UC Irvine

Stress analysis of Solid Rocket Motors (SRMs) using the finite element method provides insightful data that can be used to develop a structural diagnosis methodology. Finite element models with and without flaws were designed and subjected to thermal loads to simulate post-production storage cooling of SRMs. The models are designed with dimensions and material properties provided by researchers from the Air Force Research Laboratory (AFRL) at Edwards Air Force Base, CA. It was concluded that during the simulated cooling process, flaws create unique stress signatures dependent on flaw type, size, and location. These trends were then validated and contextualized using fracture and damage mechanic concepts. Existing methodologies for health diagnosis of SRMs are discussed and their limitations addressed. Specifically, limitations of a two-dimensional sensor-based methodology developed by AFRL and UC Irvine collaborators are critiqued for improvement. It is then proposed that a three-dimensional finite element analysis of SRMs with flaws produces more viable data for an improved health diagnosis method. In the future, results from the three-dimensional finite element analysis will serve as the basis for a new methodology supported by multi-sensor arrays and machine learning algorithms for a holistic health prognosis and diagnosis of SRMs.