Aerodynamic Optimization and Thermal Deformation Effects on Mid-Altitude Sounding Rockets: A Computational and Structural Analysis

Mid-altitude sounding rockets are essential for atmospheric research and suborbital experimentation, where aerodynamic optimization and structural integrity are crucial for achieving targeted apogees. This study uses OpenRocket v23.09 for preliminary flight performance prediction and SolidWorks 2024 to integrate aerodynamic and structural analyses through Computational Fluid Dynamics (CFD) and Finite Element Analysis (FEA). SolidWorks Flow Simulation and SolidWorks Simulation are used to assess how nose cone and fin geometries, as well as thermal deformation, influence flight performance. Among nine tested configurations, the ogive nose cone with trapezoidal fins achieved the highest simulated apogee of 2639 m, with drag coefficients of 0.480 (OpenRocket) and 0.401 (SolidWorks Flow Simulation). Thermal–structural analysis revealed a maximum nose tip displacement of 0.7249 mm for the rocket with the ogive nose cone, leading to an increasing drag coefficient of 0.404. However, thermal deformation of the ellipsoid nose cone led to a reduction in the drag coefficient from 0.419 to 0.399, even though it exhibited a slightly higher maximum displacement of 0.7443 mm. Mesh independence was confirmed with outlet velocity deviations below 1% across refinements. These results highlight the importance of integrated CFD–FEA approaches, geometric optimization, and material resilience for enhancing the aerodynamic performance of subsonic sounding rockets.