Design
Design begins with the total impulse required, which determines the fuel/oxidizer mass. Grain geometry and chemistry are then chosen to satisfy the required motor characteristics.
The following are chosen or solved simultaneously. The results are exact dimensions for grain, nozzle, and case geometries:
- The grain burns at a predictable rate, given its surface area and chamber pressure.
- The chamber pressure is determined by the nozzle orifice diameter and grain burn rate.
- Allowable chamber pressure is a function of casing design.
- The length of burn time is determined by the grain 'web thickness'.
The grain may or may not be bonded to the casing. Case-bonded motors are more difficult to design since the deformation of the case and the grain under flight must be compatible.
Common modes of failure in solid rocket motors include fracture of the grain, failure of case bonding, and air pockets in the grain. All of these produce an instantaneous increase in burn surface area and a corresponding increase in exhaust gas and pressure, which may rupture the casing.
Another failure mode is casing seal design. Seals are required in casings that have to be opened to load the grain. Once a seal fails, hot gas will erode the escape path and result in failure. This was the cause of the Space Shuttle Challenger disaster.
Read more about this topic: Solid-fuel Rocket
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