Missile Design and System Engineering Eugene L Fleeman Lilburn, Georgia AIM EDUCATION SERIES Joseph A. Schetz, Editor-in-Chief Virginia Polytechnic Institute and State University Blacksburg, Virginia Published by the American Institute of Aeronautics and Astronautics, Inc. 1801 Alexander Bell Drive, Reston, Virginia 20191-4344
CONTENTS Foreword Preface xv xvii Chapter 1 Introduction/Key Drivers in the Missile Design and System Engineering Process 1 1.1 Introduction 1 1.2 Missile Characteristics Comparison 2 1.3 Conceptual Design and System Engineering Process 8 1.4 System-of-Systems Considerations 13 1.5 Examples of State-of-the-Art Missiles 16 1.6 Aerodynamic Configuration Sizing and System Engineering Parameters 19 1.7 Example of Alternatives in Establishing Mission Requirements 21 1.8 Use of a Baseline Missile 26 1.9 Summary 1.10 Problem Review 32 31 Chapter 2 Aerodynamic Considerations in the Missile Design and System Engineering Process 33 2.1 Introduction 33 2.2 Missile Diameter Tradeoff 34 2.3 Nose Fineness and Geometry Tradeoffs 43 2.4 Body Drag Prediction 45 2.5 Boattail 49 2.6 Body Normal Force Prediction 51 2.7 Lifting Body Versus Axisymmetric Body 52 2.8 Forces, Moments, and Axes Sign Convention 55 2.9 Static Stability 56 2.10 Body Aerodynamic Center Prediction 58 2.11 Flare Stabilizer 59 2.12 Wings Versus No Wings 61 ix
x Missile Design and System Engineering 2.13 Planar Aerodynamic Surface Geometry 2.14 Normal Force Prediction for Surfaces (e.g., Wing, Tail, Parameters 64 Canard) 65 2.15 Aerodynamic Center Prediction for Planar Surfaces (e.g., Wing, Tail, Canard) 70 2.16 Hinge Moment Prediction 71 2.17 Planar Surface (e.g., Wing, Tail, Canard) Drag Prediction 73 2.18 Surface Planform Geometry and Integration Alternatives 77 2.19 Flight Control Alternatives 82 2.20 Maneuver Law Alternatives 102 2.21 Roll Angle and Control Surface Sign Convention 108 2.22 Flight Roll Orientation 109 2.23 Trim and Static Stability Margin 110 2.24 Tail Area Sizing 113 2.25 Stability and Control Conceptual Design Criteria 116 2.26 Aerodynamic Configuration Buildup 117 2.27 Summary 119 2.28 Problem Review 119 Chapter 3 Propulsion Considerations in the Missile Design and System Engineering Process 123 3.1 Introduction 123 3.2 Propulsion Alternatives Assessment 124 3.3 Turbine Propulsion Alternatives 129 3.4 Turbojet Flow Path, Components, and Nomenclature 131 3.5 Turbojet Thrust Prediction 145 3.6 Turbojet Specific Impulse Prediction 149 3.7 Subsonic Turbojet Propulsion Efficiency 155 3.8 Ramjet Propulsion Alternatives 158 3.9 Ramjet Flow Path, Components, and Nomenclature 160 3.10 Ramjet Combustion Temperature 161 3.11 Ramjet Specific Impulse Prediction 162 3.12 Ramjet Thrust Prediction 164 3.13 Ramjet Combustor Design Considerations 168 3.14 Ramjet Booster Integration 174 3.15 Ramjet Inlet Options 177 3.16 Supersonic Inlet/Airframe Integration 180 3.17 Fuel Alternatives 192 3.18 Rocket Motor Performance Prediction 194 3.19 Rocket Motor Sizing Process 199 3.20 Solid Propellant Grain Alternatives 204 3.21 Solid Propellant Rocket Thrust Magnitude Control 206
CONTENTS xl 3.22 Solid Propellant Alternatives 210 3.23 Solid Propellant Aging 213 3.24 Rocket Motor Case Material Alternatives 216 3.25 Rocket Nozzle Material Alternatives 218 3.26 Ducted Rocket Design Considerations 221 3.27 Summary 223 3.28 Problem Review 223 Chapter 4 Weight Considerations in the Missile Design and System Engineering Process 227 4.1 Introduction 227 4.2 Benefits of a Light Weight Missile 228 4.3 Subsystem Weight Sensitivity to Flight Performance 229 4.4 Missile Weight Prediction 230 4.5 Center-of-Gravity and Moment-of-Inertia Prediction 235 4.6 Missile Structure Factor of Safety 237 4.7 Missile Airframe Structure Manufacturing Processes 239 4.8 Missile Airframe Material Alternatives 251 4.9 Missile Structure/Insulation Trades 258 4.10 High Temperature Insulation Materials 261 4.11 Missile Aerodynamic Heating/Thermal Response Prediction 264 4.12 Localized Aerodynamic Heating and Thermal Stress 283 4.13 Missile Structure Design 287 4.14 Seeker Dome 305 4.15 Missile Power Supply and Flight Control Actuators 311 4.16 Summary 315 4.17 Problem Review 316 Chapter 5 Flight Performance Considerations in Missile Design and System Engineering 319 5.1 Introduction 319 5.2 Missile Flight Performance Envelope 320 5.3 Equations of Motion Modeling 323 5.4 Driving Parameters for Missile Flight Performance 326 5.5 Cruise Flight Performance 329 5.6 Steady-State Flight 331 5.7 Flight Trajectory Shaping for Maximum Range 332 5.8 Turn Performance 333 5.9 Coast Flight Performance 344 5.10 Ballistic Flight Performance 345
xii Missile Design and System Engineering 5.11 Boost Flight Performance 348 5.12 Divert Flight Performance 349 5.13 Intercept Lead Angle and Velocity 351 5.14 Comparison of Missile Design with Performance Requirements 352 5.15 Summary 352 5.16 Problem Review 353 Chapter 6 Measures of Merit and Launch Platform Integration/System Engineering 355 6.1 Introduction 355 6.2 Robustness 357 6.3 Warhead Lethality 396 6.4 Miss Distance 435 6.5 Carriage and Launch Observables 465 6.6 Missile Survivability and Safety 469 6.7 Reliability 503 6.8 Cost 506 6.9 Launch Platform Integration 523 6.10 Summary 578 6.11 Problem Review, 579 Chapter 7 Sizing Examples and Sizing Tools 583 7.1 Introduction 583 7.2 Rocket Baseline Missile Standoff Range Requirement 584 7.3 Wing Sizing Requirement and Turn Performance 603 7.4 Multi-Parameter Harmonization 607 7.5 Maximum Range Trajectory 611 7.6 Ramjet Missile Range Robustness 614 7.7 Ramjet Propulsion/Fuel Alternatives 628 7.8 Velocity Control 630 7.9 Turbojet Baseline Thrust Prediction 632 7.10 Turbojet Baseline Specific Impulse Prediction 643 7.11 Turbojet Baseline Missile Low Altitude Range Prediction 646 7.12 Turbojet Baseline Missile Maximum Range Prediction 652 7.13 Turbojet Baseline Engine Rotational Speed 655 7.14 Examples of Computer-Aided Conceptual Design Sizing Tools 656 7.15 Soda Straw Rocket Design, Build, and Fly 664 7.16 Soda Straw Rocket Range Pareto and Uncertainty Analysis 674 7.17 House of Quality 679 7.18 Design of Experiment 684
CONTENTS xl 7.19 Summary 695 7.20 Problem Review 696 Chapter 8 Development Process 699 8.1 Introduction 699 8.2 Missile Technology and System Development Process 699 8.3 New Missile Program Planning and Development 714 8.4 Example of Missile Technology Development 721 8.5 Examples of State-of-the-Art Advancement 725 8.6 New Technologies for Missiles 727 8.7 Summary 729 8.8 Problem Review 730 Chapter 9 Summary and Lessons Learned 731 9.1 Introduction 731 9.2 Conduct Unbiased and Creative System-of-Systems Design, with Rapid Evaluation and Iteration 731 9.3 Exploit Diverse Skills 731 9.4 Quickly Switch Focus from the Big Picture to... Picture to a Detail 733 9.5 Utilize Creative Skills 734 9.6 Utilize the Skills of the Entire Organization 735 9.7 Balance the Tradeoff of Importance Versus Priority 736 9.8 Identify, Quantify, and Balance the Measures of Merit, within Cost Constraints 737 9.9 Start with a Good Baseline Design 738 9.10 Evaluate Alternative Prediction Methods and Compare with Data, for Accuracy and Precision 738 9.11 Confirm Accuracy of Computer Input Data and Modeling 740 9.12 Conduct Balanced, Unbiased Tradeoffs 741 9.13 Include System Integration in Missile Conceptual Design and System Engineering 742 9.14 Evaluate Many Alternatives 743 9.15 Quickly Search a Broad Design Solution Space (Global Optimization Versus Local Optimization) 744 9.16 Evaluate and Refine as Often as Possible 744 9.17 Apply OODA Loop Process for Faster and Higher Confidence Design Convergence 744 9.18 Provide Balanced Emphasis of Analytical Versus Experimental 746
xiv Missile Design and System Engineering 9.19 Use a Design, Build, and Fly Process, for Feedback Leading to Broader Knowledge and Understanding 747 9.20 Consider Potential Consequences (Good and Bad) of Decisions 748 9.21 Keep Track of Assumptions and Develop Real-Time Documentation 749 9.22 Develop Good Documentation 750 9.23 Rapidly Evaluate Alternatives and Iterate the Design 752 9.24 Missile Conceptual Design and System Engineering Configuration Sizing Guidelines 752 9.25 Wrap-Up 755 Appendix A Homework Problems/Classroom Exercises 757 Appendix B Example of Request for Proposal 769 Appendix C Nomenclature 779 Appendix D Acronyms/Abbreviations 789 Appendix E Conversion Factors 799 Appendix F Example Syllabus 801 Appendix G CEU Credit Quizzes 805 Appendix H Design Case Studies 829 Appendix I Summary of Tactical Missile Design Spreadsheet 831 Appendix J Soda Straw Rocket Science 837 References 843 Bibliography 845 Index 849 Supporting Materials 881