Training Report

6 Weeks Training report submitted in partial requirement of B.Tech in Aerospace Engineering

B.Tech Aerospace Engineering – GNA University

Submitted
By
AMAN KUMAR
Trainee
WINGS OF AERO
Tenkasi, India

Date of Submission: AUG 12, 2022

AICTE Internship Organisation Reference

IDCORPORATE62d286bf8cc291657964223
 CANDIDATE'S DECLARATION

I hereby certify that the work which is being presented in the Training report entitled “6 Weeks Training report submitted
in partial requirement of B.Tech in Aerospace Engineering”. by “AMAN KUMAR Ubhi” in partial fulfillment of
requirements for the award of degree of Bachelors in Technology in Aerospace Engineering submitted in the Faculty of
Engineering & Technology at “GNA UNIVERSITY”, Phagwara is an authentic record of my own work carried out during a
period from July 1stt, 2022 to August 15th, 2022 at WINGS OF AERO.

NAME OF STUDENT

Aman Kumar SIGNATURE OF STUDENT

This is to certify that the above statement made by the candidate is correct to the best of my/our knowledge.

TRAINER MANAGER
WINGS OF AERO WINGS OF AE RO

INTERNAL INTERNAL
SUPERVISOR HOD
 ACKNOWLEDGEMENT

I am very thankful to “WINGS OF AERO”. For giving me the opportunity to undertake my summer internship training about
“6 Weeks Training report submitted in partial requirement of B.Tech in Aerospace Engineering”. At their prestigious
“TECHICAL CENTER AT TRIUNELVELI”. It was a very good learning experience for me to have worked at this Training
involved many new and unique practices and challenges.

I would also like to give my heart-felt thanks to BHUVANESHWARAN (manager) and AGNES MICHEAL PRAVIN and
AARAM JEHONIAH my mentor who guided and encouraged me all through the training and imparted in-depth knowledge
about the course. I would also like to thank PON MAA KISHAN, Assistant professor, Department of Aerospace engineering,
GNA UNIVERSITY who was my faculty adviser for being so helpful during training.

Name of Student

AMAN KUMAR Signature of Student

GU – 2020 – 4040
 PREFACE

In this era of fast paced manufacturing, we engineering students need to have

enough exposure to keep up with the pace. From subtraction methods like CNC
machining to more advanced Additive manufacturing i.e. 3D printing processes.

I feel highly obliged to be a part of a 6 week training at WINGS OF AERO. An

institute that is forging the future engineering minds, through their training
program I've had hands on practice on designing of rocket and aircraft models
using softwares like Catia,solid works, NASA OpenVSP and Thinker Cad and
bring my designs to reality by using various manufacturing techniques like sheet
metal and welding, Gcode conversion and 3D printing.

I'm highly thankful to WINGS OF AERO for providing me such a valuable

opportunity
 ABSTRACT

This training file is focused on the work done at Wings of Aero Company, it is
divided into nine topics.it includes the manufacturing, designing, fabrication, and
web development. The manufacturing process includes the introduction to
composite materials which is the latest type of material being used in the
Aerospace and automobile industry, web development includes a unique concept
of online engineering calculator which covers some specific fields of engineering
especially aerospace engineering, it includes the introduction to syntax creation
for mathematical operations and working at backend of website. Fabrication
includes the practical application of theoretical designing using workshop
practices, creating prototypes and scale models. Additive Manufacturing includes
the introduction to latest prototype and product manufacturing process called 3D
Printing, its current applications, future uses in industry and limitations. Model
rocket includes the introduction to basic principles of model rocketry. Designing
includes the use of NASA OPENVSP tool for basic designing and analysis of any
conventional configuration aircraft design.
 CONTENTS

TITLE PAGE NO .

Candidates Declaration
Acknowledgment
Preface
Abstract
Introduction 1

S.NO
CHAPTER -1: 2
1. MANUFACTURING
1.1. COMPOSITE MATERIALS

CHAPTER – 2: 14

2. TEMS TECH ENGINEERING CALCULATON

CHAPTER – 3: 15

3. FABRICATION
3.1. JET NOZZLE
3.2. FALCON 9 SCALE MODEL

CHAPTER – 4: 21

4. ADDITIVE MANUFACTURING
4.1. 3D PRINTING
4.2. ASSEMBLY OF FALCON 9 SCALE MODEL
4.3. ROCKET PLANE

CHAPTER – 5: 30

5. MODEL ROCKET
6. NASA OPEN VSP SOFTWARE

CONCLUSION 39

REFERENCE 40
 INTRODUCTION

This training file is focused on work done in WINGS OF AERO. The training
includes manufacturing, designing, fabrication and web development.
Manufacturing includes introduction to the composite material that are being used
in aerospace and various other industries which is made by using resin, natural
fiber and nano particles. TEMS tech solutions calculator was used and the
introduction to syntax creation for mathematical operations and working at
backend of website. Fabrication includes creation of prototypes and scale models.
3D printing includes designing of models through software and then making of
3d model through 3D printing. Model rocket includes the introduction to basic
principles of model rocketry.

1
 CHAPTER -1: MANUFACTURING

1.1 COMPOSITE MATERIALS

INTRODUCTION

Composite material is defined as the material formed by combining two or more different materials/ constituents macroscopically
that are distinct in the properties and they do not dissolve into each other. The combination of different constituents in the
composites provides the composite material with unique properties which are different from the individual constituent.

Basic structure of composite material

An example of composites is the mud building bricks used since ancient times, which is formed by combining mud bricks and
straws. This allowed the composite to have the strength and resistance of mud bricks and the tensile strength of straw.
In general, the composite material comprises three main components
(a) The matrix, the continuous phase;
(b) The reinforcements,
(c) The fine interface region.
For thousands of years, composite materials have played crucial roles in human life, starting with enabling early civilizations to
build houses and continuing on to making advances in modern technology possible. People use composite materials in their day-
to-day life, including the ceramic tiling in our bathroom, which help keep us dry. Composites can indeed be found in the majority
of common products, including building and engineering projects, medical applications, energy and transportation, sports,
aircraft, automotive, and other fields.

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PROPERTIES OF COMPOSITE MATERIALS
Composites are being increasingly developed for a multitude of tasks. For example, fiber reinforced composites are being used
to replace materials such as metals and their alloys.
Composites are designed to offer:

 low weight
 stiffness and strength
 low coefficient of expansion
 resistance against fatigue
 ease in manufacturing complex shapes
 simple repair of damaged structures
 resistance to corrosion

TYPES OF COMPOSITE MATERIALS

Types of composite material

 Ceramic matrix composite: Ceramic spread out in a ceramic matrix. These are better than normal ceramics as they are
thermal shock and fracture resistant
 Metal matrix composite: A metal spread throughout a matrix
 Reinforced concrete: Concrete strengthened by a material with high tensile strength such as steel reinforcing bars
 Glass fiber reinforced concrete: Concrete which is poured into a glass fiber structure with high zirconia content
 Translucent concrete: Concrete which encases optic fibers
 Engineered wood: Manufactured wood combined with other cheap materials. One example would be particle board. A
specialty material like veneer can also be found in this composite
 Plywood: Engineered wood by gluing many thin layers of wood together at different angles
 Engineered bamboo: Strips of bamboo fiber glued together to make a board. This is a useful composite due to the fact it
has higher compressive, tensile and flexural strength than wood
 Parquetry: A square of many wood pieces put together often out of hardwood. It is sold as a decorative piece
 Wood-plastic composite: Either wood fiber or flour cast in plastic
3
 Cement-bonded wood fiber: Mineralized wood pieces cast in cement. This composite has insulating and acoustic
properties
 Fiberglass: Glass fiber combined with a plastic which is relatively inexpensive and flexible
 Carbon Fiber reinforced polymer: Carbon fiber set in plastic which has a high strength-to-weight ratio
 Sandwich panel: A variety of composites that are layered on top of each other
 Composite honeycomb: A selection of composites in many hexagons to form a honeycomb shape.
 Papier-mâché: Paper bound with an adhesive. These are found in crafts
 Plastic coated paper: Paper coated with plastic to improve durability. An example of where this is used is in playing
cards
 Syntactic foams: Light materials created by filling metals, ceramics or plastics with micro balloons. These balloons are
made using either glass, carbon or plastic

USE OF COMPOSITE MATERIALS IN AEROSAPCE INDUSTRY

Composite materials are widely used in the Aircraft Industry and have allowed engineers to overcome obstacles that have been
met when using the materials individually. The constituent materials retain their identities in the composites and do not dissolve
or otherwise merge completely into each other. Together, the materials create a 'hybrid' material that has improved structural
properties.

Use of composite material in aircrafts

The development of light-weight, high-temperature resistant composite materials will allow the next generation of high-
performance, economical aircraft designs to materialize. Usage of such materials will reduce fuel consumption, improve
efficiency and reduce direct operating costs of aircrafts. Composite materials can be formed into various shapes and, if desired,
the fibers can be wound tightly to increase strength. A useful feature of composites is that they can be layered, with the fibers in
each layer running in a different direction. This allows an engineer to design structures with unique properties.

4
Advantages

 Weight reduction - savings in the range of 20%-50% are often quoted.

 It is easy to assemble complex components using automated layup machinery and rotational molding processes.
 Monocoque ('single-shell') molded structures deliver higher strength at a much lower weight.
 Mechanical properties can be tailored by 'lay-up' design, with tapering thicknesses of reinforcing cloth and cloth orientation.
 Thermal stability of composites means they don't expand/contract excessively with a change in temperature (for example
a 90°F runway to -67°F at 35,000 feet in a matter of minutes).
 High impact resistance - Kevlar (aramid) armor shields planes, too - for example, reducing accidental damage to the engine
pylons which carry engine controls and fuel lines.
 High damage tolerance improves accident survivability.
 'Galvanic' - electrical - corrosion problems which would occur when two dissimilar metals are in contact (particularly in
humid marine environments) are avoided. (Here non-conductive fiberglass plays a role.)
 Combination fatigue/corrosion problems are virtually eliminated.

COMPOSITION OF COMPOSITE MATERIALS

Composites, also known as Fiber-Reinforced Polymer (FRP) composites, are made from a polymer matrix that is reinforced with
an engineered, man-made, or natural fiber (like glass, carbon, or aramid) or other reinforcing material. The matrix protects the
fibers from environmental and external damage and transfers the load between the fibers. The fibers, in turn, provide strength
and stiffness to reinforce the matrix and help it resist cracks and fractures.

Composite material binding process

Generally, polyester resin is the matrix, and glass fiber is the reinforcement. But many combinations of resins and
reinforcements are used in composites and each material contributes to the unique properties of the finished product: Fiber,
powerful but brittle, provides strength and stiffness, while more flexible resin provides shape and protects the fiber. FRP
composites may also contain fillers, additives, core materials, or surface finishes designed to improve the manufacturing
process, appearance, and performance of the final product.

Fiber reinforced polymer composites

Fiber reinforced polymer composites (FRPs, also known as polymer matrix composites (PMCs)) are subdivided into:

5
a) Carbon fiber reinforced polymer composites (CFRPs)
b) Glass fiber reinforced polymer composites (GFRPs)
c) Aramid fiber reinforced polymer composites (AFRPs)
In each case the fiber is encased in a resin matrix (the continuous phase)

PHASES IN COMPOSITE MATERIALS

Fiber and particle reinforced composites usually consist of a phase which is more or less continuous. This continuous phase is
also known as the matrix, and the material that is distributed through the matrix is known as the dispersed phase

Phases of composite material

The dispersed phase is sometimes called reinforcement if it is a phase added to increase strength. Alternatively, it is called
a filler if it is added for other purposes, for example to bulk up the matrix at low cost without affecting the properties of the
composite. There may also be a phase to create a bond between layers or phases, sometimes called the interface

Matrix material

The primary function of the matrix material in polymer composite is to act as a binder and transfer the load between constituents
of the composites, provide the component its net shape, and determines its surface quality. Polymer composites uses generally
two types of matrix material viz. thermoplastic and thermosetting. Since the dawn of the composite era, both materials have been
used for the development of composites.

Fiber Reinforcement Composite material

In fiber-reinforced polymer composites, different types of fibers can be used as reinforced material. The selection of the
reinforced material is depending on the end application of the component/material. Some common fiber reinforcement is as
follows:

 GLASS FIBERS
 CARBON FIBERS
 ARAMID FIBERS
 NATURAL FIBERS

6
Classification based on reinforcement structure

Reinforcement types

MANUFACTURING DONE AT WINGS OF AERO

At WINGS OF AERO we learned about the different uses and applications of the composite materials and also learned how to
manufacture these materials on own using their facilities, we learned how to manufacture Glass fiber, Natural fibers, Nano
particles and Sandwich composite panels.
All the manufacturing process involved some repetitive processes and chemicals. To manufacture any type of composite material
we require to select two main components i.e. Reinforcements and matrix materials.
While our experience at wings of aero we used PVA resin, Gel coat and cobalt accelerator as the matrix material and the
reinforcement were changed, for reinforcement we used glass fiber, natural fibers (coconut fibers), nano particles (fine charcoal
particles).

PVA (POLY-VINYL ACETATE)

It is a man-made or synthetic polymer. It is full form us Poly Vinyl Acetate (Alcohol). It is a very useful polymer due to its
adhesive properties. PVA is a water soluble, Crystalline and flammable in nature. Presence of alcohol. Makes it flammable group
bag.
Its excellent chemical resistance and physical properties of PVA made its range of applications in different industries such as for
textile sizing, adhesives, and protective colloids for emulsion polymerization, production of PVA fibers and polyvinyl butyral
and paper sizing. It can also be used in medial and applications, as a soil stabilizer and as wood preservatives.

PVA Gel
7
PVA uses in composite materials

PVA can be used as a modifier, aggregate surface pre-treatment agent and fiber. Pretreatment agent and fiber reinforcement in
cement - based composite materials. PVA is often ward to modify the cement matrix of paste, motor and concrete, PVA is usually
added in form of aqueous solution un Small amounts (up to 2% based on the weight. of cement during mixing) to improve the
properties of cement motor and Concretes. VA is suitable for fiber reinforcement as it has high strength and elasticity.

Cobalt Accelerator

It is a compound, usually it is cobalt napthenate and cobalt octoate, these compounds are promoters used in the curing of polyester
and vinyl ester resins with MEKP (methyl ethyl ketone peroxide) type catalysts. Promoters are also called accelerators, they can
be added to the resin, and in that case the resin is said to be pre promoter and visa - versa.

Gel Coat

Gel coats are specialized polyester or vinyl ester resin formulations that are formulated as an in-mold coating to provide appealing
cosmetics and protect the underlying laminate. Gel coat is typically sprayed in a mold and the structural laminate, or cast polymer
matrix, applied behind the gel coat surface in either open molding or closed molding processes

PROCEDURE TO MANUFACTURE THE MATERIAL

1. Clean mould with mould cleaner or soapy water. Let it dry
2. Apply mould release wax with 15 minutes intervals. Buff off the wax once dried. After 5 coats let the wax dry for about an
hour
3. Apply 2 coats of PVA release agent to the mould.
4. Mix the required quantity of polyester gel coat in a disposable mixing cup. Add cobalt accelerator to it, mix well it uniform
color is seen. Then add MEKP catalyst to it, mix well.
5. Apply an even layer of gelcoat to the mould surface. Let it cure to a tacky state.
6. Pre-cut layers of fiberglass CSM to the required size.
7. Once gelcoat is tacky, le surface is sticky to touch but doesn't leave residue on the finger, mix a batch of polyester resin with
appropriate quantity of cobalt accelerator and MEKP catalyst.(never mix accelerator and catalyst, together. Always one after
Apply a coat of mixed resin to tacky gelcoat surface, lay the pre-cut fiberglass mat on it, and soak the mat with additional
another)
8. Apply a coat of mixed resin. To tacky gel coat surface, lay the precut fiberglass mat on it, and soak the mat with additional
resin Use a stippling action when applying resin to the fiberglass. Once saturated with resin the fiberglass becomes transparent
Try and remove as many air bubbles trapped beneath the mat by using additional resin.
9. Add extra fiberglass reinforcements until desired thickness is obtained
10. Let the part cure for at least 24 hours from the mould by using a flat head screwdriver or a chisel or by using wedges
11. Gently pry the part from the mould by using a flat head screwdriver or a chisel or by using wedges
12. Clean the part using soapy water and a scrubbing pad to remove the PVA release agent residue
13. Cut the part using an angle grinder or a jigsaw with carbide or metal cutting blades.
14. Then smoothen edges using and 80 grit sandpaper then finish using a 150 grit paper. 15 To paint the part sand the surface
using a 220 grit sandpaper then apply the required paint (all automotive paints adhere wet to fiberglass parts).
Tips

Never mix more than 400gms of resin at one time.

Use acetone to clean the brush and accessories.

Accelerator and catalyst mix ratio:

For room temperatures between 29-350C: Max 1% of cobalt accelerator and MEKP catalyst for working time of about 20-30
Mins
For room temperatures between 21-28 0 C: Mix 2% of cobalt accelerator and MEKP catalyst for working time of about 20-30
mins
Accelerator and catalyst ratios can be varied according to user needs. New users should make a test batch to check out the
required mix ratios. (Extra 0.5% of each can reduce working time by 10 mins.)

8
MANUFACTURING GLASS FIBER

Glass fiber is made from silica (sand), sodium carbonate and calcium carbonate together with other compounds to give the
specific properties required. The materials are heated to CA 1700 K in a furnace and then extruded directly from the furnace
through metal (a platinum/rhodium alloy) orifices of various diameters (4 - 34 urn) to produce filaments. A high speed winder
revolving faster than the exiting molten glass draws them under tension into very fine filaments. The number of orifices varies
from 200 - 8000.The filaments are coated with a lubricant to protect them and bundled together on a drum, looking like a spool
of a thread. In fiberglass, in which glass fibers are the filler (dispersed phase), the matrix is usually a polyester
resin although epoxy and acrylic polymers are also used.

APPLYING THE MOULD WAX

APPLYING THE PVA AND GEL COAT LAYER

9
 FINAL FIBER GLASS COMPOSITE PANNEL

MANUFACTURING NATURAL FIBER

These are a type of fibers that are obtained from plants and animals or mineral sources for example: cotton
Silk, wool
It has two types

• Animal fibres • Plant fibres

We worked with Plant fibre

There are bundles of elongated dead plant cells Cemented together by pectin and other non-cafés cell wall of growing
Is composed cellulosic compounds. Single fibre is composed of two walls, is primary wall and of 90% polysaccharide.
Plant call Plant fiber are considered as Composite materials; rigid and crystalline cellulose micro fibrils reinforcement
Embedded in amorphous hemi celluloses / lignin matrix. Cellulose us main Constituent of plant fibre.

ARRANGING COCONUT FIBERS AS REINFORCEMENT

10
APPLYING PRESSURE FOR UNIFORM LAYER FORMATION

FINAL NATURAL FIBER COMPOSITE PANNEL

11
MANUFACTURING NANO PARTICLE COMPOSITE
Nanoparticles are small diameter particles, very between 1-100 nm, the application of nanoparticles. Can be
tracked back to more than 3000 ago, Craftsmen in Italy had made a type of red glass from 1200 BC to 1000
BC. The red color originated from Cu nana particles. Particles at such a small scale usually show quite different
properties to their Bulk Counterparts for example, Color change melting point decrease.
Nanoparticle is a sub classification of nanotechnology it is ultrafine particle.
Nano particles are used in wide variety of products, They can be applied as coating for UV protection, They
have anti-microbial properties of materials such as silver and Copper (an be incorporated as Nano particles to
keep, Packaged food fresh, for reaction catalysis, nanoparticle Effectiveness compared to bulk – materials
Benefit of using Nano particles is that it can increase the Surface of a material. This allows more atoms to
interact interact with other materials. Stronger and this results in more durable, and more Conductive than bulk,
and has more surface to Volume ratio.

SMOOTHNING OF THE NANO COMPOSITE LAYER

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MANUFACTURING OF LAMINATE LAYER COMPOSITE
Advanced composite parts are produced using successive layers of fabrics. Each layer is referred to as a “ply”,
multiple plies of resin-impregnated fabric strongly consolidated creates a “laminate”.
An attribute of this unified laminate composite structure is that the orientation, number, type and location of
the fibers can be arranged to control and optimize the directional strength and other properties of the composite
The result is a unified anisotropic material with specific and unique characteristics not achievable with metals
or similar isotropic materials which have uniform characteristics throughout their structure. Although very
lightweight, a single layer or ply of composite is usually too flexible for most practical applications. As with
other materials, the thicker the laminate, the less flexible it becomes.

Laminate properties:
(The laminate properties are mainly dependent on a combination of the following items)
• The adhesive properties of the matrix system bonding the fibers and layers together.
• The fiber type used within each layer.
• The geometry or fiber angle in each layer.
• The ratio between matrix and reinforcement.
• The cure temperature.
• The compression pressure during the cure process.

In laminate layer we used 3 layers of glass fiber 1 layer of natural fiber and 1 layer of Nano particles.
Completing all types of basic composite material manufacturing processes.

LAMINATE LAYER

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 CHAPTER -2:

2.1 TEMS ENGINEERING CALCULATOR

INTRODUCTION
An Initiative by TEMS Tech Solutions to help students, faculty, scientists and researchers by making numerical
calculation and analysis easier ever before.TEMS Tech Solutions focused to develop such calculator to solve
various problems in the field of Technology, Engineering, Maths and Science

At wings of Aero we got an opportunity to work at the backend of the web engineering calculator, we created
the syntax for formulas to work and calculate, everybody did this task individually and added as many formula
he/she could add, the formula were posted on the website TEMS TECH ENGINEEERING CALCULATOR.

Formulas at backend

I worked on nine formulas and published them, formulas are

 Lenz formula
 RMS Speed formula
 Kinetic friction formula
 Angular acceleration formula
 Magnetic permeability formula
 Relative velocity formula
 Heat capacity ration
 Latent heat
 Capillary rise formula

14
 CHAPTER -3: FABRICATION

3.1 JET NOZZLE MODEL

INTRODUCTION
Nozzle is a relatively simple device, just a specially shaped tube through which hot gases flow. However,
the mathematics which describe the operation of the nozzle takes some careful thought. As shown above,
nozzles come in a variety of shapes and sizes depending on the mission of the aircraft.
Simple turbojets, and turboprops, often have a fixed geometry convergent nozzle as shown on the left of the
figure. Turbofan engines often employ a co-annular nozzle as shown at the top left. The core flow exits the
center nozzle while the fan flow exits the annular nozzle. Mixing of the two flows provides some thrust
enhancement and these nozzles also tend to be quieter than convergent nozzles. Afterburning turbojets and
turbofans require a variable geometry convergent-divergent - CD nozzle as shown on the left. In this nozzle,
the flow first converges down to the minimum area or throat, then is expanded through the divergent section
to the exit at the right. The flow is subsonic upstream of the throat, but supersonic downstream of the throat.
The variable geometry causes these nozzles to be heavier than a fixed geometry nozzle, but variable geometry
provides efficient engine operation over a wider airflow range than a simple fixed nozzle.
Rocket engines also use nozzles to accelerate hot exhaust to produce thrust. Rocket engines usually have a
fixed geometry CD nozzle with a much larger divergent section than is required for a gas turbine

Types of jet nozzles

15
The most basic nozzle consists simply of a duct. The air exiting the turbine is often traveling greater than Mach
1, but this creates high friction losses, so the flow is immediately slowed by diffusion. The whirl of the turbine
exit flow is reduced by the turbine rear support struts, which turn the flow straight. This straight, high-pressure
flow is fed to a converging section, which changes the pressure back to velocity. This flow is often choked; i.e.
the exit velocity cannot be increased. However, the exit pressure can be increased, resulting in pressure thrust.

For some flight plans, it is possible to use a convergent/divergent duct, which takes the flow past its choke
point and increases the exit velocity further. This is a more efficient use of the flow's energy than pressure
thrust. This is sometimes seen on engines with a very high pressure ratio.

Due to the wide range of operating conditions some engines must endure, sometimes it is advantageous to have
an adjustable nozzle. Most often this is seen on engines with afterburners as they must face a very wide range
of conditions.

The nozzle must withstand high heat and pressure. It must be insulated from the rest of the aircraft, either with
a short section of insulation, or by isolating the jet pipe from the aircraft. The nozzle is often cooled by flow
around the outside, using a variety of methods. The nozzle as a whole must be able to expand and contract with
temperature, without damage or distortion.

MODEL OF JET NOZZLE

In order to simulate the exit gases from the jet nozzle, we designed and fabricated the model by sheet metal,
and we used a gas burner to make the flame and visualize the practical flow of the flame. We did cutting,
rolling, sanding and welding

Principle of jet nozzle

 A nozzle operates according to the Venturi effect to bring the exhaust gasses to ambient pressure, while
forming them into a propulsive jet; if the pressure upstream of the nozzle is high enough, the flow will reach
sonic speed (choke). The role of the nozzle in back-pressuring the engine is explained below.
 The energy to accelerate the stream comes from the temperature and pressure of the gas. The gas expands
adiabatically with low losses and hence high efficiency. The gas accelerates to a final exit velocity which
depends on the pressure and temperature at entry to the nozzle, the ambient pressure it exhausts to (unless
the flow is choked), and the efficiency of the expansion. The efficiency is a measure of the losses due to
friction, non-axial divergence as well as leakage in C-D nozzles.

Convergent nozzle
Convergent nozzles are used on many jet engines. If the nozzle pressure ratio is above the critical value a
convergent nozzle will choke, resulting in some of the expansion to atmospheric pressure taking place
downstream of the throat (i.e., smallest flow area), in the jet wake. Although jet momentum still produces much
of the gross thrust, the imbalance between the throat static pressure and atmospheric pressure still generates
some (pressure) thrust.

PARAMETERS OF THE JET NOZZLE

TOTAL LENGTH: 2FT

DIAMETER: 15 CM

NOZZLE INLET TO OUTLET: 5 CM

16
PROCEDURE

To make the jet nozzle, first we took a sheet of metal and marked it the dimensions which we were provided.
Then we cut the metal sheet into the right dimensions after the cutting of the sheet, rolling of the sheet metal
is done according to the diameter given after the rolling the joint is open, so cover that joint we did the Tig
welding and joined the whole section after joining of the body, grinding is done onto to the weld to smoothen
any non – uniformities. After grinding we made a square cavity to mount the flame burner. After that metal
paste is applied to fill the gaps left during the welding procedure after applying the paste, we smooth that paste
using sand paper. After smoothing the surface we painted the nozzle using paint gun and then mounted the
nozzle apparatus with the stand.

CONVERGENT NOZZLE FIXING FLAME BURNER

JET NOZZLE WITH STAND

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3.2 FALCON 9 SCALE MODEL

INTRODUCTION

Falcon 9 is a reusable, two-stage rocket designed and manufactured by SpaceX for the reliable and safe
transport of people and payloads into Earth orbit and beyond. Falcon 9 is the world’s first orbital class reusable
rocket. Reusability allows SpaceX to re-fly the most expensive parts of the rocket, which in turn drives down
the cost of space access. Till date falcon 9 boosters have took off 168 times with a total of 128 successful
landing and record of 107 total refights.

The power plant used in falcon 9 is the mighty Merlin D1

Falcon 9 rocket

Merlin is a family of rocket engines developed by SpaceX for use on its Falcon 1, Falcon 9 and Falcon Heavy
launch vehicles. Merlin engines use a rocket grade kerosene (RP-1) and liquid oxygen as rocket propellants in
a gas-generator power cycle. The Merlin engine was originally designed for recovery and reuse.

PROPELLANT LOX / RP-1

THRUST 845 kN / 190,000 lbf

DESIGNING SCALE MODEL OF FALCON 9

The model has been developed using 2 different manufacturing practises namely the sheet metal and welding
method and Additive manufacturing techniques (3d printing).

Sheet metal and welding:

The cylindrical section of the main body has been developed by cutting a 2mm thick mild steel sheet.

18
This Section contains 3 sub section
a) The lower 139 cm cylindrical section (scale down 1:38)
b) The upper 263 cm cylindrical section
c) The middle tapered section between the above mentioned 2 sections

135.62
263.01
164.44

32.6
142.35

123.4
1390

39.82

A B

ORIGINAL ROCKET DIMENSIONS

19
The sections were cut according to the required parameters and rolled in to cylindrical shape by the use of specific
tools and skills. The cut sections were then welded to place by the use of electrical arc and tig welding. This section
covers the lower 1st stage booster and the upper 2nd stage booster of the Falcon 9 rocket.

Parameters of Falcon 9 model

Lower body length = 139cm
Tapered portion = 3.28cm
Upper body length =26.52cm
Length of nose cone = 13.556cm
Radius of lower body = 12.14cm
Radius of upper body and nose cone = 16.244cm

FABRICATION OF THE MODEL:

Fabrication of the model was done under the supervision of professionals, we performed cutting of sheet metal,
rolling, welding, grinding, file the joints and painting

Dimensioning of the sheet metal Marking of the sheet metal Cutting of the sheet metal

Cutting of the sheet metal Rolling of the sheet metal Welding of the sheet metal

Filing of the metal paste Painting of final model Final model

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 CHAPTER -4: ADDITIVE MANUFACTURING

4.1 3D PRINTING

INTRODUCTION
3D printing, also known as additive manufacturing, is a method of creating a three-dimensional object layer-
by-layer using a computer created design. 3D printing is an additive process whereby layers of material are
built up to create a 3D part. 3D printing involves layering materials, like plastics, composites or bio-materials
to create objects that range in shape, size, rigidity and colour.

3D Printing manufacturing process

Process of 3D Printing

Procedure for 3D Printing

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3D Printing Applications ·

1. Education ·
2. Prototyping and Manufacturing ·
3. Medicine ·
4. Construction ·
5. Art and Jewellery.

Applications in Aerospace

Jigs & Fixtures

Big benefits exist for several more mundane 3D printing applications, including the production of Jigs and
Fixtures. For each individual aircraft, companies have hundreds of fixtures, guides, templates and gauges 3D
printed, generally with 60 to 90 percent reductions in cost and lead time compared to other manufacturing
processes

Surrogates
Surrogates are placeholder parts used throughout production that represent components that are later installed
in final assemblies. Surrogates are mainly used for training. NASA and several Air Force bases commonly use
surrogate parts on the production floor.

High detail visual prototypes

3D printing with Material Jetting is able to produce multicolour designs with a surface finish comparable to
injection moulding. These visually appealing models allow designers to get a greater understanding of the form
and fit of a part before making important production decisions.

4.2 Assembly of Falcon 9 Rocket

Additive manufacturing techniques (3d printing)

The parts manufactured using 3d printing are:

a) Nosecone

b) Grid fins

c) Merlin engine nozzles

The nosecone:

The nosecone is the upper most section of the Falcon 9 rocket, it is the part were the payload is stationed.
Payload fairing is a nose cone used to protect a spacecraft payload against the impact of dynamic pressure and
aerodynamic heating during launch through an atmosphere. An additional function on some flights is to
maintain the cleanroom environment for precision instruments. Once outside the atmosphere the fairing is
jettisoned, exposing the payload to outer space.

The nosecone is printed with precision using the 3d printing facilities at WINGS OF AERO and is then fixed
onto the top of the metallic body of the Falcon 9 model.

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 Original dimensions of nose cone (scaled down to 1:38)

3D printing the nose cone section

The Grid fins:

Grid fins are used on the Falcon 9 rocket for increased precision and accuracy in control of the landing
location for reusable launch vehicles. It therefore helps the rocket to land on the landing pad or on the
autonomous spaceport drone ship more precisely with good accuracy.

Original dimensions for Grid fins

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 3D printed grid fins Grid fins

A set of 4 grid fins was designed using CATIA V5 software and 3d printed to be placed on their respective
places on the metallic body.

The Merlin engine nozzles:

A set of 9 Merlin engine nozzles was printed and were fixed at the bottom of the metallic body to represent
the power plant of the Falcon 9 rocket

3D printed engine nozzles

4.3 ROCKET PLANE

INTRODUCTION

A rocket-powered aircraft or rocket plane is an aircraft that uses a rocket engine for propulsion, sometimes in
addition to air breathing jet engines. Rocket planes can achieve much higher speeds than similarly sized jet
aircraft, but typically for at most a few minutes of powered operation, followed by a gliding flight. Unhindered
by the need for oxygen from the atmosphere, they are suitable for very high-altitude flight. They are also
capable of delivering much higher acceleration and shorter takeoffs. Many rocket aircraft may be drop
launched from transport planes, as take-off from ground may leave them with insufficient time to reach high
altitudes.

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 ROCKET PALNE MODEL: Messerschmitt Me 163 Komet

For our rocket plane we selected Messerschmitt Me 163 Komet, a world war 2 era aircraft, we selected this
aircraft as it has excellent glide performance, so as it was the design parameter for the aircraft to glide so we
selected this aircraft. We designed this aircraft in NASA openvsp and CATIA V5, by scaling it down and
modifying it. We also did limited analysis of the wings using NASA openvsp Analysis tool

Original ME 163 aircraft

DIMENSIONS (original)

 Length: 5.7 m (18 ft 8 in)

 Wingspan: 9.3 m (30 ft 6 in)
 Height: 2.5 m (8 ft 2 in)
 Wing area: 19.6 m2 (211 sq ft)

DIMENSIONS OF MODEL (WITH MODIFICATION)

We modified the original design by adding empennage section for more stability

Modified ME 163 aircraft

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  Length: 24 cm
 Wingspan: 23 cm
 Height: 8.4 cm

Modified ME 163 aircraft in open vsp

AIRFOIL USED

We used the original airfoil i.e. Gottingen 765 cambered airfoil for getting better glide ratio

Gottingen 765 airfoil

Analysis of the Wing

We used VSPAERO to do limited analysis on the wing section of the rocket plane. We set the MACH NO.
0.0538 And angle attack from – 5 to +10 and calculated 20 nodes (npts). We used our limited knowledge about
analysis to check the characteristics of the wing we designed

RESULTS OF ANALYSIS:

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Lift co efficient vs. angle of attack graphs:

Variation of Lift co efficient vs. angle of attack

Lift to drag ratio vs. angle of attack:

Variation of Lift to drag ratio vs. angle of attack

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Mach no. vs. Lift co efficient

Variation of Mach no. Lift co efficient

PRESSURE DISTRIBUTION ON WING

Variation of pressure on wing at -5 degree angle of attack

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 Variation of pressure on wing at 5 degree angle of attack

Variation of pressure on wing at 10 degree angle of attack

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 CHAPTER -5:

5.1 MODEL ROCKET

INTRODUCTION
A model rocket is a normal rocket by every definition, but usually discerned by the size and scale of the rocket.
They are typically propelled by a solid black powder or composite motor, and recovered using parachute
systems. A rocket typically looks much like the one in the image below. A tube with a pointed nose, fins and a
hole on the bottom end where the propellant goes. The propellant is often called a motor or engine as well, and
all three terms are used interchangeably.

Basic model rocket

History of model rocketry

While there were many small rockets produced after years of research and experimentation, the first modern
model rocket, and, more importantly, the model rocket motor, was designed in 1954 by Orville Carlisle, a
licensed pyrotechnics expert, and his brother Robert, a model airplane enthusiast. They originally designed the
motor and rocket for Robert to use in lectures on the principles of rocket-powered flight. But then Orville read
articles written in Popular Mechanics by G. Harry Stine about the safety problems associated with young people
trying to make their own rocket engines. With the launch of Sputnik, many young people were trying to build
their own rocket motors, often with tragic results. Some of these attempts were dramatized in the fact-based
1999 film October Sky. The Carlisles realized their motor design could be marketed and provide a safe outlet
for a new hobby. They sent samples to Mr. Stine in January 1957. Stine, a range safety officer at White Sands
Missile Range, built and flew the models, and then devised a safety handbook for the activity based on his
experience at the range.

The first American model rocket company was Model Missiles Incorporated (MMI), in Denver, Colorado,
opened by Stine and others. Stine had model rocket engines made by a local fireworks company recommended
by Carlisle, but reliability and delivery problems forced Stine to approach others. Stine eventually approached
Vernon Estes, the son of a local fireworks maker. Estes founded Estes Industries in 1958 in Denver, Colorado
and developed a high-speed automated machine for manufacturing solid model rocket motors for MMI. The
machine, nicknamed "Mabel", made low-cost motors with great reliability, and did so in quantities much
greater than Stine needed. Stine's business faltered and this enabled Estes to market the motors separately.
Subsequently, he began marketing model rocket kits in 1960, and eventually, Estes dominated the market.

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Estes moved his company to Penrose, Colorado in 1961. Estes Industries was acquired by Damon Industries
in 1970. It continues to operate in Penrose today

Working of model rocket

A model rocket works by burning propellant through a nozzle at the base of the rocket. This burning creates a
directional thrust which pushes the rocket skyward. The fins of the rocket, once an appropriate speed is reached,
create the force required to keep the rocket pointed upward. Electricity flows through the starter, heating it up
and creating a spark. That spark ignites the propellant in the motor, and the combustion pressure. That pressure
pushes out of the motor and the rocket takes off. A burst at the end of the motor's burn provides enough pressure
to separate the nose from the body tube and the rocket then comes down with one of a variety of recovery
methods, but most commonly a parachute. Once you recover your rocket after landing, you can remove the
spent motor, insert a fresh one, put the rocket back together and go again. Rockets can be flown over and over,
providing nothing breaks on them in the air or upon landing. Motors and their starters can only be used once,
and need to be replaced for each flight.

Model rocket launch procedure

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Parts of a Model Rocket

Nose Cone
The nose cone of the rocket has a shape that causes the air to flow smoothly around the rocket. It could be
conical in shape, but at subsonic speeds a rounded shape gives lower aerodynamic drag. The nose cone is
typically made from plastic, balsa wood, hardwood, fiberglass, or Styrofoam. It can be either hollow or solid.

Payload Section
Not all rockets have a payload section. The model shown has a clear plastic payload section that allows any
payload inside to be easily inspected visually. The payload section can be used to carry a variety of payloads,
such as electronic altimeters or cameras.

Transition Section
A transition section is used to connect body tubes of different diameters. Not all rocket designs incorporate a
transition. The transition could be used to either increase or decrease the rocket's diameter at that point.
Transition sections are typically made from plastic, balsa wood, hardwood, Fib or paper. They may be either
hollow or solid. In the model shown, the bottom of the transition is where the rocket separates when the
parachute is elected.

Shock Cord Mount

The shock cord must be attached to the body of the rocket. There are many ways to do this, but the most
common used in model rockets is a folded-paper mount glued to the inside of the body tube. It is also common
to connect the shock cord (or a separate anchor line) to the front of the motor mount in larger-diameter rockets.

Shock Cord
The shock cord holds the parts of the rocket together after they separate at ejection. The shock cord may be
made of an elastic material to help absorb the shock of the separating parts coming to a halt at the ends of the
cord, or it could be made from a non-elastic line (in which case it is normally longer). Typical materials for
shock cards are sewing elastic, rubber, nylon, and Kevlar.

Parachute
All model rockets require a recovery system to slow their descent and return them safely to the ground. The
most common type of recovery system is the parachute. The parachute may be made from thin plastic or cloth.
The parachute is expelled from the body tube by the ejection charge of the rocket motor after a delay to allow
the rocket to reach apogee and be traveling at a relatively slow speed. Other recovery systems include streamer,
featherweight, glide, helicopter, body drag, and tumble.

Shroud lines
The shroud lines connect the parachute canopy to the rest of the rocket. The shroud lines on most model rocket
parachutes are made of strong thread, such as carpet thread, but they may also be made of other material. The
number of shroud lines varies, but is typically 6 or 8 lines on a model rocket parachute. More shroud lines can
cause a simple flat parachute (a "parasheet") to form into a more nearly spherical shape, and therefore be more
efficient.

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Recovery Wadding
Recovery wadding is flame-resistant material that protects the parachute (or other recovery system
components) from the hot blast of the motor ejection charge. The ejection charge would melt a plastic
parachute, so this protections is necessary. Recovery wadding is typically chemically treated tissue paper or
cellulose insulation. It is vital that only flame-resistant materials be used as recovery wadding to prevent the
ejected wadding from causing fires.

Body Tube
The body tube (or tubes) are the airframe of the model rocket. Body tubes are typically made from paper,
fiberglass, or plastic, with the spiral-wound paper tube being the most common. The rocket may have multiple
body sections connected with transition sections (if the tubes are different diameters) or nose blocks or couplers
(if the tubes are the same diameter). The body tube usually contains an engine mount to hold the motor, and
space for the recovery system.

Launch Lug
When a model rocket first begins to lift off, it is traveling too slowly for the fins to provide aerodynamic
guidance, so the rocket must be guided for the first few feet by a launch rod or rail. The launch lug is what
allows the model rocket to slide along the rod. On a model rocket, the launch lug is typically a small diameter
tube. Larger rockets may use rail buttons on the side of the rocket to allow it to slide along a much stiffer launch
rail for initial guidance.

Fins
The fins of the rocket provide aerodynamic stability in flight so that the rocket will fly straight (in the same
way that the feathers of an arrow help it fly straight). The fins are typically made from plastic, balsa wood,
plywood, cardboard, or fiberglass. A rocket three or four fins, but may have more. Some rockets don't have
any fins and may rely upon a cone or other surfaces to stabilize the model in flight. On larger rockets, the fins
may be mounted through slots in the body tube for extra strength.

Engine Block
The engine block, or thrust ring, keeps the rocket motor from moving forward into the rocket body during the
thrusting phase of the flight. Engine blocks are typically thick paper rings that are glued into the motor mount
tube. If the rocket body has a larger diameter than the motor, the motor mount tube that holds the rocket motor
will be centered within the body tube using cardboard or plywood centering rings.

Rocket Engine
The engine, or motor, of the model rocket is a commercially manufactured solid-propellant rocket motor that
is good for one flight. Model rocket motors are typically made from thick wound paper tubes. The motor
contains a ceramic nozzle, a solid propellant grain (chemically similar to black powder, but compressed into a
solid piece), a slow-burning delay element, and a loose-grained ejection charge that is retained by a clay cap.
Larger rockets may use motors with plastic casings and ammonium perchlorate composite propellant. Some
motors use metal casings that can be reloaded with commercially manufactured APCP grains.

Igniter
Model rocket engines are always ignited electrically from a safe distance. The igniter (which is sold with the
motor) is typically made from wires that connect to a thin wire coated in pyrogen. This pyrogen-coated tip is
inserted into the rocket motor's nozzle and in contact with the solid propellant. When sufficient electrical
current is passed through the igniter, the thin wire heats, igniting the pyrogen, which then ignites the motor

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 propellant.

Model used and Testing

Model rocket apparatus at wings of aero

C Type Model rocket motor

Launch of model rocket

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6. NASA OPEN VSP SOFTWARE

INTRODUCTION

6.1. Open VSP

Open VSP, also known as Open Vehicle Sketch Pad, is an open-source parametric aircraft geometry tool
originally developed by NASA. It can be used to create 3D models of aircraft and to support engineering
analysis of those models. Predecessors to Open VSP including VSP and Rapid Aircraft Modeler (RAM) were
developed by J.R. Gloudem ans and others for NASA beginning in the early 1990s. Open VSP v2.0 was
released as open source under the NOSA license in January 2012. Development has been led by Rob McDonald
since around 2012 and has been supported by NASA and AFRL among other contributions. Open VSP allows
the user to quickly generate computer models from ideas, which can then be analysed. As such, it is especially
powerful in generating and evaluating unconventional design concepts.

6.2 Analysis tools

Besides the geometry modeller, Open VSP contains multiple tools that help with aerodynamic or structural
analysis of models. The tools available are:

 CompGeom - mesh generation tool that can handle model intersection and trimming

 Mass Properties Analysis - to compute properties like centre of gravity and moment of inertia

 Projected Area Analysis - to compute project area

 CFD Mesh - to generate meshes that may be used in computational fluid dynamics analysis software

 FEA Mesh - to generate meshes that may be used in FEA analysis software

 DegenGeom - to generate various simplified representations of geometry models like point, beam and
camber surface models

 VSPAERO - for vortex lattice or panel method based aerodynamic and flight dynamics analysis Results
from a panel method simulation in VSPAERO on a generic transport aircraft

 Wave Drag Analysis - for estimating wave drag of geometries

 Parasite Drag Analysis - for estimating parasite drag of geometries based on parameters like wetted area
and skin friction coefficient

 Surface fitting - for fitting a parametric surface to a point cloud

 Texture Manager - for applying image textures to geometry for aiding visualization

6.3 User interface

Open VSP displays a graphical user interface upon launch. A workspace window and a "Geometry Browser"
window open. The workspace is where the model is displayed while the Geometry Browser lists individual
components in the workspace, such as fuselage and wings. These components can be selected, added or deleted,
somewhat like a feature tree in CAD software such as Solidworks. When a component is selected in the
Geometry Browser window, a component geometry window opens. This window is used to modify the
component. Open VSP also provides API capabilities which may be accessed using Matlab, Python or Angel
Script

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By using Open VSP software I have developed a wing of P – 51 D MUSTANG, a fuselage of Cessna aircraft,
and a propeller of spitfire, a fighter aircraft design and also designed the model rocket ME 163 by finding their
design parameters from the internet. All the tools of software have been explained in a detailed form.

6.3 Wing of P – 51 D MUSTANG

It is almost a replication of the wing of P – 51 MUSTANG with the available parameters of wing on the
internet.

P – 51 mustang wing designed in openvsp

Parameters of wing
Area: S = 377 m2

Span: b = 60.1 m
Chord: Cr = 6.27 m
Wing sweep = 32.2 degree
Aspect ratio = 9.59

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6.4 Fuselage of Cessna
It is a normal replication of the fuselage of Cessna aircraft without using the original parameters. It just
resemble with the picture of Cessna and its length is considered as 28 ft.

Cessna 210 fuselage

6.5 Propeller of Spitfire (5/39 de Havilland Propeller)

It is the propeller blade of spitfire aircraft. The propeller blade is manufactured by de Havilland propellers.5/39
propeller is a variable pitch airscrew, it has a overall diameter of 10ft 0 in, it is a right hand tractor and is
hydraulically operated from coarse pitch of 54 degrees to fine pitch of 34 degree.

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 Propeller blade

6.6 Fuselage with seats and cockpit

In this assignment the normal aircraft is constructed and inside the fuselage the cockpit is shown with the two
seats and 2 pilots and further are empty passenger seats. The design is non-parametric. Taken some imaginary
parameters.

Fuselage with seats

6.7 MISCELLANEOUS
Some miscellaneous design were also created by me in open vsp and also the project model rocket was also
made using this software itself

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 CONCLUSION

As a conclusion all the different manufacturing techniques studied during this 6 week training at WINGS OF
AERO, Tenkasi, TAMILNADU will prove to add an important skill set to our carriers. Composite material
manufacturing techniques are the upcoming large scale, high durability manufacturing solutions. Sheet metal
and welding methods are the current trends of manufacturing practices. Understanding the deep rooted concepts
of using these methods for turning virtual designs into reality are going to help a students in their future projects
and innovations.TEMS calculator is a highly useful tool for an engineering student its use is as simple as a
search, select and go.
Additive manufacturing techniques are the most innovative manufacturing techniques to exist in the current
market, learning the procedures to design and fabricate components using 3d printing is a very useful skill for
an engineering student.
Carrying out model rocket activities instill an immense amount of enthusiasm among the aero enthusiasts it
helps us to visualize the actual science behind the particular shapes and curves of a rocket body. All the
calculations and estimations done during the launch help us a lot in gaining deeper understanding about the
concepts of rocket propulsion.

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 REFERENCE

1. https://www.istockphoto.com/photos/model-rocket(introphoto)
2. https://www.grc.nasa.gov/www/k-12/rocket/rktparts.html(part)
3. https://estesrockets.com/wp-content/uploads/Catalogs/In0html( working model)
4. https://www.google.com/search?tbs=sbi:AMhZZis3XRYNdarCvBRN3tFukrhTU9f5feqdmv41zvqZnSz7l9
BK9Z45V2xDexzrHJB (3d print)
5. https://ar.wikipedia.org/wiki/%D9%85%D9%84%D9%81:3d-printing-a-2014-horizonwatching-trend-
summary-report-9-638.jpg(3d print)
6. https://swiss-aerospace-cluster.ch/composites-in-aerospace/(composite plane)
7.
8. https://www.engineeringchoice.com/composite-material/ (firstimage)
9. https://romeorim.com/what-are-composites/(fibre matrix)
10. https://www.essentialchemicalindustry.org/materials-and-applications/composites.html(single)

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