Rockets and Missiles Presentation @ Zeus Numerix

1Build-to-Specifications | Product Approval | Engineering Services | Software Development
Rocket and Missiles
Presentation@ Zeus Numerix
Capabilities in design and development Rockets and
Missile systems
V3
Abhishek Jain

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©ZeusNumerixPvtLtd:ConfidentialDocument
Presentation Overview
20 June 2019 Capabilities on Rockets and Missiles @ Zeus Numerix
 Zeus Numerix – an Introduction
 Journey started from CFD and FEM simulations for rockets and missiles
 No 1 Know-Why company in design of rockets and guided missiles
 From configuration to internal and external ballistics, guidance and terminal phase
 Non-confidential Case studies
 Artillery Rocket Systems
 Missiles and Guided Projectiles
 Specialized Software Development
 Team and Closure
 The presentation is non-confidential and some data may be masked
 Legends in the presentation are not shown purposefully
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3
2004
1st Project Completed
Large Defense Project
2005 2006
1st Software Export
System design software: Korea
2007
2008
CEM Software
UAV RCS Reduced
2009
1st Built-to-Spec project
Supersonic ground
vehicle developed
2010
Fire Safety & Comfort
Building fire and HVAC
2011
Control Software
In-house development
2012
2013
Parallel GPU code Devp
Visualize big data – 4 billion points
2015
Floating Panel Design
Solar Panels in Lake
2017
1st foreign missile project
Integration & Certification
2018
1st MSME TDF Winner
D&D of Composite Sea Water Pump
2019
Incubated at IIT Bombay
Journey Begins with India’s 1st
Commercial CFD software!
400th project completed
Lockheed Innovation
Medal & India Govt
R&D Certificate
CEM Software
CEMILAC Certification
1st Store Separation
project complete
www.zeusnumerix.com/portfolio
The Journey

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4
Customers List: Partial

5
5
Accolades
R&D Recognition Innovation Medal
DST-FICCI-Lockheed Martin
India Innovation Growth
Medal 2007 for
“Numerical Simulations”
Recognition as an R&D Unit by
the Department of Scientific
and Industrial Research
“Design Approval” by Centre
for Military Airworthiness
and Certification certified
CEMILAC Certificate

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Core Offerings
Product
Development
Initial sizing from first
principles
Detailed analysis
based design
Prototype
development
Testing and validation
Product
Approval
Performance
estimate by analysis
Detailed Report
Generation
Review with approval
agency
Final submission and
product approval
Engineering
Services
Design calculation
reports
Analysis – CFD, FEM,
CEM
Failure analysis and
design suggestions
Multi-disciplinary
design optimization
Software
Development
Pre-processing
Automation
Solver development
from Literature
survey
Visualization, parallel
code CPU/GPU & GUI
System simulation
tools

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Rockets and Missiles
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Rockets
• Aerodynamics – Spinning rockets
• Aerostructural & aerothermal considerations
• Dynamics and fire control computer
Missiles
• Aerodynamics, aerothermal, structural
• Guidance and real time models
• Stealth and seeker training
Special
Software
• Automated meshing software
• Aeroelasticity, tip-off, image processing
• Thermal protection, propellant, optimization
Hypersonic vehicle
Guided Missile Aerodynamics

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Artillery Rocket Systems
Non-confidential examples of completed projects for artillery
rocket systems
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Aerodynamic MBRL Rocket
 Multi-Barrel Rocket Launcher fires spinning rockets
 Aerodynamic simulation done using structured mesh and RANS solver
 Spinning motion incorporated in solver to predict Coriolis forces (drift)
 Data matches well with limited wind tunnel studies
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Tail Fin Design for Spinning Artillery Rocket
 Simulation of various tail shapes and numbers for design considerations
 Variation in fin number (4, 6), fin shape (flat and circular) and cant angle
 Merits and demerits of each configuration
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Flat fin
Curved fin

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Custom Aero-Structural Rocket Software
 Estimate the bending loads on supersonic rocket due to pressure loads (Fluid
Structure Interaction)
 Estimate pressure forces using CFD and bending using Finite Element (loosely coupled)
 Tool developed to automatically transfer CFD loads to FEM
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Transfer of
Pressure Field
Pressure Variation
on Surface (CFD)
Finite Element Model
Bending of Rocket at
High Angle of Attack

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Nozzle Cracking in Flight
 Estimation of P-T curve for given propellant
 Nozzle liners for safe operation
 Pressure estimation (CFD) and Transient thermal (FEM)
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Heat flux – nozzle surface
Temp profile after 5 sec

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Fire Control Computer & Trajectory Correction
 Firing angle depending on the target elevation and bearing
 Corrections for tip-off, wind, manufacturing tolerances, Coriolis force, crest clearance etc.
 Trajectory correction spinning rocket implemented to improve accuracy
 Image processing to validate tip-off and rocket velocity at exit
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Aero-structural and Controls of Guided Rocket
 Guidance with range and line correction
 Aerodynamic and structural design of canard for desired Cnδ with Aeroelastic considerations
 Autopilot design for control of rocket in flight
 Design as per available actuators, motors, battery etc.
 CEP achieved below 5 m for an extended range rocket
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Twolooprollautopilot
Mesh

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Rocket Loading Trolley
 Semiautomatic rocket loader in 2×3 configuration
 Clearance 0.5 mm between rocket and pod
 Concept design – Adjustable in height and lateral motion;
 3.5 ton load on trolley; manual insertion of rocket
 FEA, Design drawings, fabrication and testing complete
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Missile Systems
Missile design including aerodynamics, controls, structural and
specialized applications
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High AoA Analysis of Missile
 Projectile has high angle of attack (AoA) manoeuvres at supersonic speeds
 To characterize lateral forces & rolling moment to maintain control
 High fidelity viscous CFD employed
 Tabulated aerodynamic coefficients including component loads
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Eddies captured on leeward side for High AoA
Literature confirms the behaviour

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Panel Separation
 Freestream flow at 6.5 Mach
 Initial 1-DoF: panel rotates about hinge; 6DoF after hinge breaking
 Panel with nose separates slowly; Thin strakes inside panels modeled
 Large stagnation region behind panels
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Mach Number

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System Software for Air-Breathing Engine
 System level software development for supersonic air-breathing engine
 CFD Analysis for intake
 1D atomization and combustion analysis
 Global and Local models for coupled simulations
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Ramjet Circular Intake

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RCS of Projectiles and Training Seeker
 Custom software made for generation of various projectile shapes
 Unstructured mesh generated with mesh density as per the incident frequency
 Parallel software implemented on the lab HPC scaled to 2000 cores
 Training of seeker with thousands of simulations from various incidence angles
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Automatic mesh generation
as per frequency
Surface current

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Missile Guidance and Control for SILS
 Development of plant module for guidance
 Take inspiration from existing code; convert to software elements with bus based technology
and flexibility of reconfiguring; real time (RT) code implemented
 Build PC-in-Loop simulation with modules of Plant, OBC and Target
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Schematicofthecode
C++codedeveloped
RTOScapabilitykeptinmind

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Specialized Software
Custom developed software for special applications
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Initial Design: SPRDesign™
 Preliminary Design of Solid Propellant Rocket
 Quick performance estimation of spinning rocket
 Includes key modules like Aerodynamics (DATCOM), structural (inertial properties),
internal ballistics (P-t for Finocyl grain) & dynamics (for range & velocity profile)
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Custom Software: Missile Configurations
 Design of missiles and rockets using CFD
 Customized software for quick and high fidelity aero analysis of missile configurations
 Automated mesh generation with clustering as per Reynolds number (y+ < 5)
 CNα & CNδ were predicted within 3% of wind tunnel values
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Customized Aero Elasticity Analysis Software for
Slender Spinning Rockets
 Estimation of aero-elastic phenomena of spinning rocket
 Good comparison with Zeta factor and Q divergence
 Limited literature on the topic causes validation issues
 Inter-code comparison with DRDL data
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DRDL

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Thermal Protection Liner
 Simulation of charring ablation of thermal protection liner on rocket nozzle
 Processes like Heat Conduction, Convection due to the pyrolysis gases, resistance to heat
diffusion in inward layer modeled
 Moving boundaries – Ablative and Pyrolysis surfaces modeled with time
 Temperature Vs. Time estimated
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Particle Packing of Solid Propellants
 Calculation of packing fraction for known particle density
 Optimization algorithm for given propellant density, weight or packing fraction
 Optimum properties for meeting one of the above criteria
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Custom Software for Solid Propellant Mixing
 Custom software development for process optimization of solid propellant mixing
 CFD simulation of planetary kneading type mixer
 Optimize mixing time and speed at each stage; achieve homogeneity
 Estimates Mixing time, Dimensionless mixing time, Volumetric strain rate, Dispersive mixing
index, Power number, Circulation number, Dimensionless Circulation number
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Shapenotshownpurposefully

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Team and Closure
Details of the team and consultants and summary of
presentation
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Core Team
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 Prof Gopal Shevare (Chairman) – PhD IIT Bombay with 40+ years research exp
 Expert in MDO, fluid dynamics, numerical methods and simulation product development
 Basant Kumar Gupta (CEO) – Masters IIT Bombay with 16 years experience
 Expert in preliminary design, project management,
 Irshad Khan (COO) – Bachelor Mechanical with 22 years experience
 Expert in mesh generation, drawings, product development and vendor management
 Sumit Jana (Head – Solver Devp) – Masters IIT Kharagpur with 12 years exp
 Expert in parallel solver development for CFD, Electromagnetics and free surface flows
 Suman Mohandas (Head – Software Devp & Visualization) – Bachelors Computer
 Expert in new software development, visualization, parallelization and GUI
 Ten engineers certified by CEMILAC including above

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Consultants and Collaborations
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 MOUs and Collaborations
 Centre for development of advanced computing – HPC usage in Teraflops
 NIT Nagpur – Joint R&D projects in coupled problems (CFD+FEM)
 IIITDM – Joint projects of analysis adding to product development
 Expert Panel (partial)
 Mr. SG Joshi – 40+ years experience in pump design and manufacturing
 Prof S C Lakkad – 45+ years experience in composite design and manufacturing process
 Prof K Sinhamahapatra – 20+ years experience in acoustic prediction
 Mr S Panse and H Ketkar – 35+ year exp in tool room, jigs/fixture design, special projects
 Mr V Kamat – 40+ years experience in hydraulic machine design, fabrication & maintenance
 Mr A Patki – 40+ years experience in space systems for reliability and weight reduction

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Closure
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 Experience of 400+ high tech projects in both strategic and industrial sectors
 Engineers trained in Aerospace grade quality and confidentiality
 Robust engineering software development experience
 Modular code development with high reusability
 Experience of parallelization and cloud computing
 Domain expertise in aforementioned sectors
 Contribution by the engineering team enhanced to design suggestions
 Flexible engagement model
 Fixed cost, Time and Material, Cost plus or models as per problem statement
 Unafraid to take R&D projects – Test Us

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www.zeusnumerix.com
+91 98190 09836
Abhishek Jain
abhishek@zeusnumerix.com
Thank You !

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