Hybrid Rocket Motor Research Articles

Development and Testing of a Fast-Acting, 8-Bit, Digital Throttle for Hybrid Rocket Motors

The potential for throttle control of hybrid rocket systems has long been known as a potential advantage for a variety of applications. Because only a single flow path is controlled, theoretically, hybrids should be significantly easier to throttle than bipropellant systems. Unfortunately, the slow response times and nonlinearity of traditional position-control valves have limited practical applications of hybrid throttling. This paper presents an alternative throttling system where the oxidizer flow path is broken into multiple streams, with each flow path controlled by a solenoid-operated on/off valve. The parallel paths allow significantly faster and more precise control than can be achieved using a single position-control valve. The achievable thrust levels are limited only by the size and number of components in the valve cascade. The 8-bit digital throttle system, developed by Utah State University’s Propulsion Research Lab, uses commercial, off-the-shelf components. The throttle system was tested using a 200-N hybrid rocket motor, burning gaseous oxygen, and ABS plastic as propellants. The testing campaign of more than 50 hot fires has demonstrated multiple profiles, including deep throttle ramps, multistep boxcars, and sine waves at frequencies varying from 0.25 to 1-Hz. Comparisons to analytical models are also presented, showing good agreement. Fourier-transform spectra demonstrating the total-system, frequency response are also presented.

The decoupled effect of oxidizer mass flux and combustion pressure on turbulent combustion characteristics of finite-length solid fuel

Combustion pressure and oxidizer mass flux are key factors influencing the performance of hybrid rocket motors. In the present work, the decoupled effects of oxidizer mass flux and combustion pressure on turbulent combustion characteristics were investigated. First, a finite-length combustion theory of fuel grains was developed to identify the main sensitive parameters, including flame structure and the recirculation zone, which affect the combustion of solid fuel. Then, a two-dimensional transient numerical model, based on the coupling characteristics of the heat transfer process in solid fuel grains and dynamic combustion flow, was developed and validated through fire experiments under a wide range of inflow conditions. A quantitative analysis was conducted to assess the impact of flame structure and the recirculation zone on the dynamic combustion characteristics of finite-length solid fuel. The results showed that the fuel characteristic temperatures of the front and central parts are negatively correlated with flame height, while the characteristic temperature of the rear part is positively correlated with the recirculation zone temperature. Both the mass flow rate and combustion pressure are negatively correlated with flame height and positively correlated with the temperature of the recirculation zone. Compared to combustion pressure, the influence of mass flow rate is more significant. The transient processes of the solid fuel regression rate under different inflow conditions exhibit a consistent tendency: an increase in mass flow flux and combustion pressure results in faster attainment of peak regression rate and stabilization.

Flow field explorations and design improvements of a hybrid rocket motor LOx feed line

The oxidizer system in a hybrid rocket motor needs to deliver the flow from a pressurized storage tank to multiple combustor ports. Pressure losses in the oxidizer system directly impacts combustor pressure and consequently the vehicle performance. However, oxidizer feed line designs till date have been done using simple 1D tools. Higher fidelity flow analysis methods have not been reported in the literature to identify loss generating features. Therefore, a design improvement study was carried out to identify and alleviate the impact of undesirable flow features in a typical oxidizer system design. An experimentally calibrated 3D RANS approach is applied to a typical LOx feed system which includes steps, splitters, ports, and pipes with multiple bends. These design features result in varying degrees of flow separation, secondary flows and vortical flow features and result in total pressure losses of up to 7 %. This loss means that the storage tank needs to be pressurized further to accommodate such losses and ensure combustor performance. A targeted design improvement approach that features simple, alternative, implementable solutions in the loss-generating regions is discussed. The best of these design improvements can reduce the total pressure loss to 4 %, indicating a 43 % reduction in the losses and reduced impact on storage tank design and combustor performance. Therefore, this paper demonstrates that a higher fidelity design enhancement process of the oxidizer feed system, which is often neglected in such detailed studies, can result in overall vehicle level design improvements to ensure mission targets are met effectively.

Numerical investigation on thrust gain mechanism of helium injected solid–gas hybrid rocket motor

Numerical investigation on thrust gain mechanism of helium injected solid–gas hybrid rocket motor

Consideration of fuel and oxidizer combinations for mass and volume limited hybrid rocket motors

AbstractThis research considers different storable oxidizer and fuel combinations for hybrid propulsion, looking for the most adequate candidates for mass and volume limited systems. High specific impulse Isp is the main indication for minimum mass, whereas high density specific impulse ρIsp is a good measure for smaller volume. Other aspects such as safety, handling, toxicity, burn rate, hypergolicity, and the oxidizer to fuel O/F ratio, may affect the final choice of propellant ingredient combination. For mass‐limited systems hydrogen peroxide H2O2 or nitrogen tetroxide N2O4 (the latter is toxic and hard to handle) oxidizers give the best results with most solid fuels (mainly hydroxyl‐terminated polybutadiene HTPB). For volume‐limited systems the same combinations may apply; however, in that case polyester fuel may be an adequate choice as well because of its high density. Nitrous oxide N2O is the most inadequate oxidizer for volume‐limited systems, yielding ρIsp lower by about 40 % compared to other oxidizers. Reducing the structure and insulation mass may result from decreasing the high‐pressure, high‐temperature section (the combustion chamber) and can be achieved from high O/F combinations employing N2O or H2O2 oxidizers. N2O gives relatively safe system, H2O2 enables hypergolic combinations, HNO3 is good for long‐term storage, whereas paraffin wax and expandable graphite additive yield high fuel regression rate and thrust. Overall, H2O2 oxidizer seems optimal for many operational aspects, but it should be chemically stabilized to minimize decomposition.

Performance estimation of hybrid rocket by varying the flow rate at multi-location swirl injector

This study attempts to evaluate the effect of varying the oxidizer mass flow rate through the secondary mid-location swirl injector on the performance of a hybrid rocket motor (HRM). The hybrid fuel used in this study was paraffin wax along with commercially available gaseous oxygen as oxidizer. Utilizing a swirl injector is crucial as it adds a tangential velocity component alongside the axial one. Introducing a secondary mid-location swirl injector heightens this effect, leading to noticeably improved performance in HRM. An increase in the oxidizer mass flow rate through the secondary mid-location swirl injector is associated with a reduction in the regression rate. This is attributed to the blowing away of wax melt layer and flame from the solid hybrid fuel grain. Furthermore, an overall increase in the oxidizer mass flow rate corresponds to a rise in combustion efficiency, closely linked to pressure development, which, in turn, correlates with the mass flowing out of the rocket nozzle. Peak thrust was observed and also maximum fuel was burnt in case where highest gaseous oxygen (GOX) rate of 50 g/s was utilized. The multi-location swirl injector assembly maintains swirling flow towards the nozzle end, presenting an optimal scenario for enhancing HRM performance.

Trajectory/propulsion integrated design optimization of the manned lunar lander propelled by hybrid rocket motors using analytical target cascading

Lunar missions are currently experiencing a significant surge in popularity, presenting expansive opportunities for further exploration and development. To thoroughly explore the design margins and potential of lunar landers, and to foster the development of overall designs driven by comprehensive performance objectives, it is crucial to conduct optimization design considering the coupling between key disciplines such as trajectory and propulsion. Considering the significant increase in computational complexity caused by conducting trajectory/propulsion integrated design optimization, the analytical target cascading method is employed to hierarchically decompose and coordinate optimization of the complex systems. This article presents a phased soft-landing strategy on the manned lunar lander propelled by hybrid rocket motors, utilizing powered explicit guidance and Apollo powered descent guidance, and proceeds with the trajectory/propulsion integrated design optimization involving diverse grain shapes and feed systems. This optimization process is separately undertaken utilizing multidisciplinary feasible method and analytical target cascading method. The analysis reveals that integrating trajectory and propulsion considerations into the optimization process facilitates a 5 % reduction in the overall mass relative to optimizations constrained solely by velocity increment and lack comprehensive trajectory design considerations. This highlights the profound impact of trajectory requirements on propulsion system design and the advantages of powered explicit guidance laws in minimizing fuel consumption. Crucially, the use of analytical target cascading achieves the better optimization results, and significantly reduces subsystem evaluation times, enhancing operational efficiency by 48 %, demonstrating the advantage in handling complex, large-scale systems. On another level, with different β values, the Mean Relative Error of the target values for the three schemes obtained by the analytical target cascading method is 0.0016, indicating good stability and strong robustness. The practical exploration in this article provides methods and frameworks for high-performance optimization design of complex aerospace mission profiles in the future.

Combustion Characteristics of Vat-Photopolymerized Fuels with a Spiral Star Port for Hybrid Propulsion.

Despite hybrid rocket motors offering distinct advantages over solid or liquid rocket motors, their low regression rate and insufficient combustion efficiency remain significantly unimproved. This study focuses on the effects of the helix lead on the regression rate distribution and combustion efficiency of vat-polymerized fuel grains with a spiral star port for a hybrid rocket. Both experimental and numerical investigations were conducted to study the combustion characteristics and regression rate distribution of three-dimensional (3D) print grains. Spiral star grains with varying helix leads of 60, 90, and 120 mm were fabricated using light-curing 3D printing technology. A 3D simulation model was developed to obtain the temperature distribution, species mass distribution, and combustion efficiency. Furthermore, firing tests were performed on a two-dimensional radial hybrid combustion test stand to measure the regression rate. Digital image processing of computed tomography images was used to determine the regression rate. Simulation results indicated that the spiral star grain port helps to improve the combustion efficiency compared with those seen with round tube and straight star port grains. With an increase in the axial distance, the flame zone gradually shrinks, and the smaller the helix lead, the faster the shrinkage. At a mass flow rate of 1.50 g/s for oxygen, the regression rate of the spiral star grains is significantly higher than that of the straight star grain and the conventional round tubular grains, and the regression rate gradually increases with a decrease in the helix lead. This finding is expected to solve the problem of the low regression rate of solid fuels with spiral star pore-shaped grains prepared by the light-curing 3D printing method.

Numerical and experimental investigations of micro Al particle additive on the performances of HTPB hybrid rocket motors

The hybrid rocket motor (HRM) emerges as a promising propulsion system offering thrust adjustment at a low cost. Prior research has indicated that the inclusion of micro Al additives enhances HRM performance, yet a comprehensive investigation remains absent. Thus, this study aims to explore the impact of Al particle additive content and size variation on the characteristics of hybrid rocket motors (HRMs) through experiments and simulations. Firing tests are conducted on HRMs employing unadulterated HTPB, 38 % additive Al (2 μm), and 58 % Al (2 μm). Experimental findings reveal enhancements of 12.6 % and 33.9 % in regression rate, and 2.5 % and 8.0 % in specific impulse for the 38 % Al and 58 % Al fuel configurations, respectively, compared to the base case. Subsequently, a numerical two-phase combustion model is built to analyze the inner flow field characteristics. The high consistency between experimental and simulation results validates the efficacy of the numerical approach employed. Following this, a series of simulations covering Al content ranging from 0 % to 58 % and Al particle sizes from 0.4 μm to 75 μm is conducted. Simulation outcomes indicate that specific impulse and combustion efficiency enhancements correlate with the increase in Al mass fraction for particles with diameters under 35 μm. However, high Al content proves detrimental to specific impulse and combustion efficiency when particle diameter exceeds 35 μm. Additionally, regression rate and thrust demonstrate an increase with Al content, albeit the rate of increment diminishes with larger Al particles. This study comprehensively examines the influence of Al particle addition on HRM performance and elucidates the underlying mechanisms, thereby offering insights into HRM design and manufacture.

Transient numerical investigation on thermochemical erosion of C/C nozzles in hybrid rocket motors

Nozzle erosion is a vital important issue that impacts the performance of hybrid rocket motors. Serious nozzle erosion may significantly decrease the combustion chamber pressure and thrust, which increases the difficulty in designing flight control systems. This paper aims to reveal erosion mechanism systematically. In this paper, transient numerical simulations of thermochemical erosion in hybrid rocket motors are conducted, and combustion flow and thermochemical erosion are coupled calculated. The numerical computation of combustion flow is based on the chemical reactions of propellants and regression rate model, and that of thermochemical erosion is based on the surface reactions between oxidizing species and carbon. The movement of burning surface and nozzle inner surface is simulated through dynamic mesh method. The hybrid rocket motor adopts 90% hydrogen peroxide and hydroxyl-terminated polybutadiene. Distributions of flow field parameters and fuel regression rate are given. The spatial developing process of nozzle surface is presented, and it is found that the roughness of nozzle profile increases with time. The nozzle wall temperature and wall pressure decline with time. Erosion by different species is calculated. OH and H2O make a major contribution to the nozzle thermochemical erosion, while nozzle erosion contributed by CO2 and O2 are quite low. Time-varying characteristics of the erosion rate are unveiled. At the first 1.5 s, the total erosion rate remains almost constant, and then it reduces over time.

Comprehensive Six-Degrees-of-Freedom Trajectory Design and Optimization of a Launch Vehicle with a Hybrid Last Stage Using the PSO Algorithm

Increased performance with reduced overall cost, and precise design and optimization of launch systems are critical to affordability. In this respect, the use of hybrid motors has increased to ease handling based on motor selection. In the current study, the launch vehicle’s performance is enhanced by incorporating a hybrid rocket motor into the last stage and optimized using particle swarm optimization to develop a six-degrees-of-freedom tool. This modification aims to increase payload placement flexibility, facilitate handling, and reduce costs. Thanks to the interactive subsystems within this research, this innovative study more comprehensively considers the launch vehicle trajectory design problem, allowing the simultaneous consideration of the effect of launch vehicle geometry along with other parameters in the system. In this context, the proposed method is applied to the Minotaur-I launch vehicle, and contributions of the detailed design and optimization are presented. Optimization results show that the percentage differences between these models for the original vehicle were observed to be 11.55% in velocity and 8.02% in altitude. However, there were differences of 10.06% and 48.8%, 15.8% and 23.2%, and 19.5% and 78.9% in altitudes and velocities when the center of gravity and moment of inertia changes were neglected, and constant aerodynamic coefficients were assumed, respectively. In all these cases, it was observed that the flight path angle was not close to zero. Moreover, the same mission was achieved by the launch vehicle with the optimized hybrid last stage and the propulsion performance was increased by about 7.64% based on the specific impulse and total impulse-over-weight ratio.

Design optimization of a low-cost three-stage launch vehicle with modular hybrid rocket motors

This article investigates the impact of modular propulsion system design on the performance and cost of a three-stage hybrid rocket. Furthermore, it conducts a multi-objective optimization of unit payload cost, take-off mass, and payload mass ratio, considering factors such as the number of motors and layout considerations. The optimization design scheme for the three-stage hybrid rocket is divided into four cases. In the first case, each stage is equipped with a fixed single motor, and each stage is independently optimized without modular design. The second case considers the use of multiple motors in the first and second stages, still without modular design. The third case also involves multiple motors in the first and second stages, but all motors in each stage have identical parameters except for the nozzle expansion ratio, implementing a modular design. In the fourth case, the number and layout of the motor design method are the same as those in the third case, with independent optimization in the third stage using partial modular design. The results indicate that the unit payload cost of the multi-motor non-modular design case can be reduced by 13.12% compared to the single-motor non-modular design case. Within the modular case, the full modular design case is slightly inferior to the partial modular design case. Based on the above data, it can be concluded that the first and second stages of modular rockets offer the best performance and the lowest cost.

Long-Duration Dynamic Numerical Simulation of Combustion and Flow in Hybrid Rocket Motors Considering Nozzle Erosion

Long-Duration Dynamic Numerical Simulation of Combustion and Flow in Hybrid Rocket Motors Considering Nozzle Erosion

Demonstration of dual-thrust capability in hybrid rockets using multi-layered tubular fuel grains

This study demonstrates the thrust modulation capabilities of a hybrid rocket motor employing a Multi-Layered Tubular (MLT) fuel grain. The MLT configuration involves arranging the fuel grains with distinct regression rates as layers. As combustion progresses, the regression rate changes based on the burning of each fuel layer, leading to variable thrust while maintaining a constant oxidizer flow rate. Variable-thrust fuel grains are suitable for diverse mission types, including employment in sounding rockets and cruise missiles, particularly those designed for anti-ship operations and missions wherein a boost-sustain thrust profile is required. The MLT fuel grains were designed for a boost-sustain phase thrust profile generally observed in missiles. Wax was used as a booster fuel, and wax with 20%EVA was used as a sustainer fuel. Two MLT configurations with different durations for the boost phase were demonstrated. During the tests, the boost-sustain phase was achieved successfully. However, a transition phase was observed while shifting from the boost to the sustain phase. The delay of the transition phase was observed to increase when the duration of the boost phase increased. The combined effect of axial variation of fuel regression rate and local mass flux is the reason for the transition phase. The Thrust Turn-Down Ratio (TDR) for Multi-Layered Tubular (MLT) fuel grains was calculated. At a web thickness (for booster fuel) of 4 mm, the TDR was approximately 1.23:1, and at a 5.5 mm web thickness, it was 1.28:1. Further, 20%Mg was added to the wax to increase the regression rate of booster fuel. The Wax/20%Mg fuel showed 41% and 14% improvement in regression rate and thrust, respectively. The TDR was improved marginally compared to pure wax-based MLT grain.

Experimental and numerical investigation on thermochemical erosion and mechanical erosion of carbon-based nozzles in hybrid rocket motors

In order to enhance energy characteristics of propellants in hybrid rocket motors, aluminum particles are added into the solid fuel. However, these particles may lead to nozzle mechanical erosion, which significantly affects the motor performance. This paper intends to study thermochemical and mechanical erosion mechanism of carbon-based nozzles in hybrid rocket motors with aluminum metallized fuel. A firing test is performed, and 95 % hydrogen peroxide and hydroxyl‑terminated polybutadiene based fuel with aluminum particles are utilized. Experimental results show that many metal particles are ejected from the nozzle, and aluminum oxide deposits heavily on the nozzle inner surface. A method of numerical calculation coupled with two-phase flow, combustion of aluminum metallized fuel, thermochemical ablation reactions, and mechanical erosion is established. The errors of combustion chamber pressure and throat erosion rate between numerical calculation and test results are 0.53 % and 7.76 %, respectively. Simulation results indicate that with the increase of aluminum content, nozzle wall pressure gradually increases, while the mass fraction of H2O, CO2, OH, and O declines. The nozzle wall temperature and thermochemical erosion rate raise first and then reduce as aluminum content increases. The mechanical erosion is mainly distributed in the convergent section, and it raises with the increase of aluminum content. When aluminum content is up to 38 %, the maximum mechanical and thermochemical erosion rates are 0.09185 mm/s and 0.0976 mm/s, respectively. This reveals that effects of mechanical erosion on hybrid rocket nozzles should be carefully considered and evaluated under conditions of high aluminum content.

Evaluation of combustion stability of single and multi-protrusion inserted hybrid rocket motor

The present study explores the influence of protrusions on the combustion stability of a hybrid rocket motor. The primary aim is to analyze single, double, and triple-protrusion configurations taking into account variables such as their location, material, and spacing between them. Protrusions used were made of Nylon (regress during combustion) and graphite (non-regress during combustion). For the base-case (without protrusion), significant pressure oscillations were observed, arising from the interaction between vortex shedding and fundamental longitudinal acoustic modes of the chamber at the fuel grain exit. A protrusion at 0.8X/L (X-protrusion insertion point from head-end, L-fuel grain length) disrupted the interaction between acoustic modes and vortex shedding, substantially dampened its amplitude (around 96% reduction). In case of double (0.2–0.8X/L, 0.5–0.8X/L) and triple-protrusions (0.2–0.5-0.8X/L), the distance between protrusions is playing a key role in inducing the pressure oscillations. When protrusions are kept close (0.5–0.8X/L and 0.2–0.5-0.8X/L), the excitation of third mode acoustics were observed. This was attributed to the continuous increase in protrusion height. If protrusion height exceeds 6–7 mm, the flow over the front protrusion separated and impinges on the subsequent protrusion. This causes pressure oscillations in double and triple-protrusion cases. These pressure oscillations were mitigated using regressable protrusions made of nylon, as they keep the height within the range of 6–7 mm. The results of this research provide valuable perspectives on the significance of protrusions in controlling combustion instability in hybrid rockets.

Dynamic laser ignition characteristics of solid fuel and oxygen for hybrid rocket system

The transient laser ignition process in a slab burner that is similar to hybrid rocket motors is investigated in this study. The coupling characteristics between solid fuel properties, pyrolysis rate, and laser power were analysed. The results show that the laser ignition process can be divided into four stages: preheating, pyrolysis, ignition, and combustion, with the preheating and pyrolysis stages primarily controlled by the solid heating rate and the mixing characteristics in the fuel-rich combustion zone. Meanwhile, the ignition and combustion stages were characterized by ignition kernel growth and flame front propagation. The ignition delay time and the establishment of steady-state combustion were significantly affected by the ignition energy and fuel properties, i.e., The ignition delay time increases exponentially with decreasing laser energy. An increase in oxidizer flow flux reduces the demand for mixing during ignition, but the corresponding increase in combustion pressure poses challenges to the ignition process. A two-dimensional transient numerical model was established based on optical-thermal coupling theory to further understand the dynamic pyrolysis process of solid fuel particles. The model was validated through fire experiments under different laser ignition energy conditions. The results indicate that the deviation of the maximum penetration depth and ignition delay time between the experiment and the simulation is within 7 %.

Phenomenological regression rate model in axial injection end-burning hybrid rocket motor using different oxidizers

Compared with conventional configurations, axial-injection end-burning hybrid rocket motors work with multiport fuel grains, which mainly burn in the axial direction. The consumption rate is controlled by the several flames developed at the end of each port. Although many studies of performance and flame stability have been carried out in the past, a phenomenological model of the axial regression rate was never provided in the past, which is the objective of the current work. The validation of the physical model is performed by a comparative study between firing tests using gaseous oxygen and nitrous oxide. Two experimental campaigns performed by a pressure-controlled combustion chamber are carried out with a single port grain in operative conditions equivalent to the multiport configuration. The axial regression rate was measured by varying the port diameter in a range between 0.5 and 4.6 mm, the mass flow rate between 0.004 and 1.7 g/s, and the chamber pressure between 0.1 and 3.4 MPa. The measured axial regression rate was quantitatively lower with nitrous oxide than oxygen, and the pressure sensitivity exponent decreased from 1.85 to 1.5, respectively. The physical reason has been attributed to the decomposition reaction of nitrous oxide occurring upstream of the flame front. In addition, a general methodology for fuel grain design is given, highlighting the benefits and drawbacks of introducing multiport grains and the effect of the oxidizer choice on the motor geometry. Finally, multiport firing tests were carried out to confirm the evidence observed in the simplified single-port campaigns.

Experimental Research into an Innovative Green Propellant Based on Paraffin–Stearic Acid and Coal for Hybrid Rocket Engines

This study focuses on an innovative green propellant based on paraffin, stearic acid, and coal, used in hybrid rocket engines. Additionally, lab-scale firing tests were conducted using a hybrid rocket motor with gaseous oxygen as the oxidizer, utilizing paraffin-based fuels containing stearic acid and coal. The mechanical performance results revealed that the addition of stearic acid and coal improved the mechanical properties of paraffin-based fuel, including tensile, compression, and flexural strength, under both ambient and sub-zero temperatures (−21 °C). Macrostructural and microstructural examinations, conducted through optical and scanning electron microscopy (SEM), highlighted its resilience, despite minimal imperfections such as impurities and micro-voids. These characteristics could be attributed to factors such as raw material composition and the manufacturing process. Following the mechanical tests, the second stage involved conducting a firing test on a hybrid rocket motor using the new propellant and gaseous oxygen. A numerical simulation was carried out using ProPEP software to identify the optimal oxidant-to-fuel ratio for the maximum specific impulse. Following simulations, it was observed that the specific impulse for the paraffin and for the new propellant differs very little at each oxidant-to-fuel (O/F) ratio. It is noticeable that the maximum specific impulse is achieved for both propellants around the O/F value of 2.2. It was observed that no hazardous substances were present, unlike in traditional solid propellants based on ammonium perchlorate or aluminum. Consequently, there are no traces of chlorine, ammonia, or aluminum-based compounds after combustion. The resulting components for the simulated motor include H2, H2O, O2, CO2, CO, and other combinations in insignificant percentages. It is worth noting that the CO concentration decreases with an increase in the O/F ratio for both propellants, and the differences between concentrations are negligible. Additionally, the CO2 concentration peaks at an O/F ratio of around 4.7. The test proceeded under normal conditions, without compromising the integrity of the test stand and the motor. These findings position the developed propellant as a promising candidate for applications in low-temperature hybrid rocket technology and pave the way for future advancements.

A comprehensive fluid–solid coupling dynamic simulation for spatiotemporal distribution of regression rate in hybrid rocket motors

The spatiotemporal distribution characteristics of the regression rate are crucial aspects of the research on Hybrid Rocket Motor (HRM). This study presents a pioneering effort in achieving a comprehensive numerical simulation of fluid dynamics and heat transfer in both the fluid and solid regions throughout the entire operation of an HRM. To accomplish this, a dynamic grid technique that incorporates fluid–solid coupling is utilized. To validate the precision of the numerical simulations, a firing test is conducted, with embedded thermocouple probes being used to measure the inner temperature of the fuel grain. The temperature variations in the solid fuel obtained from both experiment and simulations show good agreement. The maximum combustion temperature and average thrust obtained from the simulations are found to deviate from the experimental results by only 3.3% and 2.4%, respectively. Thus, it can be demonstrated that transient numerical simulations accurately capture the fluid–solid coupling characteristics and transient regression rate. The dynamic simulation results of inner flow field and solid region throughout the entire working stage reveal that the presence of vortices enhances the blending of combustion gases and improves the regression rate at both the front and rear ends of the fuel grain. In addition, oscillations of the regression rate obtained in the simulation can also be well corresponded with the corrugated surface observed in the experiment. Furthermore, the zero-dimension regression rate formula and the formula describing the axial location dependence of the regression rate are fitted from the simulation results, with the corresponding coefficients of determination (R2) of 0.9765 and 0.9298, respectively. This research serves as a reference for predicting the performance of HRM with gas oxygen and polyethylene, and presents a credible way for investigating the spatiotemporal distribution of the regression rate.