The work presented in this thesis deals with the application of optimization tools to the design of solid rocket motor grains per internal ballistic requirements. Research concentrated on the development of an optimization strategy capable of efficiently and consistently optimizing virtually an unlimited range of radial burning solid rocket motor grain geometries. Optimization tools were applied to the design process of solid rocket motor grains through an optimization framework developed to interface optimization tools with the solid rocket motor design system. This was done within a programming architecture common to the grain design system, AML. This commonality in conjunction with the object-oriented dependency-tracking features of this programming architecture were used to reduce the computational time of the design optimization process. The optimization strategy developed for optimizing solid rocket motor grain geometries was called the internal ballistic optimization strategy. This strategy consists of a three stage optimization process; approximation, global optimization, and highfidelity optimization, and optimization methodologies employed include DOE, genetic algorithms, and the BFGS first-order gradient-based algorithm. This strategy was successfully applied to the design of three solid rocket motor grains of varying complexity. The contributions of this work was the development and application of an optimization strategy to the design process of solid rocket motor grains per internal ballistic requirements.

Dans un moteur à propergol solide, des instabilités thermoacoustiques auto-entretenues, induites par le couplage de la dynamique de la combustion des gouttes d’aluminium, libérées par la combustion du propergol, avec le champ acoustique peuvent induire des oscillations de pression.L’analyse menée tout au long de ce manuscrit repose sur un ensemble d’hypothèses simplificatrices: (i) la réponse de la combustion de gouttes d’aluminium aux perturbations acoustiques est contrôlée par l’écoulement local autour de la goutte, (ii) le processus de combustion peut être supposé quasi stationnaire pour la gamme de fréquences et les amplitudes acoustiques étudiées et (iii) la combustion de l’aluminium est brusquement arrêtée lorsque le diamètre de la goutte d’aluminium diminue en dessous d’un diamètre résiduel.L’instabilité thermoacoustique est étudiée au moyen de simulations numériques de l’écoulement dans un moteur générique et d’analyses théoriques. Le diamètre résiduel des gouttes d’aluminium après la combustion, l’amplitude de la perturbation acoustique et la durée de la combustion des gouttes d’aluminium figurent parmi les principaux paramètres modifiant l’instabilité. En outre, trois comportements de réponse de la combustion à l’acoustique sont identifiés : un comportement linéaire pour les faibles niveaux de pression acoustique puis un comportement quadratique (faiblement non-linéaire) et enfin un comportement fortement non-linéaire quand l’amplitude des oscillations augmente.Ensuite, deux aspects importants de la réponse des gouttes d’aluminium sont identifiés. Ils sont associés aux oscillations de la durée du temps de combustion des gouttes, identifiables à la frontière du nuage de gouttes, et aux fluctuations du taux d’évaporation contrôlées par la convection de l’écoulement gazeux autour de chaque goutte. Tenant compte de ces dynamiques,des expressions analytiques sont obtenues permettant de reproduire avec précision les résultats numériques des simulations de l’écoulement. Quatre nombres sans dimension qui régissent la dynamique de ces instabilités sont également identifiés. Inspiré de l’analyse théorique précédente, un modèle numérique d’ordre réduit faiblement non linéaire est finalement développé pour prédire des cycles limites. / In a solid rocket motor, self-sustained thermo-acoustic instabilities, induced by the coupling of the combustion dynamics of aluminum droplets released by the burning propellant with the acoustic field can induce pressure oscillations.The analysis conducted throughout this manuscript relies thus on a set of simplifying hypothesis by assuming (i) that the response of the combustion of aluminum droplets to acoustic perturbations is controlled by the oscillating drag exerted by the local flow around the droplet, (ii) that this unsteady combustion process can be assumed quasi-steady for the range of frequencies and acoustic amplitudes studied and (iii) that aluminum combustion is abruptly quenched when the aluminum droplet diameter falls below a residual diameter.The thermo-acoustic instability is studied first by numerical flow simulations in a generic solid rocket motor and theoretical analyses. The post-combustion residual diameter of the aluminum particles, the amplitude of acoustic perturbation and the lifetime of the burning aluminum droplets are among the main parameters altering the instability. Also, three combustion response behaviors to acoustics are identified : a linear behavior for small acoustic pressure levels followed by a quadratic behavior then a highly non-linear behavior when the pressure amplitude increases in the motor chamber. Moreover, two important features of the response of aluminum droplets are identified. They are associated to oscillations of the droplet lifetime at the boundary of the droplet cloud and to fluctuations of the droplet evaporation rate, controlled by convection. The dynamics of the droplets highly depends on gas and droplet velocity fields and on droplet diameter. Taking these features into account, yields analytical expressions that allow to reproduce with accuracy the numerical results from the flow simulations. Four dimension less numbers are then identified. They govern the dynamics of these instabilities. Inspired from the previous theoretical analysis, a weakly nonlinear low-order numerical model is finally developed to predict limit cycles.

Les moteurs de fusées à ergols solides (SRMs) sont sensibles aux instabilités hydrodynamiques qui peuvent déclencher des oscillations auto-entretenues de pression de grandes amplitudes lorsqu’elles se couplent à l’un des modes acoustiques du système. Le moteur de ces instabilités est la formation de structures tourbillonnaires cohérentes synchronisées par des ondes acoustiques longitudinales. Pour certaines conditions de fonctionnement, les ondes acoustiques générées par l’interaction de ces tourbillons avec la tuyère amorcée du moteur renforcent l’oscillation acoustique. L’objectif des travaux menés dans cette thèse est de déterminer l’amplitude et la fréquence des oscillations de pression au cycle limite des instabilités. Celui-ci est atteint par saturation non linéaire des sources, qui est la conséquence de la formation de grosses structures cohérentes. Dans ce cas l’interaction tourbillon tuyère devient insensible à l’amplitude de l’onde du mode acoustique établi dans le foyer. Dans ces conditions, on peut se concentrer sur l’interaction d’un tourbillon avec la tuyère dans le mécanisme de production sonore. En considérant un écoulement incompressible et l’absence de frottement, un premier modèle analytique est développé permettant de déterminer la production sonore d’un tourbillon ingéré par une tuyère bidimensionnelle plane, lorsque le tourbillon est traité comme une ligne vorticité. Des expériences précédentes indiquent que le volume de la cavité autour de l’entrée d’une tuyère intégrée a une grande influence sur l’amplitude des oscillations de pression dans les grands SRMs. On montre que ceci est dû au champ de vitesse acoustique induit par la compressibilité du gaz dans la cavité qui produit une fluctuation de vitesse transverse à la trajectoire du tourbillon. Une seconde alternative au modèle analytique incompressible est développée en considérant toujours l’absence de frottement, mais un modèle compressible de l’interaction tourbillon-tuyère. Celui-ci repose sur un code aéroacoustique pour les écoulements internes basé sur les équations d’Euler (EIA) qui est utilisé ici pour la simulation de l’interaction tourbillon-tuyère. Une étude systématique de cette interaction a été menée pour une tuyère amorcée. Les résultats ont permis de proposer un modèle de sources localisées pour des ondes planes basé sur une analyse théorique des lois d’échelles de ces phénomènes. Les simulations de ces interactions tourbillons-tuyères ont été réalisées pour différents types de tuyères. En employant un bilan énergétique, un modèle avec un seul paramètre de contrôle est formulé, qui permet de reproduire qualitativement le comportement du cycle limite d’oscillations de pression observées dans des expériences réalisées avec des gaz froids décrites dans la littérature. Finalement le modèle Euler est utilisé pour comparer la production de son par interaction tourbillon-tuyère avec celle due à l’ingestion d’une onde d’entropie, appelée aussi tache d’entropie. Contrairement au cas des tourbillons, le bruit produit par ingestion de taches d’entropie n’est pas sensible au volume de la cavité d’une tuyère intégrée. Ces résultats indiquent que le bruit produit par les tourbillons est dominant dans le cas des SRMs étudiés. L’ensemble de ces travaux permet d’améliorer la compréhension des phénomènes d’interaction entre des non-homogénéités de l’écoulement et la tuyère. Elle permet surtout de déterminer quels sont les facteurs de l’écoulement et les éléments géométriques importants qui pilotent le niveau sonore produit par ces interactions. Les modèles développés dans ces travaux, avec divers degrés d’approximation et de complexité permettent d’enrichir la gamme des outils de conception des SRMs. / Solid Rocket Motors (SRMs) can display self-sustained acoustic oscillations driven by coupling between hydrodynamic instabilities of the internal flow and longitudinal acoustic standing waves. The hydrodynamic instabilities are triggered by the acoustic standing wave and results in the formation of coherent vortical structures. For nominal ranges of flow conditions the sound waves generated by the interaction between these vortices and the choked nozzle at the end of the combustion chamber reinforces the acoustic oscillation. Most available literature on this subject focuses on the threshold of instability using a linear model. The focus of this work is on the prediction of the limit-cycle amplitude. The limit-cycle is reached due to nonlinear saturation of the source, as a consequence of the formation of large coherent vortical structures. In this case the vortex-nozzle interaction becomes insensitive to the amplitude of the acoustic standing wave. Hence, one can focus on the sound generation of a vortex with the nozzle. Sound production can be predicted from an analytical two-dimensional planar incompressible frictionless model using the so-called Vortex Sound Theory. In this model the vorticity is assumed to be concentrated in a line vortex. Experiments indicate that the volume of cavities around so-called “integrated nozzles” have a large influence on the pulsation amplitude for large SRMs. This is due to the acoustical field normal to the vortex trajectory, induced by the compressibility of the gas in this cavity. As an alternative to the incompressible analytical model a compressible frictionless model with an internal Euler Aeroacoustic (EIA) flow solver is used for simulations of vortex-nozzle interaction. A dedicated numerical simulation study focusing on elementary processes such as vortex-nozzle and entropy spot-nozzle interaction allows a systematic variation of relevant parameters and yields insight which would be difficult by means of limit cycle studies of the full engine. A systematic study of the vortex-nozzle interaction in the case of a choked nozzle has been undertaken. The results are summarized by using a lumped element model for plane wave propagation, which is based on theoretical scaling laws. From EIA simulations it appears that sound due to vortex-nozzle interaction is mainly generated during the approach phase and that for the relevant parameter range there is no impingement of the vortex on the nozzle wall as has been suggested in the literature. Using an energy balance approach, a single fit-parameter model is formulated which qualitatively predicts limit-cycle observations in cold gas-scale experiments reported in the literature. Finally the Euler model is used to compare the sound production by vortex-nozzle interaction with that due to the ingestion of an entropy non-uniformity also called entropy spot. In addition to insight, this study provides a systematic procedure to develop a lumped element model for the sound source due to non-homogeneous flow-nozzle interactions in SRMs. Such lumped models based on experimental data or a limited number of flow simulations can be used to ease the design of SRMs.

Fast-bränsle-raketer (SRM) har funnit sin plats i en stor mängd tillämpningar sedan deras framkomst mer än 2000 år sedan. En SRMs prestanda är förutbestämd av geometrin av drivmedelskrutet och är begränsad av gjutningsmetoden, som idag främst används i produktion. Forskning inom 3D-skrivning av drivmedelskrut har undersökt nya komplexa geometrier som kan öka prestandan. Studier kring 3D-skrivning med UV-härdning är få till antalet och undersöks i detta projekt. Ett bindemedel av polyuretandiakrylat (PUDA) har syntetiserats och därefter karakteriserats, med och utan diverse monomerer genom dragprovsmätningar och differentialkalorimetri (DSC). Tillsats av tvärbindarna 1,6-hexandioldiakrylat (HDDA) samt trimetylolpropantriakrylat (TMPTA) till PUDA producerade ett mer sprött material. Denna skillnaden var mer påtaglig för TMPTA än HDDA, vilket tillskrivs den högre akrylatfunktionaliteten i den förstnämnda. Den kommersiella produkten Ebecryl 113 har karakteriserats med inerta fyllmedel. Härddjupet (DOC) undersöktes med Ebecryl 113 i ett experiment, vilket påvisade en minskning av härddjupet med ökande mängder aluminium. Orsaken är troligen de reflektiva egenskaperna för UV-ljus som aluminium innehar. Reologiska studier utfördes, från vilka en minskning i viskositet påvisades till följd av en ökad polydispersitet i partikelstorlekarna. 3D-skrivning med kolvextrudering och påföljande härdning med UV-strålning utforskades. Detta visade utmaningar med tekniken som behövs bemästras. I synnerhet uppmärksammades fasseparation och residuell härdning från reflekterat UV-ljus som begränsande faktorer för fortsatt arbete. / Solid rocket motors (SRMs) have found their place in many applications since their conception more than 2000 years ago. The performance of SRMs is determined by the geometry of the propellant grain and is limited by the cast-and-mould production method typically used today. Research has been made on 3D printing propellant grains to explore new complex geometries, which may increase performance. Studies on 3D printing techniques using UV curing are limited and are in this work investigated. A polyurethane diacrylate (PUDA) binder was synthesized and then characterized, with and without various monomers by tensile testing and differential scanning calorimetry. Additions of the crosslinkers 1,6-hexanediol diacrylate (HDDA) and trimethylolpropane triacrylate (TMPTA) to PUDA rendered the final product more brittle. This change was more noticeable for TMPTA than HDDA, as the former has a higher acrylate functionality. The commercial product Ebecryl 113 was also characterized with inert fillers added. A depth of cure (DOC) study with Ebecryl 113 was conducted, which showed a decrease in DOC with increasing amounts of aluminium. This is attributed to the reflective properties of aluminium in the UV spectrum. Rheological studies were conducted and a decrease in viscosity could be seen as a result of increasing the polydispersity of particle sizes. A 3D printing technique using plunger extrusion followed by UV curing was explored, which highlighted challenges which need to be overcome. Most notably, phase separation and residual curing from scattered UV rays are limiting factors for future work.

The present research project is carried out at the von Karman Institute for Fluid Dynamics (Rhode-Saint-Genèse, Belgium) with the financial support of the European Space Agency.<p><p>The first stage of spacecrafts (e.g. Ariane 5, Vega, Shuttle) generally consists of large solid propellant rocket motors (SRM), which often consist of segmented structure and incorporate a submerged nozzle. During the combustion, the regression of the solid propellant surrounding the nozzle integration part leads to the formation of a cavity around the nozzle lip. The propellant combustion generates liquefied alumina droplets coming from chemical reaction of the aluminum composing the propellant grain. The alumina droplets being carried away by the hot burnt gases are flowing towards the nozzle. Meanwhile the droplets may interact with the internal flow. As a consequence, some of the droplets are entrapped in the cavity forming an alumina puddle (slag) instead of being exhausted through the throat. This slag reduces the performances.<p><p>The aim of the present study is to characterize the slag accumulation process in a simplified model of the MPS P230 motor using primarily optical experimental techniques. Therefore, a 2D-like cold-gas model is designed, which represents the main geometrical features of the real motor (presence of an inhibitor, nozzle and cavity) and allows to approximate non-dimensional parameters of the internal two-phase flow (e.g. Stokes number, volume fraction). The model is attached to a wind-tunnel that provides quasi-axial flow (air) injection. A water spray device in the stagnation chamber realizes the models of the alumina droplets, which are accumulating in the aft-end cavity of the motor.<p><p>To be able to carry out experimental investigation, at first the the VKI Level Detection and Recording(LeDaR) and Particle Image Velocimetry (PIV) measurement techniques had to be adapted to the two-phase flow condition of the facility.<p><p>A parametric liquid accumulation assessment is performed experimentally using the LeDaR technique to identify the influence of various parameters on the liquid deposition rate. The obstacle tip to nozzle tip distance (OT2NT) is identified to be the most relevant, which indicates how much a droplet passing just at the inhibitor tip should deviate transversally to leave through the nozzle and not to be entrapped in the cavity.<p><p>As LeDaR gives no indication of the driving mechanisms, the flow field is analysed experimentally, which is supported by numerical simulations to understand the main driving forces of the accumulation process. A single-phase PIV measurement campaign provides detailed information about the statistical and instantaneous flow structures. The flow quantities are successfully compared to an equivalent 3D unsteady LES numerical model.<p><p>Two-phase flow CFD simulations suggest the importance of the droplet diameter on the accumulation rate. This observation is confirmed by two-phase flow PIV experiments as well. Accordingly, the droplet entrapment process is described by two mechanisms. The smaller droplets (representing a short characteristic time) appear to follow closely the air-phase. Thus, they may mix with the air-phase of the recirculation region downstream the inhibitor and can be carried into the cavity. On the other hand, the large droplets (representing a long characteristic time) are not able to follow the air-phase motion. Consequently, a large mean velocity difference is found between the droplets and the air-phase using the two-phase flow measurement data. Therefore, due to the inertia of the large droplets, they may fall into the cavity in function of the OT2NT and their velocity vector at the level of the inhibitor tip.<p><p>Finally, a third mechanism, dripping is identified as a contributor to the accumulation process. In the current quasi axial 2D-like set-up large drops are dripping from the inhibitor. In this configuration they are the main source of the accumulation process. Therefore, additional numerical simulations are performed to estimate the importance of dripping in more realistic configurations. The preliminary results suggest that dripping is not the main mechanism in the real slag accumulation process. However, it may still lead to a considerable contribution to the final amount of slag.<p> / Doctorat en Sciences de l'ingénieur / info:eu-repo/semantics/nonPublished