11/9/2011 ELF 1

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retrieval system, without the prior written permission of the Publisher and / or Author.

Eugene L. Fleeman, E-mail: GeneFleeman@msn.com, Web Site: http://genefleeman.home.mindspring.com

AIAA Distinguished Lecture on

Missile Design and System Engineering

11/9/2011 ELF 2

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 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 )

Body Airframe Structure

Typical Missile Subsystems -

Packaging Is Longitudinal, with High Density

11/9/2011 ELF 3

Dome Seeker Warhead Electronics Warhead Propulsion Flight Control

Wings Stabilizers

Note: Missile density ~ 60% density of concrete ( 0.05 vs 0.08 lbm / in3 )

Missile Design and System Engineering Requires

System Integration

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Environmental

Storage ………………….

Transportation…………………………………………..

Carriage …………………………………………………………………

Launch Platform Constraints

Geometry

Weight

Loading / Launcher / Launch Separation

Safety

Survivability / Observables

Avionics / 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

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Skid-To-Turn ( STT ): Bank-to-Turn ( BTT ) Rolling Airframe ( RA ): Divert:

Sea Sparrow JSOW HOT MKV

Video of Sea Sparrow, JSOW, HOT, and MKV Flight Trajectories

11/9/2011 ELF 6

Liquid Hydrocarbon Fuel Scramjet:

ISP typically constrained by thermal

choking

Each Type of Air Breathing Propulsion Has an Optimum Mach Number for Max Specific Impulse

Liquid Hydrocarbon Fuel Turbojet: ISP typically constrained by turbine temperature

limit

Liquid Hydrocarbon or Solid Fuel Ramjet: ISP typically constrained by

combustor insulation temperature limit

Solid Propellant Rocket: ISP typically

constrained by safety

4,000

3,000

2,000

1,000

0

I SP,

Sp

ecif

ic Im

pu

lse,

Th

rust

/ (

Fu

el o

r P

rop

ella

nt

Wei

gh

t F

low

Rat

e ),

s

0 2 4 6 8 10 12

Mach Number

Solid Propellant Ducted

Rocket

11/9/2011 ELF 7

Laminate Graphite Composite Provides a High Strength-to-Weight Airframe

200 400 600 800 1,000 0

Short Duration Temperature, F

8.0

10.0

12.0

6.0

4.0

2.0

0

u

ltim

ate,

ten

sile

/

, Ult

imat

e Te

nsi

le

Str

eng

th /

Den

sity

, 10

5 In

. Graphite / Epoxy

( = 0.065 lb / in3 )

0-±45-90 Laminate

Graphite / Polyimide ( = 0.057 lb / in3 ), 0-±45-90 Laminate

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

2219-T81 Aluminum ( = 0.103 lb / in3 )

Chopped Epoxy

Composites,

Random Orientation

( = 0.094 lb / in3 )

Ti3Al ( = 0.15 lb / in3 )

Major Limitations , Temperature

Temperature

Buckling

Cost

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Accurate Guidance Enhances Lethality

Hellfire - 24 lb shaped charge warhead …………………………..

2.4 m witness

plate

Roland - 9 kg warhead: multi-projectiles from preformed case……………..

GMLRS - 180 lb blast / fragmentation warhead ……….

Video: BILL, Roland, Hellfire, and GMLRS Warheads

BILL - Two 1.5 kg EFP warheads …

11/9/2011 ELF 9

Standard Missile 3 Kill Vehicle ( NTW ) THAAD PAC-3 GBI

LOSAT LOSAT Video

Most Kinetic-Kill Missiles Are Used Against

Ballistic Missile and Armor Vehicle Targets

Most Long Range Strike Missiles Use Either

High Speed or Low RCS for Survivability

11/9/2011 ELF 10

SS-N-22 Sunburn ( Ramjet Supersonic Propulsion )

NSM ( Faceted Dome, Decoupled Airframe, Body Chines,

Composite Structure )

High Speed

Low RCS

3M-54E Sizzler ( Rocket Supersonic Penetrator /

Turbojet Subsonic Fly-out )

JASSM ( Flush Inlet, Window Dome, Trapezoidal

Body, Single Tail, Canted Nozzle, Composite

Structure )

11/9/2011 ELF 11

Missile Carriage Size, Shape, and Weight Limits

May Be Driven by Launch Platform Compatibility

Surface Ships

CLS

~24” x 24”

263” 3400 lb

263” 3400 lb

~168” ~500 lb to

3000 lb

Fighters /

Bombers /

Large UCAVs

Rail /

Ejection

VLS

Submarines

Launch Platform Integration / Firepower

22 “

Ground Vehicles 158” 3700 lb

Helos / Small UCAVs

Launch

Pods

Helo Rail,

UCAV Rail /

Ejection

US Launch Platform Launcher Carriage Span / Shape Length Weight

13” x 13” 70” 120 lb

Tanks Gun Barrel

120 mm

40” 60 lb

11/9/2011 ELF 12

1. Homing Active /

Passive Seeker

Guidance

2. Homing Semi-

Active Seeker

Guidance

3. Command

Guidance

Active Seeker Transmitted Energy

Target Reflected / Emitted Energy

Target Reflected Energy

Rear-looking Sensor Detects

Fire Control System Energy

Missile Guidance / Launch Platform Integration

Varies from Autonomous to Command Guidance

Seeker

Semi-Active Seeker

Fire Control System Tracks Target

Fire Control System Tracks Target, Tracks Missile, and Command Guides Missile

Launch / Midcourse Guidance

Launch / Midcourse Guidance

Launch / Midcourse Guidance

11/9/2011 ELF 13

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 5% to 100%

Rain Rate 120 mm / h**

Surface Wind 150 km / h***

Salt Fog 3 g / mm2 per year

Dust / Sand / Dirt 2 g / m3, 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

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. 20% probability temperature lower than – 60

°F during worst month / location.

** Highest recorded rain rate = 436 mm / h. 0.5% probability greater than 120 mm / h during worst month / location.

*** Highest recorded wind = 407 km / h. 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.

ATACMS Launch Video: Ground / Sea Environment

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Sizing Examples and Sizing Tools

Rocket Baseline Missile

Ramjet Baseline Missile

Turbojet Baseline Missile

Computer Aided Conceptual Design Sizing Tools

Soda Straw Rocket

11/9/2011 ELF 15

Airframe Wind Tunnel Test ………………………………………………………

Propulsion Static Firing with TVC ……..

Propulsion Direct Connect Test …………………………………….

Propulsion Freejet Test …………

Examples of Missile Development Tests and

Facilities

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Examples of Missile Development Tests and

Facilities ( cont )

Warhead Arena Test ……………………………………………………….

Warhead Sled Test ………………………

Insensitive Munition Test ……………………………………………..

Structure Load Test …………………………………………..

11/9/2011 ELF 17

Examples of Missile Development Tests and

Facilities ( cont )

Seeker Test ……………………………………………………….

Hardware-In-Loop ………

Environmental Test ……………………………………………..

Submunition Dispenser Sled Test ……………………

11/9/2011 ELF 18

RCS Test ……………………………………………………………….

Store / Avionics Integ Test

Flight Test ……………………………………………………………………….

Video of Facilities and Tests

Examples of Missile Development Tests and

Facilities ( cont )

11/9/2011 ELF 19

Missile Development Flight Test Should Cover

the Extremes / Corners of the Flight Envelope

Flight 7

Flight 7

Flight 3

Flight 7 ( 500 s )

Flight 1

Flight 3 ( 200 s )

Flight 3

Flight 7

High Aero Heating

High L / D Cruise

Bo

ost

er

Tran

siti

on

: T

hru

st -

Dra

g

Flight 1 failure of fuel control. As a result of the high thrust, the flight Mach number exceeded the design Mach number.

Flight 2 failure of flight control. Because the missile was out of control, the flight was intentionally terminated.

Example: Ramjet Baseline Missile Propulsion Test Validation ( PTV )

Note: Seven Flights from Oct 1979 to May 1980 ( ≈ 1 / month )

( 60 s ) ( 40 s )

( 140 s )

Flight 5 ( 160 s )

( 140 s )

Missile Technologies Have Transformed Warfare

11/9/2011 ELF 20

1950 1960 1970 1980 1990 2000 Future

1969: GBU-10 Laser Guid

Precision Strike

1972: SRAM Low Observables

Survivability

1979: Tomahawk Light Turbine

Long Range Strike

1987: Archer TVC

Lethality

1989: Hellfire Digital Processor

Multi-purpose & High Reliability

2000: JDAM GPS / INS

Low Cost X Weather Strike

2001: PAC-3 Accuracy

Ballistic Missile Defense

1985: Stinger Two Color Seeker

Target Acquisition in Clutter

Note: Year is initial operation application ( IOC )

1982: Sunburn Ramjet

Time Critical Strike

Surface Targets

2002: SM-3 Accuracy

High Alt Missile Defense

1957: R-7

ICBM

1973: Sea Dart Radar Seeker

BVR Intercept

1957: SA-2 Rocket Motor

High Altitude Intercept

1956: Sidewinder Proportional Guidance

Lethality

Air Targets

11/9/2011 ELF 21

Conduct Unbiased and Creative System-of-

Systems Design, with Rapid Evaluation / Iteration

• Mission / Scenario

/ System Definition

• Weapon System

Requirements,

Trade Studies

and Sensitivity

Analysis

• Launch Platform

Integration

• Weapon Concept

Design Synthesis

• Technology

Assessment and

Dev Roadmap

Initial

Tech

Initial

Reqs

Baseline

Selected

Alt

Concepts

Initial Carriage /

Launch Iteration

Refine

Weapon

Req

Initial Revised

Trades / Eval Effectiveness / Eval

Tech

Trades

Initial

Roadmap

Revised

Roadmap

Update

Note: Conceptual design requires fast cycle, ~ 3 to 9 months.

Alternate Concepts Select Preferred Design Eval / Refine

11/9/2011 ELF 22

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-of-systems modeling

System integration engineers launch platform integration

Missile design engineers missile concept synthesis

Technical specialists technology assessment / technology roadmap

11/9/2011 ELF 23

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

11/9/2011 ELF 24

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: GeneFleeman@msn.com

Web Site: http://genefleeman.home.mindspring.com