies assembly ● Transfers thrust load to body ● tube Retainer Attaches to body tube with four ● #8-32 screws Retainer: Retentianer Ring Aeropack flanged 75 mm ● Motor Retention retainer Assembly Attaches to thrust plate with ● twelve #6-32 screws Transfers thrust to thrust plate ● Retainer ring holds motor after ● burnout Vehicle - Jacob Zilke 17

Thrust Plate FEA ● Material ○ Aluminum 6061-T6 ○ Yield Stress of 40 ksi ● Loading ○ Constrained at airframe mount holes ○ Boost ■ Compression load of 1050 lbf Thrust Plate ■ Safety factor of 1.5 Boost FEA ■ Max stress 35 ksi ○ Coast/Descent ■ Tensile load of 500 lbf ■ Max stress 18.5 ksi Thrust Plate Coast/Descent FEA Vehicle - Jacob Zilke 18

Payload Retention System ● Cage Information: ● Forward Bulkhead ● Cage Bars ○ Height is 18.25 inch ○ OD 5.77 inch ○ 0.25” x 1” x 18” ○ Mass is 2.58 lbm ○ Thickness is 0.25 inch ○ 6061-T6 Aluminum ○ Fabricate in House ○ 6061-T6 Aluminum ○ 3 Bars Total ○ Located in the Upper ○ Hole OD 1.5 inch Airframe ● Aft Bulkhead ● 6061-T6 Aluminum ○ OD 5.9 inch ○ Yield Stress is 40 ksi ○ Thickness is 0.25 inch Density is 168.6 lbm/ft 3 ○ ○ 6061-T6 Aluminum Vehicle - Jacob Zilke 19

Cage Aft Bulkhead FEA ● Von Mises Stress ○ Used to determine if a material will yield or fail ○ Good representation of the magnitude of stress on a material ● FEA Analysis ○ Tetrahedral Mesh applied ○ Mesh Size is 0.497 inches ○ Force applied on center hole Fixed Constraints ○ Due to parachute shock load ○ FEA ran at 900 lbf ○ Actual shock load estimated to be 714 lbf at a Factor of Safety of 1.5 ● FEA Results ○ Max Von Mises is 48.1 ksi due to Hot Spot ○ True value is 1 Element from Hot Spot location ○ Actual Max Von Mises is ≅ 32.1 ksi ○ Structural Safety compared to Factor of Safety is 1.25 Applied Force Vehicle - Jacob Zilke 20