Lakeroadster's Lifting Rocket

Discussion in 'Scratch Built' started by lakeroadster, Dec 27, 2018.

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  1. Jan 14, 2019 #121

    lakeroadster

    lakeroadster

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    I revised the fin design a bit where the cargo strut rods attach to the fins. Basically added an internal piece (that's not wood) that is sandwiched between the plies of balsa. This should spread the forces out and prevent any shearing / tearing through of the balsa.

    I may use plastic for the insert since the code says using metal fins is verbotten... kind of a gray area, since it is a metal piece, but it isn't the fin itself.

    All the bolts and bolting plates add to the "Steam Punk Look". I'm thinking Spar Urethane for the fins, and then faux rusty-crusty paint for the rest of the rocket.... except for the sacred Mercury capsule... which needs to look historically correct.
    Lifting Rocket Dwg Rev 7 Sheet 14 of 19.jpg
     
  2. Jan 14, 2019 #122

    Nytrunner

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    In my unsolicited viewpoint, painting the capsule traditionally would make it look really out of place on this rocket.

    Maybe weathered a bit, as if it was somehow recovered and repurposed?
     
  3. Jan 14, 2019 #123

    lakeroadster

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    And that's the plan.. Are you familiar with Steam Punk? Kind of repurposing of old antique stuff.

    Steam Punk Rocket Launcher.jpg

    steampunk3.jpg
     
    Last edited: Jan 14, 2019
  4. Jan 14, 2019 #124

    Nytrunner

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    I am. I may have misinterpreted your previous post and was imagining a shiny black and red capsule conspicuously atop an otherwise hodgepodge vehicle.

    Oh hey, where on earth have I seen that rocket car before....
     
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  5. Jan 14, 2019 #125

    lakeroadster

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    Historically.. meaning like it's been to orbit and back to earth previously. Maybe "toasted" is a more accurate description. ;)

    Mercury After Reentry.jpg
     
  6. Jan 14, 2019 #126

    Nytrunner

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    Ah! We were thinking along the same lines the whole time, just different directions lol
     
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  7. Jan 15, 2019 #127

    lakeroadster

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    Made a couple changes to the design today.

    A) Changed the center ply of the fins to a "Through The Wall" design,
    B) Extended the outer plies of the fins to fully capture the tie rods,
    C) Added an exterior 0.04" thick BT stiffener to the body tube at very back of body to help keep it round,
    C) Updated the standard center motor mounts to allow for E9 and E12 motors, along with D12,
    D) Added templates for the BT-60 to BT-80 conical transitions.

    Also tried to update the Open Rocket file by making the Cargo Bay a 2nd stage. For some reason it's throwing up error messages of "An error occurred during the simulation Simulation Value Exceeds Limits. Try Selecting a shorter time step." I changed the time step from 5 seconds to one second, then the error message is the same but also states "Discontinuity in rocket body diameter. Large angle of attack encountered". Weird... :confused:


    Lifting Rocket Dwg Rev 8 Sheet 15 of 23.jpg
    Lifting Rocket Dwg Rev 8 Sheet 3 of 23.jpg
     
    Last edited: Jan 16, 2019
  8. Jan 17, 2019 #128

    Jonathan 7

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    LR, question... where did you get the Inventor Parts for this? Did you sketch them from scratch?
     
  9. Jan 17, 2019 #129

    lakeroadster

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    Yes, every component of the rocket was created as an individual part, then assembled. The only parts I used that I didn't create myself are the fasteners.

    Scratch Build
     
    Last edited: Jan 17, 2019
  10. Jan 17, 2019 #130

    Jonathan 7

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    Very impressive! And materials too?
     
  11. Jan 17, 2019 #131

    lakeroadster

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    Most of the materials I buy from Balsa Machining Service (BMS). Good folks. Their website outlines the raw materials they stock, it's simply a matter of designing the rocket components based on available materials.

    To build a good widget... ya gotta have a good widget raw materials supplier... https://www.balsamachining.com/

    I ordered all the parts for The Lifting Rocket from BMS last Friday. They all arrived yesterday, Tuesday.

    Bill and Mary at BMS are awesome.
     
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  12. Jan 17, 2019 #132

    Jonathan 7

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    Lol, materials in Autodesk :)
     
  13. Jan 17, 2019 #133

    lakeroadster

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    Lol?? I must admit that I truly hate the use of that acronym except in response to comedy... it's way overused and lacks civility.

    I use property values for "Phenolic" for wood, cardboard body tubes, etc. It really doesn't matter unless your doing FEA or cg calc's.
     
  14. Jan 17, 2019 #134

    Crawf56

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    "Space: 1899" ;)

    Great stuff in this build. :cool:
     
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  15. Jan 17, 2019 #135

    BABAR

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    Very clever!
     
  16. Jan 17, 2019 #136

    lakeroadster

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    The Lifting Rocket in kit form.... some assembly required :D 001.JPG 000.JPG 002.JPG
     
  17. Jan 17, 2019 #137

    Jonathan 7

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    I would like to give it a try, yes.
     
  18. Jan 17, 2019 #138

    lakeroadster

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    Give what a try?
     
  19. Jan 17, 2019 #139

    Jonathan 7

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    Doing that in Inventor and CFD
     
  20. Jan 19, 2019 #140

    lakeroadster

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    Cut and stack sanded the balsa fin ply's for The Lifting Rocket.

    Since it's a 3 layer construction I wanted the grain of the wood different to add strength.

    Once I make the insert I'll lay it on the center ply, trace around it, and then cut out that section.... at least that's the plan. Any suggestions for an alternate to aluminum? Some sort of plastic would probably work just as well.

    001.JPG 002.JPG
    Lifting Rocket Dwg Rev 8 Sheet 15 of 23.jpg
     
  21. Jan 20, 2019 #141

    lakeroadster

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    Cut the Canted Motor Tubes and the Body Tube in the Canted Section. Pretty pleased with the results thus far.

    Trying to hold the cluster for gluing wasn't realistic so I made a fixture to hold the pieces in place.

    000.JPG 001.JPG 001A.JPG 002.JPG 003.JPG 004.JPG Lifting Rocket Dwg Rev 9 Sheet 24 of 24.jpg
     

    Attached Files:

    Last edited: Jan 22, 2019
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  22. Jan 21, 2019 #142

    Jonathan 7

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    Thank you so much for this thread. I’ve learned an incredible amount about design and construction from almost every post.
     
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  23. Jan 22, 2019 #143

    lakeroadster

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    Revised the cluster design to have a BT-50 stiffening tube up the center below the cluster, and a heavy wall short tube at the top, centering rings on both ends. This helps transfer the thrust load into the couplers, instead of the thin wall BT-60 body tube.

    Just needs to add a bit more Quick and Thick Titebond and do some internal glue fillets.

    Lifting Rocket Dwg Rev 10 Sheet 9 of 25.jpg 002.JPG
    _____________________________________________________
    The tube on the end shown below is from a "Reynolds Wrap Heavy Duty Foil" tube. I'll coat the inside with CA once I'm done attaching it to the BT and Centering Ring with wood glue.
    003.JPG 004.JPG 005.JPG 006.JPG
     
    Last edited: Jan 22, 2019
  24. Jan 23, 2019 #144

    neil_w

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    Looks great so far!
     
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  25. Jan 24, 2019 #145

    BABAR

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    I love the “note to self: put wax paper on so I don’t glue the temporary alignment piece to the model”!
     
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  26. Jan 25, 2019 #146

    lakeroadster

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    More progress on the canted cluster sub-assy. fabrication.

    I revised the design again to make the bottom coupler longer and scallop it to fit around the cluster. This will allow the BT-60 split body tube to have be glued to the coupler.

    I've been building up the glue joints over the past few days. Today I cut the centering rings out of 1/8" balsa, glued them on, internally glued all the seams on the cluster and then glued / installed the couplers.

    The wooden dowels are merely fixturing to help to ensure the upper coupler is aligned with the bottom coupler.

    Lifting Rocket Dwg Rev 12 Sheet 9 of 27.jpg 002.JPG 003.JPG 004.JPG 005.JPG 006.JPG 007.JPG 008.JPG
     
  27. Jan 25, 2019 #147

    kuririn

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    That seems quite robust. Looks like the difficult part is over.
     
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  28. Jan 27, 2019 #148

    lakeroadster

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    How about some FEA? I plugged in the loading of (4) D12's to see what the stresses and deformation looks like.

    Canted Cluster FEA Model.JPG Canted Cluster FEA Stress.JPG Canted Cluster FEA Deformation Actual.JPG

    And here is the lawn dart look.. :confused:

    Canted Cluster FEA Deformation 2 to 1.JPG

    And a lawn dart video.. ;)

     
    Last edited: Jan 27, 2019
  29. Jan 27, 2019 #149

    lakeroadster

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    Installed the BT-60 over the canted cluster. In order to install it I had to cut it near the bottom of the scallops. Now.... more glue fillets.

    001.JPG 002.JPG 003.JPG
     
  30. Jan 27, 2019 #150

    neil_w

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    Very nice indeed. To echo what kuririn said... that looks really robust.
     

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