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USMKKj INDUSTRIAL TRAINING REPORT 2010

1

ACKNOWLEDGEMENTFirst of all, Alhamdulillah, praise to Allah S.W.T and his Prophet Muhammad S.A.W, for enabling

me to finish my industrial training which I have been blessed with good health and peaceful mind when

doing this project. I would like to express my sincere gratitude to my supervisor, Dr.KamarulArifin b.Ahmad for giving me a chance to doing Industrial Training at School of Aerospace Engineering as not

many other lecturers would do.

During these 10 weeks of my industrial training, I have gained a lot of useful and beneficial

experience especially on rocket and CFD area. Thanks to NurFaraihanbt. Abdullah, Dr.Kamaruls Master

Student, I experienced wider and better knowledge related to CFD software including FLUENT and

GAMBIT.

Then I also would like to have special appreciation to my fellow friends, Nik Muhammad Zubaidi

and MohamadFaiz b. Kamaruddin for their assist in helping me in completion of some of my work/project

during the training.

Last but not least, I also would like to thank my parent, course mates, CATIA LAB technicians, and

whoever had given full support and helping during my training.

Thats all.

Thanks.


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CONTENTNO. TITLE PAGE

1. ACKNOWLEDGEMENT 1

2. TRAINING SCHEDULE 33. FIRMS BACKGROUND 5

4. ORGANISATION CHART 10

5. TASK DESCRIPTION 12

6. ACTIVITIES REPORT 14

7. COMMENTS/SUGGESTIONS 47

8. CONCLUSION 48


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TRAINING SCHEDULE


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DATES WEEK TASK

03 MAY 2010 - 07 MAY 2010 1 CFD WORKSHOP

10 MAY 2010 21 MAY 2010 2-3 SPRM PROJECT

24 MAY 2010 04 JUNE 2010 4-5 PREPARATION FOR CFD

SHORTCOURSE

07 JUNE 2010 11 JUNE 2010 6 CFD SHORTCOURSE

14 JUNE 2010 09 JULY 2010 7-10 CONTINUE ON SPRM PROJECT


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FIRMS BACKGROUND

Firms Background:

I- An Introduction

School of Aerospace Engineering, UniversitiSains Malaysia, Engineering Campus, was

established on the 1st March 1999. Before that, Aerospace Engineering Unit was established which

operated from 13 May 1998 until 28 February 1999. The school was established in realizing the needs to


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produce aerospace engineering graduates with high expertise, creativity, and societal values, and

competent in following the rapid technology development in aerospace industry. After graduation, the

graduates shall be eligible to work in government institution, half-government bodies, or private

institutions which are actively involved in aerospace industry or those which are relevant.

In order to produce engineers who are able to face the challenges in the work place, students will

be provided with theoretical knowledge as well as practical, in which case they will be required toundergo practical training in laboratories, and industrial training in government or private agencies.

This program also emphasizes the multidisciplinary engineering concept such as Mechanical,

Electrical and Electronic Engineering. Non-technical subjects which are of equal importance to an

engineer, such as Management, Language, Computer, Accounting, Thinking Techniques, and Engineer in

Society, are also included in the course.

II- Philosophy and Objective

The Bachelor of Engineering in Aerospace program is designed to meet the demand of the

industry today. The program covers in detail principal knowledge in the aerospace profession. Students

are also given practical learning and are given sample exposure to the real work situation; an effort in

preparing them to face the challenges in this challenge profession.

The school's vision is to be the premier center that generates and continuously supports a

community of aerospace professionals that will spearhead and strengthen the development of aerospace

and aerospace-related industries and institutions in Malaysia. To achieve this vision the school will carry

out its mission to lead and innovate through high quality knowledge and skills in aerospace engineering

and through education and research for the development of human resources in the aerospace

engineering field in Malaysia. In conjunction with the vision, the program educational objectives of the

School of Aerospace Engineering are:


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y To produce graduates for professional practice in aerospace engineering,related engineering and

scientific fields.

y To prepare students for graduate studies as their aptitude and professional goals may dictate.

These objectives are attainable as the program is designed to train students to poses the following

attitudes:

y An ability to understand and apply knowledge of mathematics, sciences, and engineering in

dealing with aerospace-related problems.

y An ability to design and conduct experiments as well as to analyze and interpret data related to

aerospace engineering work or research.

y An ability to identify, and solve aerospace engineering problems.

y An ability to use techniques, skills, and engineering tools necessary for aerospace engineering

practice.

An ability to design aerospace system components or processes to meet desired needs within realistic

constrains such as economic, environmental, social, political, ethical, health and safety, and technical.

y An ability to write and communicate effectively.

y An ability to work efficiently in a multidisciplinary team as well as independently.

y An understanding of ethical and professional responsibility towards oneself, other individuals,

organizations, societies, and nation.

y An ability to recognize the need for self-improvement and self-advancement.

y An aptitude to engage in the process of life-long learning.

y An understanding of the impact of aerospace engineering influence in a societal, economics,

environmental, and global context.

In fulfilling the school's curriculum and professional requirements, students are required to undergo

industrial training in order to gain experience and exposure towards the professional engineering

practice. The industrial training is a continuation to the Engineering Practices course which is offered and

conducted by the school. The industrial training is conducted in the period of ten weeks at the selected

aerospace industries premises or relevant industries

III- Vision and Mission

VISION


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To be the premier center that generates and continuously supports a community of aerospace

professionals that will spearhead and strengthen the development of aerospace-related industries and

institutions in Malaysia

MISSION

To lead and innovate through high quality knowledge and skills in aerospace engineering and through

education and research for the development of human resources in the aerospace engineering field in

Malaysia

IV -Outcome Based Education

PROGRAM EDUCATIONAL OBJECTIVES

Starting from the 2006/2007 Academic Session, the OBE practice has been adopted in the teaching and

assessment of all Engineering Degree Programmes at the School of Aerospace Engineering. The

implementation of the OBE emphasizes on the definite objective of the attributes of the graduates to be

produced by the program. In this relation, the development of Program Educational Objective (PEO) has

incorporated the input from all stakeholders, which include industries, government, parents, alumni,

students and lecturers. Thus the following PEO have been set:

1) To produce employable graduates with the knowledge and competency in mechanical and

manufacturing engineering.

2) To produce graduates with capacity and ethics to lead.

3) To produce graduates for innovative engineering design tasks

4) To produce graduates for sustainable technology development

5) To produce graduates who poses interest in research and lifelong learning, as well as continuously

striving for the forefront of technology

PROGRAM OUTCOMES

In relation to the PEO, a set of Program Outcome (PO) has been formulated to ensure that the program

curriculum is aligned with the mentioned attributes in the PEO. Therefore the Engineering Degree

Programmes at the School of Aerospace Engineering has been developed and monitored to successfully

produce engineer with the following qualities, skills and characters:

1) Apply knowledge of mathematics, science, and engineering principles.


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2) Design and conduct experiments as well as analyze and interpret data.

3) Design a system, component or process to meet desired needs within realistic constraints such as

economic, environmental, social, political, ethical, health and safety, manufacturability and sustainability.

4) Function in multi-disciplinary teams.

5) Identify, formulate and solve engineering problems.

6) Use the techniques, skills and modern engineering tools necessary for engineering practice.

7) Understand professional and ethical responsibilities.

8) Communicate effectively.

9) Understand the impact of engineering solutions in global, economic, environmental and societal

contexts.

10) Recognize the need to undertake lifelong learning.

*Resources: [1] Bachelor of Aerospace Engineering Book (Academic Session 2007/2008)

[2]School of Aerospace Engineering websitehttp://aerospace.eng.usm.my


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USMKK I USTRI L TR I I REP RT 2010

11

A

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Dr Farzad Ismail

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Madam Farah Hamid


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TASK DESCRIPTION


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Basically, during this industrial training, the author had gone a memorable-10-week training. In

the first part of the training, the author and his two other friends were asked to practice on 2 orkshop of

CFD based soft2

are like FLUENT and GAMBIT for the first two weeks.

Then, during the middle of the training, the author was helping the School of Aerospace under

Dr.ZukiflyAbudullah supervision in organizing CFD Short Course 2010, an annual event which popularly

well-known among both CFD experts and amateurs.

The main task that was given to the author is to design, fabricate, and test a Solid Propellant Rocket

Motor3SPRM

4.

Mission Requirement:

1. Solid Propellant Rocket Motor (SPRM) by using Potassium Nitrate ()

2. Total Impulse (>1000/sec)

Designing, fabricating, and testing a Solid Propellant Rocket Motor (SPRM) involve a lot of skills both

in using software and hardware. For example, CATIA software used in designing the SPRM, while Latheand CNC machine were used to fabricate it.


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ACTIVITIES REPORT


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Basically5 I had divided my work during Industrial Training (IT) into TWO parts5 first part is for C6 7

Wo8 9

shop and thesecond one is for the real work during my IT which is for Solid Prop@

llA

nt RoB 9 @

t

Motor (SPRM)C

PART I: CFD WORKSHOP (Week 1)

Workshop 1: Inviscid, IncompressibleFlow over a Sine Wave Channel Hump

PurD E F

eE

f tG

e lH

I

E

rH

tE

rP

In this laboratoryyou will compute the flow in a channel (Figure1). Thechannel is1 unit deep and 3 units

long. The upper surface is flat, while in the middle of the lower surface there is a sine wave hump of

length 1 unit and depth 0.1 units. The flow is assumed to be inviscid, irrotational and incompressible. A

uniform velocity of10 m/s is applied on the left hand boundaryQ the right hand boundary is the outflow;

the upper and lower surfaces are walls, and because the flow is inviscid, the flow tangencycondition is

applied on them.

FiR

ure 1: Computational domain

Because the flow is assumed to be inviscid, irrotational and incompressible, it can be modelledusing

potential flow theory. The panel method has been used to obtain the theoretical pressure distributions

on the lower and upper walls; thissolution is provided in an Excel spreadsheet namedvalidation.xls, and

can becompared with the predictions produced byFluent.

RefereS

T

eU

:

Workshop 1Sheet ,byDrKamarulArifin Bin Ahmad, School of AerosopaceEngineering,UniversitiSains Malaysia

0

0.5

1

0 0.5 1 1.5 2 2.5 3

Uniform inflow, 10 m/s


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Workshop 3: 2D Pitching Airfoil via User DefineFunction (UDF)

Purg h i

eh

f tp

e lq

r

h

rq

th

rs

In this laboratoryyou will compute the flow around a pitching airfoil (Figure1). The airfoil is a NACA 0012

airfoil. The airfoil is being subjected into a sinusoidal motion governed bysimple harmonic and reduced

fre t uencye t uations as given below:

Eq. 1

Eq. 2

Where w is the oscillation frequency, c the airfoil chord (c=1), and u is the freestream velocity. For a

starter, F+

will beset to be0.15.

Figure1: A Pitching Airfoil (thesize of the airfoil isexaggerated for the benefit of theviewers)

The Reynolds number isset to be1x106. Thecomputational domain extends until 20chord upstream and

downstream of the airfoil. Theexternal boundaries areset to bevelocity inlet and pressure outlet. You

are expected to be able to set up the basic elements time-dependent calculation of this laboratory

without explicit instructions. Clear guidance will be given for running the dynamic mesh. You can check

thesourcecodepitch.c in thesame directory for thecurrent casestudy.

wtcos12

1minmaxmin

! EEEE

g

!

u

wcF

2


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PART II: SOLID PROPELLANT ROCKET MOTOR (SPRM)


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au LITERATURE REVIEW

A solid propellant rocket motor (SPRM) is the simplest of all

rocket propulsion system designs. A solid-propellant rocket

motor consists of a casing, usually steel, filled with a solid

propellant charge, called the grain, which contains all the

chemical constituents (fuel plus oxidizer) for complete burning.

When ignited, the propellant compounds burn rapidly, expelling

hot gases from a nozzle to produce thrust. The propellant burns

from the center out toward the sides of the casing. The shape

of the center channel determines the rate and pattern of the burn, thus providing a means to control

thrust. Unlike liquid-propellant engines, solid-propellant motors can't be shut down. Once ignited, they

burn until all the propellant is exhausted.

Solid propellant motors have a variety of uses. Small solids often power the final stage of a launch

vehicle, or attach to payloads to boost them to higher orbits. Medium solids such as the Payload Assist

Module (PAM) and the Inertial Upper Stage (IUS) provide the added boost to place satellites intogeosynchronous orbit or on planetary trajectories.

The Titan, Delta, Ariane, and Space Shuttle launch vehicles use strap-on solid propellant rockets to

provide added thrust at liftoff. The Space Shuttle uses the largest solid rocket motors ever built and

flown. Each booster contains 1,100,000 pounds (499,000 kg) of propellant and can produce up to

3,300,000 pounds (14,680,000 newtons) of thrust.

Solid propellant rockets includes all of the older firework rockets, however,

there are now more advanced fuels, designs, and functions with solid

propellants.

Solid propellant rockets were invented before liquid fueled rockets. The solid

propellant type began with contributions by scientists Zasiadko, Constantinov,

and Congreve. Now in an advanced state, solid propellant rockets remain in wide

spread use today, including the Space Shuttle dual booster engines and the Delta

series booster stages.

Hov

a Solid Propellant Functions

A solid propellant is a monopropellant fuel, a single mixture of several chemicals i.e. the oxidizing

agent and the reducing agent or fuel. This fuel is in its solid state and has a preformed or molded shape.

The propellant grain, this interior shape of the core is an important factor in determining a rocket's

performance. The variables determining grain-relative performance are core surface area and specific

impulse.


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Surface area is the amount of propellant exposed to interior

combustion flames, existing in a direct relationship with thrust.

An increase in surface area will increase thrust but will reduce

burn-time since the propellant is being consumed at an

accelerated rate. The optimal thrust is typically a constant one,

which can be achieved by maintaining a constant surface areathroughout the burn.

Examples of constant surface area grain designs include:

end burning, internal-core and outer-core burning, and internal

star core burning.

Various shapes are used for the optimization of grain-thrust

relationships since some rockets may require an initially high

thrust component for takeoff while a lower thrust will suffice its

post-launch regressive thrust requirements. Complicated grain core patterns, in controlling the exposed

surface area of the rocket's fuel, often have parts coated with a non-flammable plastic (such as celluloseacetate). This coat prevents internal combustion flames from igniting that portion of fuel, ignited only

later when the burn reaches the fuel directly.

Specific Impulse

Specific impulse is the thrust per unit propellant burned each second, it measures rocket

performance and more specifically, internal thrust production a product of pressure and heat. Thrust in

chemical rockets is a product of the hot and expanding gasses created in the combustion of an explosive

fuel. The degree of the fuel's explosive power coupled with the rate of combustion is the specific impulse.

In designing the rocket's propellant grain specific impulse must be taken into account since it can be

the difference failure (explosion), and a successfully optimized thrust producing rocket.

Modern Solid Fueled Rockets

The departure from the use of gunpowder to more powerful fuels (higher specific impulses) marks

the development of modern solid fueled rockets. Once the chemistry behind rocket fuels (fuels provide

their own "air" to burn) was discovered, scientists sought the evermore-powerful fuel, constantly

approaching new limits.

Advantages/Disadvantages

Solid fueled rockets are relatively simple rockets. This is their chief advantage, but it also has its

drawbacks. Once a solid rocket is ignited it will consume the entirety of its fuel, without any option for

shutoff or thrust adjustment. The Saturn V moon rocket used nearly 8 million pounds of thrust that would

not have been feasible with the use of solid propellant, requiring a high specific impulse liquid propellant.

The danger involved in the premixed fuels of monopropellant rockets i.e. sometimes nitroglycerin is

an ingredient.


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Once a solid rocket is ignited it will consume the entirety of its fuel, without any option for shutoff or

thrust adjustment. The Saturn V moon rocket used nearly 8 million pounds of thrust that would not have

been feasible with the use of solid propellant, requiring a high specific impulse liquid propellant.

The danger involved in the premixed fuels of monopropellant rockets i.e. sometimes nitroglycerin is

an ingredient.

Oneadvantage, is the ease of storage of solid propellant rockets. Some of these rockets are small

missiles such as Honest John and Nike Hercules; others are large ballistic missiles such as Polaris,

Sergeant, and Vanguard. Liquid propellants may offer better performance, but the difficulties in

propellant storage and handling of liquids near absolute zero (0 degrees Kelvin) has limited their use

unable to meet the stringent demands the military requires of its firepower.

References: [3] http://www.daviddarling.info/encyclopedia/S/solid-propellant_rocket_motor.html

[4] http://inventors.about.com/od/rstartinventions/a/SolidPropellant.htm

On my IT project, the solid propellant rocket motor designed was basically an amateur one. For that

purpose, we referred a lot from Richard Nakkas website. He, who is a well-known amateur scientist in

producing a lot of successful launched amateur rocket to the sky, provide detailed design and calculation

on how to produce an SPRM from scratch.

A basic SPRM consists of a motor casing, combustion chamber, propellant grain, igniter, and

nozzle. Motor casing is considered as a pressure vessel. It is designed to withstand the pressure and

resulting stresses of the rocket motor. Combustion chamber is the place to store the propellant grain and

the combustion process also taking place here. The propellant grain is the fuel of the rocket. There are

two type of propellant grain. The first one is the Double-base Propellant. It is a homogeneous propellant

grain; consist mainly of fibrous nitro-cellulose and a gelatinizer, or plasticizer, such as nitro-glycerin or a

similar compound (ethylene glycol dinitrate), each containing oxygen and fuel in the same compound. It

produces nearly smokeless exhaust, hence suitable for application where minimal smoke situation isdesired. The second type of propellant grain is composite propellant grain, which consisting of powder

fuel and oxidizer bind together by a binding polymer, such as Polybutadiene. By add in some curing agent,

the cross linking process of the binding polymer will harden the grain. The igniters function is to trigger

the combustion, and lastly the nozzle is designed to accelerate the exhaust gas to a very high velocity

through a converging and diverging

References: [5] FYP2009/2010 Th wx

y

x

b

Kok Soon 92242

Misson Requirement:

3. Solid Propellant Rocket Motor (SPRM) by using Potassium Nitrate ()

4. Total Impulse (>1000/sec)


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b) Design Process

In this process, CATIA V5R19 was used as the main software in completing the design.

The detail drawing is provided in the next page.


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d Fabrication Process

For fabrication step, it consists of three separate parts to be manufactured.

1. Bulkhead

2. Motor casing

3. Nozzle

All these part involve Lathe Machine or manual machine. But for nozzle, it required to use CNC machine

as there are some of constraints in Lathe Machine.

1. Bulkhead

First, by using turning tool, some parts of the raw material(Aluminium7071) were removed in order to

achieve desirable diameter of the bulkhead.


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Then, grooving of the bulkhead also been done by using turning tool as in the picture above.

After that, boring tool was used to create a semi-hole part of the bulkhead.


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2. Motor Casing

The combination of boring and turning process was done to the casing to achieve the desired diameter of

the casing.


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C) Nozzle

i) Using CNC Lathe Machine

The drill bit and tools from CNC Machine

Programming Setting


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CNC Machine used: OKUMA LB15

OKUMA LB 15 Basic SpecMachine Type : Horizontal

Control : OSP

Number of Axes : 2

Cutting Diameter : 250 mm

Cutting Length : 230 mm

Bar / Bore : 56 mm

Tool Stations : 12

Spindles : 1

Motor Power : 11.2 kw

Spindle Speed : 3500 rpm

Extra Functions : None

Resources: h p://www

nda

ah

n

o

/

ah

/OK

/LB_15


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Tools section part

The raw material (mild steel) is placed on the 3-axis holder


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The technician set the programming in computer section in order to tell the CNC machine what to do.


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After the setting is done, the shield is closed and the machining process begins.


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The product after the machining process is done. Note that the CNC machine only can machine the outer

part of the nozzle. For the inner part of the nozzle, we will continue it by using Manual Lathe Machine.


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ii) Using Manual Lathe Machine

The nozzle again placed on 4-axis holder of Lathe Machine. The adjustment to make sure the nozzle on

the straight line took quite long time as it need a lot of skills and experienced worker.


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The nozzle first is drilled by using drill bit to ease the drilling process and avoid the tool from broken.

Then, by using a different size of drill tools, the nozzle had been processed.


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The step method used produced the shape as in the above picture.

Mr.Azhar, the technician that involved in the process.

The final part of the nozzle. Due to the difficulties in machining the inner part of the nozzle, the rest of the

fabrication has been done at outside company.


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PART II: SOLID PROPELLANT ROCKET MOTOR (SPRM)


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a) Literature Review

Solid Propellant Requirements for the Amateur Experimentalist

With amateur rocketry, unlike professional rocketry, the availability of materials, the facilities and

processes by which rocket propellants and motors may be produced, as well as available financing, vary

greatly. And clearly these pale in comparison. As such, a clear distinction must be made between the

needs of the professional, and the needs of the amateur, with regard to requirements defining an ideal

rocket propellant. More importantly, what works well for one person, may not work at all for another.

Expanding on this thought, what is suitable for one person, may not be at all suitable for another.

Therefore, the list that follows is not presented in any particular order, as the importance of each would

vary by individual. The exception are the first two items, which must always be of primary importance.

1. Safety of handling, storage, and usage

2. Toxicity of the constituents and products of combustion

3. Availability of the constituents

4. Predictability of performance

5. Consistency of performance

6. Adequacy of performance

7. Formability (or castability)

8. Cost

9. Practical burning characteristics

10.Ease of formulation

The following is a partial list of solid rocket propellants that have been used successfully by amateur

experimentalists. Note that there are are certainly other formulations that I am not presently familiar

with:

1. Potassium Nitrate/Sucrose (or KN/SU)2. Potassium Nitrate/Sorbitol (or KN/SO)

3. Potassium Nitrate/Dextrose (or KN/DX)

4. Zinc/Sulphur (or Micrograin)

5. Blackpowder (KN/Charcoal/Sulphur)

6. Potassium Perchlorate/Sucrose (or PP/SU)

7. Potassium Perchlorate/Epoxy

8. Potassium Perchlorate/Asphalt


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b) Solid propellant preparation

1. Potassium Nitrate ()/epoxy.

MATERIAL/SUBSTANCE PERCENTAGE (%)

Potassium Nitrate () 68

Ferric Oxide 8

Epoxy (Resin + Hardener) 24

2. All the material had been prepared.


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The mixture is inserted into the mould (small PVC pipe).


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The final product of Potassium Nitrate ()/epoxy solid propellant.


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c) Burn rate test

Burn rate test is done to compare the theoretical value and experimental value for Potassium Nitrate

()/epoxy solid propellant.

After taking all the dimension for the propellant, it had been inserted into a small bowl.

Thermocouple is used to measure the highest temperature during the burning.

Mr.Hasfizan, the technician responsible to conduct this test ready to start the burning


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The burning process


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d) Testing of SOLID PROPELLANT ROCKET MOTOR (SPRM)

Unfortunately, due to time constraint, the test which was scheduled to be done at the end of the

training could not be completed. However, we were given second chance by Dr.Kamarul to further our

research in this area by doing Final Year Project (FYP) on the same title.


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COMMENT

&SUGGESTIONIn the future, the fabrication of rocket motor, if possible, could be submitted

to the outside company to be completed.


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CONCLUSION1. From my point of view, industrial training at School of Aerospace

Engineering should be continue and further enhanced as a lot of beneficial

experience gained here.

2. Although this school is not really an industry, we also can achieve and

experience how to work in engineering field especially on fabrication part.

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