Neural Network-Based Optimization of Hybrid Rocket Design for Modular Multistage Launch Vehicle

In this paper, an integrated optimization is carried out to find the optimal hybrid rocket engine design for a modular multistage launch vehicle targeting a 500 km polar circular orbit. A single hybrid rocket engine unit is reused across the whole launch vehicle, with each stage constituted by a cluster of a specified number of units. Only the nozzle exit diameter of the units is allowed to change across each stage. This clustering approach is aimed at reducing the costs of the launch vehicle and at simplifying the optimization procedure. After a brief mission analysis based on Tsiolkovsky’s equation, a three-stage configuration is chosen for the launch vehicle, employing 16, 4, and 1 engine units for, respectively, the first, second, and third stage. A neural network-based surrogate model is employed to approximate the complex hybrid rocket internal ballistics, with the aim to reduce the computational cost of the optimization process. The surrogate model is trained to map a reduced number of design parameters to the performance and mass budget of a single engine unit using data from a 0-D hybrid rocket engine model. The accuracy of the trained network in predicting crucial features is then assessed. Finally, the trained network is integrated into a multidisciplinary optimization process. The aim is to identify the optimal rocket engine design and launch vehicle ascent trajectory that maximize the payload capacity to the target orbit.