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Design pressure: 1500 psi

Sustainer:

Aluminum Case: OD: 4", ID": 3.75" (thickness 1/8")

Phenolic Liner: OD: 3.75", ID: 3.5" (thickness 1/8")

Casting Tube: OD: 3.5", ID: 3.375" (thickness 1/16")

Booster:

Aluminum Case: OD: 6", ID: 5.625" (thickness 3/16")

Phenolic Liner: OD 5.625", ID: 5.375" (thickness 1/8")

Casting Tube: OD: 5.375", ID: 5.25" (thickness 1/16")

Constraints:

• manufacturing Manufacturing capability
  • lathes Lathes can machine up to 6" diameter
• available Available liners' specs (lengths)
  • 48", 53.1", 59.1", 65"
• need Need for a casting tube within liner
  • unless Unless multicast in one liner is feasible
  • available tube size
  • • • While potentially feasible, many have told us it is better practice to use a casting tube with each grain in sections with o-rings in between each ring
  • Available tube size
  • Tolerances of the tubes are not within rocketry tolerance (+-.001")
    • Solution: Use a simulator piece while machining the parts to achieve as good of a seal as possible
      
      • Simulator piece is a cut piece of the case stock. Get part to nominal diameter then test fit with simulator until it fits by hand
      • Use 300 or 400 series o-rings to hold a better seal.

  Design Specs:

  • 6' ish " OD
  • Internal pressure expected to be around 1500-2000 1000 psi max
  • Safety factor 2
  • min. thickness: 0.350"

  Motor Case:

  • order from Speedy Metals? (lengths: 1', 2', 3', 4', 6', 8')
  • 1/2" thick
  • ID: 5.25', OD: 6'
  • 1.5
  • Thickness: 3/16"

  Phenolic Tubes:

  • order Order from Franklin Fibres (lengths: 48", 53.1", 59.1", 65")
  • 1/8" thick for liner
    • ID: 5.375.25'", OD: 5.5'625"
  • 1/16" thick for casting tube
    • ID: 5.125'25", OD: 5.25'375"
  • long lead times, order in bulk this semester

  Bolts:

  2 rows of 16x 1/4-20 bolts.

  Total of 64 bolts on the booster.

   

   

  Align
  class A
  Medusa Sustainer

  ...

  • available liners' specs (lengths)
    • 48", 53.1", 59.1", 65"

  Design Specs:

  • 4' ish OD" OD, 3.75" ID
  • Internal pressure expected to be around 1500-2000 300 psi max
  • Safety factor 23
  • min. thickness: 0.241" - closest thickness is 0.25Thickness: 1/8"

  Motor Case:

  • order Order from McMaster or Online Metals
  • 1/28" thick
  • ID: 3.575', OD: 4'

  Phenolic Tubes:

  • order Order from Franklin Fibres (lengths: 48", 53.1", 59.1", 65")
  • long lead times, order in bulk this semester
  • 1/8" thick for liner
    • ID: 3.5", OD: 3.75"
  • 1/16" thick for casting tube
    • ID: 3.
    25'
    • 375", OD: 3.5
    '
    • "
  • long lead times, order in bulk this semester

  Bolts:

  1 rows of 8x 10-20 bolts.

  Total of 16 bolts on the sustainer.

  
  

   

  Align
  class A
  Case Spec Calculations

  Case calcs done using 2000 1800 psi as internal pressure

  Thin vs Thick Case Assumption: thin case assumption can be used if  

  Mathinline
  body \frac{Diameter}{thickness} < 20

  ...

  Calculated with thin case assumption -> safety factor = 2, case thickness = 0.371"Move onto thick case assumption -> safety factor = 21.5, case thickness = 0.350191"

   

  Sustainer

  Sustainer thin case assumption if t < 0.2"

  ...