2. TABLE OF CONTENTS
2
PROJECT PAGE
1. Project Legacy (Senior Design)
2. Burning Man Pulsejet Design, Build, Test
3. Cold Gas Thruster
4. EXOS Aerospace Payload
5. Rocket Nose Cone Design and Drag Analysis
3-6
7-9
10-11
12-13
14-15
3. PROJECT LEGACY SENIOR DESIGN
3 Project Legacy Pulsejet Thruster Design EXOS Payload Nose Cone
Spring 2016
https://engineering.purdue.edu/AAECourses/aae450/2016/spring
4. PROJECT OVERVIEW
4 Project Legacy Pulsejet Thruster Design EXOS Payload Nose Cone
“In-Situ Resource Utilization” (ISRU) system . Left to right: fuel
depot, re-usable lander vehicle, ISRU rover
Scope:
44 person team designed systems
including landers, orbiting stations,
habitation modules, fuel production and
rovers.
Purpose: Design the lunar base portion
of Dr. Buzz Aldrin’s view of Mars
colonization. The lunar base is to be a
“proving ground” for technology
needed for future missions to Mars.
Role:
Lead designer for the “In-Situ Resource
Utilization” system to produce fuel from
the lunar surface. Includes fuel selection,
system, P&ID and CAD design.
5. IN-SITU RESOURCE UTILIZATION SYSTEM
5 Project Legacy Pulsejet Thruster Design EXOS Payload Nose Cone
ISRU system fuel depot (top) and rover (bottom)
ISRU Rover:
• Uses microwaves to sublimate water
from ice crystals under the surface of
the Moon’s cold region.
• Condenses water into a usable liquid
and carries it to the fuel depot.
Fuel Depot:
• Uses electrolysis of liquid water and
heat exchangers to produce liquid
hydrogen and oxygen propellants.
• Storage tanks hold up to 2 launches
worth of fuel.
6. BURNING MAN PULSEJET
6 Project Legacy Pulsejet Thruster Design EXOS Payload Nose Cone
Spring 2016
7. PROJECT OVERVIEW
7 Project Legacy Pulsejet Thruster Design EXOS Payload Nose Cone
Approach:
Design 2 pulsejets to go a top speed of 15
miles per hour
Purpose: Design and manufacture two
pulsejets and a track system for them to run
on for an attraction at Burning Man event.
Implementation:
8 person team designed, built and tested a
pulsejet and a track support system.
Role:
Machine drawings, material selection for
track assembly, track assembly design, CAD
and FEA analysis, pulsejet test contributor Entire track/wheel system (top) and wheel
assembly system (bottom).
8. FEA ANALYSIS FOR TRACK SYSTEM
8 Project Legacy Pulsejet Thruster Design EXOS Payload Nose Cone
FEA analyses used to determine beam dimensions/material
(top) and structural integrity of wheel assembly (bottom).
Wheel Assembly Analysis:
• Designed to hold the weight of 2
pulsejets as well as the horizontal
beam.
• The structure is welded channel
and plate pieces.
• Required safety factor above 5.
Beam Analysis:
3 load cases simulating scenario
maximums, all required a safety factor
above 5.
i. General case of two 50lb loads
ii. 3g load case
iii. 3500lb centrifugal load case
9. COLD GAS THRUSTER DESIGN
9 Project Legacy Pulsejet Thruster Design EXOS Payload Nose Cone
Fall 2014
10. PROJECT OVERVIEW
10 Project Legacy Pulsejet Thruster Design EXOS Payload Nose Cone
Purpose: Design a chamber,
throat and nozzle of a maximum
characteristic length to produce
a minimum amount of thrust in a
cold gas application.
Approach:
Used nozzle and
chamber equations to
design thruster shape
and size
Role:
CAD designer, sizing
and design analysis
contributor
CATIA sketch showing the calculated thruster profile
11. EXOS AEROSPACE PAYLOAD RACK
11 Project Legacy Pulsejet Thruster Design EXOS Payload Nose Cone
Fall 2014
12. Early CATIA sketch of cubesat
arrangement (top) and design of
sliding payload plate (bottom).
PROJECT OVERVIEW
12 Project Legacy Pulsejet Thruster Design EXOS Payload Nose Cone
Approach:
Design for maximum capacity of cubesats and
include removable shelves.
Purpose: Design a payload rack to house cubesat
experiments in the payload bay of a rocket from
EXOS Aerospace.
Implementation:
Using CATIA, we designed a lightweight and space-
saving rack to be made out of carbon fiber.
Role:
Overall design contributor, CAD model contributor,
manufacture team collaborator
14. PROJECT OVERVIEW
14 Project Legacy Pulsejet Thruster Design EXOS Payload Nose Cone
Nose cone CATIA models. Left to right, top to bottom: “blunt”
cone, “star” cone, “Launch Escape System” cone and
“conventional” cone
Approach:
3D print plastic nose cones and run a
drag analysis using a wind tunnel and
Labview data.
Purpose: Evaluate the differences in
drag for 4 different rocket nose cone
shapes.
Implementation:
Using a force balance, we obtained
drag and lift data for three wind tunnel
frequencies (10, 20, 30 Hz)
Role:
CAD designer, 3D printer, analysis and
report contributor
15. RESULTS AND CONCLUSION
15 Project Legacy Pulsejet Thruster Design EXOS Payload Nose Cone
After the analysis, we
concluded that the “Launch
Escape System” cone shape
caused the most drag, while
the “blunt” cone caused the
least. We discovered a direct
correlation between the cone
surface area and the drag.
The “LES” cone shape also
caused poor airflow,
contributing it to its high drag.
