IJSRD - International Journal for Scientific Research & Development| Vol.

4, Issue 03, 2016 | ISSN (online): 2321-0613

Burn Back Analysis & CFD Simulation of Finocyl Grain in Solid

Propellant Rocket Motor
Chirag B. Patel1 Akash Raj2 Amit Ranjan3
1
M.Tech. Scholar 2,3Assistant Professor
1,2,3
Department of Mechanical Engineering
1,2,3
Marwadi College of Engineering, Rajkot, Gujarat, India
Abstract— Design and analysis of propellant grain
configurations for determination of the grain geometry II. LITERATURE REVIEW
which is an important and critical step in the design of solid “Design and geometrical analysis of propellant grain
propellant rocket motors, because accurate calculation of configurations of a solid rocket motor” by Patan Stalin,
grain geometrical properties plays a vital role in Y.N.V.Santosh Kumar [4] have study, grain burn back
performance prediction. The performance prediction of the analysis for 3-D star grain geometries for solid rocket motor.
solid rocket motor can be achieved easily if the burn back The design process involves parametric modeling of the
steps of the grain are known. In this study, grain burnback geometry in CATIA software through dynamic variables
analysis for 3-D grain geometries was investigated. The that define the complex configuration also equilibrium
method used was solid modeling of the propellant grain for pressure method is used to calculate the internal ballistics
predefined intervals of burnback. In this method, the initial and numerical results from the CATIA are checked with the
grain geometry was modeled parametrically using Creo MATLAB and to verify the correct area of the remaining
parametric software. For every burn step, the parameters propellant.
were adapted and the new grain geometry was modeled. By “Design and Performance Optimization of Finocyl
analyzing these geometries, burn area change of the grain Grain” by Ali Kamran, Liang Guozhu [5] was developed
geometry was obtained. CFD simulation of the core flow 3D design methodology to design and optimize Finocyl Grain
grain of solid propellant rocket motor. And the field of considering particular test case for which the Average thrust
SRMs various types of CFD models were used for and constraints have been given. Genetic algorithm to be
simulation purpose. But in the present research work K-E used for optimized to design constraints and to evaluate the
standard Ansys fluent model used for simulation. effects of uncertainties in design parameters.
Key words: Analysis, Equilibrium Chamber Pressure “Internal ballistics simulation of a solid propellant
Technique, Finocyl Grain, Pro-E, k-ɛ Standard Ansysis rocket Motor’’ by Marc Faria Gomes [6] was study a 2-D
Fluent model R-15 axis symmetric internal ballistics model was developed to
simulate the Solid Propellant Rocket Motor internal flow
I. INTRODUCTION field conditions during the Quasi Steady State. And K-E
“Design and optimization of 3D radial slot grain with RNG (Renormalization Group Theory) model was
configuration” by Ali Kamran, Liang Guozhu [1] have chosen for this study.
studied geometrical calculations of grain burnback are based “Universal erosive burning model performance for
on volume and change-in-volume calculations and solid rocket motor internal ballistics” by Afroz Javed [7]
Equilibrium pressure method is used to calculate the internal was study related to erosive burning model and applied to
ballistics. “3-D grain burnback analysis of solid propellant cylindrical port motors with high and moderate mass flux, as
rocket motors” was studied by G. Püskülcü, A. Ulas [2, 3]. well as finocyl grain motors. And observed for cylindrical
To verify the predictions from the model, subscale ballistic port motors, computed pressures with the burning time. Also
rocket motor tests were performed in this study. Composite developed this model makes it a useful tool for design and
propellants containing Aluminum/HTPB/AP were cast into analysis of solid rocket motors of any size and port
3-D Finocyl grains. Five different Finocyl geometries were geometry.
selected for static firings to obtain different boost and “A hybrid optimization approach for SRM finocyl
sustain thrust profiles. And in, grain burnback analysis for grain design” by Khurram Nisar and Qasim Zeeshan [8] was
Finocyl 3-D grain geometries was investigated. The method investigated A hybrid optimization (HO) technique is
used was solid modeling of the propellant grain for established by associating genetic algorithm (GA) for global
predefined intervals of burnback. In this method, the initial solution convergence with sequential quadratic
grain geometry was modeled parametrically using CAD programming (SQP) for further local convergence of the
software. For every burn step, the parameters were adapted solution, thus achieving the final optimal design.
and the new grain geometry was modeled. By analyzing “Solid rocket motor internal ballistics simulation using
these geometries, burn area change of the grain geometry different burning rate models” by Marius Ionuţ [9] was
was obtained. Using this data and internal ballistic developed 0-D internal ballistic mathematical model has the
parameters, the performance of the solid propellant rocket capability to provide a high degree of accuracy information
motor in terms of motor pressure was achieved. The on solid rocket motor performances. The 0-D internal
comparison between the results from this study and the ballistics model provides the capability to approximate first-
results from the actual rocket. order rocket performance.

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 Burn Back Analysis & CFD Simulation of Finocyl Grain in Solid Propellant Rocket Motor
(IJSRD/Vol. 4/Issue 03/2016/308)

III. FINOCYL GRAIN – BURN BACK ANALYSIS A. Solution Methodology Using CFD
In the present research work, finocyl grain geometry is CFD stands for Computational Fluid Dynamics. It means
chosen. The finocyl geometry is 3D grain geometry predicting physical fluid flows and heat transfer using
composed of a cylindrical and star shaped parts attached computational methods. Computational fluid dynamics has
together. The reason for finocyl geometry to be chosen is the certainly come of age in industrial applications and
widespread usage of such geometries. The main parameters academia research. In the beginning this popular field of
of finocyl geometry are given on Figure 1. [2] study was primarily limited to high-technology engineering
areas of aeronautics and astronautics, but now it is a widely
adopted methodology for solving complex problems in
many modern engineering fields. CFD, derived from
different disciplines of fluid mechanics and heat transfer, is
also finding its way in too there important uncharted areas
especially in process, chemical, civil, and environmental
engineering.
Fig. 1: Dimensions of Finocyl Geometry There are several assumptions made in order to set-up the
The initial 3D model of grain is created then, one CFD model.
by one, each successive webstep of the receding grain is There are several assumptions made in order to set-up the
created and saved within Creo software. The main CFD model.
parameters that were changed are finned part length, circular 1) The combustion gas follows the Ideal Gas law.
part diameter, fin width, and fin length. 2) Steady-state pressure predictions are calculated for
The outer diameter of 66.7 mm and length of the each webstep.
whole grain of 150 mm are left constant. The nozzle used 3) The combustion gases have constant properties.
for the analysis has a throat diameter of 11 mm and exit 4) The gas is calorically perfect (constant specific
section diameter of 39 mm and table I shows other heats).
dimensions of parameters. 5) The case wall of the motor is adiabatic.
N R1 (mm) R2 (mm) L2 (mm) LS (mm) 6) The motor grain ignites instantaneously.
4 15 5 20 30
B. Geometry Modeling
Table 1: Dimensions of propellant grain
The propellant used for the analysis is a composite
propellant composed of “ammonium perchlorate, HTPB
(Hydroxyl-terminated PolyButadiane) and aluminum”. The
properties of propellant have been shown in table II.
Nomenclature Value Unit
Burn rate coefficient (a) 7.25E-5 m/s
Burn rate exponent (n) 0.3179 n/a
Density (ρb) 1799.2 kg/m3
Characteristic velocity* 1600 m/s
Table 2: Properties of solid propellant
The burnback analysis of finocyl geometry, the
fixed burnback distance should be selected. For the selection
of such fixed distance, the effects of burnback distance are Fig. 3: Inner cavity of finocyl grain with nozzle
examined first on finocyl geometry. The burnback analysis
is done with several burnback distances.
Here, assuming of fixed distance is about 5% of
web thickness approximate 1mm (∆x).Each 1mm webstep;
new solid geometry is created in Creo software and to obtain
burning area of grain. After to getting burning area we can
find easily chamber pressure, burning rate and mass flow
rate with help of using equation.
Figure 2 shows the grain geometry after several burnstep.

Fig. 4: Inner cavity of finocyl grain with nozzle (1/4 th

model)
Solving a CFD problem starts with a two-dimensional 2D or
three-dimensional 3D drawing of the geometry of the
system. A CAD program is included in all commercial CFD
programs but the geometry of the system can usually be
drawn in any CAD program and imported in to the grid-
generation program. In this analysis Ansys design modular
Fig. 2: Solid model of initial propellant grain and propellant was used for the generation of inner cavity of solid model of
grain after several burn steps finocyl grain.

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 Burn Back Analysis & CFD Simulation of Finocyl Grain in Solid Propellant Rocket Motor
(IJSRD/Vol. 4/Issue 03/2016/308)

Each webstep new 3D model was as modeling 0.018 60.652 0.010 0.36
0.0 0.1
2 0.002
into Ansys design modular with changes parametric 6 8 7 0293 89
dimension. Also analysis done with minimum time then, we 0.019 65.683 0.011 0.39
0.0 0.2
have to model of 1/4th geometry of grain. 3 0.003
7 7 0 0191 80
C. Meshing 0.020 70.843 0.011 0.42
0.0 0.3
4 0.004
7 6 3 0789 68
After completing geometry modeling, geometry file is edit 0.021 76.128 0.011 0.45
0.0 0.4
in to meshing. In meshing first step is repair geometry up to 5 0.005
8 7 5 2187 55
specified tolerance 0.01mm. In next step mesh method and 0.022 81.530 0.011 0.48
0.0 0.5
types of element is defined for surface mesh i s s we e p 6 0.006
8 2 8 4285 40
a n d h e x d o m i n a t e d m e t h o d wi t h all quad element is
. . . . . . . .
selected.
. . . . . . . .
0.023 82.616 0.011 0.49
0.0 1.2
15 0.015
0 2 9 0684 85
0.022 80.901 0.011 0.48
0.0 1.3
16 0.016
7 1 8 0585 70
0.022 78.823 0.011 0.46
0.0 1.4
17 0.017
3 2 7 8186 56
0.021 76.377 0.011 0.45
0.0 1.5
18 0.018
8 8 6 3687 42
0.0 1.6
19 0.019 0 0 0 0
87 29
Table 3: Calculation of ballistic parameters
The grain boundary mass flow for the individual
model using the Ab data obtained by the Design Modeler in
Fig. 5: Meshing of 1/4th part of model of grain ANSYS FLUENT. Using the relationship between chamber
pressure, Pc, and the grain surface area, Ab, in equation
3.14, the pressure is found for Solid Propellant Rocket
Motor each webstep. This pressure is used to determine the
mass flow of the grain only.
The pressure reported in the final solution is obtained from
FLUENT.
The external temperature and pressure are ambient,
at 300 K and 101; 325 kPa, respectively. The grain surface
is defined as a mass flow inlet boundary. The mass flow
direction is specified as normal to the surface. Turbulence
kinetic energy and dissipation rate are both set to zero as
required in laminar, transpired flow. The total temperature is
equal to the flame temperature, 2300 K.
E. Post Process Result
Fig. 6: In the post processing, after completing the solution in the
solver then graph of convergence criteria is generated after
D. Boundary and Initial Condition the validating the convergence criteria. Different contour
The insulated case and the nozzle are modeled as stationary diagram e.g. pressure, temperature and velocity are
walls. They use a no-slip shear condition and the default generated in the post processing.
value wall roughness. Two boundary conditions include the F. Result and Discussion
center line and the working fluid. The motor center line is
the x-axis about which the case, throat and grain geometries Based on the procedure mentioned in the experimental
are rotated. program and the burnback analysis carried out in the
previous section, the present section discusses the results
Cham Mas Del
Tot and discussion.
Burni ber Burni s ta
al Table III - shows typical result of the burnback
Sr Webs ng Pressu ng flow Ti
Ti analysis conducted in this study: Burn area, chamber
. tep rate re Rate in me
me pressure, burning rate at several burnback distances.
N (m) Ab Pc rb m ∆t
2 (sec From the analysis done, burn area versus web
o. (m ) (Pasca (m/s) (kg/ (sec
) burned, burn area versus time and pressure versus time data
l) s) )
are obtained and given in figure 7 to figure 9).
0.016 50.994 0.010 0.30 0.0 0.0
0 0 As seen from the pressure versus time graphs, the
6 0 2 28 00 00
pressure curve at the steady state operation is determined
0.017 55.754 0.010 0.33 0.0 0.0
1 0.001 mainly by the burning area change. Also pressure curve
6 7 5 11 96 96
firstly go to progressive and after sometime to rest neutral

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 Burn Back Analysis & CFD Simulation of Finocyl Grain in Solid Propellant Rocket Motor
(IJSRD/Vol. 4/Issue 03/2016/308)

and further decreases means regressive form. That, we can

say that solid propellant rocket motor has been working
based on dual thrust motor nearly.

Fig. 11: Pressure contour Webstep-2

Fig. 7: Burn area vs. Web burned distance

Fig. 8: Burn area vs. Time

Fig. 12: Pressure contour Webstep-3

Fig. 9: Chamber pressure vs. Time

In the first webstep chamber pressure 54.92 bar is obtained
by CFD simulation, while 55.754 bar is obtained by
burnback analysis. The difference between two results is
1.49 %. Fig. 13: Pressure contour Webstep-4

Fig. 10: Pressure contour Webstep-1 Fig. 14: Pressure contour Webstep-5

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 Burn Back Analysis & CFD Simulation of Finocyl Grain in Solid Propellant Rocket Motor
(IJSRD/Vol. 4/Issue 03/2016/308)

IV. CONCLUSION
In the present research work finocyl grain is used for
burnback and CFD simulation. The main advantage of this
type of grain is dual thrust profile.
CFD simulation based on steady state with
equilibrium pressure. At the present time research work is
done for burnback analysis and CFD simulation of first five
websteps.

REFERENCES
[1] Ali Kamran, Liang Guozhu, 2010, Design and
Optimization of 3D Radial Slot Grain Configuration,
Chinese Journal of Aeronautics , Vol. 5, Pages 409-414
[2] G. Püskülcü a, A. Ulas, 2008, 3-D grain burnback
analysis of solid propellant rocket motors: Part 1 -
ballistic motor tests, Aerospace Science and
Technology Vol.12, Pages 579–584
[3] G. Püskülcü a, A. Ulas, 2008, 3-D grain burnback
analysis of solid propellant rocket motors: Part 2 -
modeling and simulations, Aerospace Science and
Technology Vol.12, Pages 585–591
[4] Patan Stalin, Y.N.V.Santosh Kumar, 2014, Design and
geometrical analysis of propellant grain configurations
of a solid rocket motor, IJEDR, Volume 2, Issue 4
[5] Ali Kamran, Liang Guozhu, Junaid Godil, Zeeshan
Siddique, Qasim Zeeshan,2009, Design and
Performance Optimization of Finocyl Grain,Modeling
and Simulation Technologies Conference, Chicago
[6] Marc Faria Gomes, 2013, Internal ballistics simulation
of a solid propellant rocket Motor, MS Thesis, Dept. of
Mechanical Engineering, METU, 2013
[7] Afroz Javed, Debasis Chakraborty, 2015, Universal
erosive burning model performance for solid rocket
motor internal ballistics, Aerospace Science and
Technology, Vol. 45
[8] Khurram Nisar and Qasim Zeeshan, 2008, A hybrid
optimization approach for SRM finocyl grain design,
Chinese Journal of Aeronautics, Vol.21
[9] Marius Ionuţ, 2014, Solid rocket motor internal
ballistics simulation using different burning rate
models, U.P.B. Sci. Bull., Series D, Vol. 76,
[10] Book, Rocket and Spacecraft Propulsion - Principles,
Practice and New Developments, Professor Martin J. L.
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