Overview
As a part of Duke Aero, I worked as a part of the Payload and Structures subteam, with the goal of launching a rocket to 10,000'. The rocket is 8.5' long with a 6" diameter, weighing in at nearly 70lbs. Thrust was provided with an M-class solid rocket motor.
On the payload subteam, I worked with 2 other engineers to make a payload and deployer system to land safely on the ground after ejection at 1,200ft. As a member of the structures subteam, I worked on various pre-preg layups and forged carbon fiber molding as well as designing and performing FEA on the motor bulkhead.
The rocket - affectionately dubbed "Blue Reaper" - has now successfully flown twice with nominal system and recovery performance.
Payload
On the payload subteam, I designed and manufactured the outer structure of the CubeSat as well as designing the parachute deployment spring plate. The structure of the CubeSat was designed for smooth deployment along the precision machined rails and rigidity to withstand the forces of deployment and recovery.
1 | Reliability
Deploy parachute consistently and make mechanism as simple as possible to eliminate failure points
2 | Precision
Critical that payload fits and slides in and out of deployer well for smooth deployment
3 | Durability
Must be able to survive forces of deployment and touchdown under parachute
Parachute Plate
The parachute plate is spring-loaded and facilitates reliable parachute deployment. A cutout in the plate allows the parachute to be coupled to the body of the CubeSat with an eyebolt. All parts were waterjet cut out of 6061 aluminum and testing was done to ensure the plate does not shear under the high initial force of parachute deployment.
Corner Pieces
I machined the 4, ~11" long corner pieces out of 6061 aluminum in the student shop. The 8 mounting holes evenly spaced on the outside of the rail allow the sides of the CubeSat to be mounted securely.
Testing
Testing was done throughout the design and manufacturing process to ensure that the parachute deployed consistently and that the payload came out of the deployer easily.
Structures
On the structures subteam, I participated in multiple pre-preg carbon fiber layups for the main rocket body tubes as well as designing and performing simulations on the motor bulkhead to ensure an appropriate factor of safety.
1 | Strength
Body tubes and bulkhead needs to be strong in order to withstand max thrust of M-class motor
2 | Optimization
Weight must be minimized while preserving appropriate factor of safety determined from simulation
3 | Precision
Precision of all parts must be maintained in order to ensure no loss in aerodynamic capabilities
Pre-preg Layup
Using a 6" mandrel, the team was able to perform completely in-house carbon fiber pre-preg layups for the body tubes of the rocket. Fabrication was conducted with care to optimize surface finish for and aerodynamics.
The 3 fins that keep the rocket stable were created from a sheet of G10 fiberglass sandwiched between 4 sheets of carbon fiber.
Additionally, the forged carbon fiber fin mounts securely fix the fins around there rocket with little extra weight.
Motor Bulkhead
I designed the motor bulkhead to minimize weight while keeping sufficient strength to withstand 3.7kN during max thrust (4.0 factor of safety).Â
Testing
Multiple separation and fitment tests were conducted throughout the design and fabrication process to ensure nominal rocket flight.
Launches!
Copy of BAYBORO_EDIT.mp4Test Launch in Bayboro, NC (4/2023)
SAC2023LAUNCHLaunch at Spaceport America in New Mexico (6/2023)
