Identified Company (CompositeX) to manufacture Custom Composite Pressure Vessel ● Working pressure...

Identified Company (CompositeX) to manufacture Custom Composite Pressure Vessel

●Working pressure 1000psi●Holds 8 kg Nitrous Oxide●700 cubic inch volume ●HDPE lined●1.4 lbs

Composite Pressure Vessel(Chalice Concept)

Liquid NitrousOxide

NitrousOxide Vapor

8”

14”


Helium Gas

Liquid NitrousOxide


●Ideal gas law used to model helium pressure

➔ p=m*R*T/V

●Verified from pressure/ temperature data that Helium will remain gaseous

➔ Compressibility factor ~1, so ideal gas assumption valid

●Tank weights listed estimated from quote of 700ci=1.4 lbs

➔ Also includes weight of Helium (case dependent)

Aluminum/Titanium Comparison

Aluminum alloy Aluminum alloy Titanium Alloy

Property 7075-T6 (ww-T-700) drawn tubing 7075-T6; 7075-T651 Grade 5 Ti6Al4V % Different

Source Casing.xls Matweb Matweb

Yield Strength (Mpa) 455 503 1103 219.28%

Ultimate Strength (Mpa) 531 572 1172 204.90%

E (Gpa) 71.76 71.76 113.85 158.65%

0.33 0.33 0.33

Density (g/cc) 2.81 4.43 157.65%

Melting Temp (oC) 477 1600 335.43%

Thermal Conductivity (W/m-K) 130 6.7 5.15%

Specific Heat (J/g-K) 0.96 0.5263 54.82%

Mass Calculation

Short Grain

HTPB Mass(kg) N2O Vol (m^3) N2O Vol (m^3) Structure Mass Allowable (10:2)

Multiplier 6 8 6 8

1.5 0.01144 0.01526 2.1 2.7

1.55 0.01182 0.01576 2.17 2.79

1.6 0.01220 0.01627 2.24 2.88

1.65 0.01259 0.01678 2.31 2.97

1.7 0.01297 0.01729 2.38 3.06

1.75 0.01335 0.01780 2.45 3.15

Long Grain

HTPB Mass(kg) N2O Vol (m^3) N2O Vol (m^3) Structure Mass Allowable (10:2)

Multiplier 3 6 3 6

2.5 0.00953 0.01907 2 3.5

2.55 0.00973 0.01945 2.04 3.57

2.6 0.00992 0.01983 2.08 3.64

2.65 0.01011 0.02021 2.12 3.71

2.7 0.01030 0.02059 2.16 3.78

2.75 0.01049 0.02098 2.2 3.85

Mass CalculationChalice Design, 7075-T6 Al

240mm OD, 1.75mm Thickness, FS 1.25

Short Grain

Low Height (cm) Low Mass (g) % All. Mass High Height (cm) High Mass (g) % All. Mass

26.05 973 46.32% 33.72 1259 46.65%

26.91 1005 46.32% 34.85 1301 46.65%

27.78 1038 46.32% 35.97 1343 46.65%

28.65 1070 46.32% 37.09 1385 46.65%

29.52 1102 46.32% 38.22 1427 46.65%

30.39 1135 46.32% 39.34 1469 46.65%

Long Grain


21.70 811 40.53% 42.15 1574 44.98%

22.14 827 40.53% 43.00 1606 44.98%

22.57 843 40.53% 43.84 1637 44.98%

23.01 859 40.53% 44.68 1669 44.98%

23.44 875 40.53% 45.52 1700 44.98%

23.88 892 40.53% 46.37 1732 44.98%

Mass CalculationEmbedded Outer Shell Design, 7075-T6 Al

180mm OD, 61mm ID, 1.3mm Thickness, FS 1.25

Short Grain


51.67 1075 51.19% 65.18 1356 50.23%

53.21 1107 51.02% 67.17 1398 50.10%

54.76 1139 50.86% 69.17 1439 49.97%

56.30 1171 50.71% 71.17 1481 49.86%

57.84 1203 50.57% 73.17 1522 49.75%

59.39 1236 50.43% 75.17 1564 49.65%

Long Grain


43.75 910 45.51% 82.17 1710 48.85%

44.62 928 45.51% 83.67 1741 48.77%

45.50 947 45.51% 85.17 1772 48.68%

46.37 965 45.51% 86.67 1803 48.61%

47.25 983 45.51% 88.17 1834 48.53%

48.12 1001 45.51% 89.67 1866 48.46%

Mass CalculationEmbedded Inner Shell Design, Grade 5 Titanium

61mm OD, 0.5mm Thickness

Short Grain


45.50 192 9.12% 45.50 192 7.09%

45.50 192 8.83% 45.50 192 6.87%

45.50 192 8.55% 45.50 192 6.65%

45.50 192 8.29% 45.50 192 6.45%

45.50 192 8.05% 45.50 192 6.26%

45.50 192 7.82% 45.50 192 6.08%

Long Grain


63.00 265 13.26% 63.00 265 7.58%

63.00 265 13.00% 63.00 265 7.43%

63.00 265 12.75% 63.00 265 7.29%

63.00 265 12.51% 63.00 265 7.15%

63.00 265 12.28% 63.00 265 7.02%

63.00 265 12.06% 63.00 265 6.89%

Inner Shell (fuel grain housing)

Inner and Outer Shell ANSYS Stress Modeling (Embedded Fuel Grain Concept)

Outer radius: 2.40” (~61mm)

Inner radius: 2.36” (~60mm)

Height: 21.46” (~545 m)

Mat’l: Aluminum 7075 T6

Outer radius: 1.75” + 0.5 mm (0.03225 m)

Inner radius: 1.25” (0.03175 m)

Height: 1.5” (0.0381 m)

Mat’l: Al 7075 T6 with Composite over-wrap

Composite: IM7 Carbon (fiber) / PEEK (matrix)

Model Geometry

Outer Shell (NOS/rocket housing)

Material Properties

Al 7075-T6

(Modeled as Isotropic)

Density: 2810 kg/m3

Longitudinal Mod., E1: 71.7e9 Pa

Poisson’s Ratio, v12: 0.33

PEEK (matrix)

Density: 1376 kg/m3

IM7 Carbon Fiber (12,000 filaments)

(Modeled as Orthotropic)

Density: 1780 kg/m3

Longitudinal Mod., E1: 278e9 Pa


Carbon/PEEK Composite

(Modeled as Isotropic)

Density: 1600 kg/m3

Longitudinal Mod., E1: 71.7e9 Pa

Transverse Mod., E2: 10.2e9 Pa


Shear Modulus, G12: 5.7e9


Outer Shell (w/ composite)


Figure 1: Outer Shell of Imbedded Fuel Grain Design(Meshed Elements – 8node93)



Figure 2: Outer Shell of Imbedded Fuel Grain Design: Plot Results Contour Plot Element Solution Stresses von Mises stress



Figure 3: Outer Shell of Imbedded Fuel Grain Design: Plot Results Deformed Shape Def + undeformed



Figure 4: Outer Shell of Imbedded Fuel Grain Design: (Pressure & Constraints – Rotated view)



Figure 5: Outer Shell of Imbedded Fuel Grain Design: (Pressure & Constraints - Front View)



Figure 6: Outer Shell of Imbedded Fuel Grain Design: (Pressure & Constraints - Side View)

Inner Shell (All Aluminum)


Figure 7: Inner Shell of Imbedded Fuel Grain Design(Meshed Elements – 8node93)



Figure 8: Inner Shell of Imbedded Fuel Grain Design: Plot Results Contour Plot Element Solution Stresses von Mises stress



Figure 9: Inner Shell of Imbedded Fuel Grain Design: Plot Results Deformed Shape Def + undeformed



Figure 10: Inner Shell of Imbedded Fuel Grain Design: (Pressure & Constraints – Rotated view)



Figure 11: Inner Shell of Imbedded Fuel Grain Design: (Pressure & Constraints – Front view)



Figure 12: Inner Shell of Imbedded Fuel Grain Design: (Pressure & Constraints – Side view)

Outer Shell (Aluminum only)


Figure 13: Outer Shell of Imbedded Fuel Grain Design(Meshed Elements – 8node93)



Figure 14: Outer Shell of Imbedded Fuel Grain Design: Plot Results Contour Plot Element Solution Stresses von Mises stress



Figure 15: Outer Shell of Imbedded Fuel Grain Design: Plot Results Deformed Shape Def + undeformed



Figure 16: Outer Shell of Imbedded Fuel Grain Design: (Pressure & Constraints – Rotated view)



Figure 17: Outer Shell of Imbedded Fuel Grain Design: (Pressure & Constraints - Front View)



Figure 18: Outer Shell of Imbedded Fuel Grain Design: (Pressure & Constraints - Side View)


Figure 19: ELEMENT LAYERS


Figure 20: LAYER ORIENTATION AND THICKNESS


Figure 21: LAYER ORIENTATION AND THICKNESS continued…


Figure 22: COMPOSITE PROPERTIES


Figure 23: ALUMINUM PROPERTIES


Figure 24: FAILURE CRITERIA FOR COMPOSITES


Figure 25: INVERSE TSAI-WU STRENGTH RATIO INDEX


Figure 26: X-COMP OF STRESS


Figure 27: Y-COMP OF STRESS


Figure 28: X-COMP OF STRESS


Figure 29: SHEAR XY-DIR


Figure 30: SHEAR YZ-DIR


Figure 31: SHEAR XZ-DIR

Top and Bottom Fixture Solidworks Stress Model(Embedded Fuel Grain Concept)

Model Geometry

Mass = 0.520526 kg

Volume = 0.00018 m3

Geometry is the same for both the top and bottom fixture

Material Properties, Loading, and Meshing

Al 7075-T6

Density: 2810 kg/m3

Modulus of Elasticity: 71.7 GPa

Shear Modulus: 28 GPa


1000 psi 1000 psi

Meshing done with Solidworks and Cosmos finite element analysis

Elements: 25306

Nodes: 49277

Factor of Safety Results


Discussion of Results

•This model demonstrates how the top and bottom fixtures will hold up against the required loads. The loading is purely theoretical at this point, but the model is made, and all that needs to be done is substitute the correct loads for the theoretical ones.


External Shell Solidworks Stress Model(Embedded Fuel Grain Concept)

Model Geometry

Mass = 1.63918 kg

Volume = 0.00058 m3



Elements: 43804

Nodes: 87448


1000 psi

Al 7075-T6

Density: 2810 kg/m3



Internal Shell Solidworks Stress Model(Embedded Fuel Grain Concept)

Model Geometry

Mass = 5.64597 kg

Volume = 0.002 m3


Al 2024

Density: 2780 kg/m3




Elements: 34919

Nodes: 68256


1000 psi

Al2O3 Post Combustion Chamber

Post Combustion Chamber ANSYS Thermal Model (Embedded Fuel Grain Concept)

Outer radius: 1.25” (0.03175 m)

Inner radius: 1” (0.0254 m)

Height: 1.5” (0.0381 m)

Outer radius: 1.75” + 0.5 mm (0.03225 m)

Inner radius: 1.25” (0.03175 m)

Height: 1.5” (0.0381 m)

Al 7075-T6 Housing (0.5 mm)

Model Geometry


Material Properties

Al2O3

Density: 3970 kg/m3

Specific Heat: 774.977 J/(kg-K)

Thermal Conductivity: variable

Al 7075-T6

Density: 2810 kg/m3

Specific Heat: 960 J/(kg-K)

Thermal Conductivity: 130 W/(m-K)

Assumptions•Constant Aluminum properties

•Chamber ends are adiabatic

•Constant film coefficients

•Constant bulk temperatures


Meshed Model

Nodes: 9,589

Elements: 5,602

Volumes meshed using ANSYS SmartSize 1 with tetrahedral elements


Boundary Conditions

Outer Surface•Film coefficient, h = 5 W/(m-K)

•Bulk temperature, T∞ = 298 K

Simulates free convection of N20 on Al housing

Inner Surface•Film coefficient, h = 300 W/(m-K)

•Bulk temperature, T∞ = 3000 K

Simulates convection of the propellant gas inside the combustion chamber

All nodes initially set to 298 K


Transient Results1

MN

MX

X

Y

Z

Model of Post Combustion Chamber and Al Housing

15391567

15941622

16501677

17051733

17601788

FEB 13 200719:27:23

NODAL SOLUTION

STEP=1SUB =101TIME=50TEMP (AVG)RSYS=0SMN =1539SMX =1788



•This model demonstrates heat transfer across multiple ANSYS volumes, which will be necessary to derive a film coefficient from thermocouple data

•A transient analysis was also performed by hand using ANSYS input conditions with results matching ANSYS output to within 100 Kelvin. The transient model is considered validated for this test case.

Post Combustion Chamber ANSYS Thermal Model (Engine Core)

Future Models

A model of the post combustion chamber and nozzle is being developed to utilize data that will be collected by the test stand team.

The model will be used to back out an average film coefficient and to determine if the engine structure will meet the Guidance burn time of 50 seconds.

Identified Company (CompositeX) to manufacture Custom Composite Pressure Vessel ● Working pressure...

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