Investigation on the Structural Integrity of Solid Propellant Grains with Different-Sized Void Defects

During the service of solid rocket motors, propellant grains need to bear various loads such as curing cooling, gravity, and combustion internal pressure. The internal pore defects will seriously affect the structural integrity. In this paper, a three-dimensional finite element model of propellant–insulation layer–mold is established to study the structural responses of pore defects with different sizes (30–100 mm) under three typical working conditions: curing cooling, curing cooling coupled with gravity, and internal pressure loading. It is found that under the curing cooling condition, compared with the non-porous propellant grain structure, the structure with pores will raise the overall mechanical response of the propellant grain, and the maximum stress and strain are mainly concentrated in the front end of the core hole and the wing groove area. The pore size has a limited impact on the overall stress distribution, but will change the local stress concentration degree. Among them, the 80 mm pore reduces the stress in the wing groove area through stress field interference. Moreover, large-size pores will significantly weaken the structural bearing capacity and increase the contact pressure between the propellant and the core mold. Under the condition of curing cooling coupled with gravity, the stress and strain are mainly distributed at the edge of the pores, and the values increase with the increase of pore size. Under the action of internal pressure load, the stress and strain in the middle section of the propellant grain have no obvious change, but stress concentration occurs in the transition area between the core hole and the wing groove and at the end of the wing groove. The results of this study provide a reference for the integrity evaluation and structural optimization of propellant grains with pore defects