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Booster and Sustainer Case Dimensions

Design pressure: 1500 psi

Sustainer:

Aluminum Case: OD: 4", ID": 3.625" (thickness 3/16")

Phenolic Liner: OD: 3.625", ID: 3.375" (thickness 1/8")

Booster:

Aluminum Case: OD: 6", ID: 5.5" (thickness 1/4")

Phenolic Liner: OD 5.5", ID: 5.25" (thickness 1/8")

Casting tube: OD: 5.25", ID: 5.125" (tickness 1/16")

Medusa Booster

Constraints:

  • manufacturing capability
    • lathes can machine up to 6" diameter
  • available liners' specs (lengths)
    • 48", 53.1", 59.1", 65"
  • need for a casting tube within liner
    • unless multicast in one liner is feasible
  • available tube size

Design Specs:

  • 6' ish OD
  • Internal pressure expected to be around 1500-2000 psi max
  • Safety factor 2
  • min. thickness: 0.350"

Motor Case:

  • order from Speedy Metals? (lengths: 1', 2', 3', 4', 6', 8')
  • 1/2" thick
  • ID: 5.25', OD: 6'

Phenolic Tubes:

  • order from Franklin Fibres (lengths: 48", 53.1", 59.1", 65")
  • 1/8" thick for liner
    • ID: 5.25', OD: 5.5'
  • 1/16" thick for casting tube
    • ID: 5.125', OD: 5.25'
  • long lead times, order in bulk this semester

 

Medusa Sustainer

Constraints:

  • available liners' specs (lengths)
    • 48", 53.1", 59.1", 65"

Design Specs:

  • 4' ish OD
  • Internal pressure expected to be around 1500-2000 psi max
  • Safety factor 2
  • min. thickness: 0.241" - closest thickness is 0.25"

Motor Case:

  • order from McMaster or Online Metals
  • 1/2" thick
  • ID: 3.5', OD: 4'

Phenolic Tubes:

  • order from Franklin Fibres (lengths: 48", 53.1", 59.1", 65")
  • long lead times, order in bulk this semester
  • 1/8" thick for liner
  • 1/16" thick for casting tube
  • ID: 3.25', OD: 3.5'

 

Case Spec Calculations

Case calcs done using 2000 psi as internal pressure

Thin vs Thick Case Assumption: thin case assumption can be used if   \frac{Diameter}{thickness} < 20

Booster

Booster thin case assumption if t < 0.3"

Calculated with thin case assumption -> safety factor = 2, case thickness = 0.371"

Move onto thick case assumption -> safety factor = 2, case thickness = 0.350"

 

Sustainer

Sustainer thin case assumption if t < 0.2"

Calculated with thin case assumption -> safety factor = 2, case thickness = 0.229"

Calculated with thick case assumption -> safety factor = 2, case thickness = 0.241"

MATLAB file for case calculations: case calcs.m

Python file for case calculations: case_calcs.py

 

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