Surrogate based constrained optimization methods are widely utilized in practical solid rocket motor (SRM) design problems. To improve the design performance, this paper proposes an inaccurate search based sequential approximate constrained optimization (ISSACO) method consisting of an efficient recursive evolution Latin hypercube design (RELHD) method and a three-stage constrained sampling method. The RELHD method divides large-sample experiment design problem into several small-sample design problems to ensure the computational efficiency and the design uniformity at the same time. The three-stage constrained sampling method employs the elite archives mechanism to balance the feasibility and the optimality in optimization. Results of the numerical cases indicate that the proposed ISSACO algorithm is competitive with other state-of-art constrained optimization method in efficiency and effectiveness. The finocyl grain design and the impulse mass ratio optimization are also conducted to make further verifications, and the ISSACO method can efficiently obtain feasible optimum and proves to be a potential method for computationally intensive solid rocket motor design problems.
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