In a high-temperature test of the gas generator with a free-loading composite propellant, an abnormal jitter appeared in the latter part of the internal ballistic curve, whereas no such abnormality was observed in the low-temperature and normal-temperature tests. To investigate the cause, quasi-steady-state simulations of the internal flow field, as well as strength and buckling simulations of the grain, were conducted. The strength simulation revealed that the maximum stress experienced by the composite propellant during operation at 323 K is 0.7 MPa, which is lower than the ultimate stress of the grain (1.01 MPa), indicating no stress failure. The buckling simulation demonstrated that the instability arises from an imbalance of pressure on the inner and outer surfaces of the grain. In the original structure, the ventilation effect on each surface of the grain varied with the regression of the burning surface, leading to a pressure imbalance on the inner and outer surfaces of the composite propellant. Consequently, a non-ablative cladding layer was applied to ensure that the ventilation effect of each channel remains constant. The simulation demonstrated that the pressure on the surfaces of the composite propellant gradually balanced with the operation of the gas generator. Upon retesting at high temperatures, no abnormal jitter was observed in the internal ballistic curve. This indicates that maintaining a constant ventilation area for the combustion chamber and preventing changes in the ventilation effect can ensure the structural integrity of the composite propellant during operation. The working state of the composite propellant with this non-ablative cladding layer is not affected by variations in the design of the solid rocket motor. This approach enhances the adaptability and reliability of the free-loading composite propellant under different motor structures.
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