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SOLID PROPELLANT ROCKET MOTOR COMPONENTS INITIAL DESIGN

Conference Paper · October 2011

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 SOLID PROPELLANT ROCKET MOTOR
COMPONENTS INITIAL DESIGN
SAŠA ŽIVKOVIĆ
Military Technical Institute, Belgrade, e-mail: sasavite@[Link]

DR MILORAD SAVKOVIĆ
Military Technical Institute, Belgrade, e-mail: [Link]@[Link]

DR NIKOLA GLIGORIJEVIĆ
Military Technical Institute, Belgrade, e-mail: [Link]@[Link]
Abstract: A geometric – gas dynamics method for optimal chamber pressure determination, for solid propellant rocket
motor, is described. Optimization criterion is minimum initial motor weight. The method gives the motor components
basic geometry parameters. This is very useful in the design initial phase. The method’s simplicity allows different
concept solutions comparison. The geometry parameters mathematic models were explained in detail. Dual thrust
phase and two-chamber rocket motors were calculated and compared for example.
Keywords: Rocket motor, solid propellant, components geometry, chamber pressure, dual thrust.
1. INTRODUCTION typical parts can be designed and untypical can be added
into the calculation by designer’s evaluation of they mass.
The chemical energy transformation into the combustion
products kinetic energy occurs in the solid propellant
rocket motor (SPRM) combustion chamber [1, 2 and 3].
In same time the chamber is used like the propellant
reservoir [4]. The chamber with cylindrical section is the
most common SPRM case shape. Because of the
exploitation and the aerodynamic characteristics, small
caliber is suitable for a projectile. The case is usually Figure 2: Special purposes SPRM’s.
several calibers long. Because of that reason, in this
paper, calculation procedure is limited to the SPRM with
2. PROPELLANT GRAIN
cylindrical case and single nozzle. The SPRM basic
components (figure 1) included in this procedure are: Mass of the propellant grain is determined by parameters
1. propellant grain, of the projectile mission: total impulse – Itot, type of the
2. case (cylindrical section), propellant, nozzle efficiency, aerodynamic characteristics,
3. nozzle (with aft closure), etc. Specific impulse of propellant can be determined by
4. igniter, characteristic velocity – C*, thrust coefficient – CF and
5. forward closure, efficiency coefficients (velocity correction factor – ηv and
6. insulation, discharge correction factor - ηd):
7. attachment skirt.
I sp = ηv ⋅ηd ⋅ λ ⋅ C * ⋅ CF (1).

The divergence angle correction factor, for half angle of

the conical nozzle exit – αd:

λ = 0.5 ⋅ (1 + cos α d ) (2).

Figure 1: SPRM typical design. The characteristic velocity is related to the efficiency of the
combustion process and thermodynamic properties of the
The SPRM can have various design approaches and the combustion products – gas constant – Rg, combustion
parts composition, particularly in case when they have temperature – T, specific heat ratio – κ:
special purpose. For example in figure 2 are shown two
special purposes SPRM [5]. In spite of that they have κ +1
some typical components. The calculation procedure Rg ⋅ T ⎛ κ + 1 ⎞ κ −1
*
C = ⋅ (3).
κ ⎜⎝ 2 ⎟⎠
doesn’t include untypical components. However the
The thrust coefficient is defined as the thrust divided by the
chamber pressure – Pc and the throat area – At. The thrust
δ tc = ν p ⋅ t + δ th ≥ 1.5 mm (10).
coefficient is also function of the products properties, the
products pressure at the nozzle exit – Pe, the ambient The liner and the inhibitor thickness can be approximately
pressure – Pa and the nozzle area ratio – Ae/At: calculated with same approach2.
At this point, the cylindrical section insulation mass can
κ +1 ⎡ κ −1 ⎤ be calculated, for known insulation material gravity – ρt:
2 ⋅ κ 2 ⎛ 2 ⎞ κ −1 ⎢ ⎛ Pe ⎞ κ ⎥ Pe − Pa Ae
CF = ⋅ ⋅ ⎢1 − ⎜ ⎟ ⎥ + ⋅ (4).
κ − 1 ⎜⎝ κ + 1 ⎟⎠ P Pc At M tc = 2 ⋅ (r − δ c ) ⋅ π ⋅ ρt ⋅ L ⋅ δ tc (11).
⎢⎣ ⎝ c ⎠ ⎥⎦

The igniter propellant mass is small, usually less than 1%

The nozzle exit plane area and the throat area ratio can be of the motor propellant mass [5]. For SPRM with large
obtained from the gas dynamics relation: burning surface, igniter can have plastic case. Total mass of
this igniter type is roughly two or three times larger then the
1 1 ⎡ 1−κ ⎤ igniter mass – factor k = 2 ÷ 3. For large SPRM the most
Ae ⎛ 2 ⎞ κ −1 ⎛ Pc ⎞ κ κ + 1 ⎢ ⎛ Pc ⎞ κ ⎥ common igniter design is pellet-basket [5]. The hardware
=⎜ ⎟ ⋅⎜ ⎟ / ⋅ 1− ⎜ ⎟ (5).
At ⎝ κ + 1 ⎠ ⎝ Pe ⎠ κ − 1 ⎢ ⎝ Pe ⎠ ⎥ mass of the igniter is considerable larger k > 10. Total
⎢⎣ ⎥⎦ igniter mass is proportional to the chamber free volume:

Finally, the propellant mass can be calculated from given M pr = k ⋅ 2 ⋅10−6 ⋅ r 2 ⋅ π ⋅ (1 − ε ) ⋅ L (12).
relations, and it can be defined as a pressure function:
The cylindrical section often has attachment skirts, for
I rocket parts assembling. They must carry all exploitation
M b = tot (6).
I sp loads, and they mass are roughly proportional to caliber:

M v = 0.0025 ÷ 0.005 ⋅ r 2 ⋅ π ⋅ ρ (13).

3. MOTOR CASE SECTION
The motor case is usually made from metal (steel,
aluminum or titanium alloy). The case cylindrical section 4. FORWARD CLOSURE
middle radius is nearly equal to half of caliber1 – r ≈ D/2. The forward closure of the case can be made from one
The cylindrical section thickness can be calculated like material piece with cylindrical section. If they are made
pressure vessel, for known material allowable stress – σ separately, they can be joined by welding, or with
and required degree of security – ν. threaded or bolts joint flange. The closure should be same
strength like other motor parts, and minimal mass [6].
Pc ⋅ r ⋅ν Additional criterion can be the closure length.
δc = ≥ 1.5 mm (7). Hemispherical closure has minimal thickness and greatest
σ
strength, but his length is maximum – equal to half of the
The cylindrical section length is defined with the grain caliber (fig. 3). This closure could be acceptable for
mass and gravity – ρb, total chamber volume and SPRM without strict length limitation, with mass
volumetric loading fraction – ε = 1 – free/total chamber reduction benefit. In opposite case, flat closure can be
volume: used when its mass is small in comparison with motor
total mass (small caliber and large length).
The most common closure shape is torispherical. They
Mb
L= (8). have good strength and small length (fig. 3). Geometric
π ⋅ ( r − δ c ) 2 ρb ⋅ ε parameters of the torispherical closure can be expressed
with factors, dependent of cylindrical – r, spherical – R
The cylindrical section mass for known material gravity – and torical – R1 radius:
ρ, is pressure function:
R1 R 1⎛ k ⎞
M c = 2 ⋅ r ⋅π ⋅ ρ ⋅ L ⋅δc k1 = ; k= ; kC = ⎜3+ ⎟ and
(9). r r 4 ⎜⎝ k1 ⎟⎠
⎡ (14).
⎛ 1 − k1 ⎞ ⎤⎥
2
The cylindrical section can be covered with thermal
insulation, liner for propellant bounding or the grain γ = a sin ⎢ 1 − ⎜ ⎟
⎢ ⎝ k − k1 ⎠ ⎥⎦
inhibitor. The insulator thickness can be calculated from ⎣
known ablation rate – vp and motor burning time – t, with
additional supporting thickness – δth, (limited with The torispherical closure thickness is [7]:
assumed technological minimum thickness)

1 2
To provide the method simplicity, many simplifications have Like for many other motor components witch has small mass
been done, when small error is estimated. contribution, this approximation brings small calculation error.

2
 Мd(Pc) can be generated. This function is mass of optimal
Pc ⋅ R ⋅ν closure, for given problem.
δ d = kC ⋅ ≥ 1.5 mm (15);
2 ⋅ σ − 0.2 ⋅ Pc + kC ⋅ Pc Thickness of the closure insulation – δtd can be calculated
similarly like in eq. 10. Mass of insulation can be
and its mass is: approximately calculated from next equation:

M d = 2 ⋅ π ⋅ R 2 ⋅ ( 1 − sin γ ) ⋅ δ d ⋅ ρ + δ td ⋅ ρt
M td = M d ⋅ (18).
⎡
δd ⋅ ρ
⎛ sin γ ⎞ ⎤ (16).
2 ⋅ R1 ⋅ y ⋅ ⎢ r − R1 ⋅ ⎜ 1 − ⎟⎥ ⋅ δ ⋅ ρ
⎣ ⎝ γ ⎠⎦ d
5. NOZZLE WITH AFT CLOSURE
According to [1], conical nozzle section inner contour
should have shape shown on figure 5 and dimensions as
follows:
R2 - torical section radius of the closure (0.5 ÷ 1)r;
αk - convergence half angle from 45º ÷ 60º;
Rg - throat contour radius (1.5 ÷ 2)rt;
αd - divergence half angle from 10° ÷ 15º.

Figure 3: Hemispherical and torispherical forward

closures.
The mass Мd is function of Pc, R и R1. Recommended
values for R1 are from 0.12r to r [6]. This function for
constant Pc, is shown in figure 4. Zone of Md minimum is Figure 5: The nozzle inner contour.
for R→r and R1→r. This is conformation of clam that
hemispherical closure has minimal mass. Generally, it can be told that larger radius values and
The closure length – b is frequently limited. For constant smaller angles bring better flow characteristics and less
b, an optimal combination of values R and R1 exists. The nozzle flow losses. On the other hand these values make
torispherical closure length is: nozzle longer and heavier. Optimal values of these
parameters can be found, but this is complex problem.
Approximately, smaller radiuses and larger angles are
b = r ⋅ ⎡k − ( k − k1 ) − (1 − k1 ) ⎤
2 2
⎢⎣ ⎥⎦ (17). closer to optimal construction. The flow losses in that
case are smaller then benefit from mass reduction.
Nozzle section for SRPM with long burning time (more
Value R1 can be given through R(R1), and function Мd can
then 1 s), usually has next parts:
be defined with two independent R and Pc, by using
equation (17). • graphite throat insert,
• housing of throat insert and insulation,
• aft closure and insulation,
• exit cone and insulation,
• attachment flange.
The insert mass depends of many factors and its
calculation is complex. For initial calculation can be used
empiric relations. For required thrust – F and throat
radius:

F ⋅ C*
rt = (19);
I sp ⋅ Pc ⋅ π

roughtly, the insert should has radius rul = 2·rt, and length
lul = 1.5·rul. For graphite gravity – ρul, mass of the insert
is:
Figure 4: Functions Мd(R, R1, Pc=const) and Мd(R, Pc).
M ul = ( rul − rt ) ⋅ π ⋅ lul ⋅ ρul (20).
Function Мd(R, Pc), for exact values Pc=const, have
minimum near value R=2r [6]. This minimum values for
discreet values of Pc, can be interpolated and function

3
Housing and insulation of the insert can have form of
⎡ r-R2 ⋅ (1-cosαk ) ⎦⎤ -r22
2
cylinders (fig. 1). They dimensions depends of thermal, ⎣
pressure loads and nozzle geometry. M mk =δk ⋅ ρ ⋅ π +
sinαk
The insulation thickness can be obtained according to eq. (30);
10, and the housing radius is r3 = r2 + δtc. ⎡ ⎛ sinαk ⎞⎤
2 ⋅ π ⋅ R2 ⋅ αk ⋅ δk ⋅ ρ ⋅ ⎢ r-R2 ⋅ ⎜1- ⎟⎥
Pressure load for the housing can be estimated from ⎢⎣ ⎝ αk ⎠ ⎥⎦
nozzle flow calculation. Pressure level around the
housing beginning – P3 can be determined from Mach
number at this section – M3: δ tc ⋅ ρt
M tk = M mk ⋅ (31).
δk ⋅ ρ
2
κ +1
⎛ rt ⎞ 1 1 ⎛ 2 ⎛ κ − 1 2 ⎞ ⎞ 2(κ −1)
⎜ ⎟ ≈ = ⎜ ⎜1 + M3 ⎟⎟ (21); The nozzle section is frequently designed from two parts
⎝ r3 ⎠ 4 M3 ⎝ κ +1⎝ 2 ⎠⎠ assembled with joint flange. Dependently of construction
mass of this segment – Mmv can be calculated according to
Pc eq. 13.
P3 = κ The nozzle and the aft closure total mass is:
⎛ κ − 1 2 ⎞ κ −1 (22).
⎜1 + M3 ⎟
M m = M ul + M mc + M md + M mk + M tc + M td + M tk + M mv (32).
⎝ 2 ⎠

The housing and exit cone thickness – δmc and δme, can be
6. MOTOR TOTAL MASS
calculates according to eq. 7, using appropriate pressure
levels – P3 and Pe, and radiuses – r3 and re, instead Pc and Total mass function of typical design SPRM (fig. 1) is
r. sum of functions for all described components. Additional
The housing length can be calculated from defined nozzle parts characteristic for exact solution can be also included
geometry: – ΣMx:

r3 -rt -rul +rul ⋅ cosαd r -r -r +r ⋅ cosαk M = M b + M C + M tC + M D + M tD + M M + M v + M pr + M R + ΣΜ X (33).

Lc =rul ⋅ sinαk + +rul ⋅ sinαk + 3 t ul ul (23);
tgαd tgαk

and finally, the housing and insulation mass can be

calculated:

M mc = 2 ⋅ r3 ⋅ π ⋅ Lc ⋅ δ mc ⋅ ρ (24);

M tc = 2 ⋅ r3 ⋅ π ⋅ Lc ⋅ δ tc ⋅ ρt (25).

Exit cone and its insulation mass are also geometrically

defined:

π ⋅ρ
⋅ cot gα d ⋅ ⎡( re + δ tc + δ me ) − ( r3 + δ mc ) − ( re + δ tc ) + r33 ⎤
3 3 3
M md =
3 ⎣ ⎦ (26);

Figure 6: SPRM components mass functions.

π ⋅ ρt
⋅ ctgαd ⋅ ⎡( re +δtc ) - ( r2 +δtc ) -re3 +r23 ⎤
3 3
M td = (27).
3 ⎣ ⎦ The total mass function (fig. 6) has minimum – optimal
value for pressure – Popt.
Aft closure is toriconical. According to [6], for defined
geometry, thicknesses of torical – δtk and conical – δtk 7. EXAMPLE
parts are:
This example is illustration of this method application.
Two conceptually different solutions are compared for
⎡ r-R2 ⋅ ( 1-cosαk ) ⎤ one direct inner ballistics problem: to design propulsion
0.25 ⋅ Pc ⋅ ν ⋅ ⎢ 3+ ⎥ ⋅ ⎡ r-R2 ⋅ ( 1-cosαk ) ⎤⎦
⎢⎣ R2 ⋅ cosαk ⎥ ⎣ (28); unit with minimal total mass, which will realize dual
δtk = ⎦
thrust phase (fig. 7). Given is: caliber, propellant, case
( σ-0.1 ⋅ Pc ) ⋅ cosαk
and insulation materials and required degree of security.
First solution is dual thrust phase SPRM (dual phase), and
Pc ⋅ ν ⋅ ( r-R2 ⋅ cosαk ) second solution is two-chamber SPRM with constant
δkk = (29).
( σ-0.6 ⋅ Pc ) ⋅ cosαk pressure in both chambers.
The dual phase motor is contractually simpler. The two-
Both sections of the closure should be made with same chamber motor has more components and in many cases
thickness – larger of these two δk = max(δtk, δkk). The aft larger mass. Also is necessary to design of two
closure and the insulation mass are: propellants and examination of two motors.

4
 • The buster can have single or multi grain propellant
charge. The buster has blast tube (sustainer nozzle)
and can’t be reached significant volumetric loading
fraction. In this case about 0.4.
• The forward closure of the sustainer has same
concept like the dual phase. The buster doesn’t have
the forward closure.
• The sustainer nozzle also has same concept like dual
Figure 7: Required thrust.
phase motor, except the throat housing witch is
On the other hand propellant for the dual phase motor is prolonged like blast tube. Convergence angle is
technologically more difficult to produce. It must have increased for better fitting of the buster propellant.
good working parameters on two different pressure levels. • The buster has four nozzles. More nozzles always
This motor also can’t have optimal working regime in mean larger flow loses, but in this case this number
both phases. Construction is designed for higher pressure was necessary, because of limited space on aft motor
phase, which is usually several times higher then other. section. The aft closure of the buster is semi-
Initial design is conducted for both solutions. toroidal. The torus radius is relatively small and
Construction of the dual phase motor is shown in fig. 1, closure length is acceptable. The aft closure has
and total mass function in fig. 6. Two-chamber motor is flanges for nozzles assembly – four buster nozzles
shown in fig. 8, and its total mass function in fig. 9. The and central for sustainer nozzle.
component masses of both motors, for chosen pressure • The sustainer insulation has also same concept like
levels are given in table 1. dual phase motor.
The dual phase motor has next components: • The buster works one second, so it is possible to use
• The propellant grain with inhibitor on the outer either passive insulation or thermally unprotected
surface, and dendrite configuration. Volumetric parts. However, same ablative insulation material is
loading fraction for this configuration and required chosen, to simplify calculation. The AG-4V is used
thrust levels can be about 0.75 [7, 8]. on cylindrical case section, blast tube, closures, and
• Forward closure long 0.4r, welded with cylindrical nozzles inlet. The P5-12 is used for nozzle parts.
section. Welding zone has larger thickness because • The sustainer igniter is identical to dual phase motor.
the material degradation. This mass increase is • The buster igniter has plastic case and is placed in
calculated with forward attachment skirt. closure’s empty space. The case of the igniter is also
• Aft closure has two threaded flange joints. Forward support for propellant grains.
flange is for assembly with case and aft with nozzle. • Similarly like dual phase motor, this motor have
• Closures insulation is phenolic reason – glass fiber forward and aft attachment skirts.
ablative composite – AG-4V; and for nozzle
components phenolic reason – carbon fiber
composite – P5-12 [9]. Throat insert is made from
high density graphite. The propellant grain inhibitor
protects cylindrical section of the case.
• Pellet-basket igniter is attached to forward closure.
Attachment mass is calculated by increasing mass of
the igniter.
• Attachment skirts are added on forward and aft closure
because they are common SPRM parts. The Forward
skirt is for joining with forward rocket parts, and the aft
skirt for aerodynamic section joint.

Figure 8: Two-chamber SPRM.

Two-chamber motor has sustainer and buster sections,
with next components:
• The sustainer has the grain with inhibitor on the
outer surface, and star configuration to obtain
neutral burn regime. More configurations are
possible for this task (in same cases even end- Figure 9: Two-chambers SPRM components mass
burning), and usually is possible to achieve good functions. Buster functions – up and
volumetric loading fraction about 0.85. sustainer functions – below.

5
 Table 1: Motors components masses. better solution is dual phase motor, because of
Optimal pressure [bar] Dual phase Two-chamber motor technological simplicity. If the phase levels difference are
Mass [kg] motor Buster Sustainer larger: thrust level more then three times and total
Popt 150 - 60 80 60 impulse more then six times; or if sustainer phase have
M 87.0 17.3 65.0 very long burning time, two-chamber motor can have
Mb 46.4 7.7 42.0 significantly smaller mass.
MC 12.6 2.1 4.1
MtC 4.0 0.6 3.2 10. REFERENCES
MD 3.3 0 1.3
[1] Ђ. Јауковић: "Конструкција и унутрашња
MtD 0.8 0.3 0.8
балистика пуњења од чврстих погонских
MM 8.5 1.7 6.6
материја", кумулативна научно - техничка
MV 3.0 3.3 2.9 информација ВТИ, број 4, 1978
Mpr 8.4 1.2 4.0
[2] Ђ. Јауковић: Основи ракетне технике, I део -
MR 0 0.6 0
Ракетни погон, Војна академија КоВ-ЈНА, 1972.
Regarding the table 1, mass of these solutions are similar. [3] Љ. Мамула: "Анализа и прорачун перформанси
Although double phase motor has 5.4% higher mass, it is ракетног мотора са чврстом погонском
better solution, because is simpler for manufacturing. материјом", кумулативна научно - техничка
Difference in masses of these two solutions will be larger информација ВТИ, број 13, 1979.
in some other cases: when difference in phases thrust [4] Davenas: "Solid - propellant rocket propulsion",
level is larger, smaller total impulse of buster phase or Defence & Technology International, No 1, April
larger sustainer burn time. In these cases two-chamber 1990.
motor could be considered for better solution.
[5] K. P. Suton: ’’Rocket Propulsion Elements’’, John
Wiley & Sons, Inc., New York, 2001.
8. CONCLUSION [6] Канторовиц З.Б.:“Основи расчета хемических
A simple method for initial SPRM components масин и апаратов“, Москва, 1960.
calculation is assembled. The components mass sum is [7] М. Савковић: „Утицај облика погонског пуњења
expressed in dependency of the chamber pressure. Typical на карактеристике ракетног мотора са чврстом
SPRM construction is considered: propellant grain, погонском материјом“, кумулативна научно-
cylindrical case, nozzle, igniter, aft and forward closure, техничка информација, ВТИ, Београд, Вол. XLIII,
insulation, attachment skirt etc. бр. 1, , 2009., ст.70.
Conclusion is that mass sum function usually has [8] М. Савковић, С. Живковић: „Два поступка за
minimum. Pressure level for function minimum is optimal одређивање површине сагоревања погонског
working regime, and the method also gives initial пуњења ракетног мотора“, Зборник радова 3.
construction parameters. научно-стручног скупа ОТЕХ 2009 са
Potential of the model is demonstrated in dual thrust међународним учешћем, Београд 2009.
phase SPRM concepts evaluation. The dual phase and the [9] М. Савковић: "Оптимизација ракетног мотора са
two-chamber motor are initially designed and calculated. чврстом погонском материјом", НТП, Вол.
It is concluded, if thrust phase differences are moderate, XЛВИИ, број 1, 1997., ст. 3-9.

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