DESIGN ANALYSIS AND

OPTIMIZATION OF THRUST
MEASUREMENT SYSTEM FOR
TESTING SEMI-CRYOGENIC
ROCKET ENGINE
 UNDER THE GUIDANCE OF
Mr. G. MICHAEL JOSE, M.E.,
ASSISTANT PROFESSOR
Dept. of Mechanical Engineering,
UDAYA SCHOOL OF ENGINEERING, Vellamodi

PRESENTED BY,
CHELVAPRABAHARAN S
M.E- CAD/CAM ENGINEERING
Reg.No. 962618402004
Dept. of Mechanical Engineering,
UDAYA SCHOOL OF ENGINEERING, Vellamodi
 ABSTRACT

 The rocket engines are tested statically to evaluate the

performance of engine based on thrust produced.

 One of the most important parameters of the rocket engine

static testing evaluation is to measure the thrust produced by
the engine.

 The thrust produced is measure using a Thrust Measurement

System (TMS) which is a structural element equipped with
load cells.
 The upward movement due to the thrust developed by the
rocket engine is felt through the load cells and its linkages.

 This project is aimed at designing and analyzing the TMS.

The various configurations of the TMS for a heavy thrust
semi cryogenic engine are planned.

 TMS consists of structural elements and load cell link

assembly so as to measure and transfer the thrust to the test
stand structure.

 This project is aim at structural design using Creo and

analysis of a structural configuration using ANSYS v14.5
INTRODUCTION
 The thrust developed by the engine has to be measured durin
g static testing to qualify the engine for flight condition.
In order to measure the thrust, Thrust Measurement System (
TMS) is configured.

 The configuration is designed and is made to undergo static

analysis to calculate about its stability in the working enviro
nment.

 The ANSYS analysis is used to compare the theoretical esti

mation and the equivalent stress induced and the total defor
mation based on the applied load.
 OBJECTIVE

 The main objective is to identify the maximum deflection

and induced stress in the load transfer members of TMS,
When the engine thrust acts in the upward direction.
 The major parts of TMS are thrust frame, load cell,etc.
 NEED FOR THE ANALYSIS

 The different parts of the TMS are found to undergo differe

nt kinds of effect during the time of analysis.
 Different kinds of analysis that can be carried out includes
Buckling analysis to demonstrate stability under gimbal
condition, vibration analysis to obtain the systems natural
frequencies, an elastic stress analysis to evaluate resistance
to plastic collapse including localized stress concentration,
and detailed analysis of bolted fasteners in order to evaluate
the behavior of the connections.
 DESIGN METHODOLOGY
Thrust Measurement System (TMS)
Multiple load cells in tension type thrust measurement syste
m are configured for measuring vertical thrust developed by the engine.
Tension type load cells are employed in TMS for accurate measurement
of the thrust. TMS consists of
1. Thrust frame
 Top flange
 Bottom flange
 Interconnecting pipes
2. Load cell linkages
Design of top flange
 The top flange is connected with the bottom flange by using the inter
connecting pipes.
 The top flange is double to size of the bottom flange. The load cells a
re connected with the top flange. The circular dimension of the top
flange is taken double than the bottom flange.
 The moment of inertia is calculated as 64 × 10 and the section modul
us is 106 ×10. In this case the maximum stress value is 7% of the all
owable stress of the same material. Higher range of deflection is exp
erienced in the top flange when compared with the bottom flange.
Design of interconnecting pipes
 Interconnecting pipes are found to be the linkage between the bottom
and top flange. It acts as the major component to transfer the thrust
exerted by the engine to the load cell fitted in the top flange. Hence i
t must high higher load carrying capacity.
 According to this system 12 numbers of interconnecting pipes are us
ed to connect the two flanges.
 Hollow circular pipes of similar material is selected which has highe
r thrust transferring capacity. The axial load through each pipe is tak
en as 330 kN and the moment of inertia for the system is obtained as
12.37 × 10.
Design of bottom flange
 The bottom flange calculate the stress and strain simple. To per-form
the calculations, the beam is split into two equal length beams in sim
ple deflection.
 Using one of the beams, the stress on the beam and the maximum de
flection are determined.
 The rocket design thrust was 50 lbf maximum, but the transducer sys
tem was initially designed for a 30 lbf maximum due to the less than
optimal nozzle design that could cause a decrease in thrust output.
Design of load cell

 A load cell is an important component in measuring thrust generated

by rocket in rocket technology research and development. It aims to t
est the rocket thrust in achieving the targeted objectives of the projec
t.
 A load cell is a transducer that is used to convert a force into electrica
l signal and it usually consists of four strain gauges assembled in Whe
atstone bridge configuration.
 The strain gauge converts the deformation (strain) to electrical signals
. This conversion occurs in two stages. First, the strain gauges on the l
oad cell will detect the deformation of load cell structure (tension or c
ompression) and
 second, the strain gauge will convert the changes in the load cell in te
rms of voltage readings.
Assembled view of TMS
 CONCLUSION
 The thrust measurement system is designed by using the assumed
values. Verification of the assumed values for the stability under
specific load will be done by using the theoretical calculations.
 Suitable drawings will also be made for the thrust frame and load
cell adapter using the Creo software.
 The assembled load cell linkage and thrust frame will be analyzed by
using the ANSYS v14.5 software and the distribution of stress across
the thrust frame and load cell linkage.
 The deformation that occurs due to the application of load in the diff
erent part of the thrust frame and the load cell linkage will be studied
in Phase -II.
THANK YOU