Simulation and optimization of HTPB propellant aging detection sensor based on cantilever structure

Purpose The aging detection of solid rocket-terminated hydroxy polybutadiene (HTPB) propellant is crucial for improving the reliability and safety of rocket motors, and cantilever beam sensors have been widely used in the detection field. Design/methodology/approach In this paper, the cantilever structure is selected as the elastic element, and the deflection of straight and curved cantilever beams are derived and calculated by using the differential equation of the deflection curve and Carpenter’s theorem, respectively. At the same time, the cantilever structure detection unit is analyzed by numerical simulation using ABAQUS, and the sensor results are calibrated by simulation with modulus change. The modulus change of HTPB propellant aging process is detected by structural design, the factors affecting the measuring range of the cantilever structure detection unit are analyzed, and the effects of different stiffness ratios on the measuring range are obtained, the changes in the mechanical properties of HTPB propellant aging are tested by gel fraction test and the performance of the cantilever structure sensors is finally fabricated and verified. Findings This study shows that modeling analysis using ABAQUS numerical simulation software can verify the accuracy of the sensor design scheme, the elasticity coefficient ratio of the center cantilever straight beam and the outer ring cantilever curved beam of the cantilever structural detection unit should be in the range of 1.5–2, and the stiffness ratio should be in the range of 2.5–3.5, and the initial modulus of HTPB propellant within the range of effective service should be in the range of 3–7 MPa, the results can be used to guide the structural design and physical fabrication of HTPB propellant aging detection sensor. 7 MPa range, the results can be used to guide the structural design and physical fabrication of the HTPB propellant aging detection sensor. Originality/value Tests were conducted on HTPB propellants with different aging times, and sensors were produced to recognize HTPB propellants with different degrees of aging, realizing safe detection of HTPB propellant aging.