AIAA 2016-5098

Propulsion and Energy Forum

July 25-27, 2016, Salt Lake City, UT
52nd AIAA/SAE/ASEE Joint Propulsion Conference

Solid Rocket Motor Burn Simulation Considering Complex

3D Propellant Grain Geometries

G.L. Mejia*, R.J. Rocha†, L. Rocco Jr‡, S.R. Gomes§, K. Iha** and J. A. F. F. Rocco††
Departamento de Química - Instituto Tecnológico de Aeronáutica - CTA,
São José dos Campos – 12228-901 - S.P. – Brasil

Solid rocket motors (SRM) are extensively employed in satellite launchers, missiles and gas
generators. The design takes into account propulsive parameters with dimensional,
manufacture, thermal and structural constraints. Experiments using real scale rocket
models are expensive, therefore simulations are required to decrease the overall project time
and cost. Solid propellant geometry and computation of its burning rate are essential for the
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calculation of pressure versus time and thrust versus time curves. The propellant grain
geometry changes during SRM burning are also important for structural integrity and
analysis. A computational tool for tracking the propagation of tridimensional interfaces and
shapes is necessary for this task. In this sense, the objective of this paper is to present the
developed computational tool (named RSIM) to simulate the burning surface regression
during the combustion process of a solid propellant. This tool handles complex grain
geometry for versatility, including multiple separate surfaces. The SRM internal ballistics
simulation is based on 3D propagation, using the level set method approach. Geometrical
and thermodynamic data are used as input for the computation, while simulation results of
chamber pressure versus time are presented for NAWC SRM number 6.

Nomenclature
A = area
ṙb = burn rate
x, y, z = cartesian coordinate system axes
c* = characteristic velocity
θ, r, z = cylindrical coordinate system axes
ρ = density
n = exponential parameter of burn rate law
ϕ = level set function
a = linear parameter of burn rate law
m = mass
P = pressure
t = time
V = velocity
b = burn
c = chamber
p = propellant
i,j,k = space discretization
p = pressure
th = throat
n = time discretization
*
Doctoral Student, Chemistry Department, guilhermemejia@gmail.com
†
Postdoctoral Researcher, Chemistry Department, robertajr@gmail.com
‡
Postdoctoral Researcher, Chemistry Department, leopoldorocco@gmail.com
§
Professor, Aeronautical Department, susane@ita.br
**
Professor, Chemistry Department, koshun@ita.br
††
Professor, Chemistry Departament, friz@ita.br

Copyright © 2016 by Guilherme Mejia. Published by the American Institute of Aeronautics and Astronautics, Inc., with permission.
 I. Introduction

R ockets based on chemical energy (with solid or liquid propellants) are currently the only means to access Space.
Therefore, research and development of this area has vital importance for Aerospace Engineering. The
Brazilian Aerospace Program has a long history using Solid rocket motor (SRM) technology since the sounding
rocket Sonda I (1965). In this context, the reduction of project costs with modern computational simulations is an
important interest of the involved companies and institutes.
Solid rocket motors are employed in satellite launchers, missiles and gas generators. The design takes on account
propulsive parameters such as thrust versus time, with dimensional, manufacture, thermal, structural constraints.
Experiments using real scale rocket models are costly, therefore computational simulations are required to decrease
the overall project cost.
The combustion mechanisms for solid rocket propellants are quite complex and dependent on many local fluid,
chemical, and thermal phenomena. Many solid rocket propellant burning-rate models are greatly simplified because
of limited computational power and understanding of the combustion process 1. In the exhaust gas of typical SRM
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engines, a considerable amount of small aluminum oxide particles is included. Aluminum is used as an additive in
the motor propellant in order to increase performance and to dampen burn instabilities. During the burn process
most of this aluminum is transformed into aluminum oxide. A large number of micron-sized dust particles are
generated continuously during a burn. At the end of a burn, a second group of much larger fragments from a slag
pool clustering inside the motor leaves the nozzle.
There are several quasi-steady formulations to predict the burning rate of an energetic solid material. One of
them is the Vieille’s or Saint Robert’s law2, which is an empirical model that represents the pressure dependence on
burn rate, as will be shown further on.
Solid propellant geometry and modeling of its burning are essential for calculation of pressure versus time and
thrust versus time curves3. In addition, propellant structural integrity is mandatory during the rocket burn. Structural
analysis use propellant geometry as input and should consider the burning surface regression, i.e., the propellant
grain geometry changes during rocket burn. A computational tool for tracking the propagation of tridimensional
interfaces and shapes is necessary for this task. This developed tool for SRM burning simulation (named RSIM)
handles complex grain geometry for versatility. Figure 1 presents the design flowchart.

Figure 1. Program design flowchart.

II. Level Set Method

The level set method is a numerical technique for tracking the evolution of interfaces and shapes 4. It allows
performing computations involving curves and surfaces on a fixed grid without the need of parameterizing these
objects, consisting of an Eulerian approach5-7. This method is employed in the geometry module (GEOM) of RSIM
program, providing a time step iteration process over a discretized 3D space.
The problem of evolving interfaces in a 2D space is considered to illustrate the level set method. The
perpendicular propagation of a boundary is determined by the time evolution of a function  (x,y), where s, t and n
are the surface, time and time discretization, respectively. The propagation is given by a velocity V. The overall
scheme is shown in Figure 2.

2
 Figure 2. Schematics of a propagating curve8.
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The level set equation, which describes the time evolving interfaces in a certain space, is the following:

 t  V   0 (1)

Since it is not always possible to express  as a function, a numerical solution for the previous equation is
necessary. This level set equation can be expressed in the class of Hamilton-Jacobi equations9, where H is Hamilton-
Jacobi function:

t  H (x , y ,z )  0 (2)

Taking advantage of the cylindrical symmetry of most propellants, the level set equation can be expressed as
follows:
t  rb r 2   r 2   z 2 0 (3)

The space and time first order approximation gives the following numerical equation 10,11:

 
1/ 2 
     
2 2

 max  max  1 D   ijkn  

,0  , min  1 D   ijk
n
,0     
    rj   rj    
  
 
n 1
 ijk   ijk
n
 t n  rb

n 
ijk 


r n 2
  r n
 max  max D  ijk ,0 , min D  ijk ,0   2






(4)
   

 
 ijk   ijk 
 max  max D  z  n ,0 2 , min D  z  n ,0 2 




 
   
 

3
 Where:

 ijk
ijk
n n
 in1 jk  n
 ijk
n
in1 jk  ijk
n

D   n
 ; D ijk  
   
ijk


 n
  ij1k
n n

 n
 n
 ijk
n

D rijk
n
 r ijk  ijk ; D rijk
n
 r ijk  ij1k (5)
r r r r
zijk
n
ijk  ijk
n n
1 zijk
n
ijk1  ijk
n n

D 
z n
  ; D 
z n
 
z z z z
ijk ijk

A. Solid Composite Propellant Burn Law

The most frequent requirements for ballistic characteristics of rocket motors embedded with composite solid
propellants (CSP) regard burning rate values at particular working pressures and pressure exponent as the burning
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rate law parameters. In the case of low burning rate propellants, the presence of some additives is necessary to
obtain desirable ballistic properties. Besides that, it is important to eliminate unstable burning as a consequence of
higher binder content (propellant of limited properties).
The solid propellant burn rate model employed in the burn module (BURN) of RSIM program is St. Robert's
law, as follows12:
rb  aPcn (6)

Considering stationary regime, the chamber pressure Pc is calculated by the following equation6:


Pc  a S b Ath  p c *  1 (1 n )
(7)

Thermochemical parameters (a, n), propellant density (ρp), characteristic velocity (c*) and nozzle throat area (Ath)
are inputs for RSIM.

III. Results
The NAWC SRM n. 6 was analyzed using RSIM, written in C++ code. Figure 3 shows the propellant grain
geometry.

Figure 3. NAWC SRM n. 6 - Propellant grain8.

4
 Cylindrical and mirror symmetry are exploited in grid construction and level set computation. The geometry was
created using a CAD tool and a proper curve discretization was done for RSIM input.
Simulation result - chamber pressure versus time plot - is presented in Figure 4. Note that the burn is progressive
until 5 s and after that it becomes regressive as sliver appears. The pressure vs time integral calculated is 27.50
MPa.s.
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Figure 4. NAWC SRM n. 6 - Chamber pressure (MPa) versus time (s).

IV. Conclusion
The solid rocket motor burn simulation with 3D propagation RSIM, based on level set method, was verified with a
case of study. Results of chamber pressure versus time were calculated considering the geometrical and
thermodynamic data as input. The finocyl propellant grain of NAWC SRM n. 6 is a good test case, which
demonstrated that RSIM program is capable to handle complex grain and case geometries inputs, useful for solid
rocket motor designs.

References
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NASA SP-8039.

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