Rocket Rocket Motor Motor Design Design and and Flight Flight Performance Performance Analysis Analysis for

for Tactical Tactical Missiles Missiles

R

Eugene L. Fleeman Senior Technical Advisor Georgia Institute of Technology

7/24/2002

ELF

Outline

Differences of Missiles from Aircraft Examples of Parameters That Drive Missile Flight Performance Conceptual Design Process Rocket Motor Design Missile Flight Performance Analysis Summary

7/24/2002

ELF

Tactical Missiles Are Different From Fighter Aircraft

Tactical Missile Characteristics
Acceleration Maneuverability Speed Dynamic pressure Size Weight Production cost Observables Range Kills per use Target acquisition
Superior
7/24/2002

Example of State-of-the-Art

Comparison With Fighter Aircraft

AGM-88 AA-11 PAC-3 PAC-3 Javelin FIM-92 GBU-31 AGM-129 AGM-86 Apache LOCAAS
Better Comparable
ELF

Inferior
3

Outline

Differences of Missiles from Aircraft Examples of Parameters That Drive Missile Flight Performance Conceptual Design Process Rocket Motor Design Missile Flight Performance Analysis Summary

7/24/2002

ELF

Parameters That Drive Flight Performance

Propellant / Fuel Nose Fineness Diameter Wing Geometry / Size

Stabilizer Geometry / Size Thrust Profile

Flight Conditions ( , M, h ) Flight Control Geometry / Size Length

7/24/2002

ELF

Cruise Range Is Driven By L/D, Isp, Velocity, and Propellant or Fuel Weight Fraction
R = ( L / D ) Isp V In [ WL / ( WL WP )] , Breguet Range Equation Typical Value for 2,000 lb Precision Strike Missile
Parameter Subsonic Turbojet Missile Liquid Fuel Ramjet Missile Hydrocarbon Fuel Scramjet Missile Solid Rocket

L / D, Lift / Drag Isp, Specific Impulse VAVG , Average Velocity WP / WL, Cruise Propellant or Fuel Weight / Launch Weight R, Cruise Range
Note:

10 3,000 sec 1,000 ft / sec 0.3 1,800 nm

5 1,300 sec 3,500 ft / sec 0.2 830 nm

3 1,000 sec 6,000 ft / sec 0.1 310 nm

5 250 sec 3,000 ft / sec 0.4 250 nm

Ramjet and Scramjet missiles booster propellant for Mach 2.5 to 4 take-over speed not included in WP for cruise. Rockets require thrust magnitude control ( e.g., pintle, pulse, or gel motor ) for effective cruise. Max range for a rocket is usually a semi-ballistic flight profile, instead of cruise flight.
ELF 6

7/24/2002

Specific Impulse of Tactical Missile Propulsion Alternatives

4,000 Turbojet 3,000 Thrust / ( Fuel Flow Rate ), Specific Impulse, ISP, Seconds

2,000

Ramjet Scramjet

1,000

Ducted Rocket Solid Rocket

0 0 2 4 6 Mach Number
7/24/2002 ELF 7

10

12

High Propellant Fraction Increases Burnout Velocity

5000 V = -gc Isp ln (1 - Wp / Wi)
Note: T >> D, T >> W sin , = const

4000 Isp = 250 sec V, Missile 3000 Isp = 200 sec

Incremental Burnout Velocity, 2000 ft / sec

1000

Example: Rocket Baseline Wi,boost = WL = 500 lb, Wp, boost = 84.8 lb ISP, boost = 250 sec WP, boost / Wi = 84.8 / 500 = 0.1696 V = -32.2 ( 250 ) ln ( 1 - 0.1696 ) = 1496 ft / sec

0.1

0.2

0.3

0.4

0.5

WP / Wi, Propellant Weight / Initial Missile Weight

7/24/2002 ELF 8

Flight Trajectory Shaping Provides Extended Range

Apogee or Cruise

Climb

Altitude
Rapid Pitch Up Line-Of-Sight Trajectory RMAX

Glide

Range
Design Guidelines for Horizontal Launch:

RMAX

High thrust-to-weight 10 for safe separation Rapid pitch up minimizes time / propellant to reach efficient altitude Climb at a 0 deg with thrust-to-weight 2 and q 700 psf minimizes drag / propellant to reach efficient cruise altitude for ( L / D )MAX High altitude cruise at ( L / D )MAX and q 700 psf maximizes range Glide from high altitude at ( L / D )Max and q 700 psf provides extended range
ELF 9

7/24/2002

Dynamic Pressure Varies With Altitude and Mach Number

q = 1 / 2 ( V2 )
120 100 h, Altitude, Kilo feet 80 60 40 20 0 0 1
Wingless Turbojet Low Aspect Ratio Wing Turbojet Ramjet Scramjet

q = 200 psf q = 500 psf q = 1,000 psf q = 2,000 psf q = 5,000 psf q = 10,000 psf q = 20,000 psf

M, Mach number
Note: U.S. 1976 Standard Atmosphere For Efficient Cruise, (L / D)Max for Cruising Lifting Body Typically Occurs for 500 lb / ft2 < q < 1,000 lb / ft2 (L / D)Max for Cruise Missile with Low Aspect Ratio Wing Typically Occurs for 200 lb / ft2 < q < 500 lb / ft2
ELF

7/24/2002

10

Design Robustness Requires Consideration of Type of Atmosphere

Variation from Standard Atmosphere
1.5
( + 30 % )

( - 23% )

Ratio: Cold-to-Standard Atmosphere Ratio: Hot-to-Standard Atmosphere Ratio: Polar-to-Standard Atmosphere Ratio: Tropic-to-Standard Atmosphere

0.5

Temp

Density Speed of Sound

Note: Based on properties at sea level U. S. 1976 Standard Atmosphere: Temperature = 519 Deg. Rankine, Density = 0.002377 slugs / ft3, Speed of sound = 1116 ft / sec
7/24/2002 ELF 11

Missile Guidance and Control Must Be Robust for Changing Events and Flight Environment
Example High Performance Missile Has Low-to-High Dynamic Pressure Negative-to-Positive Static Margin Thrust / Weight / cg Transients High Temperature High Thermal Load High Vibration High Acoustics Pitch-Over at High Alpha Dive Terminal at High Dynamic Pressure Precision Impact at 0 Deg

Level Out Engine Start Transient Booster Shutdown Transient at High Mach Pitch-Up at High Alpha Climb Booster Ignition Air Launch at Low Mach gives high Pitch-Over at High Alpha Vertical Launch in Cross Wind gives high
7/24/2002 ELF

Cruise

Engine Shutdown Transient

12

A Collision Intercept Has Constant Bearing

Example of Miss ( Line-of-Sight Angle Diverging )
Overshoot Miss t2
( LOS
L

Example of Collision Intercept ( Line-of-Sight Angle Constant )

)1 > ( LOS )0
A

t1 t0 Missile ( LOS )1 = ( LOS )0

L

t1 t0

Seeker Line-of-Sight

Seeker Line-of-Sight

Missile

Target

Target

Note: L = Missile Lead A = Target Aspect

7/24/2002

ELF

13

Solid Rockets Have High Acceleration Capability

( T / W )Max , ( Thrust / Weight )Max,
1,000

Solid Rocket
TMax = 2 PC AT = m Ve 100
.

10 TMax = ( / 4 ) d2 V2 [( Ve / V ) -1] 1 0 1 2

Turbojet

TMax = ( / 4 ) d2 V2 [( Ve / V ) -1] 3 4 5

Ramjet

M, Mach Number
Note: . PC = Chamber pressure, AT = Nozzle throat area, m = Mass flow rate d = Diameter, = Free stream density, V = Free stream velocity, Ve = Nozzle exit velocity ( Turbojet: Ve ~ 2,000 ft / sec, Ramjet: Ve ~ 4,500 ft / sec, Rocket: Ve ~ 6,000 ft / sec )
7/24/2002 ELF 14

Subsystem Weight Is Sensitive to Flight Performance ( Range, Speed, Maneuverability )

Dome Seeker Guidance and Control Propulsion Wings Stabilizers

Structure

Power Supply

Warhead and Fuzing

Aerothermal Insulation

Data Link

Flight Control

Very Strong

Strong

Moderate

Relatively Low

7/24/2002

ELF

15

Examples of Kinetic Kill Missiles

Standard Missile 3 ( NTW )

PAC-3

THAAD

LOSAT
7/24/2002 ELF

LOSAT Video
16

Outline

Differences of Missiles from Aircraft Examples of Parameters That Drive Missile Flight Performance Conceptual Design Process Rocket Motor Design Missile Flight Performance Analysis Summary

7/24/2002

ELF

17

Conceptual Design Process Requires Iteration

Mission / Scenario Definition Weapon Requirements, Trade Studies and Sensitivity Analysis Physical Integration Platform and Weapon Weapon Concept Design Synthesis Technology Assessment and Dev Roadmap
Note: Typical conceptual design cycle is 3 to 9 months
7/24/2002 ELF 18

Update Prelim Final Trades / Eval Initial Reqs Alt Concepts Baseline Selected Iteration Effectiveness / Eval

Initial Carriage / Launch

Refine Weapons Req First-Cut Designs Design Studies Initial Tech Tech Trades Eval / Refine Initial Revised Roadmap Roadmap

Outline

Differences of Missiles from Aircraft Examples of Parameters That Drive Missile Flight Performance Conceptual Design Process Rocket Motor Design Missile Flight Performance Analysis Summary

7/24/2002

ELF

19

Missile Concept Synthesis Requires Iteration of Propulsion

Define Mission Requirements Alt Mission Establish Baseline Alt Baseline Aerodynamics Propulsion Weight Trajectory Meet Performance? Yes Measures of Merit and Constraints Yes
7/24/2002 ELF 20

Resize / Alt Config / Subsystems / Tech

No

No

Large Propellant Burn Area Is Required for High Chamber Pressure

Ab, Rocket Baseline Propellant Burn Area, in2 600

Ab = gc pcAt / ( c*r ) r = rpc=1000 psi ( pc / 1000 )n

Example for Rocket Baseline: At= 1.81 in2 = 0.065 lb / in3 n = 0.3 rp = 0.5 in / sec

400

c = 1000 psi

c* = 5,200 ft / sec Tatmosphere = 70 deg Fahrenheit For sustain ( pc = 301 psi ): r = 0.5 ( 301 / 1000 )0.3 = 0.35 in / sec Ab = 149 in2 For boost ( pc = 1,769 psi ) r = 0.59 in / sec Ab = 514 in2

200

0 0 500 1000 1500 Pc, Rocket Baseline Motor Chamber Pressure, psi

2000

Note: Ab = propellant burn area, gc = gravitation constant, At = Nozzle throat area, = density of propellant, c* = characteristic velocity, r = propellant burn rate, rp =1000 psi = propellant burn rate at pc = 1,000 psi, pc = chamber pressure, n = burn rate exponent
c

7/24/2002

ELF

21

High Propellant Weight Flow Rate Requires A Large Nozzle Throat Area
At = c* w p / ( gc pc )
.

(pc)At, Chamber Pressure x Nozzle Throat Area, lb

100000

10000

1000

c* = 4800 ft/sec c* = 5200 ft/sec c* = 5600 ft/sec

Rocket Baseline During Boost: c* = 5200 ft / sec ( pc )boost = 1,769 psi

100 1 10 Propellant Weight Flow Rate, lb/sec

.

100

w p = Wp / tb = 84.8 / 3.26 = 26.0 lb / sec pc At = c* w p / gc = 5200 ( 26.0 ) / 32.2 = 4,200 lb At = 4200 / 1769 = 2.37 in2
.

7/24/2002

Note: At = nozzle throat area, c* = characteristic velocity, w p = propellant weight flow rate, gc = gravitational constant, pc = chamber pressure
ELF

22

Maximum Specific Impulse And Thrust of Rocket Occur at High Chamber Pressure and Altitude
ISP = cd {{[ 2 2 / ( - 1)] [ 2 / ( + 1)] ( - 1 ) / ( + 1 ) [ 1 ( pe / pc ) ( - 1 ) / ]}1/2 + ( pe / pc ) - ( p0 / pc ) } c* / gc T = ( gc / c* ) pc At ISP = {[ 2 / ( + 1)1 / ( - 1 ) ][( -1) / ( + 1 )]1/2 ]} / {( pe / pc )1 / [ 1 - ( pe / pc ) ( - 1 ) / ]1/2 }
Isp, Specific Impulse of Rocket Baseline 280
Note: = nozzle expansion ratio pe = exit pressure pc = chamber pressure p0 = atmospheric pressure At = nozzle throat area = specific heat ratio = 1.18 in figure cd = discharge coefficient = 0.96 in figure c* = characteristic velocity = 5,200 ft / sec in figure Example for Rocket Baseline: = Ae / At = 6.2, At = 1.81 in2

260

240

220 0 5 10 15 20 Nozzle Expansion Ratio h = SL, pc = 300 psi h = SL, pc = 3000 psi h = SL, pc = 1000 psi h = 100K ft, pc > 300 psi
ELF

h = 20 Kft, p0 = 6.48 psi ( pc )boost = 1769 psi, ( ISP )boost = 257 sec ( T )boost = ( 32.2 / 5200 ) ( 1769 ) (1.81 )( 257 ) = 5096 lb ( pc )sustain = 301 psi, ( ISP )sustain = 239 sec ( T )boost = ( 32.2 / 5200 ) ( 301 ) (1.81 )( 239 ) = 807 lb
23

7/24/2002

Single Burn Solid Rocket Thrust-Time Design Alternatives With Propellant Cross-Section
Example Mission
Thrust ( lb ) Thrust ( lb ) Cruise

Thrust Profile
Constant Thrust Burning Time ( sec ) Regressive Thrust Burning Time ( sec ) Progressive Thrust Burning Time ( sec ) Boost-Sustain Thrust Burning Time ( sec ) Boost-SustainBoost Thrust

Propellant Cross-Section

Typical Volumetric Loading (%) 82%

Dive at constant dynamic pressure Climb at constant dynamic pressure Fast launch cruise Fast launch cruise high speed terminal

79%

Thrust ( lb ) Thrust ( lb )

87%

85%

Thrust ( lb )

85%
Medium Burn Rate Propellant High Burn Rate Propellant 24

7/24/2002

Burning Time ( sec ) Note: Thrust and chamber pressure proportional to surface burn area.
ELF

Solid Rocket Propulsion Alternatives of Single Burn and Thrust Magnitude Control
Single Burn ( Boost-Coast )

End Burning

Radial Burning

Single Burn ( Boost-Sustain-Coast )

Radial Boost End Burning Sustain Simultaneous Burning

Concentric Radial Burning High Burn Rate Boost Low Burn Rate Sustain

Thrust Magnitude Control ( Boost-Coast-Sustain-Coast, with Delay Between Pulses )

Radial Boost End Burning Sustain Separate Burning ( Pulsed Motor )

Radial Boost Radial Sustain Separate Burning ( Pulsed Motor ) Boost Propellant Sustain Propellant
25

Note: Each pulse increases motor cost approximately 40%.

7/24/2002 ELF

Solid Rocket Motor Thrust Magnitude Control

Solid Pulse Motor

Thermal or Mechanical Barriers

Solid Pintle Motor

Pintle Pressurization Gelled Oxidizer Gelled Fuel

Bi-propellant Gel Motor

7/24/2002

ELF

26

Solid Rocket Propellant Alternatives

ISP, Specific Impulse, sec

220 - 255

Type
Min Smoke. No Al fuel or AP
oxidizer. Either Composite with Nitramine Oxidizer ( CL-20, ADN, HMX, RDX ) or Double Base. Very low contrail (H2O).

Burn , Rate @ Density, 1,000 psi, lb / in3 in / sec Hazard Observables

0.055 - 0.062 0.25 - 1.0

Reduced Smoke. No Al ( binder

fuel ). AP oxidizer. Low contrail ( HCl ). 250 - 260 0.062 0.1 - 1.5

High Smoke. Al fuel. AP oxidizer.

High smoke ( Al2O3 ). 260 - 265 0.065 0.1 - 3.0

Superior
7/24/2002

Above Average

Average
ELF

Below Average
27

Motor Case Material Alternatives

Type Steel Aluminum Strip Metal / Epoxy Laminate Titanium Composite Superior
7/24/2002

Temperature

Volumetric Efficiency

Weight

Airframe and Launcher Attachment

Cost

Above Average
ELF

Average Below Average

28

Heating Drives Rocket Nozzle Materials, Weight, and Cost

Dome Closeout Housing Throat
Rocket Nozzle Element High Heating ( High Chamber Pressure or Long Burn ) High Cost / Heavy Nozzle Steel Tungsten Insert Molybdenum Insert Low Heating ( Low Chamber Pressure or Short Burn ) Low Cost / Low Weight Nozzle Cellulose / Phenolic Aluminum Cellulose / Phenolic Insert Silica / Phenolic Insert Graphite Insert Carbon Carbon Insert

Exit Cone

Housing Material Alternatives Throat Material Alternatives

Exit Cone, Dome Closeout, and Blast Tube Material Alternatives

7/24/2002

Silica / Phenolic Insert Graphite / Phenolic Insert Silicone Elastomer Insert

ELF

No Insert Glass / Phenolic Insert

29

Subsystems Densities - Rocket Powered Missiles

Guidance: Flight Control: 0.04 lb / in3 0.04 lb / in3

Warhead: 0.07 lb / in3

Propellant: 0.06 lb / in3

Data Link: 0.04 lb / in3

Dome: 0.1 lb / in3

Structure and Motor Case: 0.10 ( Al ) to 0.27 ( steel ) lb / in3

Aero Surfaces: 0.05 ( built-up Al ) to 0.27 ( solid steel ) lb / in3

7/24/2002

ELF

30

Strength Elasticity of Airframe Material Alternatives

Ft = P / A = E 400
Kevlar Fiber w / o Matrix Graphite Fiber w / o Matrix ( 400 800 Kpsi ) Glass Fiber w / o Matrix Note: High strength fibers are: Very small diameter Unidirectional Very elastic No yield before failure Non forgiving failure Metals: Yield before failure Allow adjacent structure to absorb load More forgiving failure E, Youngs Modulus, psi P, Load, lb , Strain, in / in A, Area, in2 Room temperature

300 Ft, Tensile Stress, 103 psi 200

High Strength Steel ( PH 15-7Mo )

Titanium Alloy ( Ti-6Al-4V )

100

Aluminum Alloy ( 2219-T81 )

0 0
7/24/2002

2
ELF

5
31

, Strain, 10-2 in / in

Structural Efficiency at High Temperature of Short Duration Airframe Material Alternatives

12.0

FTU / , Ultimate Tensile Strength / Density, 105 In.

10.0 8.0 6.0

Graphite / Polyimide ( = 0.057 lb / in3 ), 0-45-90 Laminate Graphite / Epoxy ( = 0.065 lb / in3 ) 0-45-90 Laminate Ti3Al ( = 0.15 lb / in3 ) Ti-6Al-4V Annealed Titanium ( = 0.160 lb / in3 ) PH15-7 Mo Stainless Steel ( = 0.282 lb / in3 )

Graphite

4.0 2.0 0

Glass Chopped Epoxy 2219-T81 Composites, Random Orientation Aluminum ( = 0.101 lb / in3 ) ( = 0.094 lb / in3 )

200

400
ELF

600

800

1,000
32

Short Duration Temperature, Degrees F

7/24/2002

Composites Are Good Insulators / Ablators at High Temperature

6,000 5,000 4,000 Max Allowable Temperature, 3,000 R 2,000 1,000 0
Graphites Pyrolytic ~ 0.08 lb / in3 Carbon / Carbon Bulk Ceramics Melt ~ 0.20 lb / in3 Zirconium Ceramic, Hafnium Ceramic Porous Ceramics Melt Resin Impregnated ~ 0.12 lb / in3 Carbon-Silicon Carbide Medium Density Plastic Composites Charring ~ 0.03 lb / in3 Nylon Phenolic, Silica Phenolic, glass phenolic, carbon phenolic, graphite phenolic Low Density Composites Subliming ~ 0.01 lb / in3 Micro-Quartz Paint, Glass Cork Epoxy, Silicone Rubber

Low Density Plastics Subliming Depolymerizing ~ 0.006 lb / in3 Teflon

Insulation Efficiency, Minutes To Reach 300F at Back Wall

Note:
7/24/2002

Assumed Weight Per Unit Area of Insulator / Ablator = 1 lb / ft2

ELF 33

Motor Case Stresses May Be Determined from the Pressure Vessel

For an axisymmetric motor case with a hemispherical dome, motor

case cylinder hoop stress is twice the motor dome longitudinal stress Motor Case Cylinder /2 Ft t = - 0 p r sin d p Hoop p ( Ft )Hoop Stress = p r / t Stress
Motor Dome Nozzle

Motor Case

Motor Dome Longitudinal Stress

Total Load p r2

Ft = p r2 / ( 2 r t ) ( Ft )Longitudinal Stress = p r / ( 2 t )

With metals the material also reacts body bending In composite motor designs, extra ( longitudinal ) fibers must

usually be added to accommodate body bending

7/24/2002 ELF 34

Motor Case Design May Be Determined by Operating Pressure

Calculate Maximum Effective Operating Pressure ( M.E.O.P. )
M.E.O.P. = ( O.P. ) R.T. x ek T x ( Margin for ignition spike and other design uncertainty ) Rocket Baseline: Motor diameter = 8 in., length = 55 in. ( O.P. )RT = Operating pressure at room temperature = 1,769 psi at R.T., k = ( p / T ) / pc = .14% / F Hot day T = 140F, ek T = e0.0014 ( 140 - 70 ) = 1.10 For 3 margin, M.E.O.P. 1769 x 1.10 x 1.10 x 1.10 = 2,355 psi

Use FOS = factor of safety = 1.5 Try Steel at Ft = 200,000 psi ult tHoop = ( M.E.O.P. ) x r x ( FOS ) / Ft = 2355 x 4.0 x 1.5 / 200,000 = 0.071 in
tDome = 0.035 in Weight = Wcyl + WDome = d tHoop l + ( / 2 ) d2 tDome = 29.9 lbs for steel case

Try glass at Ft = 450,000 psi ult, assume 60% glass / 40% epoxy composite tHoop = 2355 x 4.0 x 1.5 / [( 450,000 ) ( 0.60 )] = .052 in radial fibers for internal pressure load
tDome = .026 in Must also add .015 in of longitudinal fibers to counteract body bending load Weight = 10.1 lbs for composite case
7/24/2002 ELF 35

Minimum Smoke Propellant Has Low Observables

High Smoke Example: AIM-7 Particles ( e.g., metal fuel ) at all atmosphere temperature.

Reduced Smoke Example: AIM-120 Contrail ( HCl from AP oxidizer ) at < -10 Fahrenheit atmospheric temperature. High Smoke Motor

Minimum Smoke Example: Javelin Contrail (H2O ) at < -35 Fahrenheit atmospheric temperature.

Reduced Smoke Motor

Minimum Smoke Motor

7/24/2002

ELF

36

Insensitive Munitions Improve Launch Platform Survivability

Critical Subsystems
Rocket motor propellant or engine fuel Warhead Detonation ( ~ 0.000002 sec rise time ) Partial detonation ( ~ 0.0001 sec rise time ) Explosion ( ~ 0.001 sec rise time ) Deflagration or propulsion ( ~ 0.1 sec rise time ) Burning ( > 1 second ) Fragment impact or blast Fast / slow cook-off Drop Temperature Vibration Carrier landing ( 18 ft / sec sink rate )
ELF 37

Severity Concerns Ranking of Power Output - Type

Design considerations ( MIL STD 2105B )

7/24/2002

High System Reliability Is Provided by High Subsystem Reliability and Low Parts Count
Rsystem = 0.920 = RArm X RLaunch X RStruct X RAuto X RAct X RSeeker X RIn Guid X RPS X RProp X RFuze X RWH Arm ( 0.995 ) Launch ( 0.990 ) Structure ( 0.997 ) Autopilot ( 0.993 )
Launch Platform Integration / Firepower Robustness Cost Lethality Reliability Miss Distance Survivability Observables

Reliability

Event / Subsystem

Actuators ( 0.990 ) Seeker ( 0.985 ) Inertial Guidance ( 0.995 ) Power Supply ( 0.995 ) Propulsion ( 0.995 ) Fuze ( 0.987 ) Warhead ( 0.995 ) 0.90 0.92 0.94
ELF

0.96

0.98

1.00
38

Typical Reliability
7/24/2002

Sensors, Electronics and Propulsion Drive Missile Production Cost

Cost
Launch Platform Integration / Firepower Robustness Cost Lethality

Dome

Seeker

Guidance and Control

Propulsion Rocket Airbreather

Wings

Reliability

Miss Distance

Survivability

Observables

Stabilizers

Structure Rocket Airbreather

Power Supply

Warhead and Fuzing

Aerothermal Data Link Insulation

Flight Control

Very High (>25% Production Cost)

High (>10%)

Moderate (>5%)

Relatively Low (<5%)

Note: System assembly and test ~ 10% production cost Propulsion and structure parts count / cost of airbreathing missiles are higher than that of rockets
7/24/2002 ELF 39

Rail Launched and Ejection Launched Missiles

Example Rail Launcher: Hellfire / Brimstone

Example Ejection Launcher: AGM-86 ALCM

7/24/2002

Video of Hellfire / Brimstone Carriage / Launch

ELF

Video of AGM-86 Carriage / Launch

40

Examples of Safe Store Separation

Laser Guided Bombs Drop from F-117

AMRAAM Rail Launch from F-16

7/24/2002 ELF

Video of Rapid Drop ( 16 Bombs ) from B-2

41

Examples of Store Compatibility Problems

Unsafe Separation Hangfire Store Aeroelastic Instability

7/24/2002

ELF

42

Robustness Is Required to Satisfy Carriage and Storage Environmental Requirements

Environmental Parameter Typical Requirement
Surface Temperature Surface Humidity Rain Rate Surface Wind Salt fog Vibration Shock Acoustic -60F* to 160F 5% to 100% 120 mm / hr** 100 km / hr steady*** 150 km / hr gusts**** 3 grams / mm2 per year 10 g rms: MIL STD 810, 648, 1670A Drop height 0.5 m, half sine wave 100 g / 10 ms: MIL STD 810, 1670A 160 dB

Video Example Environment: MLRS

Note: MIL-HDBK-310 and the earlier MIL-STD-210B suggest using 1% climatic extreme as a typical design requirement. * Lowest recorded temperature = -90F. 20% probability temperature lower than -60F during worst month of worst location. ** Highest recorded rain rate = 1,900 mm / hr. 0.5% probability greater than 120 mm / hr during worst month of worst location. *** Highest recorded steady wind = 342 km / hr. 1% probability greater than 100 km / hr during worst month of worst location. **** Highest recorded gust = 378 km / hr. 1% probability greater than 150 km / hr during worst month of worst location.
7/24/2002 ELF 43

Missile Design Validation / Technology Development Is An Integrated Process

Propulsion Propulsion Model Airframe Aero Model Guidance and Control Seeker Actuators Sensors Autopilot / Electronics Power Supply Warhead
7/24/2002

Rocket Static Turbojet Static Ramjet Tests Direct Connect Freejet Wind Tunnel Tests

IM Tests

Structure Test Hardware In-Loop Simulation Tower Tests Flight Test Progression
( Captive Carry, launch, Separation, Unpowered Guided Flights, Powered Guided Flights, Live Warhead Flights )

Model Simulation Lab Tests

Lab Tests

Environment Tests Vibration Temperature IM Tests Sled Tests

44

Ballistic Tests

Witness / Arena Tests

ELF

Examples of Missile Development Tests and Facilities

Propulsion Static Firing with TVC

Airframe Wind Tunnel Test

G&C HWL

Warhead Arena Test

7/24/2002

ELF

45

Examples of Missile Development Tests and Facilities ( cont )

Warhead Sled Test

Structure Test

Insensitive Munition Test

Submunition Dispensor Sled Test

7/24/2002

ELF

46

Examples of Missile Development Tests and Facilities ( cont )

RCS Test

Environmental Test

Flight Test

Video of Facilities and Tests

7/24/2002

ELF

47

Outline

Differences of Missiles from Aircraft Examples of Parameters That Drive Missile Flight Performance Conceptual Design Process Rocket Motor Design Missile Flight Performance Analysis Summary

7/24/2002

ELF

48

Missile Concept Synthesis Requires Iteration of Flight Trajectory

Define Mission Requirements Alt Mission Establish Baseline Alt Baseline Aerodynamics Propulsion Weight Trajectory Meet Performance? Yes Measures of Merit and Constraints Yes
7/24/2002 ELF 49

Resize / Alt Config / Subsystems / Tech

No

No

Missile Concept Synthesis Requires Iteration to Meet Flight Performance Requirements

Define Mission Requirements Alt Mission Establish Baseline Alt Baseline Aerodynamics Propulsion Weight Trajectory Meet Performance? Yes Measures of Merit and Constraints Yes
7/24/2002 ELF 50

Resize / Alt Config / Subsystems / Tech

No

No

Missile Flight Performance Envelope

Rear Flyout Range Max Min

Forward Flyout Range Max Min

Beam Flyout Range Min Max

7/24/2002

ELF

51

Example of Evolution of Short Range Air-to-Air Missile Range and Off Boresight Requirements

Sidewinder AIM-9L ( IOC 1977 ) Performance

+/- 25 degrees off boresight 6.5 nm range

Archer AA-11 / R-73 ( IOC 1987 ) Performance

> +/- 60 degrees off boresight 20 nm range

New Technologies
TVC Split canard Neutral static margin +/- 90 deg gimbal seeker Imaging infrared seeker Digital autopilot Helmet mounted sight

7/24/2002

ELF

52

Conceptual Design Modeling Versus Preliminary Design Modeling

Conceptual Design Modeling
1 DOF [ Axial force ( CDO ), thrust, weight ] 2 DOF [ Normal force ( CN ), axial force, thrust, weight ] 3 DOF point mass [ 3 forces ( normal, axial, side ), thrust, CDO CN CA CN CA CN CA CN CA CN CA Cn Cm CY
53

weight ]
3 DOF pitch [ 2 forces ( normal, axial ), 1 moment ( pitch ),

CY Cm

thrust, weight ]
4 DOF [ 2 forces ( normal, axial ), 2 moments ( pitch, roll ),

Cm

Cl

thrust, weight ] Preliminary Design Modeling

6 DOF [ 3 forces ( normal, axial, side ), 3 moments ( pitch,

Cl

roll, yaw ), thrust, weight ]

7/24/2002 ELF

1 DOF Coast Equation Has Good Accuracy Near Zero Angle of Attack
2.0 1.5 ( V )2 DOF / ( V )1 DOF, Predicted Deceleration 1.0 Comparison for Rocket Baseline 0.5 0
Note:
7/24/2002

. (V . )2 DOF = Two degrees of freedom deceleration ( V )1 DOF = One degree of freedom deceleration Rocket baseline during coast Mach 2, h = 20,000 ft Trim 0.3 deg for 1 g flyout
ELF

2 4 6 8 Trim, Trim Angle of Attack, Deg

10

54

3 DOF Simplified Equations of Motion Show Drivers for Configuration Sizing

+ Normal Force + Thrust << 1 rad V + Moment

+ Axial Force y q SRef d Cm + q SRef d Cm

..

Configuration Sizing Implication

( W / gc ) V q SRef CN + q SRef CN - W cos ( W / gc ) V T - CA SRef q - CN 2 SRef q - W sin

High Control Effectiveness Cm > Cm , Iy small ( W small ), q large Large / Fast Heading Change CN large, W small, q large High Speed / Long Range Total Impulse large, CA small, q small
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Note: Based on aerodynamic control

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For Long Range Cruise, Maximize V Isp, L / D, And Fuel or Propellant Weight Fraction
1.00E+08 R, Cruise Range, ft

R = ( V Isp ) ( L / D ) ln [ WBC / ( WBC - WP )] , Breguet Range Equation

irframe A D / L h th Hig Ramjet wi irframe A c i r t e xisymm A h t i w t Ramje Typical ocket R l a c i p y T
Example: Ramjet Baseline at Mach 3 / 60 Kft alt R = 2901 ( 1040 ) ( 3.15 ) ln [ 1739 / ( 1739 - 476 )] = ( 9,503,676 ) ln [ 1 / ( 1 - 0.2737 )] = 3,039,469 ft = 500 nm

1.00E+07

1.00E+06

1.00E+05 0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 WP / WBC, Propellant or Fuel Weight / Weight at Begin of Cruise (VISP)(L/D) = 2,000,000 ft (VISP)(L/D) = 25,000,000 ft (VISP)(L/D) = 10,000,000 ft

Note: R = cruise range, V = cruise velocity, ISP = specific impulse, L = lift, D = drag, WBC = weight at begin of cruise, WP, weight of propellant or fuel
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For High Rate of Climb, Maximize Thrust and Velocity While Minimizing Drag and Weight
Steady Level Flight
L D W T=W/(L/D)
Note:

Steady Climb
TD L C

Steady Descent
DT

T=D L=W T

D W

D
C

L D W VD T
D

VC

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Small Angle of Attack Equilibrium Flight VC = Velocity of Climb VD = Velocity of Descent C = Flight Path Angle During Climb D = Flight Path Angle During Descent V = Total Velocity h = Incremental Altitude RC = Horizontal Range in steady climb RD = Horizontal Range in steady dive ( glide )

SIN c = ( T D ) / W = Vc / V Vc = ( T D ) V / W RC = h / tan C = h ( L / D )

SIN D = ( D T ) / W = VD / V VD = ( D T ) V/ W RD = h / tan D = h ( L / D )

Reference: Chin, S.S., Missile Configuration Design, McGraw Hill Book Company, New York, 1961
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Small Turn Radius Requires High Angle of Attack and Low Altitude Flight
RT = V / . 2 W / ( gc CN SRef )
10,000,000

RT, Example Instantaneous Turn Radius, Feet

1,000,000 100,000

Note for Example: W = Weight = 2,000 lb a / b = 1 ( circular cross section ), No wings CN = sin 2 cos ( / 2 ) + 2 ( l / d ) sin2 l / d = Length / Diameter = 10 SRef = 2 ft2 CDO = 0.2 ( L / D )Max = 2.7, q( L / D ) = 1,000 psf Max ( L / D ) = 15 degrees Max T( L / D ) = 740 lb
Max

h = 100 K ft ( M(L/D)Max = 7.9 ) h = 80 K ft ( M(L/D)Max = 5.0 ) h = 60 K ft ( M(L/D) = 3.1 ) Max Example: h = 40 K ft ( M(L/D)Max = 1.9 )

10,000

= 10 deg CN = 0.99 h = 40K ft ( = 0.00039 slugs / ft3 ) RT = 2 ( 2,000 ) / [( 32.2 ) ( 0.99 ) ( 2 ) ( 0.00039 )] = 161,000 ft 0 5 10 15 20

1,000

= Increment in Angle of Attack Required to Turn, Degrees

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Turn Rate Performance Requires High Control Effectiveness

= gc n / V = [ q SRef CN + q SRef CN - W cos ( ) ] / [( W / gc ) V ] Assume Rocket Baseline @ Mach 0.8 Launch, 20K ft Altitude
(Cm)xcg=84.6 = (Cm)xcg=75.7 + CN ( 84.6 75.7 ) / d = - 0.40 + 0.68 ( 8.9 ) / 8 = 0.36 per deg (Cm)xcg=84.6 = (Cm)xcg=75.7 + CN ( 84.6 75.7 ) / d = 0.60 + 0.27( 8.9 ) / 8 = 0.90 per deg / = - Cm / Cm= - 0.90 / 0.36 = - 2.5 = + < 22 degrees, max = 30 deg = 30 deg, = - 12 deg . = [ 436 ( 0.349 )( 0.68 )( 30 ) + 436 ( 0.349 )( 0.27 )( - 12 ) 500 ( 1 )] / [( 500 / 32.2 )( 830 )] = 0.164 rad / sec or 9.4 deg / sec / = 0.75 = + = 22 degrees = 12.6 deg, = 9.4 deg . = [ 2725 ( 0.349 )( 0.60 )( 9.4 ) +2725 ( 0.349 )( 0.19 )( 12.6 ) 367 ( 1 )] / ( 367 / 32.2 )( 2074 ) = 0.31 rad / sec or 18 deg / sec Note: High q, statically stable, forward wing control, lighter weight higher climb capability Note: Forward wing deflection to trim increases normal force

Assume Rocket Baseline @ Mach 2 Coast, 20K ft Altitude

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For Long Range Coast, Maximize Initial Velocity

1.2 1 0.8 0.6 0.4 0.2 0 0 0.5
0

V / VBO = 1 / { 1 + t / { 2 WBO / [ gc AVG SRef ( CD0 )AVG VBO ]}} R / { 2 WBO / [ gc AVG SRef (CD0 )AVG ]} = ln {1 + t / { 2 WBO / [ gc AVG SRef ( CD0 )AVG VBO ]}}
Note: Based on 1DoF dV / dt = - gc CD0 SRef q / W Assumptions: = constant 0 deg D > W sin

V = velocity during coast

1.5

VBO = velocity @ burnout ( begin coast ) R = coast range Vx = V cos , Vy = V sin Rx = R cos , Ry = R sin

t / [ 2 W / ( g S CD VBC )], Non-dimensional Coast Time

Example for Rocket Baseline:

0

WBO = 367 lb, SRef = 0.349 ft2, VBO = 2,151 ft / sec, = 0 deg, CD = 0.9, h = 20,000 ft ( = 0.00127 slugs / ft3 ), t = 10 sec t / [ 2 WBO / ( gc SRef CD VBO )] = 10 / { 2 ( 367 ) / [ 32.2 ( 0.00127 ) ( 0.349 ) ( 0.9 ) ( 2151 ) ]} = 10 / 26.6 = 0.376
0

V / VBO = 0.727, V = 0.727 x 2151 = 1564 ft / sec, R / [ 2 WBO / ( gc SRef CD )] = 0.319, R = 18,300 ft or 3.0 nm
0

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For Long Range Ballistic Flight, Maximize Initial Velocity

Vx / ( Vi cos i ) = 1 / { 1 + t / { 2 WBO / [ gc AVG SRef ( CD0 )AVG Vi ]}}
1.2 1 0.8 0.6 0.4 0.2 0 0 0.5
0

( Vy + gc t ) / ( Vi sin i ) = 1 / { 1 + t / { 2 WBO / [ gc AVG SRef ( CD0 )AVG Vi ]} Rx / { 2 WBO cos i / [ gc AVG SRef (CD0 )AVG ]} = ln { 1 + t / { 2 WBO / [ gc ( )AVG SRef ( CD0 )AVG Vi ]}} ( h hi + gc t2 / 2 ) / { 2 WBO sin i / [ gc AVG SRef (CD0 )AVG ]} = ln { 1 + t / { 2 WBO / [ gc AVG SRef ( CD0 )AVG Vi ]}
Assumptions: T = 0, = 0 deg, D > W sin , flat earth Nomenclature: V = velocity during ballistic flight, Vi = initial velocity, Rx = horizontal range, h = altitude, hi = initial altitude, Vx = horizontal velocity, Vy = vertical velocity

1.5

t / [ 2 W / ( g S CD Vi )], Non-dimensional Time

Example for Rocket Baseline:

WBO = 367 lb, SRef = 0.349 ft2, Vi = VBO = 2,151 fps, i = 0 deg, ( CD )AVG = 0.9, hi = 20,000 ft, AVG = 0.001755 slugs / ft3, t = 35 sec
0

t / [ 2 WBO / ( gc SRef CD Vi )] = 35 / { 2 ( 367 ) / [ 32.2 ( 0.001755 ) ( 0.349 ) ( 0.9 ) ( 2151 ) ]} = 35 / 19.22 = 1.821
0

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Vx / ( Vi cos i ) = 0.354 Vx = 762 ft / sec, ( Vy + 32.2 t ) / ( Vi sin i ) = 0.354 Vy = - 1127 ft / sec, Rx / [ 2 Wi cos i / ( gc SRef CD )] = 1.037 Rx = 42,900 ft or 7.06 nm, ( h hi + 16.1 t2 ) / [ 2 WBO cos i / ( gc SRef CD )] = 1.037 h = 0 ft
0

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High Propellant Weight and High Thrust Provide High Burnout Velocity
V / ( gc ISP ) = - ( 1 - DAVG / T ) ln ( 1 - Wp / Wi )
Delta V / ( g ISP ), Nondimensional Incremental Velocity

Example for Rocket Baseline: Wi = WL = 500 lb For boost, WP = 84.8 lb WP / WL = 0.1696 ISP = 250 sec TB = 5750 lb Mi = ML = 0.8, hi = hL = 20,000 ft DAVG = 635 lb DAVG / T = 0.110 V / [( 32.2 ) ( 250 )] = - ( 1 0.110 ) ln ( 1 - 0.1696 ) = 0.1654 V = ( 0.1654 ) ( 32.2 ) ( 250 ) = 1331 ft / sec

0.7 0.6 0.5 0.4 0.3 0.2 0.1 0 0 0.1 0.2 0.3 0.4 0.5
Wp / Wi, Propellant Fraction DAVG / T = 0 DAVG / T = 0.5

DAVG / T = 1.0

Note: 1 DOF Equation of Motion with 0 deg, = constant, and T > W sin , Wi = initial weight, WP = propellant weight, ISP = specific impulse, T = thrust, Mi = initial Mach number, hi = initial altitude, DAVG = average drag, V = incremental velocity, gc = gravitation constant, Vx = V cos , Vy = V sin , Rx = R cos , Ry = R sin
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Note: R = ( Vi + V / 2 ) tB, where R = boost range, Vi = initial velocity, tB = boost time

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High Missile Velocity and Lead Are Required to Intercept High Speed Crossing Targets
4

VM sin L = VT sin A, Proportional Guidance Trajectory

VM
L A

VT

Note:

VM / V T

2 Example: 1
L = 30 degrees A = 45 degrees VM / VT = sin ( 45 ) / sin ( 30 ) = 1.42

Proportional Guidance VM = Missile Velocity VT = Target Velocity A = Target Aspect L = Missile Lead Angle Seeker Gimbal

A = 90 A = 45

10

20
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30

40

50
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L, Lead Angle, Degrees

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High Missile Velocity Improves Standoff Range

RF-Pole / RL = 1 ( VT + VL ) / ( VM + VT )
Note: Head-on intercept RF-Pole = Standoff range at intercept RL= Launch range VM = Missile average velocity VT = Target velocity VL = Launch velocity

1 F-Pole Range / Launch Range 0.8 0.6 0.4 0.2 0 0 0.2 0.4 0.6 0.8 1 Target Velocity / Missile Velocity
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VL / VM = 0 VL / VM = 0.2 VL / VM = 0.5 VL / VM = 1.0

Example: VL = VT VM = 2 VT Then VT / VM = VL / VM = 0.5 RF-Pole / RL = 0.33 RF-Pole = RD = 3.3 nm RL = 3.3 / 0.33 = 10.0 nm
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Missile Flight Range Requirement Is Greatest for a Tail Chase Intercept

( RF / RL )Head-on = ( VM / VT ) / [(VM / VT ) + 1 ]
RF / RL, Missile Flight Range / Launch Range

3 2.5 2 1.5 1 0.5 0 0 1 2

( RF / RL )TailChase = ( VM / VT ) / [(VM / VT ) - 1 ]

( RF / RL ) Head-on ( RF / RL ) Tail Chase

Examples: Head-on Intercept VM = 1,640 ft / sec, VT = 820 ft / sec VM / VT = 1640 / 820 = 2 RF / RL = 2 / ( 2 + 1 ) = 0.667 RL = 10.0 nm RF = 0.667 ( 10.0 ) = 6.67 nm Tail Intercept at same conditions RF / RL = 2 / ( 2 1 ) = 2.0 RF = 2.0 ( 10.0 ) = 20.0 nm

VM / VT, Missile Velocity / Target Velocity

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Example of Spreadsheet Based Conceptual Sizing Computer Code - TMD Spreadsheet

Conceptual Sizing Computer Code

Tactical Missile Design ( TMD ) Spreadsheet PC compatible Windows Excel spreadsheet

Based on Tactical Missile Design Short Course and Textbook

Aerodynamics Propulsion Weight Flight trajectory Measures of merit

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Example of Spreadsheet Based Conceptual Sizing Computer Code - TMD Spreadsheet

Define Mission Requirements [ Flight Performance ( RMax, RMin, VAVG ) , MOM, Constraints ] Establish Baseline ( Rocket , Ramjet )

Alt Mission Alt Baseline

Aerodynamics Input ( d, l, lN, A, c, t, xcg ) Aerodynamics Output [ CD , CN, XAC, Cm , L / D, ST ]

0

Propulsion Input ( pc, , c*, Ab, At, A3, Hf, , T4, Inlet Type ) . Propulsion Output [ Isp, Tcruise, pt / pt , w , Tboost, Tsustain, VBoost ]
2 0

Resize / Alt Config / Subsystems / Tech

Weight Input ( WL, WP, max ) Weight Output [ Q, dTskin / dt, Tskin, skin , tskin, buckling, MB, ( Ft )Motor, W, xcg, Iy ] Trajectory Input ( hi, Vi, Type ( cruise, boost, coast, ballistic, turn, glide ) Trajectory Output ( R, V, and versus time ) Meet Performance? Yes Measures of Merit and Constraints Yes
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No [ RMax, RMin, VAVG ] No [ pBlast, PK, nHits, Vfragments, PKE, KEWarhead, Total, HE, MAN, Rdetect, CWeight, Cunit x ]

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Outline

Differences of Missiles from Aircraft Examples of Parameters That Drive Missile Flight Performance Conceptual Design Process Rocket Motor Design Missile Flight Performance Analysis Summary

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Summary of Rocket Motor Design

Design Methods
Thrust Specific impulse

Design Trades
Propellant burn area requirement Nozzle throat area Nozzle expansion ratio Rocket motor grain Thrust magnitude control Solid propellant alternatives Motor case material Nozzle materials

New Rocket Propulsion Technologies

Higher density propellant Solid rocket thrust magnitude control Low observable fuel / propellant

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Summary of Flight Performance Analysis

Flight Performance Analysis Activity in Missile Design
Compute range, velocity, time-to-target, off boresight Compare with requirements

Discussed in This Lecture

Equations of motion Flight performance drivers Propulsion flight performance comparison Steady state flight relationships Steady climb and steady dive range prediction Cruise prediction Boost prediction Coast prediction Ballistic flight prediction Turn prediction Target lead for proportional homing guidance

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Flight Performance Strongly Impacted by Aerodynamics, Propulsion, and Weight ELF

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