Rocket 6: Level 3 Certification

(project in progress/page under construction)

PROJECT SUMMARY

As a personal project following everything I've learned leading the Tufts Rocketry Team, I am building a high-powered rocket for my NAR L3 certification. I hope this project will allow me to test and implement the extensive knowledge and experience I've gained designing, building, and flying large-scale team project rockets during my four years at Tufts. This is no "kit rocket" or simple build; this is a 4" minimum diameter fiberglass vehicle capable of pushing Mach 2+ and punching well above 30,000 feet.

My key goals are flexibility, adaptability, and performance. As such, I plan to make the rocket reconfigurable with a detachable fin can; the high-drag fin can will let me keep altitude lower and fly at more launch sites, but without sacrificing the opportunity to push the limits if a higher ceiling becomes available. I designed the rocket in Onshape and simulated it in OpenRocket, and it will fly sometime in the near future.
LENGTH (IN)
MAX SPEED ON CERT FLIGHT (MPH)
MAX CAPABLE SPEED (MPH)
MAX ALTITUDE ON CERT FLIGHT (FT)

DESIGN, SIMULATION, AND ANALYSIS

Because I want to use this project as a test of the skills I have learned, I am focusing on the following areas within the overall rocket design.
  • Fin flutter & composites design
  • Structural analysis
  • Flow analysis--high vs low drag configurations
  • Flow analysis--transonic and supersonic flight
  • Recovery dispersion calculations
  • Power budget calculations
  • Transmission & link budget calculations
Picture
Flight profile simulation graph

RISK MANAGEMENT

This will be my first large-scale minimum-diameter rocket. In combination with the aggressive flight profile, this increases risk  dramatically. I aim to balance the higher risk required for aggressive performance with the more conservative risk posture typically adopted for certification flights. Mitigation plans start at the design level (with fin flutter calculations, structural analysis, flow simulations, passive safety elements, and full redundancy). At the construction phase, they comprise strict process control (surface preparation, epoxy mixing, cure times and conditions) and use of proven techniques. Finally, various operational steps will minimize launch-day risks and increase the likelihood of a successful recovery.

CONSTRUCTION

Once I finalize the design, I will employ several construction techniques to build the vehicle.
  • Metalworking: I plan to CNC and manually mill certain key structural components, avoiding outsourcing unless otherwise impossible.
  • Wet Layups & vacuum-bagging: The processes I helped develop when on the Tufts Rocketry Team will help be build strong, robust fins that can survive flight at Mach 2+.
  • Pre-preg/molding: Camera aeroshells and other light components are well-suited to this method, 
  • Forged carbon/chopped tow is my current method of choice for the bulkheads and other structural fiberglass or carbon fiber components. I may use waterjet-cut stock instead, depending on available resources.
  • Additive manufacturing provides flexibility for mounting electronics, cameras, and other smaller internal components
  • Soldering & wire harnessing: for connecting the flight computers, deployment charges, cameras, batteries, antenna(s), and other electronics 

INTEGRATION AND TESTING

Once built, I will need to fully test the rocket. This will include ground deployment tests and possible a low-altitude flight test.
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CERTIFICATION FLIGHT!

<description coming soon>

CHALLENGES & LESSONS LEARNED

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