(UBC Rocket) Liquid Rocket Propulsion: Thrust Structure Design
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ThrustStruc_SolidWorks.movThis project focuses on the design of a lightweight thrust structure for UBC Rocket’s 5 kN nitrous oxide / ethanol liquid rocket engine.
The structure serves as the primary load path between the engine injector plate and the airframe, ensuring that all thrust and engine torque are reacted structurally while keeping internal plumbing and feed lines load-isolated.
The design prioritizes:
Clear, intentional load paths
Minimal structural mass
Manufacturability using conventional machining
Robust performance under combined axial and torsional loading
Structural Design & Load Path
The thrust structure was topology-optimized and refined to transfer:
5 kN axial thrust
20 N·m engine-induced torsional loads
directly into the airframe, preventing any thrust or bending loads from being carried by internal plumbing or fittings.
Key outcomes:
Final mass: 383.6 g
Minimum factor of safety: 2.5
Plumbing remains pressure-loaded only, eliminating fatigue and misalignment risks.
Finite Element Analysis
Static multi-load-case FEA was performed in SOLIDWORKS to validate the structure under worst-case loading.
FOS Plot:
Factor of Safety plot confirms a minimum FOS of 2.5, with high-stress regions intentionally localized in low-risk areas.
Von Mises Stress Plot:
Von Mises stress plot shows peak stresses well below aluminum-6061’s yield strength, with smooth stress gradients and no sharp concentrations.
Geometry was iterated to remove non-load-bearing material while preserving stiffness along primary load paths.
Manufacturing
The thrust structure is designed for 3-axis CNC machining from 6-inch OD aluminum-6061 tube stock with ¼-inch wall thickness.
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