Mechanical design and fabrication of stage separation mechanism for a sounding rocket

Basically a two stage rocket consists of an upper stage which carries the payload/warhead and a lower stage which is known as booster stage. At launch, the booster stage fires and carries the upper stage to a certain distance where after consuming fuel it gets separated from the upper stage via stag

Project Title

Mechanical design and fabrication of stage separation mechanism for a sounding rocket

Project Area of Specialization

Mechanical Engineering

Project Summary

Basically a two stage rocket consists of an upper stage which carries the payload/warhead and a lower stage which is known as booster stage. At launch, the booster stage fires and carries the upper stage to a certain distance where after consuming fuel it gets separated from the upper stage via stage separating mechanism. In this project we will be working on design of a stage separating mechanism for a two stage sounding rocket, provided with the facilities at DMAE and testing labs around in our approach.

Project Objectives

• Basic understanding and concept development regarding the working of stage separating mechanism in multistage rockets.
• Design and analysis of mechanical stage separating mechanism for a two stage sounding rocket.
• Fabrication and testing of the mechanism.

Project Implementation Method

1. Perform all the literature review regarding different mechanical stage separating mechanisms.
2. Selecting the most feasible mechanism according to the design of sounding rocket for which the mechanism is to be made.
3. Selecting the suitable trajectory for a two stage rocket and evaluating atmospheric parameters at the point of separation.
4. Making 2D and 3D drawings of selected mechanism in modelling software using appropriate dimensions.
5. Performing analytical calculations using evaluated atmospheric parameters to meet necessary and sufficient conditions for separation.
6. Doing market survey for required equipment.
7. Procurement of required equipment.
8. Assembly.
9. Testing the mechanism.

Benefits of the Project

This project represents many advantages. It is cost effective in such a way that it reduces fuel cost of the rocket because in multistage rockets small rocket motors are used which require less fuel. Another advantage is that with the help of stage separation mehanism dead weight of rocket can be reduced, therefore it can travel with greater velocity and can travel farther. Also this phenomenon of stage separation is being implemented for the first time in sounding rockets.

Technical Details of Final Deliverable

Labelled cross-sectional view of the mechansim is shown in picture above. When explosive will go off it will move the piston bush assembly towards left side, steel balls which are resting on the piston will fall in the hollow cavity. These steel balls are basically locking the internal and external cylinder of the mechanism. When these steel balls fall into the hollow cavity the separating force provided by separating spring will cause the internal and external cylinder to slide over each other, therefore separating the rocket stages.

Final Deliverable of the Project

Hardware System

Core Industry

Others

Other Industries

Core Technology

Others

Other Technologies

Sustainable Development Goals

Good Health and Well-Being for People, Climate Action

Required Resources

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