RE-1 (Rocket Engine - 1) Conceptual Design of a Mini Liquid-Fuel Rocket Engine

5.2022

RE-1 presents the conceptual design of a small-scale liquid-fuel rocket engine using principles of thermodynamics and propulsion. Literature from Rocket Lab and Thermodynamics: An Engineering Approach (Çengel, Boles, Kanoglu) informs design methodology and analytical calculations. The project develops a cost-effective engine with validated performance predictions, demonstrating feasibility through CFD simulations and thermodynamic analysis, despite fabrication constraints.

Thermodynamic Analysis: Energy balance equations for reacting systems are employed to calculate chamber pressure, combustion temperature, and specific impulse. Isentropic flow relations are applied to design the nozzle and throat, ensuring optimal expansion and efficient propellant utilization.

Propellant and Combustion Assessment: Oxidizer-to-fuel ratios are selected based on enthalpy of reaction data and established combustion stability criteria. Characteristic velocity (c*) and expected performance metrics are calculated and validated against published benchmarks.

Mechanical and Thermal Design: Chamber geometry is iteratively refined using CAD software, taking into account thermal stresses, material limits, and injector atomization patterns. Cooling methods, including regenerative and ablative approaches, are evaluated to maintain structural integrity under high-temperature conditions.

Simulation and Validation: Computational simulations are conducted to estimate flow patterns, pressure distribution, and thermal loads. These simulations serve to validate theoretical calculations and confirm design feasibility.

Fabrication was limited to a 3D-printed PLA prototype; however, analytical calculations and CFD simulations indicate that, with appropriate high-temperature metals and cooling methods, the engine design meets expected performance parameters. RE-1 demonstrates that careful application of thermodynamic principles, propulsion analysis, and simulation can produce a feasible small-scale rocket engine, providing a foundation for further experimental development.