Short answer

Consider alternative mandrel materials and dissolution methods to overcome extraction challenges and unlock new design possibilities in composite material manufacturing.

Field: Commercial Production
Source: Journal of Aerospace Technology and Management (2015)
Method: Experimental and materials science research.
Evidence: Strong effect

Utilizing chemically collapsible mandrels in solid rocket motor processing significantly simplifies extraction, enabling more complex internal grain geometries and improving operational safety. This commercial production research insight is drawn from a 2015 study published in Journal of Aerospace Technology and Management. Using Experimental and materials science research., researchers explored how this design variable affects real-world outcomes. The key design takeaway: Consider alternative mandrel materials and dissolution methods to overcome extraction challenges and unlock new design possibilities in composite material manufacturing.

Study

Commercial ProductionHigh ImpactStrong effect

Chemically Collapsible Mandrels Enhance Solid Rocket Motor Grain Geometry and Safety

Utilizing chemically collapsible mandrels in solid rocket motor processing significantly simplifies extraction, enabling more complex internal grain geometries and improving operational safety.

Journal of Aerospace Technology and Management · 2015

Key Findings

01Chemically collapsible mandrels simplify the extraction process, reducing associated hazards.
02The use of collapsible mandrels allows for the creation of more intricate internal grain geometries.
03The mandrel material and dissolution solvent do not negatively affect the physicochemical or ballistic properties of the propellant.
04Collapsible mandrels are potentially cheaper, recyclable, and lighter than metal mandrels.

Application

Design takeaway

Consider alternative mandrel materials and dissolution methods to overcome extraction challenges and unlock new design possibilities in composite material manufacturing.

How to apply

When designing composite parts that require internal tooling, explore materials and methods that allow for easy, safe, and non-destructive removal of the tooling after curing.

Project actions

01When designing a product with internal features, think about how you will remove any molds or supports.
02Research materials that can be easily removed or dissolved without damaging the main product.

Method & Evidence

AimTo investigate the feasibility and benefits of using chemically collapsible mandrels for solid rocket motor propellant casting.

MethodExperimental and materials science research.

ProcedureThe study involved developing and testing a chemically collapsible mandrel for casting solid rocket motor propellants. The process was compared to traditional metal mandrel extraction, and the impact of the mandrel material and dissolution solvent on propellant properties was evaluated.

ContextAerospace manufacturing, specifically solid rocket motor production.

Variables

IVType of mandrel (chemically collapsible vs. metal).

DVEase of extraction, complexity of achievable grain geometry, propellant properties (physicochemical and ballistic).

CVPropellant composition, casting process parameters, curing conditions.

Strengths & Limitations

Strengths

+Addresses a critical safety and manufacturing bottleneck.
+Demonstrates a clear benefit in terms of design complexity and potential performance gains.
+Suggests cost and sustainability advantages.

Limitations

The specific chemicals used might be hazardous or expensive. The process might add extra steps or time compared to very simple designs.

Reliability & validity

The validity of the findings relies on rigorous testing of propellant properties post-extraction. Reliability would be enhanced by repeating the extraction and property tests multiple times to ensure consistency.

Think critically

What are the potential environmental impacts of using specific chemical solvents for mandrel dissolution, and how might these be mitigated in a large-scale production setting?

Design Principles

"Design for Disassembly and Safety: Incorporate features that facilitate safe and efficient post-manufacturing removal of tooling, thereby enhancing product complexity and operational safety."

This innovation addresses critical safety concerns and manufacturing limitations associated with traditional metal mandrels. By reducing the hazards of extraction and facilitating intricate designs, it opens avenues for enhanced rocket motor performance and more efficient production processes.

What This Means for Your Design

Imagine building a cake inside a mold. Usually, you have to carefully pull the mold out, which can break the cake. This new method uses a mold that can be dissolved or shrunk with a special liquid, making it super easy to get the cake out perfectly every time, and you can even make fancier cake shapes.

How to use in your project

1.Use this research to justify choosing a manufacturing method that prioritizes ease of tool removal or uses dissolvable components in your design project.

Add to My Project

Quick Cite

Paragraph starter

The development of chemically collapsible mandrels offers a significant advancement in the manufacturing of complex composite structures, such as solid rocket motors. By enabling safer and simpler extraction of internal tooling, this approach allows for the creation of intricate grain geometries that were previously unachievable or prohibitively difficult with traditional methods. This directly impacts design possibilities by permitting optimization of internal flow paths and combustion characteristics, leading to enhanced product performance and efficiency.

Source

Journal of Aerospace Technology and Management

Chemically Collapsible Mandrel for Solid Rocket Motor Processing

journal · 2015

View source

Questions About This Research

What does the research say about chemically collapsible mandrels enhance solid rocket motor grain geometry and safety?: Consider alternative mandrel materials and dissolution methods to overcome extraction challenges and unlock new design possibilities in composite material manufacturing. Evidence: Journal of Aerospace Technology and Management (2015).
Why does "Chemically Collapsible Mandrels Enhance Solid Rocket Motor Grain Geometry and Safety" matter for design?: This innovation addresses critical safety concerns and manufacturing limitations associated with traditional metal mandrels. By reducing the hazards of extraction and facilitating intricate designs, it opens avenues for enhanced rocket motor performance and more efficient production processes.
How can designers apply this research?: Consider alternative mandrel materials and dissolution methods to overcome extraction challenges and unlock new design possibilities in composite material manufacturing.
What were the main findings?: Chemically collapsible mandrels simplify the extraction process, reducing associated hazards.. The use of collapsible mandrels allows for the creation of more intricate internal grain geometries.. The mandrel material and dissolution solvent do not negatively affect the physicochemical or ballistic properties of the propellant.. Collapsible mandrels are potentially cheaper, recyclable, and lighter than metal mandrels.
What research method was used?: Experimental and materials science research..
How strong is the evidence?: Evidence strength is rated Strong effect, based on a 2015 journal from Journal of Aerospace Technology and Management.
What should I do differently in my next project?: When designing composite parts that require internal tooling, explore materials and methods that allow for easy, safe, and non-destructive removal of the tooling after curing.
What are the limitations?: The long-term effects of repeated use and the scalability of the process for mass production require further investigation. Specific chemical compatibility with all propellant formulations needs to be thoroughly assessed.