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8/6/2019 VVI Solid Rocket Motor Design and Testing
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SOLID PROPELLANT ROCKET MOTOR
DESIGN AND TESTING
Richard A. Nakka
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SOLID PROPELLANT ROCKET MOTOR
DESIGN AND TESTING
A Thesis
Presented to
The Department of Mechanical Ensineerins
The Faculty of Ensineerins
The Univer5it~ of Manitoba
In Partial Fulfillment
of the re~uirements for the deSree
Bachelor of Science in Mechanical Ensineerins
b~
Richard Allan Nakka
April 1984
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ABSTRACT
This thesis examines the theoretical performance of a
solid propellant rocket motor which was developed for launchinS
small amateur research rockets. The theoretical results are pre-
sented irithe form of two limiting cases concerning the behaviour
of the two-phase exhaust flow. Actual testing of the motor is
performed utilizinS a speciall~ desiSned test rig in order to
compare the results. As well, optimization of the motor's per-
formance is investigated.
The theoretical performance is found to be in sood asree-
ment with the test results, providinS a basis for future design
of larger engines.
No significant improvement in overall motor performance
as a result of modifications is foreseen.
ii
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ACKNOWLEDGEMENT
I would like to ex~ress sratitude to m~ thesis advisor
Dr.B.R. Sat~a~rakash for the time and patience he has devoted to
me in preparinS for this thesis. I would also like to thank Dr.
s . Balakrishnan for aauaintins me with proSramming the computer
N-C lathe. and Dr.D. M. McKinnon for his devotion to the
problems of propellant combustion. As well, special thanks to
Blair W. Nakka for supplying the microcomputer facilities and for
providing assistance with the softWare and circuit development.
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CHAPTER
ABSTRACT
TABLE OF CONTENTS
........ I I o f .. o f " ..
ACKNOWLEDGEMENTS
INTRODUCTION
1.1
1.2
1.3
2: THEORY
3 :
Propellant
Rocket Motor
11 .
Experimentation
................. 1
....................................................................Solid Propellant Rocket
Propellant
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I ..
Composition
Combustion
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Propellant Grain
NOZZLE THEORY t t of .
3.1
3.2
Nozzle Flow ................ t " .
3.2.1
Rocket Performance Parameters
Thrust ........ + , ..
.... t .
Thrust Coefficient . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Characteristic Exhaust Velocit~ t + ..
Impulse
Chamber Pressure t .
Corrections for Two-Phase Flow
Corrections for Real Nozzles
. . . . . . . . . . . .. . . . . . . . . . . . . .
PAGE
ii
iii
1
1
1
2
4
4
5
5
6
12
16
16
22
23
24
25
26
28
30
34
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4 : EXPERIMENTAL TECHNIQUE
Motor .................................. I ..1
4.2
4.3
4.4
4.5
4.6
5 :
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cubic Nozzle Profile . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Propellant Preparation ................... t to to
Var~in~ OIF Ratio ...... l' I .
Burnrate Testin~ ................. f to to .
Motor Static Testin~ ................ t ..
Test Ri~ Construction . .. . .. . .. .. . o fof t .... t ....
Calibration ...............................
RESULTS (Theoretical and Actual)
Nozzle Testin~ to f o f ..
........ ttt.tf
5.5.1
5.1.2
5.1.3
5.1.4
Motor Testins of Var~inS OIF Ratio Grains
Burnrate Testins ... .. ... ... ... to of o f ...
Performance Parameters
6.1
DISCUSSION OF RESULTS
Nozzle Testina .................. 1 ....... 1 .... 1
6.3
6.4
CONCLUSIONS
RECOMMENDATIONS
Motor Testins of Var~ing OIF Ratio Grains t ........
37
37
38
40
42
42
43
44
49
51
51
54
57
60
61
61
62
64
65
68
69
NOMENCLATURE 70
73EFERENCES
Burnrate Testing .11 .
Performance Paramete~s I to o f o f ..
..................................... 11 .
..... ...... ...... ...... ...... ..... ...... ...... ...... ...... .... +
........................................................... t .. t ......
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APPENDIX At Calculation of AFT for the 65/35 OIF ratio
APPENDIX B: Calculation of k for flow throush the nozzle
APPENDIX C: Derivation of eouation for exhaust velocit~, modifiedfor two-phase flow.
APPENDIX D: Derivation of eQuation for thrust, modified for two-phase flow.
APPENDIX E: Rocket motor design and specifications.
APPENDIX F: Strain gauge bridse-ampifier circuit diasram.
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2
essionall~ designed rockets. Therefo~e, there was no known data
available on the performance characteristics of this propellant.
This necessitated a theoretical anal~sis coupled with experiment-
ation on combustion product anal~sis, combustion temperature
measurements, burn rate ~easurement and the effects of varYing
the oxidizer-fuel (O /F ) ratio.
1.3 EXPERIMENTATION
Testin~ of the actual motor was conducted on a specially
desi~ned static testing stand. The static testin~ stand ~er-
mitted the motor thrust to be recorded continuously throughout
the firing, accomplished by converting the thrust to an electric
analo~ue siSnal which was amplified, di~itized by an AID converter,
then stored in a computer for processinS.
Optimization of the propellant involved testin~ the
effects upon its performance by var~inS O I F ratios. The motor
optimization consisted of modification to the nozzle desisn, inorder to attempt to increase the nozzle efficiency.
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FiSure 1.1. Rocket launch eauipped with small solid motor.
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CHAPTER 2: THEORY
2.1 Solid Propellant Rocket
A twpical solid propellant motor (fiSure 2.1) is of simple
construction, contain ins no movable parts. The maJor components
-SHEAR PIN-CASING
HEAD -NOZZLE
. SECTION A-A.
GASKETS PROPELLANT GRAIN
FiSure 2.1. A twpical solid propellant motor
include the combustion chamber, which contains the propellant
Srain of particular Seometr~ which in turn determines the surface
burninS area. Combustion of the Srain Senerates hiSh temperature
Sases, which are ejected throush an exhaust nozzle. designed to
accelerate the Sases to as hish a velocit as possible. The
throat is the point in the nozzle of least diameter, and the head
being the front of the motor. Combustion is initiated by passing
an electrical current through an isniter which contains a charge
,of black powder.
The theoretical anal~sis of the rocket motor necessitates
certain simplifications. that is. the assumptio~ of an ideal
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5
rocket. The usefulness of this concept is indicated b~ the ~act
that measured performance can be expected to be within 1 to 10
per cent of calculated ideal values [2].
An ideal rocket assumes the followinS:
(1) The propellant combustion is complete and nonvariant to that
assumed b~ the combustion eauation.
(2) The work inS substance obeys the perfect Sas law.
(3) There is no friction.
(4) The combustion and flow in the motor and nozzle is adiabatic.
(5) Stead~-state conditions (unless stated otherwise).
(6) Expansion of the workins fluid occurs in a uniform manner
without shock or discontinuities.
(7) Nozzle flow is one dimensional.
(8) The sas velocitw. pressure, and densitw is uniform across
anw cross section normal to the nozzle axis.
(9) Chemical eauilibrium is established in the combustion chamber
and does not shift in the nozzle.
An~ additional assumptions will be stated as necessarw.
2.2 Propellant
2.2.1 Composition
The important considerations for amateur rocket propellants
are the availabilitv of the constituentsr costr safet~ of hand-
lins csstabilitYr consistenc~ of performance, and adeQuate perfor-
mance. The propellant that is investisated here easily meets or
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exceeds these reQuirements.
The propellant consists of sucrose (suSar) fuel with potas-
sium nitrate as the oxidizer. The O/F ratio is chosen on the basis
of which ratio Sives the sreatest overall perfrmance for a siven
propellant Srain desiSn. For most propellants includins this one,
it is on the fuel rich side of stoichiometric. More accuratel~,
var~ins the O/F ratio affects both the characteristic exhaust
velocit~, CV, (essentiall~ relates to the ener9~ available), the
burnrate, r, and the Quantit~ of non-Saseous exhaust products.
These aspects are trealed in closer detail elsewhere.
Combustion
The assumed combustion eauation is based on the reaction of
potassium nitrate (KN0 3) with ox~~en (02) [3J, and upon the decom-
osition of sucrose (C12H22011) upon heatins [4J. The assumed
combUstion eauation is;
a C12
H22
011 + b KN03--> c CO + d CO
2+ e H
20 + f K
2C0
3+ 5 1 N2 +
h C + i 02
where K 2C03 represents potassium carbonate, where the coefficients
a throush i are dependant upon the OIF ratio with c,h or i often
beins zero.
This eQuation assumes that secondar~ exhaust products (such
as NO,K 20, etc.) are formed in negligible Quantities. As well, the
effects of dissociation are assumed neSlisible. This second assum-ption is ser~erall~ valid for combustion temperatures below 1700 K.
particularly at hi~her pressures [5J. It should be noted that
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there are two non-SaseOU5 products formed, K2 C0 3 and carbon, from
which no expansion work can be derived.
Knowled~e of the combustion eauation allows the calculation
of the adiabatic flame temperature (AFT), the maximum possible
balance:
combustion temperature. The AFT is determined from an enthalpv
+ .6 h ] = L: n [hOp e f
+i
where Rand P refer to the reactants and products, respectivel~,
nj and ne are the individual reactant and product molal numbers-0 -
respectivel~'Ahf ' the enthalp~ of formation per mole'Ah , the
standard enthalp~ at the specified temperature, per mole, and
where:
.6.h =
and .6.h =tr
T =1
T =K
C =p
T K
f .e dTT1 penthalpv of transition/mole
+ .6.htr
reference temperature, t~picall~ 300 K
AFT
specific heat at constant pressure/mole
O/F := 65/35.
Appendix A contains a sample calculation for the case of
flame temperatures [7].
Fi~ure (2.2) shows a comparison of theoretical to actual
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4000
3000
8
Fi~ure 2.2. The relationship between calculated and actualtemperature.
The AFT varies with the O/F ratio. particularl~ stronSl~
in the ranse close to stoichiometric. where the AFT is maximum.
as shown in fiSure (2.3).
The two points of sharp slope chBnse are at stoichiometric
tion eauation is
mixture (peak) where the O/F ratio is 73.3/26.7 and the combus-
C'2 H 22 0 11 + 9.6 KN0 3 --> 7.2 CO 2 + 4.8 N2 + 4.8 K 2 C0 3 + 11 H 2 0
(2.3)
and the point where partial oxidation of C to CO is completed,
with an O/F ratio of 63.9/36.1 , with the combustion eauation:
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2600
,---_200::.:::oI-< 1 :
514000..~wI-
1000
9
600
200~--~40~---5~O~--~6~O----~--~~--~9~O~~PERCENT
Figure 2.3. Adiabatic Flame Temperature as a function of OIF ratio.
The OIF ratio that is normall~ emplo~ed for this motor is
65/35. This gives the following combustion sauationl
C12 H22 011 + 6.28 KN03--> 8.29 CO + 0.56 CO 2 + 11 H 20 +
3.14 K 2C03 + 3.14 N2 (2.5)
The performance anal~sis of the rocket motor is based upon
this combustion ratio, unless stated otherwise.
Another parameter that is used extensivelw in ideal perfor-
manes analwsis is the average molecular weight of the gaseous
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10
exhaust products. 1'1'. This is calculated from the combustion
eauation and from the individual molecular weishts of the
products:
1'1' := M'i
t 1 ' 1 'k
t
where i, j and k are the individual constituents, n is the mole
number, and where t re~ers to the total number of moles.
The ratio of specific heats. k , is another important
~uantit~ in the anal~sis of compressible fluid flow, which is the
t~pe of flow encountered in rocket nozzles, where k is defined b~
k = (2.7)
where , for an ideal ~as, k is a function of temperature onl~.
The value of k can be determined from knowledse of the
specific heats' C p , of the individual exhaust sases, where
k :=C - R'
where R' is the universal ~as constant, and
n .I
(2.9)
However, complications arise in the flow throuSh a supersonic
nozzle where the temperature of the ~ases drop appreciabl~ (as
will be shown later), since C p can be a strons function of temp-
erature. It is possible to anal~se such a flow utilizin~ a vari-
able isentropic component e8J, however, a sufficientl~ accurate
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result can be obtained b~ calculatins an ave rase value of k for
flow throush the nozzle (see appendix B). Testins has found that
for a 150 conical nozzle with a small area ratio (6 to 8), the
variation in k does not have a pronounced effect [93. This is
simi liar to the nozzle t~pe used for the motor under consideration.
The remaininS combustion parameter to be determined is the
burnrate, r (also called the surface regression rate). This is
normall~ determined empirically, and is a function of the pro~el-
ant composition and certain conditions within the combustion
chamber. These conditions include propellant initial temperature,
chamber pressure, and the velocity of the gaseous combustion
products over the surface of the solid (erosive burninS). It is
necessary to combine a theoretical model together with empirical
data in order to particulariZe the burnrate for a siven propellant.
The usual model is to approximate the burnrate as a function of
pressure;
nr ::::a Po (2.10)
where a and n are empiricallY determined constants, and ~ is the
combustion chamber pressure. The pressure exponent n, associated, . '
with the slope of the pressure-burnratecurve is almost independant
of the propellant temperature. The coefficient a is a function of
the initial propellant temperature, but not of pressure. From
eQuation (2.10) it can be seen that the burnrate is very sen-
sitive to the exponent n. Hish values of n Sive a rapid chanse of
burnrate with pressure. This implies that even a small chanse in
chamber pre$su~e produces substantial chanSes in the auantit~ of
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hot Sases produced. As n approaches unit~, burnrate and chamber
pressure become ver~ sensitive to one another and disastrous rises
in chamber pressure can occur in a ~ew milliseconds. When the value
of n is low and becomes closer to zero, burnins can become unstable
and ma~ even extinsuish itself. Most producton propellants have a
pressure exponent ran~inS from 0.3 to 0.6 (10J.
A correction is senerall~ made for erosive burning where
the increased burnins can be accounted for b~ an empirical
correction of the form:
r = ro ( 1 + ku ) (2.11)where k is an empirical constant and u is the ~as velocit~.
However, for this report this form of correction will not be
applied. Instead, the burnrate is calculated with the erosive
term taken directl~ into account.
Propellant Grain
The srain is prepared b~ casting the molten propellant into
the desired shape. Several common confi~urations are shown in
figure (2.4). The main criterion for choosing the geometr~ is to
achieve the desired thrust- time characteristics. Thrust is a
function of the instantaneous bUrning area which itself is de-
pendant upon the initial Srain confisuration. The most common
desisns are those which achieve proSressive, regressive, or
neutral thrust- time curves, as shown in fisure (2.5).
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Bonded
S egmen te d r ub e ( ca rt ri dg e lo ad e d)
=.I~IEI~ e ~~t~( __ ~t nt em lll- ex temat b ur nin g r ub e(inhibited a t e nd s)
.I~~.I~~ntemlll burning tube ( case b onded and end restr_!ed) ~ Star (easebonded)
------
Figure 2.4. Several common srain confisurations
Tub.:iaT
.1Neutral
~UTimetar
FiSure 2.5.
~nime
DU31 thr us t
Multi-fin
~e
~rsDouble anchor TimeTwo-stepthrust
Dual c ompos iti on
Internal burning grain designs with their thrust-timecharacteristics.
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The srain confiSuraton of the motor beinS considered is an
internal- external burninS tube~ unrestricted at the ends. The
theoretical thrust- time characteristic is slishtl~ to moderatel~
resressive, depend inS upon the lensth/diameter ratio.
The initial burnins area, Ab is Siven bw:
(2.12)
where L is the srain lensth, Do and D j are the srain outside and
inside diameters, respectivel~.
A slishtl~ modified version of this Srain is also used in
the motor (fiSure 2.6), where Ab is siven b~:
rr { La -~~[31
(DI + Do) ]= (Do t DI ) + D -0b 2
1 1 2 2 _ 2D I2 ]![ - - - (D + D I ) + Do (2.13)4 4 0
These two expressions can be modified bw utili2inS eQuation
(2.11) to obtain the instantaneous burnins area, A ",() :b
rr [(L-n )2 ]A bet) = a t Po ) ( Do + DI > + 0.5 ( Do - D (2.14)1
and
T { (L an Lc
[ 3D o-1
+ Do> ](t):;;: - atP a ) (Do + D ) + - - - (D
b i 4 2 i
1
[1 2 2 2
] }- - - (D t [I ) + D 2D (2.15)4 4 0 i 0 i
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where t represents the time from initial burnin~. It is important
to recosnize that these expressions represent ideal burninS
which assumes that simultaneous ignition of all surfaces occurs
at the beSinning of the burn. As well the effects of increased
burnins surfaces due to flaws in the srain such as bubble holes
and other flaws, as well as the effects of erosive burnins are
nesUected.
These expressions are useful in calculatinS the chamber
pressure and therefore thrust, as will be shown subseauentl~.
Propellant density, Pp and srain density, PI are two
additional properties that will prove useful. Ideall~ these two
are identical but as a result of voids in the srain its density
is somewhat lower.
The ideal propellant density is a function of the O/F
ratio, since the density of the two constituents are different
(P KNO = 2.11 S/cm. tllH PSUCR05E= 1.58 S/cm. (12] ). The ideal3
propellant density can be expressed as:1 fo f f 3
-=-+-= 1.888 g/cm (2.16)p p p
where f 0 and f ~ r-efer 1:.0- tne --massfraction of the oxidizer and
fuel, respectively. For the 65/35 O/F ratio the actual propellant
density has been found to be about 5 percent lower than ideal.
--- -- ----------_----;..
- - - ~ -= ;- - - - - - - r -1 .43 3.36
--~_J __Figure 2.6. Modified Grain for the motor.
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CHAPTER 3: NOZZLE THEORY
The anal~sis of a rocket nozzle flow involves the stud~ of
stead~, one-dimensional compressible flow of an ideal ~a5. The
actual flow differs somewhat from this simplified model particu-
larl~ in regard to the presence of solid or liauid particles in
the flow stream. The necessar~ modifications will be dealt with
in the next chapter.
The analwsis of compressible flow involves four eouations of
particular interest: continuitw; momentum; eners~. and the
eauation of state. These eouations are applied to desisn a nozzlewith the objective of acceleratins the combustion Sases (and
particles) to as hish an exit velocitw as possible This is
achieved b~ designing the necessarw nozzle profile with the
condition that isentropic flow is to be aimed for This
necessitates minimizins frictional effects. flow disturbances.
and conditions which can lead to shock losses. As well, heat
losses would have to be minimized.
3.1 Nozzle Flow
In describing the state of s fluid at snw point in a flow
field it is convenient to emplow the stasnation state as a
reference state (the state characterized bw a condition of zero
velocitw ). Local isentropic stasnation properties are those
properties that would be attained at anw point in a flow field
if the fluid at that point were decelerated from local conditions
to zero velocitw followins a frictonless adiabatic. that is.
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isentropic process.
The enersY eQuation for an adiabatic flow between points
x and y in which the decrease in enthalp~ is eQual to the increase
in kinetic enerS~ is siven as:
1 2 2h - h =x ~ 2
(v - V
'::I X=
where h. v. and T are the enthalpy, velocitv. and temperature.
respectivel!:l.
The stasnation temperature To is defined from the enersy
eQuation as:
2(3.2)
For an isentropic flow process, the followins relations for
stasnation conditions hold:
= (3.3)T
The local acoustic velocit!:l of an ideal sas is defined as:
a :::: ..JkRT
where R is the sas constant. The Mach number is defined as the
ratio of flow velocity to the local acoustic velocity:
v
H : : : :a
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F~om eauations (3.2), (3.4), and (3.5) the total te~pe~atu~e
Mach number relationship can be w~itten:
~2 =T
k-l 21 + M
2
It can be shown from the first and second laws of thermo-
d~namics [13] that for an ideal Sas undersoins an isentropic
process assuminS constant specific heats. that:
p
--k' = constantp
(3.7)
From this result and from the eauation of state, P = pRT,
the staSnation pressure~ densit~ - Mach number relationship
can be expressed as:
kp
[1 +k-l H2 ].~-!--~ =P 2
1
Po [1 +k-l H2] . - : - i=
p 2
(3.8)
(3.9)
The use of eauations (3.6), (3.8), and (3.9) allow each
propert~ (T,P, p) to be dete~mined in a flow field if the Hach
number and the stasnation properties are known. From the eners~
eauation for an adiabatic flow (3.1) the stasnation enthalp~ is
defined:2
h = h to (3.10)2
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PhYsically. the stagnation enthalpy is the enthalpy that
would be reached if the fluid were decelerated adiabatically to
zero velocity. We note that the stagnation enthalpy is constant
throughout an adiabatic flow field. Since the above stagnation
properties (Po' Po and To> are related to the stagnation enthalp!:I
by the specific heats and by the eQuation of state, it is
apparent that each of these stasnation properties is constant
throushout the adiabatic flowfield.
For stead~, one-dimensional flow, the continuitv eQuation
can be written
* * *A v = constant = P A v (3.11>
where A is the passage area, v is the velocity of the flow, and
a starred (*) variable indicates critical conditions, or where
M is unity.
From eQuations (3.4), (3.6), (3.9) and
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where M becomes unit~ is seen to exist at the throat (point of
minimum area) of the nozzle.
The variation of the properties durins flow throush the
nozzle is illustrated in fiSure (3.2). From eouation (3.1 ),
the nozzle exit yelocit~, va' can be found b~:
Ya= -/2(h - h ) + Y 2
" x e x
3,0
2.5
AA*
1.5
1.0
0.5
00 3.0
(3.13)
*iSyre 3.1. Variation of AlA with Mach number in isentropicflow for k = 1.4.
where h and v are the enthal~~ and velocitw at an~ pointx x
within the nozzle. This relation a~~lies to both ideal and
nonidaal rocket units. This eouation can be rewritten with the
aid of eQuations (2.8) and (3.3) ,(3.1)
vk-1
2k R'T o=e
(3.14)
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.. ..- .-- ... - .-_ . --. _ _ .. .-.. .---- . ... .. -- --.--.---~ x
l,Of-----.....---..
.9
.8
.7
.6
.5
.4
.3
.2
.1
O~--_L--~2~--~3~--~4--~~5~~~6~=-~-~-7~-=-~-=-~8~-=-~-~9
X (eM,)
L
\
\\
\\ J '/
IY p - ,/J;,'0 \
21
for flow between the chamber, where staSnaticn conditions are
Fis. 3.2 Variation of densit~ P, pressure p, andtempe~ature T, throush the rocket nozzle.
assumed to exist, and the nozzle exit.
From this e~uation it is seen that the maximum exit velocit~
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o ccu rs at an in fin i t e p res s u re ra t io Po /P g o r when exhau s t in S
in to a vacuum.
The r a t io between the th ro a t an d an ~ down s t ream area a t
which p res s u re P x p reva i l s can be ex p res s ed as a fu n c t io n o f the
p res s u re rat io an d k as fo l l ows , u s in S eQua t io n s ( 3 .3 ) ' (3.9>r(3~,},.(3A-)
an d ( 3 .14 ) ( n o t in S tha t a t the th ro at M is un i t~ ) :
* Px Vx= -~~r~*
x
1 1
( T '( - ;~ f~- ; -~ k + 1= ------ 1k - 1(3.15a)
(3.15b)
This eQu a t io n i s impo r tan t in tha t i t a l l ows the ex i t area,
Ae to be determin ed s u ch tha t the ex i t p res s u re i s eo ua l to the
ambien t p res s u re P a ( t ! : : l p i c a l l ! : : l a tm. ) . Th i s i s kn own as the
des is n co n d i t io n where i t wi l l l a ter be s hown tha t fo r s uchco n di t ion s max imum thru s t i s ach ieved . Fo r th i s des iSn , As / A*is
kn own as the op t imum exp an s ion ra t io .
3 .2 Rocket Per fo rman ce Parameter s
Thi s s ec t io n deal s wi th the var io u s p erfo rman ce p arameter s
tha t a re u s ed to determin e an d compare the p er fo rman ce o f s o l id
p ro pel l an t ro cket mo to r s . As wel l , modi fi ca t io n s to the s imp l i -
f ied model a re con s idered to co r rec t fo r rea l o r ac tu a l p s rfo r -
man ce. As wel l the effec ts o f two phas e f l ow are con s i d e r ed .
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The thrust F, of s rocket motor can be shown to be ~iven
b~ [14]:
F ... f P dA ." " m v + ( p - P ) A (3.16)e e a e
where the first expression represents the inte~ral of the pressure
forces actin~ on the chamber and nozzle proJected on a plane normal
to the nozzle axis (fi~ure 3.3), m is the mass flowrate of theexhaust products and veis the exit velocit~. The second term of
the second expression is called the pressure thrust and is eaual
to zero for a nozzle with an optimum expansion ratio.
From continuit~, e~uation (3.16) can be rewritten:
* * *= p v A v +e
P - P )A (3.17)e a
and modified usins (3.14), (3.9), and
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INozzle Nozzlethroat exit
c b C D
Atmosphere C DP3
t't_ _ _ _ _ " I _ ~
III P, . Pl
Chamber
Pl
FiS. 3.3 Pressure balance on chamber and nozzle walls;internal Sas pressure is hishest inside chamberand decreases steadily in nozzle, while externalatmospheric pressure is uniform.
3.2.2 Thrust Coefficient
The thrust coefficient C f , is defined as the thrust divided
b~ the chamber pressure and throat area:
F
*o A
(3.19)
The thrust coefficient determines the amplification of the
thrust due to the Sas expansion in the nozzle as compared to that
would be exerted if the chamber pressure acted over the throat
area onl~. From eauation (3.18):
(P - p ) A+
e a e- - - - - - - - -
P o A*
(3.20)
For an~ fixed pressure ratio Pe/P o the maximum C f can be
found b~ takinS the derivitive = O. Therefore, the
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maximym C f will occur when P = P , or when the nozzle is designede a
for optimum expansion (desi~n condition).
Eouation (3.19) is useful for comparins the measured Cf
to the theoretical value as determined from eauation (3.20).
3.2.3 Characteristic Exhaust Velocit~
The characteristic exhaust velocit~, c v , is defined as
CV = c I C f where c is the effective exhaust velocit~:
F
.III ... v eAe
+ ( p - P ) - -- (3.21)... .e a mThe CV can be expressed as a function of the ~as properties
in the combustion chamber using eauations (3.21), (3.19), (3.1 ) , (J .~
and (3.11):
CVR To
. . . . . . . . . . . . . ._ - - - - - _. . . .
(2 ) ! . . . !11-1
k+l
(3.22)
CV is usualls used as a fisure of merit of a propellant
combination an d combustion chamber design, and is essentiall~
independant of nozzle characteristics. This makes CV useful as
a comparison for different propellants.
It is interesting to note that cv -. rr' recallinS that-v -~ ~
R = R' I H' A hi~h value of CV is desirable~ however a hish value
of To might not be. High combustion temperatures ma~ cause ex-
cessive heating of the parts of the rocket motor that are exposed
directl~ to hot ~ases. Nozzle erosion can be severe with conven-
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tional materials particularl~ when burn durations exceed several
seconds. For this reason it ma~ be more desirable to increase
CV b~ reducin~ M I rather than increasin~ To This can often be
accomplished b~ usins a propellant that is on the fuel rich side
of stoichiometric.
The CV can also be considered an expression of the impetus
(n R T) of the propellant. This is useful for determinins a
propellant CV in the laborator~ b~ means of a closed bomb
(constant volume) measurement (15].
3.2.4 Impulse
The impulse (or total impulse),!, is the intesral of the
thrust over the operatins duration, t:
l ~ f to
or the area under the thrust- time curve (fi.ure 3.4).
I = (3.23)
Figure 3.4. Area under thrust-time curve represents thetotal impulse of the motor.
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The operating duration is approximatelw e~ual to the burn
time, t , for motors with lonser burn times (t b> several seconds)b
For short burntimes such as those associated with small motors
the duration of thrust would be considered the burntime plus the
time duration for the residual gases to exhaust from the combus-
ticn chamber after burnout. The total impulse would then be siven
b\:l[16]:
2C P A* Tf 0 (3.24)=
k+l
where T is a time constant siven bw
1 A*Po-=----l' P () V IJCV
where n is tFleOurnrate expone~aho---V:- ~-'S-,,-ne hamber volume.o
The specific impulse is one of the most important perfor-
manee parameters used in rocket research. It is defined as thethrust that can be obtained from an eQuivalent rocket which has
a propellant weisht flow of unit\:l.It is siven by:
F cI = = (3.25)sp
.w
With solid rocket motors it is difficult to measure the
weisht flowrate, sO the average specific impulse is usuallw
emplowed , where I = II t.SP
The ideal specific impulse can be calculated for a siven
propellant and motor combination from e~uations (3.25) aryd (3.14):
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I =sp
(3.26)
For comparison purposes Po is usuall~ taken as 1000 psia
and P e as 14.7 psia, b~ convention. A simplified semi-empirical
method for determining specific impulse was developed b~ Free
and Saw~er (17] with a claimed accuracw of 3 to 5 percent.
Recallins that CV is also a measure of the propellant
enerS~, the actual specific impulse can be determined b~ utili-
zins the ballistic bomb method as previousl~ mentioned, where
I is related to CV b~:SF'
r (3.27)-----
however, reQuirins the use of the ideal C f unless the actual value
is knowrl.
3.2.5 Chamber Pressure
The combustion chamber of a solid propellant rocket isessentiall~ a hish pressure tank containins the entire solid mass
of propellant. Combustion proceeds from the surface of the Srain
where the rate of Sas Seneration is eaual to the rate of consump-
tion of solid material, in the ideal case where onl~ gaseous pro-
ducts result {no solids or liQuids>!
(3.28)
.where m is the Sas Sene ration rate, Ab is the area of the burninS5 1
surface. and r is the surface reSression rate (burnrate). The rate
at which sas is stored within the combUstion chamber is given b~:
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dt
d= -- - - (Po Vo )
dt(3.29)
where pais the instantaneous gas densit~ and vois the instantaneous
chamber volume. The use of these two eauations as well as the
expression for the rate at which Sas flows throuSh the nozzle and
the expression for burnrate. leads to the followinS expression
for chamber pressure [19]:
= ~ - - - - - - - - - - - - - - -
For constant Po and therefore constant thrust it is clear
that the burning area must remain constant. such as with a neutral
burnins grain. The instantaneous chamber pressure can be siven b~
the same expression, in which Ab is the instantaneous burning
area. The variation of Ab with time depends uPon the burning rate
and the initial seometr~ or the propellanv srain.
For short burn time motors such as the one under consid-
eration (less than one second burntime) the duration under which
stead~-state conditions exist, where eauation (3.30) applies,
accounts for perhaps one- third to one- half of the total thrust
time. Prior to iSnition, the combustion chamber is filled with
cool air of ambient pressure. The start-up period where the
pressure builds UP to the stead~-state value is a complex
problem that has been studied bw Von Karman and Malina [19J.
The~ have developed an expression for the pressure as a function
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of time durins start-uP, siven by:
(3.31)
where P is the instantaneous pressure at time t and where T is
previously defined.
Immediately after burnout the combustion chamber remains
filled with hish pressure sas. The expression for chamber pressure
is siven as a function of time by [20]~
p =k - 1
(3.32)2
3.2.6 Corrections for Two Phase Flow
The ~revious analYsis of nozzle flow and performance psra-
meters considered the ideal case where the workins fluid is a pure
Sas. This analYsis is fine for the case where there is no solid
or linuid particles in the exhaust (such as for liauid propellants)but must be modified for the case where such particles are present.
The presence of particles is detrimental to the overall rocket
performance, with the extent dependant upon several factors.
One of these factors is motor size. It has been found by4
Gilbert, Allport, and Dunlop (21J that for larSe motors ( >10
pounds thrUst) the overall specific impulse losses are low, but2
for small motors (~10 pounds thrust) the losses can be sisni-
ficant. The motor under consideration is of this magnitude thrust
makinS corrections for two phase flow necessary.
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The lo s s es in p er fo rma~ce are du e to two facto rs :
i ) vel o c i t~ l as , where the p ar t ic l es a re n o t accel era ted
thro u~h the n o zzl e to the s ame vel oc i t~ as the Sas es ; a~d
i i ) thermal l aS , where the p ar t ic l es are n o t in thermal
eau i l ibr ium wi th the s u rro un d in s Sas es .
I t has been fo u n d tha t the l a t t er has a smal l effect , u s u a l l y
a l l owin s the as s ump t io n tha t the p ar t ic l es a re in thermal
eau i l ibr ium [22J .
The s ta r t in s p o in t in the con s idera t io n o f the effec t s o f
s o l id ( l i au id ) mat ter fo rmat io n i s wi th the eau at ion rel a t in s to
the Sas Sen era t io n ra te ( eQua t io n 3 .28) . Th i s eQua t io n becomes :
m
S
=(l-X)p A rp b ~
where i den o tes a p ar t icu l a r co n s t i tu en t . I f a l l the par t i c l es
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are assumed to have the same velocity this can be expressed as!
1
I
=spTo accurately describe the erfects of particles on a
rocket's performance reauires knowledse of heat transfer proper-
ties and draS processes or the particles in order to express Vs
and Ts in terms of the overall flow properties. It is possible,
however, to derive the limitinS cases to determine the least and
most detrimental effects.
In the first model, the particles are assumed to be very
smallr where Ts ::::: gand Vs ~ Vg This wo;uld slive the followin!!i
expression for exhaust velocity (see appendix c for derivation>:
T [ c sx+(1 _ X ) ~ _~~ __ ] [1 _( _ ~ ~ _ )m ]o (k - l)M' P o
(3.37)
~ = [~~-~~;;~;~ + -;.-~ -~ ]- .
where Cs is the ave rase specific heat of the solid (liauid) matter.
where
Note that this eauation reduces to the familiar form (3.14) when
X = 0 (no particles).
The expression ror thrust would be modified to this form
(see appendix D for derivation):
F = * 1A Po-----1 - X (
~
~~II
.z.. [Xk + 1
c +s
fr . R' J [l -X) -- . : :----- 1(k-l) H'
+ ( P - P ) A e a e
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Note asain that the eauation reduces to the familiar form (3.18)
when X = O.
The expression for the thrust coefficient is derived in the
same manner, ~ieldinS the expression:k+1
( ;_~- J -OI [~ : ;~ - :~+ ~:~ -= -~11:nc = -- - - -f 1 - X(3.39)
It is interestinS to note that the thrust coefficient in-
creases with the ~resence of particles compared to the Sas onl~
value. This eauation im~lies a 75 percent increase in the thrust
coefficient for a t~pical propellant where X = 0.45.The second limitins case models the particles Sych that the
particle velocit~ and temperature remain essentiall~ constant.
This implies a combination of relativel~ large ~h~sical size,
slow heat transfer, and low draS. With such a model. the ex~res-
sions for the performance parameters remain identical to theoriginal (gas onl~) expressions. i.e. the gas flow is not affected
b~ the presence of particles. However, the specific impYlse is
reduced. From eauation (3.36) where m v m v :SSg S
1I =Sf>
( 1 - X ) vst !Ii
(3.40)
Therefore, the specific impulse is reduced b~ a factor of i-X.
Research conducted into two phase flow also indicates that
the nozzle t~pe has a bearinS on the effect of particles in the
exhaust stream [23J. As well ,it has been found that particle
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size (and dist~ibution) is independant of motor size, and is
therefore larsel~ a property of the particular propellant [241.
Another detrimental effect of liauid particles is the tendency
for the material to build UP on the nozzle surfaces, reducinS the
effective nozzle area. Additional losses are introduced bw the
resultinS rough surface which increases skin friction [251.
For the motor being considered, the losses due to particle
presence will be accounted for in the enerSY conversion factor,
discussed below.
3.2.7 Corrections for Real Nozzles
The precedins analwsis considers ideal rockets, which of
course do not exist. The ideal case represents the maximum per-
formance that can be attained, with the actual performance being
reduced by a number of factors. These factors are accounted for
in real n02zles bw using various correction factors.
Conical nozzles reQuire a factor to correct for the non-
axial component of the exit Sas velocit~ as a result of the
diver~ence ansle, defined as 2a (where a is the half anSle).
This factor ~ , is given bw:
1
2
As well. the flow in an actual nozzle differs from ideal
( 1 t cos a ) (3.41)
because of frictional effects, heat transfer. imperfect sases.
nonaxial flow, nonuniforrnity of the working fluid and flow
distribution. and the effects of particles. The degree of de-
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parture is indicated b~ the enerSw conversion efficienc~ of the
nozzle. This is defined as the ratio of the kinetic enersw per
unit of flow of the Jet leavinS the nozzle. to the kinetic enerSwper unit flow of a hwpothetical ideal Jet leavinS an ideal nozzle
that is supplied with the same workins fluid at the same initial
state and velocitw and expands to the same exit pressure as the
real nozzle. This is expressed as;
2v
e = --!!. (3.42)2
vaI
where the subscpipts i and a refer to the ideal and actual states
and e denotes the enerSw conversion efficiencw.
The velocitw correction factor,f v ' is defined as the sauare
root of e. For most production motors, the value lies between 0.85
and 0.98. This factor is also approximatel~ the ratio of the
actual to ideal specific impulse.
The discharse correction factor ~ , is defined as the ratio
of the mass flow rate in a real nozzle to that of an ideal ~zzle
that expands an identical work inS fluid from the same initial
conditions to the same exit pressure:
r ::::cI
ma
.m ca
(3.43). .ffi.
IF
The value of the discharSe factor is often larser than
unitw. because the actual flow can be larser than theoretical
for the followins reasons:
i) the molecular weiSht of the Sases increases slishtlw
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when ~lowin~ through a nozzle, thereb~ chanSinS their densit~.
ii) some heat is transferred to the nozzle walls. lowerins
the Sas temperature, increasins its den$it~.
iii) the specific heat and other Sas properties chanse in
an actual nozzle in such a wa~ as to slishtl~ increase the value
of the discharSe coefficient.
tv) incom~lete combustion increases the densit~ of the
exhaust Sases.
These correction factors result in a thrust lower than for
the ideal casel
F := ! !d X Fa v i
*:= r rx c p Av d f 0a aI
(3.44)
(3.45)
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3 7
CHAPTER 4 : EXPERIMENTAL TECHNIQUE
4.1 Motor
The motor under consideration is illustrated in the fiSure
below (fi~ure 4.1), with a complete description Siven in appendix
( E ).
- 2 .5 em .
-" ' -
3.8 c m .
I
/nozzle grain
//
/ head
head gas kets (5) s afety bol t
FiSure 4.1. Actual motor used in testins.
The standard n0221e has a conical profile with a 12 degree
divergence half angle. It was fabricated from mild steel bar stock
turned and bored to the desired dimensions on a standard lathe.
The nozzle contour is rounded at the throat to avoid sharp dis-
continuities which could lead to shock losses. As well, the entire
n0221e inside surface is polished to reduce friction losses.
The nozzle is retained to the combustion chamber bw siw high
strength allen screws.
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The head of the motor is readil~ removable to allow for
eas~ loadins of the Srain. Constructed as well from mild steel,
the head is retained b~ a sinsle safet~ bolt(3/16
X 1112
in.;Srade 8) desisned to shear if the chamber pressure should attain
an unsafe level (17 MPa.). The combustion Sases are sealed from
escapins around the head b~ five asbestoes-fibre composite Sas-
kets. The nozzle is sealed aSainst the combustion chamber b~
utilizins a tool which rolls a circular die under hish pressure
around the perimeter of the chamber outside wall esainst the
nozzle section forward of the retention srcove. This effectivel~
seals the chamber wall asainst the nozzle to reduce sas leakase.
4.2 Cubic Nozzle Profile
Althoush the exact nozzle profile is not critical for
sood performance as the flow occurs in a resion of favourable
pressure Sradient, optimum performance is achieved bw desisnins
the nozzle b~ the method of characteristics. A thoroush dis-
cussion of this techni~ue is presented in references [263 and
[27]. This method is lensthw and complex and will not be consid-
ered here. However, an approximation to this desisn is that of a
cubic profile where the nozzle contour follows the curve of a
cubic eGuation [28].
A nozzle was constructed with the aid of a computer numer-
icall~ controlled lathe. The criterion for desisn was based on the
same throat, entrance and exit areas as the conical nozzle. The
conver~ent section was based on a maximum half an~le of 30 deSrees+
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and a maximum diver~ent angle of 20 degrees. F i au re (4.2 )
39
shows the dimensions of the nozzle where the eouations of the
contours are:2 3
R = 1.748 - 0.762 x + 0.226 x em. (Region I)
2 30.037 x em. (Resion II)= 0.461 t 0.201 x
where R is the inside radius.
. . . ! rTC~~~: ' - - '!; , . . . . . . ' - - ,+-- ' -c -+c- i" - ' -++_ . : .c . - ; Id- ,LU- j+ + _ ...: 'j T ~
-~ - i~~-=f i ji I-' --h~~:_ ;,~ .. '- , .".j.1 "- '- . ~ - , , .. . . . - . - :I
._J_ - - ~ r ' "T I!, . . , '~; , ; 1 1 '- , '.l- ~'-I--I'I .
Fi~ure 4.2. Cubic nozzle profile.
( 4.1>
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4 0
This nozzle was constructed of cold rolled mild steel
bar stock, and was hi~hl~ polished on the flow surfaces. The
diver~ence exit an~le was machined to zero deSrees, to eliminate
radial flow losses (non-truncated).
It should be noted that while the critical dimensions
of the cubic nozzle are coincident with the conical nozzle, the
overall lensth is about 17 percent shorter.
4.3 Propellant Preparation
As stated previousl~, the standard propellant com-
bination is 65? oxidizer (KN0 3 ) and 35~ fuel (sucrose). The
propellant
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The commerciall~ obtained potassium nitrate oxidizer has
an average particle size of 250 ~. The oxidizer is subseouentl~
around down to an averaSe particle size of 100~. The sucrose is
obtained in powder form with t~pical particle size of approxi-
matel~ 10 ~
It has been found that the particle size of the oxidizer
has an important influence on both the burnins rate and more
importantl~ on the impulse delivered. Therefore, careful attempt
was made in the experimentation to obtain consistenc~ in oxidizer
particle size.After accuratel~ weiShinS the desired Quantities of both
constituents, the~ are placed in an electric rotating drum mixer
where mixinS occurs for twentw hours.
The Srain cast ins procedure involves heatins the mixture
in a container maintained at a temperature of 190 to 200 desrees
celcius bw immersion in an electricallw heated oil bath. The
sucrose, (mt? 182 desrees C.) combines with the non-meltinS KN0 3
(mtp. 441 C.), to form a slurr~. Decomposition of the sucrose
initiates as well at this temperature being both a function of
of temperature and time. Therefore, the temperature has to be
maintained within this ranSe, and for the minimum time duration
necessarw for the entire mixture to melt.
This decomposition (caramelization), if kept in check, has been
found to have no detrimental effect on the propellant performance.
Investigation of the effects of low desree caramelization of
sucrose indicates that there is no sisnificant mass chanse. which
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is i~portant since the occurance of such would alter the effective
OfF ratio. As well, it has been found that less than 1 percent
moisture is absorbed b~ the finel~ divided suSar, which is again
an important consideration for an~ moisture initiall~ present
would be Siven UP upon heating.
Once the slurrY has become sufficientlw fluid, it is
cast into the desired shape. This shape (hollow cylindrical)
is achieved bw pouring the slurry into a lubricated cYlindrical
mould, of slightl~ smaller diameter than the combustion chamber.
A lubricated bore rod is inserted down the central axis. After
allowins to cool and harden for approximatelw forty-five minutes,
the grain is removed, trimmed to siZe, weiShed and measured. The
grain is then stored in a sealed container. This is to prevent ex-
posure to the open air for the propellant in its final form is
verY hysroscopic.
4.4 Varying OfF Ratio
A number of Srains were prepared to determine the effect
of varyins OfF ratios upon the motors impulse. As well, several
small cylinders (1.5 x 10 cm) of varying OfF ratios were prepared
for burn rate testinS.
4.5 Burnrate testing
In order to auantify burnrates under conditions of one
atmosphere and at room temperature, several samples of different
OfF ratios were prepared. The samples were cast into cylinders
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as indicated earlier. These c~linders were mounted u~ri~ht b~
adhering one end to a base. A specified length was marked off.
tspicall~ 7 cm. The top end was then ignited b~ a flat surfaced
tool, heated prior in a flame. As the sample burned down, the
elapsed time was measured between marks. This t~pe of burnrate
test ins sives results for conditions of constant temperature
propellant and non-erosive burning.
More complete burn rate testing would involve determining
the dependance of burnrate on pressure. In order to conduct such
testins , it would be necessar~ to construct a suitable vesselthat would allow burning to occur at constant pressure. Such an
investigation has not ~et been condUcted, however. Research of
this tspe has indicated that the burnrate measured b~ this tech-
ni~ue is not in complete aSreement with the actual burnrate
that occurs in the actual motor, being about 7 percent hisher
(29J. No explanation could be found for this discrepanc~.
4.6 Motor Static Testins
Static testing of the motor (fisure 4.3) to obtain the
thrust-time characterics is conducted on a specialls built test
ris (figure 4.4). A remotels located Heath H-B microcomputer is
used for data acauisition. with the measured signal sent to it
via a 50 metre shielded cable. The ac~uisition swstem is potent-
ialls capable of handling UP to four channels of data input (e.g.
thrust, chamber pressure, temperature. and wall 5tress). For this
series of tests. onls thrust measurements were attempted, however.
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FiSure 4.3. Static ~irinS of the rocket motor mountedin test rig.
4.6.1 Test Ris Construction
The frame of the rig is constructed of heavw steel I-beam
to eliminate undesired deflections under hish thrust. Althoush
the maximum thrusts endured bw the motor under consideration
were 1.1 kN (250 lbs.), the riS can handle much larser values of
thrust.
The motor is mounted verticallw. nozzle upward, in a
holder desisned to allow for the small vertical motion encountered
b~ the motor durins firins.
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1. Deflection bar 7. Electrical islniter2. Lower stoP 8. Deflection bar tensionel'3. Upper stop 9. Frame4. Strain transducer 10. Hwd~aulic damper5. Motor mount 11. Damper adJust valve6. Rocket motor
Fi~ure 4.4. Rocket motor static testins riS.
4 5
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The frame sUPPorts a double cantilever deflection bar
assembl~. It is asainst this bar that the motor acts during firing
resulting in the bar deflecting. The thrust is therefore trans-
duced into a lineal deflection. In order to obtain high resolution
of the thrust transduction, it is desirable to have a relatively
large defection of the bar. This maximum deflection is determined
bw the transducer unit, havins been determined to be 0.635 cm.
(1/4 in.). Bw knowing the maximum expected thrust of motor it is
possible to choose the bar-cantilever assembl~ to achieve this
(for an~ motor).
The deflection w for a double cantilever assembl~ is given
bw [301:3
F L(4.3)
192 E I
where F is the force (thrust), E is the YounS's modulus of the
bar material, I is the moment of inertia of the bar, and L is the
bar lensth. For a rectanSular bar of thickness d and width b, this
can be rewritten as:3
F L
316 E b d
The deflection is therefore proportional to LID cubed
and inverselw proportional to the width. Therefore, the choice
of the bar gives great flexibilit~ in achievins the maximum
deflection, ~ max
A lower stop is placed directlw below the centre of the
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4 7
bar to prevent damage to the transducer unit in case of over-
thrusting, or a blowout of the motor head (see figure 4.5).
The thrust induced displacement of the transducer bar
results in an eaual displacement of the end of the transducer
unit, located directly under the motor mount. This transducer
unit uses a strain SauSe bridSe fastened to its fixed end. This
strain sause bridse forms the fundamental component of the data
aauisition s~stem, illustrated in fiSure (4.6). The amplifier
BA RTEN510NER
\
/i
L : JWERSTOP
Ef jO SUPPORT (2:( AO-USTABL )8EA~
Figure 4.5. Deflection bar assembly of static test ris.
COMPUTER
HEATH He
PRINTERj----.-.-~DECWRI TER
LA-36
AID C'I---~8-81 T
STRAIN
GAUGEBRIDGE ZERO
ADJU 5 T
TERMINAL
HEATH H19
Fisure 4.6. Data acauisition sYstem used to measuremotor thrUst-time characterics.
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4 8
circuit is reproduced in Appendix ( F). The A/D converter is an
8-bit, four channel unit capable of samplins 581 points per second
(samples ever~ 1.72 milliseconds), These points are stored in the
computer memor~ for post-proces5in~.
Due to the sprin~-mass nature of the deflection bar assembl~,
it was found necessarw to provide adeauate dampins to reduce
oscillations of the deflection bar. A variable h~draulic damper
was desisned and built to allow a larse degree of flexibilit~ of
dampins. The damper is detailed in tisure (4.7). The operation of
CONNECT.ROD /'0' RING (2)
FiSure 4.7. Hydraulic damper used with test ria.
HEAD
AaH- -- '0' RINGVP--.L_,L..J......(_~ I
JET
df'-:~L1\"'-LJ.:. . .LLL.I:!II----"_'_-"_"'_-FL U lD
CHANNELS
the device is straightforward. A connecting rod with a piston at
~MOUNT.HOLE (4)
BLEEDSCREW
\\
NEEDLEVALVE
one end is attached to the deflection bar. The reversed vertical
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4 9
motion of the rod alternatel~ forces fluid from and back into the
fluid chamber throush a small Jet. The effective area of the Jet
is controlled b~ an adjustable needle valve, the adjustment of
which Soverns the desree of dampins. This allows for a wide ranSe
of damping from essentiall~ nil
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The force applied at the deflection bar F, is Siven bw:
F =Wa + W
2
where W is the total weisht huns at the bar end, Wa is the arm
weisht. Since Wa ' L" L2 are constant for a siven arm, this
can be written as:
F = C,W + C2
where C, = L2/ L, and C 2 = C,Wa /2 Calibration is carried out b~ hansins a series of weights and
recordins the output voltase. The calibration data is presented
in the form of voltase V, as a function of force, havins fitted
the points throuSh a second order curve (through the oriSin)
to yield a calibration curve of the following form:
2F = C3V + C4 V
where C 3 and C 4 are constants.
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CHAPTER 5: RESULTS (Theoretical and Actual)
5.1.1 Nozzle Testins
The thrust-time curves for the conical and cubic nozzle
are presented in fiSure (5.1) and (5.2), respectivel~. The time
period between successive points is 8'0 milliseconds (i.e. ever~
5th point is printed). For comparison purposes, both results are
presented on a sinsle curve illustrated in fi~ure (5.3) (note:
different time base).
A summar~ of the performance for both of these nozzles
is presented in Table 5.1.
Conical Cubic
Total impl .. Jlse (N-s) 2se 281Specific impulse ( s ) 130.5 127.3Max. thrust ( N ) 1155 1075Thrust duration ( s ) 0.38 0.40Propellant mass 10)
makinS the motors indefinitel~ reusable.
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52
0-J: III ...=:I'"E(Ij
....7..._-..... - ...- - - ....- .... - .... + :; - .......- - - ...- - .... - - ..... - .......-- - - - - ..- - -I
)(In[In I ++ I I I:1:.... I + ! 1 ! +++ I. . . I +1 ! I J I J J I
I I I I I I I I I ++++ II I I I I I I I I I I I +I + I I I I I ! I I I I I 1+ II I I I I I I I I I I I 1 1++ I I I I I I I , I I I I I I I II I I I 1 I I I I I I I I I I I +I I I I I I I , , I I I I I I I I ++ Ir I I , I I I 1 I I I I I I I I I I I
+ I I I I I I I I I I I I I I I I I +L I j 1 I I I I I I I I I I 1 I I I II I I I I I I I I I I I I I I I I I I +I I I I I I I I I I I I , I I I I I I I II I I I I I I I I I I 1 L I I I 1 I I + L I I I 1 I I I I I I I I I I I 1 I I I \I I I I I I I I I I I J I 1 I I I I I II I I I I I I I I I I I I I I I I I I I
,,I + I I t I I I I I I I I I I I I I I I I + ,
1 . 11 I t I I , I I I I I I I I I I I I 1 I 1 I I II I I I I 1 I I I I I ! I I I I 1 I I I I I ,
E I I I J I I I I I I I I I I I I I I I I I + ,I I , I I I I I I I I , I I I I I I I I I I- I I I t I I I I I I I I I I I 1 I I I I I I ,I I I I I I I I I I I I I I I I I I I I I I I
. . . . . I I I I I I , I , I I I I I I I I I I I ,I I I I I I I I I I I I I I I I I I I I I I I I I , I I I I I I I I t I I I I ! I I I I + tI I I I , I I I I I I I I I I 1 I I I I I 1 I I IUl , I I I , I I I I I I 1 I I I I I I I I I 1 1 I I I ,I + I I I I I I I I I I 1 I I J I I I I I I I I I I I
I I I I I I I I I I I I I I J I I J I I I I I I I 1I , I I I I I I I I I J I I I I I I I I I I I I I I II I I I , , I I I I I I I I I I I I I I I I I I I I tI I I I I I I I I I I I I I I I I I I I I I I I ,. . . . I 1 I I 1 I I I , I I I I I I t I I I I I I I I + ,I I I 1 I I I I I I I I I I 1 I I ! I I I I I I I 1on I I 1 I I I I I I I I I I I I I I I 1 I I 1 I , I II I I I I I I I I I I I 1 I I I I I I I I ! I I I ,
;::. I I I I I I I I I I I I ! I I I I I I I 1 I I , I II I I I I I I I I I I I I I I I , I I I I I I I I + I
i:l! I I I ! I I ! ! , I I I t I I ! I I I I I I I I I II I I I 1 I I I , , I ! I I I I I I I I I I I I I:I: I I I 1 I I ! I I I I I I I I I I , I I I I I I I II ! ! I I ! I I I I I I I I I I I I I I I I I I I ,. . . I 1 1 L I I I ! 1 1 I I I I I ! I I I I I I 1 I II + 1! I I I I I I I I I I ( , I I I 1 I I I I I II , I I I I I I I I I I I I I I I I I I ! I I I II ! ) I I I I I I 1 I I I 1 I I I I I 1 I I ! I I.. . I I I I ! I I I I I I I ! I I I I I I I I I I I I! , I I I I I I I I I I ! I I I I I I I I I j I I
w I 1 I I 1 ! ! , I I ! I I I I I I I I I I I I I II I I I I I I 1 I I I I I I I I I I I I 1 I I I +:: . : I I I I I I I I I I I I I I I I 1 I I I I I I I I I II I I I I I I 1 I I 1 I I I I I 1 I I 1 I ( I ! I I I , I
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0-E........: '0-:Cl?
- .-----------------+-+---------------------------
)(In + +1
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C ONIC AL --CUBIC
54
Figure 5.3. Comparison of the conical and cubic ~ozzlemotor thrust-time curves.
!-(f)
:Ja:If---
JIII
,-,\ ,
Ii TIME
5.1.2 Motor Testing of Var~inS OIF Ratio Grains.
The results of this series of tests are prese~ted in
Table 5.2. Onl~ the values for the averaSe specific impulse are
presented because it is felt that this would provide the most
useful base for comparison. It should be noted that a non-
standard conical nozzle was used for this series of tests. result-
ins in lower overall values of specific impulse as compared to
the standard conical nozzle as described earlier. Therefore, the
results should be used for comparison purposes onl~.
The impulse for the 75/25 OIF ratio was not measurable due
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55
to poor burnins resultins from the hiSh oxidizer percentame. A
larme Guantit~ of liQuid matter (potassium carbonate> was ejected
from the nozzle, and burninS continued for about half a minute.
-OIF Ratio Isp ( s >
50/50 49.955/45 93.660/40 10065/35 10670/30 10675/25 ---
Table 5.2 Co~parison of var~inS OIF ratio motor tests.
The 50/50 OIF ratio Srain also resulted in poor firins.
Larse volumes of carbon were ejected with much remainins in the
combustion chamber after firinS in the form of a sinsle porous
mass.
Each of these test firinms were recorded on 8mm colour
movie film for post tirins examination of the test. The results
showed that the exhaust flame varied in size and colour with
differinS OIF ratios. For the more fuel rich ratios, the flame
was smaller and more oranse in colour. For the more oxidizer
rich ratios, the flame increased in size with a more purple
coloured hue, a result of the potassium compound in the exhaust.
As well, it was found that the nozzle throat became hotter with
increasins oxidizer percentaSe, with the exception of the 75/25
O/F ratio. The throat colour ranSed from a dull red (50/50 OIF
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56
ratio) to a bri~ht ~ellow (70/30 O/F ratio). This res~lt is
consistent with the theoretical prediction for combustion temp-
erature as a function of O/F ratio as disc~s$ed earlier.
A comparison of the propellant properties To ' H' , CV
and X for var~inS O/F ratios as predicted b~ theor~ is shown in
f i S~ re (5. 4) t
f.,cC)
2000
1800
1600T o
M CV(m,s) 1400
J O
1200
25
900
20 ao o CV
700 X
600 0,6
500 X
o.~
0,2
440 48 642 686 720 76 80PERCENT OXID IZER
Fi~ure 5.4. Comparison of theoretical properties:(1) Combustion temperature, T o(2) Avera~e molecular weisht of exhaust
gases, H'(3) Characteristic velocit~, CV(4) Particle mass fraction, X.
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5.1.3 Burnrate Testing
The results of burnrate testins for ~arious O IF ratios
are presented in figure (5.5). The conditions of testing were
atmospheric pressure and room temperature. The burnrate results
encountered.
for the 75/25 O I F ratio are not shown due to the erratic burning
As mentioned earlier, burnrate testing has not ~et been
conducted for conditions of elevated pressures to determine the
burnrate-pressure relationship. However, it is possible to est-
05
~02. .a
zB:;
ii l0.1
55 60 65 7Q
)!; CXIQIZER
Figure 5.5. Comparison of atmospheric burnrate testinSfor var~ing O IF ratios.
imate the pressure dependence in order to determine an appro~imate
value for both the coefficients a and n (from eauation 2.10),
usinS the results of the motor testing. This method involves
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58
estimatins the time reauired for the Srain web (wall thickness)
to burn through under ~otor operating conditions. The validit~
of this method lies in the assumption that essentiall~ all the
surface regression occurs at high pressure. This pressure, taken
as Po' occurs during the stead~-state operation of the motor,
allowing an estimation of this time period from the thrust-time
curve (see figure 5.6>
. . . .lI)
~0 : : -I. . . .
TIME
Figure 5.6. Estimation of web burnthroush timefrom actual thrust-time curve.
Since burning progresses from both the inside and out-
side surfaces of the grain, the web expension rate is effectivelw
ast
doubled. The burnrate at a pressure of Pocan then be expressed
rR - R-~---!..2 tw
=::
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59
where Ro and Ri are the srain-outside and inside radii.
Combinins this e~uation with the results of the atmos-
pheric burnrate testins:
r l = aP=P atm
and the stead~-state pressure e~uation
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60
5.1.4 Performance Parameters
The theoretical performance parameters of the motor based
upon the two particle flow models, as well as the actual results
are presented in Table 5.2. These results are based upon the
motor eouipped with the standard conical nozzle and the 65 /35 O I F
ratio propellant.
THEORE TICAL THEORE TICAL ACTUALPARAMETER
PAR TIC LE MODEL PARTlCLE MODEL
Ts"..T~ VS"'Vg Ts""const. VsVg VALUE
THRUST (MAX), N, 1691 1153 1155
THRUST TIME, SEC, - -- 0.318V " m/s. 1490 1821 --T o ," c 1406 1406 1347Po , MPa 10.55 10.55 --Ct 2.36 :2:.00 --1, N-s. 408 226 288I sp , sec. 152 103 131"x 0.989 0.989 ----..td 0.998 ~.998 --tv -- -- 0.833e -- -- 0.401
"average
Table 5.2. Comparison of theoretical performanceparameters to actual performance parameters.
The ener~~ conversion efficienc~ is based upon the actual
performance of the motor as compared to the maximum performance
possible, which would be attained for the first particle flow
model.
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CHAPTER 6 : DISCUSSION OF RESULTS
6.1 Nozzle Testing
Contrarw to expectations, the performance of the cubicnozzle was somewhat lesser to that of the conical nozzle, deliv-
ering a specific impulse 2.5 percent lower. This result however,
is tentative for onl~ a sins Ie firinS of the cubic nozzle was
performed due to time limitations. Clear'lw, however, no signifi-
cant increase in nozzle efficiency is implied. This suggests
that the conical nozzle is certainly a satisfactor~ desiSn. Con-
siderins the far greater simplicity of fabrication, the conical
desisn would have to be considered the superior choice for the
amateur rocket enthusiast.
If further testing reinforces the present findings, the
lesser performance of the cubic nozzle could be a result of its
greater maxi~um divergence angle (20 degrees v.s. 12) and/or its
shorter length (17X shorter). The latter of these would be con-
sistent with the particle flow theory where a decrease in perfor-
mance would be a direct result of particle las. In a shorter
nozzle the particles would have less time to accelerate to the
gaS yelocit~ before exiting the nozzle. This would suggest that
for a small motor with a high mass fraction of particles, the
nozzle should have a small divergence angle in order to increase
the length. The e>:istingdivergence angle should possibl~ be re-
duced to 10 or 8 degrees. As well, the effects of reducinS the
conversence ansle in order to increase the overall lensth of the
nozzle should be investiSated. Possibl~ the best approach to the
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design of a nozzle for such conditions would be to sha~e the con-
tour in a manner such that the maximum flow acceleration is re-
duced, to minimize ~article lag.
6.2 Motor Testin~ of Var~inS O/F Ratio Grains
Maximum performance for the hollow c~lindrical ~rain is
achieved with a moderatel~ fuel rich O/F ratio. Testing indicates
that the specific impulse is highest in the ranse of 65 to 70
percent oxidizer, taperinS off with a lower oxidizer percentage,
and being drasticallw lowered at high oxidizer ratios. The sen-
sitivit~ at high oxidizer ratios is shown b~ the results that a
maximum impuse is achieved at 70 percent oxidizer. but b~ incr-
easins the ratio b~ 5 percent results in an immeasurable impulse.
The hishl~ fuel rich ratios 70/30). the reduction in
performance could as well be explained bs this particle flow model.
Examination of the exhaust blast area revealed that the potassium
carbonate particles ejected from the nozzle were actuall~ in the
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form of sizeable droplets. This would create the conditions of
v ~ constant, where the relativel~ larse particle size would nots
allow acceleration of the particles to a hish velocit~. The for-
mation of the droplets could be explained thuslw: durins combus-
tion a voluminous auantitw of potassium carbonate is formed, beinS
in the liauid state. As flow occurs throuSh the nozzle multiple
collisions occur between the liauid particles. resultins in co-
hesion and effective srowins in particle size until either the
maximum stable size is achieved, or exit occurs from the nozzle.
The practical ranse, therefore, for O/F ratio selectionappears to be an oxidizer percentage of between 55 and 70 percent.
Coupling this result with the realization that actual combustion
temperatures appear to parallel theoretical. would indicate that
since lower combustiOn temperatures might be more desirable, the
lower OIF ratios misht be more suitable. If however, the combus-
tion temperatures encountered at the upper end of the O/F ratio
pose no practical problem, the ranse for best performance could
be reduced to the 65 to 70 percent oxidizer renSe. Since no
erosion or other problems have been encountered due to these tem-
peraturesr this would appear to be the optimal ranse. One final
factor to be considered is the castabilitw of the srain. Since
a more sucrose rich propellant is easier to cast, the best over-
all ratio would then appear to be the existin~ 65/35 OIF ratio.
It should be noted that since testinS occurred in $te~s of 5
percentase points, that the optimum ratio is therefore within
a certain plus-minus ranee of this value.
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6.3 Burnrate Testins
The results of testins indicate that burnrate is Guite
sensitive to the O/F ratio. with the maximum occurrins at the
65/35 O/F ratio. For small rocket motors. a Sreater rate of bur-
nins is desirable to develop the high chamber pressures that such
motors can readil~ operate at. With lower burnrates. it would be
necessar~ to increase the srain surface (burnins) area to compen-
sate for the reduced rate of burnins in order to maintain the Sas
Seneration rate. A decrease in throat area would as well be a
solution to developing the desired pressure, however. a corres-
pondins thrust loss would result.
Increased srain surface area can be achieved b~ modif~ins
the seometr~ of the central bore, b~ moulding a star or other
shape as discussed in section 2.2.3. This result can also be
achieved b~ increasinS the lenSth/diameter ratio of the srain.
However, both methods eomplicate the grain castins procedure and
increase the likelihood of srain casting flaws. Therefore, practi-
cal considerations make the hisher burnrate that can be achieved
with the 65/35 O/F ratio a desirable trait.
The method of estimatins the burnrate-pressure relation-
ship appears to be satisfactor~ for a first approximation. However,
it is difficult to Sause the accurac~ at this point. Knowledse of
the actual chamber pressure would certainl~ increase the precision
of this techniQue. Due to the nonlinearit~ of the eauations, the
value for the chamber pressure, however, could be subject to app-
reciable error.
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6 5
6.4 Pe~formance Parameters
Fronltable 5.2 it can be seen that there is an ap?reci-
able difference in ideal thrust for the two particle flow models.
In the second case where the particles are assumed to have no app-
reciable velocit~, the thrust is 32 percent lower than the first
case where all the particles are assumed to have a velocit~ e~ual
to that of the Sas flow. As a result of this rather sisnificant
variance, the choice of model will importantl~ affect the expected
perfo~mance of a siven motor desisn. Neither model would be ex-
pected to accuratel~ represent the actual flow conditions since
these are the two limitinS cases. The actual particle flow cond-
itions would reauire a consolidaten of the two models, where the
expected performance would lie somewhere between these two bounds.
As well. the actual flow would be difficult to model since the
real particle size would certainl~ be distributed, where the smal-
ler particles misht follow closel~ the Sas flow velocit~ whereas
the larger pa~ticles misht have a sisnificant velocit~ las.
The actual thrust produced b~ the metor would therefore
be expected to lie somewhere between these two ideal values. which
it in fact does. The actual maximum thrust value (1155 N.) almost
coincides with the ideal value for the second particle flow model
(1153 N.), sussestins that the actual flow would be accuratel~
described b~ this model. However, such a conclusion would be hi~hl~
tentative, is not incorrect, since the calculated thrust values
for these two models are almost directl~ proportional to chamber
pressure. The chamber pressure used for these two calculations
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66
(10.55 MPa.) is based on the value arrived at throuSh the pressure-
burnrate calculations described in the previous section which, as
mentioned, could be subject to appreciable error. Ans such error
would be almost directl~ reflected in the ideal thrust compu-
tations. This factor renders the thrust parameter a poor basis of
comparison of the actual to theoretical flow conditions. A far
better comparison would be made uti IizinS the specific im.pulse,
which is insensitive to chamber pressure variations.
The value of the actual avera_e specific impulse (131 5.)
is in fact close to the midpoint of the values predicted b~ the
two particle flow models (152: first model9 103: second model).
This implies that a consolidation of the two models would closel~
predict the behaviour of the actual flow.
The ene rS'ldeff icienc'lde, and the ve Ioc it'ldcoeff i cient r,v
are emplo~ed to relate the actual thrust to the ideal thrust that
would be achieved, as explained in section 3.2.7. The values ob-
tained appear to be on the low side, asain possibl~ as a result
of error in the chamber pressure assumed.
The actual value for the thrust coefficient C , wouldf
also likel'ldlie between the two values as shown. This result
demonstrates that the thrust can be more than doubled with a
properl~ desisned nozzle, with the importance of the diverSent
section apparent.
The nozzle exit velocit'ld v ,is shown to be siSnificantl~e
hiSher for the second particle flow model, where this represents
the Sas only value. The exit velocity for the fi~st model where
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6 7
the particles are assumed to have the same velocit~ as the ~as
flow is reduced as a result of acceleratin~ the particles.
The actual combustion temperature (1347 C.) was found
to be in close a~reement with the theoretical value (1406 C.) beinS
4 percent lower. The sli~htl~ lower combustion temperature would
be a result of incomplete combustion and nonadiabatic conditions.
The final parameters to be considered are the dischar~e
coefficient td and the diver~ence correction A. It can be seen
that onl~ minor thrust losses are a result of these two factors.
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68
CHAPTER 7: CONCLUSIONS
Theoretical anal~si$ of a small solid propellant rocket
motor was conducted, with the performance results presented in
the form of two limiting models. The actual findinss were ex-
pected to lie within this range, and experimental measurements
found this to be the case. This result demonstrated the impor-
tance of considering the effects of two-phase flow for small
solid propellant rocket motors.
Theoretical anal~sis suggested that the propellant per-
formance should remain essential1~ constant over a fairl~ wide
range of oxidizer/fuel ratios, however, other factors such as burn-
rate and castabilit~ reduced the acceptable ranSe. The best over-
all ratio was found to be the presentl~ emplo~ed ratio of 65/35.
Significant improvement of the motor1s performance does
not appear likelw to be achieved bw variation of the nozzle de-
sign. The conical n022le emersed as a hiShl~ satisfactor~ designwhen the simplicit~ of fabrication is considered. Marsinal in-
crease in nozzle efficien~ might be obtained b~ reducing the con-
vergence and/or diveraence anales.
A thrust-time curve of the rocket motor's performance was
obtained, providing a basis upon which to determine the expected
acceleration, velocity, and altitude of the roc~et in actual flight.
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6 9
RECOMMENDATIONS
The followins recommendations are suggested to provide a
more complete understanding of the rocket motor's and propellant's
performance, and to provide a sound basis for the desi~n of
larger rocket motors:
1. Conduct testing in order to determine the actual cham-
ber pressure during firing, possibl~ utilizins a pressure trans-
ducer s~stern to obtain a pressure-time curve. As well' a method
of determinins burnrate as a function of chamber pressure should
be investigated utilizing this data.
2. Other methods of determining the pressure-burnrate rel-
ationship should be considered, such as construction of a constant
pressure vessel to studw the rate of burning at elevated pressures.
3. Investigation into modif~ins the conical nozzle design
in order to reduce particle acceleration misht be attempted.
4. Further stud~inS of two-phase flow in an attempt to con-
solidate the particle flow models would certainl~ prove useful.
As well, it is suggested that a computer prOSram be de-
veloped to solve the eQuations of motion involved with a rocket
vehicle in flisht, utilizins the obtained thrust-time data in con-
Junction with vehicle draS data (either experimentall~ obtained or
theoreticall~ modeled>.
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70
NOMENCLATURE
a burnrate coefficient
a acoustic velocit'ol
A area
A burninsi areab
A/D analosiue I disital
AFT adiabatic flame temperature
* critical throat areac effective exhaust velocit~
c. Celsius
C Coefficient of thrustf
C Specific heat at constant pressurep
C Specific heat of solid (limuid>s
C Specific heat at constant volumev
CV characteristic velocit'ol
D srain inside (bore) diameteri
D Srain outside diametero
e enerSy conversion efficienc~
f mass fraction
F thrust
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S acceleration of gravit~
h enthalp~
hO enthalp~ of formationf
I total impulse
I specific impulsesp
k ratio of specific heats
K Kelvin
L grain lensth
m mass flow rate.m Sas mas s flowrate
5 1
.m particle (solid) mass flowrates
m.p. melting point
M Mach number
M' molecular weisht
n burn rate exponent
N Newton
OfF oxidizer/fuel
p pressure
P ambient pressurea
P nozzle exit pressureE ll
P stasnation pressureo
r burn rate
R molar gas constant
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R' IJ nivers al !las cons t an t
t t ime
t blJ rn timeb
T temperature
T s t a sna t i on temperature0
v veloci t l : l
v n ozzle ex it ve loc i t l : le
v S ia s v el oc it l: l
s
v par t ic le (so l id) ve loc i t l : l5
V chamber volumec
X part icle (s o l id) mas s fraction
a. divers en ce an s l e
dis chars e coefficien t
v el o ci tl : l c o ef fi ci en t
divers en ce correc tion fac tor
p dens i t l : l
gas den sit l : l
ppo
propel lan t den sit l : l
po
s tas n at ion den s i t l : l
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7 3
REFERENCES
1. Lancaster, O.E., edt Jet Propulsion EnSines. Princeton, N.J:Princeton Universit~ Press, 1959. Section H:Solid Propellant Rockets, bw Bartlew, C.E. andMills, H.M., P. 613
2. Sutton, G.P. and Ross, D.M., Rocket Propulsion Elements, 4th.ed., New York: John Wile~ and Sons, 1976. P. 47
3. Johnson, C.A. ed Encsclopedia of Chemical Reactions, 2nd.ed New York: Reinhold Publishing Corp., 1953.
4 . McKinnon, D.M., Private Communication, Orsanic Chemistr~Department, Universit~ of Manitoba. 1984.
5. Smith J. and Stinson, Fuels and Combustion, Maple Press, p.100
6. Van W~len, G.J. and Sonntas, R.E., Fundamentals of ClassicalThermod~namics, 2nd. ed., New York: John Wilesand Sons, 1978, P. 502.
7. Free, B.A. and Sarner, S.F., A Rapid Method For Estimationof Specific Impulse, ARS Journal, Januarw, 1959.
8. Gventert, E.C. and Neumann, H.E., Design ofAxis~mmetric Ex-haust Nozzles b~ Method of Characteristics In-corporating a Variable Isentropic Component, NASATR R-33. 1959.
9. Oliver, R.C. and Stephanov, S.E., 'Y Larse or Sn,all". ARSJournal, Oct. 1961.
10. Sutton, G.P Rocket Propulsion Elements, P. 396.
11. The Merck Index of Chemicals and DruSs, 6th ed 1952
12. Ibid
13. Fox, R.W. and McDonald, A.T Introduction to Fluid Mechanics,2nd. ed New York: John Wilew and Sons. 1978. p490
14. Sutton,G.P Rocket Propulsion Elements, p.36
15. Griffin. D.N Turner, C.F., and Angeloff, G.T., A ballisticBomb Method For Determinins the Experimental Per-formance of Rocket Propellants, ARS Journal,Jan. 1959