Internal Cooling Channels
Detailed view of regenerative cooling manifold design
Cornell's First Regeneratively Cooled Bipropellant Engine
Designed Cornell's first 1,250 lbf ethanol/N2O regeneratively cooled bipropellant rocket engine, introducing the team to cutting edge propulsion technologies and metal additive manufacturing techniques.
Project Overview:
This project involved the design, analysis, and manufacturing of a additive manufactured regeneratively cooled bipropellant rocket engine. The engine utilizes ethanol as fuel and nitrous oxide (N2O) as oxidizer, with regenerative cooling to manage the incredibly high heat flux during operation.
Design
Complete Engine Assembly
Full 3D assembly showing combustion chamber, injector, and cooling manifold integration
Injector Manifold
Isometric view of the ethanol injector manifold with cooling channel integration
Chamber Top View
Chamber top view showing injector interface and ethanol fuel port.
Nozzle View Details
Nozzle view showing cooling manifold.
CFD Analysis, Thermal Management & Structural Analysis
Performed comprehensive computational fluid dynamics analysis using ANSYS Fluent to validate the regenerative cooling system design and ensure thermal limits are maintained throughout the engine operation. Combined with structural analysis to optimize design under both thermal and mechanical loading conditions.
FLUENT CFD Coolant Flow Analysis
CFD streamlines showing ethanol coolant flow through regenerative cooling channels
Thermal Analysis
Steady-state temperature distribution showing temperature gradients across the chamber and nozzle
Structural Analysis
ANSYS structural analysis showing stress distribution under 2x MEOP ultimate loading conditions
Yield Analysis
High stress locations identified for optimization
CFD Analysis Results:
- Validated numerical calculations of ethanol flow through regenerative cooling manifold
- Analyzed pressure drop across cooling system
Structural Analysis Results:
- Created combined thermal and structural ANSYS model to analyze thermal and mechanical stresses
- Validated bolted joint hand calculations using detailed ANSYS bolted joint analysis
- Analyzed combustion chamber design under thermal and mechanical loading
- Optimized geometry to reduce stress concentrations, smooth cooling channel layout, and minimize wall thickness
Material Selection:
Completed comprehensive material trade study considering thermal conductivity, manufacturability, and structural properties. Selected AlSi10Mg aluminum alloy for optimal balance of thermal conductivity and additive manufacturing compatibility.
Manufacturing & Production
Manufacturing Drawings:
Created detailed technical drawings for metal 3D printing and post-processing operations, ensuring design manufacturability and quality control.
Production Coordination:
Coordinated with manufacturing sponsor to optimize design for additive manufacturing processes and machining operations.
Technical Drawings & Documentation
Post-Processing Instructions
Manufacturing Process:
The design was optimized for metal 3D printing using AlSi10Mg aluminum alloy by XMAKE, with detailed post-processing drawings for machining operations to ensure dimensional accuracy and surface finish.
Technical Report
Complete Technical Documentation - 1250 lbf Regeneratively Cooled Bipropellant Rocket Engine
Key Achievements & Skills
Key Achievements:
- Designed Cornell's first 1,250 lbf ethanol/N2O regeneratively cooled bipropellant rocket engine
- Performed Fluent CFD on ethanol flow through regenerative cooling manifold to validate thermal limits
- Created combined thermal and structural ANSYS model to analyze and iterate combustion chamber design
- Completed material trade study, selecting AlSi10Mg for additive manufacturability and thermal conductivity
- Coordinated manufacturing with sponsor, created detailed drawings for metal 3D printing and machining of chamber
Skills: ANSYS Fluent CFD, ANSYS Structural Analysis, SolidWorks CAD, Additive Manufacturing Design, Material Selection, Manufacturing Coordination, Technical Documentation