AIAA Distinguished Lecture on
Missile Design and System Engineering
Eugene L. Fleeman, E-mail:
[email protected] [email protected],, Web Site: http://genefleeman.home.mindspring.com All rights reserved. No part of this publication may be reproduced, distributed, or transmitted in any form or by any means, or stored in a database or retrieval system, without the prior written permission of the Publisher and / or Author.
AIAA Textbook and Short Course: Missile Design and System Engineering Chapter 1: Introduction / Key Drivers in the Missile Design and System Engineering Process Chapter 2: Aerodynamic Considerations in Missile Design and System Engineering Chapter 3: Propulsion Considerations in Missile Design De sign and System Engineering Chapter 4: Weight Considerations in Missile Design and System Engineering Chapter 5: Flight Performance Considerations in Missile Design and System Engineering
Chapter 6: Measures of Merit and Launch Platform Integration / System Engineering Chapter 7: Sizing Examples and Sizing Tools Chapter 8: Missile Development Process
Chapter 9: Summary and Lessons Learned References and Follow-up Communication Appendices ( Homework Problems / Classroom Exercises, Example of Request for Proposal, Nomenclature, Acronyms, Conversion Factors, Syllabus, Quizzes, Design Case Studies, TMD Spreadsheet, Soda Straw Rocket Science )
Typical Missile Subsystems - Packaging Is Longitudinal, with High Density Dome Seeker Warhead
Electronics
Warhead
Propulsion
Wings
Body Airframe Structure Note: Missile density ~ 60% density of concrete ( 0.05 vs 0.08 lbm / in3 )
Flight Control
Stabilizers
Missile Design and System Engineering Requires System Integration Environmental Storage …………………. Transportation………………………………………….. Carriage
Launch
…………………………………………………………………
Platform Constraints
Geometry Weight Loading
/ Launcher / Launch Separation
Safety Survivability / Avionics
Observables
/ Vetronics
Targeting Command,
Control, Communications, Computers, Intelligence, Surveillance, and Reconnaissance ( C4ISR ) Fire
Control System
Most Missiles Use Skid-to-Turn Maneuver, Other Options: Bank-to-Turn, Rolling Airframe, Divert
Skid-To-Turn ( STT ): Sea Sparrow
Bank-to-Turn ( BTT ) JSOW
Rolling Airframe ( RA ): HOT
Video of Sea Sparrow, JSOW, HOT, and MKV Flight Trajectories
Divert:
MKV
Each Type of Air Breathing Propulsion Has an Optimum Mach Number for Max Specific Impulse t n a l l e p o r P r o l s e , u ) F e ( t / a t R s u r w o h l T F , t e h s i g l u e p W m I c i f i c e p S , P S I
4,000 Liquid Hydrocarbon Fuel Turbojet: ISP typically constrained by turbine temperature limit
3,000
Liquid Hydrocarbon or Solid Fuel Ramjet: ISP typically constrained by combustor insulation temperature limit
2,000
Liquid Hydrocarbon Fuel Scramjet: ISP typically constrained by thermal choking
1,000 Solid Propellant Ducted Rocket
Solid Propellant Rocket: ISP typically constrained by safety
0 0
2
4
6 Mach Number
8
10
12
Laminate Graphite Composite Provides a High Strength-to-Weight Airframe Graphite / Polyimide ( Graphite / Epoxy ( = 0.065 lb / in3 ) 0-±45-90 Laminate
12.0 e l i s . n n 10.0 e T I 5 0 e t 1 a , y m t i i 8.0 t l s U n , e D / / e 6.0 l i h t s n g e n t , e e r t t a m S 4.0 i t
Ti3Al (
= 0.057 lb / in3 ), 0-±45-90 Laminate
= 0.15 lb / in3 ) Ti-6Al-4V Annealed Titanium (
= 0.160 lb / in3 )
PH15-7 Mo Stainless Steel ( = 0.277 lb / in3 ). Note: High strength ( thin wall ) steel susceptible to buckling.
Graphite Glass
l u
Major Limitations Chopped Epoxy 2219-T81 Composites, Random Orientation Aluminum ( = 0.103 lb / in3 ) ( = 0.094 lb / in3 )
2.0
, Temperature Temperature Buckling Cost
0 0
200
400
600
Short Duration Temperature, F
800
1,000
Accurate Guidance Enhances Lethality
BILL - Two 1.5 kg EFP warheads …
Roland - 9 kg warhead: multi-projectiles from preformed case……………..
Hellfire - 24 lb shaped charge warhead …………………………..
GMLRS - 180 lb blast / fragmentation warhead ……….
2.4 m witness plate
Video: BILL, Roland, Hellfire, and GMLRS Warheads
Most Kinetic-Kill Missiles Are Used Against Ballistic Missile and Armor Vehicle Targets
Standard Missile 3 Kill Vehicle ( NTW )
LOSAT
THAAD
PAC-3
GBI
LOSAT Video
ost ong ange tr e ss es se t er High Speed or Low RCS for Survivability High Speed
SS-N-22 Sunburn ( Ramjet Supersonic Propulsion )
3M-54E Sizzler ( Rocket Supersonic Penetrator / Turbojet Subsonic Fly-out )
Low RCS
NSM ( Faceted Dome, Decoupled Airframe, Body Chines, Composite Structure )
JASSM ( Flush Inlet, Window Dome, Trapezoidal Body, Single Tail, Canted Nozzle, Composite Structure )
Missile Carriage Size, Shape, and Weight Limits May Be Driven by Launch Platform Compatibility Launch Platform Integration / Firepower
US Launch Platform Surface Ships
Submarines
Fighters / Bombers / Large UCAVs
Ground Vehicles
Helos / Small UCAVs
Tanks
Launcher
Carriage Span / Shape VLS
CLS
Length
Weight
263”
3400 lb
263”
3400 lb
~168”
~500 lb to 3000 lb
158”
3700 lb
22 “ Rail / Ejection
~24” x 24”
Launch Pods Helo Rail, UCAV Rail / Ejection
13” x 13”
Gun Barrel 120 mm
70”
120 lb
40”
60 lb
Missile Guidance / Launch Platform Integration Varies from Autonomous to Command Guidance Active Seeker Transmitted Energy
1. Homing Active / Passive Seeker Guidance
Seeker Target Reflected / Emitted Energy Launch / Midcourse Guidance
Semi-Active Seeker
2. Homing SemiActive Seeker Guidance Launch / Midcourse Guidance
Target Reflected Energy
Fire Control System Tracks Target
3. Command Guidance Launch / Midcourse Guidance
Rear-looking Sensor Detects Fire Control System Energy
Fire Control System Tracks Target, Tracks Missile, and Command Guides Missile
Missile Climatic Environment Requirements Are Typically Based on the 1% Probability Extreme Environment Parameter Typical Requirement Surface
Temperature - 60 °F to 160 °F*
Surface
Humidity
Rain
Rate
5% to 100% 120 mm / h**
Surface Wind
150 km / h***
Salt
3 g / mm2 per year
Fog
Dust
/ Sand / Dirt
2 g / m 3, wind @ 18 m / s
Vibration
10 g rms at 1,000 Hz: MIL STD 810G, 648, 1670A
Shock
Drop height 0.5 m, half sine wave 100 g / 10 ms
Acoustic
160 dB
External
Power Fluct +/- 10%, MIL-HDBK-781
ATACMS Launch
Video: Ground / Sea Environment
Note: MIL-HDBK-310 and earlier MIL-STD-210B suggest 1% world-wide climatic extreme typical requirement. * Highest recorded temperature 136 F. Lowest recorded temperature = - 129 °F. °F during worst month / location. ** Highest recorded rain rate = 436 mm / h. *** Highest recorded wind = 407 km / h.
20% probability temperature lower than – 60
0.5% probability greater than 120 mm / h during worst month / location.
1% probability greater than 100 km / h during worst month / location.
Typical external air carriage maximum hours for aircraft 100 h. Typical external carriage max hours for helicopter 1000 h.
Sizing Examples and Sizing Tools
Rocket Baseline Missile
Ramjet Baseline Missile
Turbojet Baseline Missile
Computer Aided Conceptual Design Sizing Tools
Soda Straw Rocket
xamp es o
ss e eve opmen Facilities
Airframe Wind Tunnel Test ………………………………………………………
Propulsion Static Firing with TVC ……..
Propulsion Direct Connect Test …………………………………….
Propulsion Freejet Test …………
es s an
xamp es o
ss e eve opment ests an Facilities ( cont )
Warhead Arena Test ……………………………………………………….
Warhead Sled Test ………………………
Insensitive Munition Test ……………………………………………..
Structure Load Test …………………………………………..
xamp es o
ss e eve opment ests an Facilities ( cont )
Seeker Test ……………………………………………………….
Hardware-In-Loop ………
Environmental Test ……………………………………………..
Submunition Dispenser Sled Test ……………………
Examples of Missile Development Tests and Facilities ( cont ) RCS Test ……………………………………………………………….
Store / Avionics Integ Test
Flight Test ……………………………………………………………………….
Video of Facilities and Tests
Missile Development Flight Test Should Cover the Extremes / Corners of the Flight Envelope Example: Ramjet Baseline Missile Propulsion Test Validation ( PTV ) High L / D Cruise Flight 7 Flight 3
High Aero Heating Flight 7 g Flight 1 : a r n D o r i t t Flight 7 e i t s s s ( 140 s ) u o n r o a r h Flight 5 ( 160 s ) B T T
Flight 7 ( 500 s )
( 140 s )
( 60 s )
( 40 s )
Flight 1 failure of fuel control. As a result of the high thrust, the flight Mach number exceeded the design Mach number. Flight 3 Flight 3 ( 200 s )
Flight 2 failure of flight control. Because the missile was out of control, the flight was intentionally terminated.
Note: Seven Flights from Oct 1979 to May 1980 ( ≈ 1 / month )
Missile Technologies Have Transformed Warfare Air Targets 1957: SA-2 Rocket Motor High Altitude Intercept
1987: Archer TVC Lethality 1985: Stinger Two Color Seeker 2002: SM-3 Accuracy Target Acquisition in Clutter High Alt Missile Defense
1956: Sidewinder Proportional Guidance Lethality
1950
2001: PAC-3 Accuracy Ballistic Missile Defense
1973: Sea Dart Radar Seeker BVR Intercept
1960 1957: R-7 ICBM
Surface Targets
1970
1980
1990
2000
Future
1969: GBU-10 Laser Guid 1982: Sunburn Ramjet Precision Strike Time Critical Strike
1972: SRAM Low Observables 1989: Hellfire Digital Processor Multi-purpose & High Reliability Survivability 1979: Tomahawk Light Turbine Long Range Strike
Note: Year is initial operation application ( IOC )
2000: JDAM GPS / INS Low Cost X Weather Strike
Conduct Unbiased and Creative System-of- Systems Design, with Rapid Evaluation / Iteration •
Mission / Scenario / System Definition
Update Initial
•
•
Weapon System Requirements, Trade Studies and Sensitivity Analysis Launch Platform Integration
Revised Trades / Eval
Initial Reqs
Alt Concepts
Initial Carriage / Launch
Effectiveness / Eval
Baseline Selected Iteration
Refine Weapon Req •
•
Weapon Concept Design Synthesis Technology Assessment and Dev Roadmap
Alternate Concepts
Select Preferred Design Initial Tech
Tech Trades
Note: Conceptual design requires fast cycle, ~ 3 to 9 months.
Eval / Refine Initial Revised Roadmap Roadmap
Wrap Up ( Part 1 of 2 )
Missile Conceptual Design and System Engineering Is a Creative, Fast, and Iterative Process that Includes
System requirements flow-down
System integration considerations
Missile concepts and sizing
Technology assessment
Flight trajectory evaluation
Measures of merit evaluation
Cost / Performance / Risk Drivers Are Often “Locked In” During Conceptual Design
Missile Conceptual Design and System Engineering Is Best Conducted by a Diverse Group
Military customer
mission / scenario definition
Operations analysts
System integration engineers
Missile design engineers
Technical specialists
system-of-systems modeling
launch platform integration
missile concept synthesis technology assessment / technology roadmap
Wrap Up ( Part 2 )
The Missile Conceptual Design – System Engineering Philosophy Requires
Iteration, iteration, iteration
Evaluation of a broad range of alternatives
Traceable flow-down allocation of requirements
Starting with a good baseline
Pareto sensitivity analysis to determine most important, driving parameters
Awareness of System Engineering Boundaries / Constraints
Synergistic compromise / balanced subsystems and technologies that are high leverage
Follow-up Communication I would appreciate receiving any questions, comments, and corrections that you may have on this presentation, as well as any data, photographs, drawings, videos, examples, or references that you may offer.
Thank you, Gene Fleeman Missile Design and System Engineering E-mail:
[email protected] Web Site: http://genefleeman.home.mindspring.com
