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S.H.A.R.P.

S.H.A.R.P. S lender H ypervelocity A erothermodynamic R esearch P robe. SHARP genesis. development of new UHTC’s, ultra high temperature ceramics shingles on shuttle max temp- 3000 F new UHTC max temp- 5000 F result- sharp leading edge profiles are now possible. SHARP profile.

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S.H.A.R.P.

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  1. S.H.A.R.P. Slender Hypervelocity Aerothermodynamic Research Probe

  2. SHARP genesis • development of new UHTC’s, ultra high temperature ceramics • shingles on shuttle • max temp- 3000 F • new UHTC • max temp- 5000 F • result- sharp leading edge profiles are now possible

  3. SHARP profile • advantages • more efficient atmospheric exit and re-entry • better cross-range capability • (wider range of re-entry angles) • minimized radio blackout during re-entry • disadvantages • generates extremely high temperature at the sharp edge/tip

  4. SHARP future • Next generation space shuttles- X-33 • nosecones • re-entry vehicles • launch vehicles (rockets & boosters)

  5. SHARP PROJECTS • B-series • sharp nosecones • B1 re-entry vehicle already launched (B2 near launch) • S-series • university & small business partnership • test a knife edge geometry • 4 launches • L-series • full size • 2 launches • UHTC test

  6. SHARP S-series • Atmospheric re-entry vehicles with knife edge profiles • reaches Mach 3.5 • UHTC not required • prototype sounding rocket launch vehicle • halfway to near earth orbit S4

  7. S1 launch schedule • Orion class rocket launches • 4,000 lb thrust, 5g vibrations • S1 deploys at apogee • 270,000 ft • data acquisition begins • fin-tube stabilizer jettisoned • 150,000 ft • primary data capture • temperature, pressure, accelerations • S1 re-enters atmosphere • S1 parachute deployed • 20,000 ft • rocket and S1 recovery via helicopter

  8. SHARP S-series goals • Create working relationships between NASA, universities and small businesses • gather aero & thermodynamic data on the SHARP-S profile • compare with computer simulations • Provide data for the L-series • S-series serve as prototypes • same geometry, ~ 2x size • UHTC equipped (mach 20 vs. 3.5)

  9. SHARP-S program timeline

  10. SHARP S-series GROUPS NASA Ames Research Center project co-ordinator, aero/thermodynamics Montana State University re-entry vehicle structure Stanford University re-entry vehicle avionics Wickman Spacecraft & Propulsion launch vehicle & site

  11. MSU SHARP TEAM PI: Dr. Doug Cairns MSGC: Dr. Bill Hiscock manager: Aaron Sears consultant: Will Ritter students: Mike Hornemann Kevin Amende Cindy Heath Crystal Colliflower Dustin Cram

  12. MSU research groups • Montana Space Grant Consortium • federally funded program which disperses grant money to space oriented projects • Composites Research Group • co-directors: Dr. Cairns, Dr. Mandell • material characterization, structures & manufacturing • wind energy, aerospace

  13. NASA designated responsibilities • Design and build the S1-4 re-entry vehicles using composite materials • integrate the structure with: • avionics (Stanford) • sounding rocket (Wickman Spacecraft) • low operating budget • faster, better, cheaper motto • $ 50k/year budget

  14. S1 shape • S1 dimensions supplied by NASA 17” 4.4” 39.5” 6.6” 11.3o

  15. mold peripherals assembly 4 part design ProE design FEM analysis design manufacturing * all design, analysis and manufacturing performed in-house at MSU

  16. S1 design constraints results - epoxy matrix - metal tip (aluminum/steel) -composite shell w solid tip - carbon/epoxy • Withstand high temperatures • 600 F in shell (one use) • 1000+ F at tip • lightweight • CG in front of center of pressure • smooth aerodynamic surface • withstand dynamic pressures of 10 psi with minor deflections • unlimited systems integrations • provide locations & mounting for • pressure and temperature sensors • avionics components

  17. S1 design • 4 part design • shell • component mounting frame • parachute • tip • base • peripheral & equipment • shell mold • fin-tube

  18. S1 design fin-tube shell (mounting frame internal) base plate sensor arrangement tip S1 with fin-tube drag stabilizer cutaway view of internal mounting frame (spar system)

  19. shell design • Provides the aerodynamic surface and serves as a main structural member • only surface interruptions are 6, ~1/16” holes for pressure and temperature sensors • One piece • only joint along aero-surface at tip interface • pressure bladder manufactured • IM7/8552 carbon/epoxy laminate • ~ 0.10” thick

  20. shell/spar structure • Integrates the component mounting frame into the vehicle structure • spar system is removable for unlimited avionics & systems integration spars

  21. spar system • 2 axial, 3 lateral • carbon/epoxy plates • mechanically connected • guided in by L-rails bonded into shell • spars mechanically attach into L’s for unlimited systems integration • 4th lateral spar of aluminum • sensor board mount on left axial

  22. structural design drivers • aerodynamic pressures • ~ 10 psi at Mach 3.5 • launch vibrations • as Orion class sounding rocket • 6-g random vibration • heat • 600 F at tip/shell interface • +1000 F at tip • component space allocation • forward CG required advanced placement of heaviest components • governed possible placements of spars

  23. hypersonic pressure analysis (inches) (02/±45/903)s hoop = 90, axial = 0, E1 = 20 Msi (~65% Vf, 0.058 lbf/ft3), t = 0.09” hypersonic skin pressure = 2.78 psi (Mach 3.5, 85,000 ft)

  24. natural frequency analysis mode 1: 56 hz mode 2: 111 hz mode 3 : 180 hz (02/±45/903)s hoop = 90, axial = 0, E1 = 20 Msi (~65% Vf, 0.058 lbf/ft3), t = 0.09” (base plate constrained boundary condition)

  25. tip & interface • design drivers • forward the CG location for aerodynamic stability • temperature resistance • pull-off (drag difference) force • smooth external interface • features • aluminum • better machining control • 1/2” lip for shell overhang • improves transition and connection • steel parachute line mounts • better impact/fracture properties than composites

  26. tip interface sketch mounting bolt steel mounting plate tip link parachute line lip retention cup epoxy shell epoxy gap sanded flush

  27. tip & interface

  28. S1 sensor locations Pressure (8) Temperature (4) • The

  29. parachute specifications • manufacturer • Rocketman recovery parachutes • Ky Michaelson • specifications • R7 pro experimental • 2.12 lbs • reinforced panels • specially formed canvas deployment bag

  30. parachute deployment • Deployment mechanism • single bay door • hinged • latched by #2 nylon bolt • black powder charge pushes parachute through door • Altitude • 20,000 ft

  31. shell mold Top half of mold Male preform plug

  32. mold design result Constraint • Must be able to withstand temperatures up to 400F for curing of the resin • Aerodynamic surface shape requires tight tolerances • Seam lines kept to a minimum • Must be able to withstand pressures up to 80 psi • requires a metal mold • CNC provides tightest tolerances • machined from solid blocks

  33. P Aluminum - lower weight & thermal mass - no warpage during machining Steel - better damage tolerance O mold design • Negative of S1 model • All dimensions to .0001 inch • ProE IGES to MasterCam for CNC • Equivalent commercial mold cost • $ 35,000 • Estimated MSU mold cost • materials: $ 1,600 • labor: $ 5,000 • tooling: $ 500

  34. plug • CNC machined from ProE model • Accurate shape insures that pre-form will fit snugly into the mold • The plug is .25 inch smaller than real sharp in all directions

  35. manufacturing - tip current tip pic in HAAS

  36. composites manufacturing 1. preforming 2. curing (w pressure &/or vacuum) 3. trim & assembly

  37. prototyping • Aid troubleshooting • design methodology • details • 2 prototypes (full scale) • G1 • glass polyester/shell, wood tip • S1 deployment test • G2 • glass polyester/shell • avionics mounting trouble shooting

  38. S1 structure parts

  39. assembly & integration • first full assembly at Stanford for flight certification tests • total weight 44.5 lbs. • CG: 52% of length

  40. flight certification tests • mass properties *! • center of gravity • moment of inertia • vibration loading (shake test) *! • sine sweep (natural frequency) • random vibrations (launch loading) • deployment tests, • altitude chamber (Stanford only) * performed at NASA Ames Research Center ! passed

  41. moment of inertia roll CA DAQ- proximity detector yaw

  42. shake testing yawwise shake pitchwise shake CA DAQ- acceloremator w FFT

  43. Launch TBA Avionics software at 90% complete altitude chamber test Rocket static fire- 10/18/00 weld failure at 4 seconds good propellant fire S1 status

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