DESIGN OF AN OPTICAL CLOSED BOMB (OCB)

"AD-A149 991

B I

R MEMORANDUM REPORT BRL-MR-3388

LDESIGN OF AN OPTICAL CLOSED BOMB (OCB)

Didier Devynck

October 1984 DTICFEB 11 1985L

8 B _

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US ARMY BALLISTIC RESEARCH LABORATORYABERDEEN PROVING GROUND, MARLAD

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MEMORAND1,M REPORT BRL-MR-3388 C; 1:/4 TITLE (and Subtitle) 5 TYPE OF REPORT & PERIOD COVERED

DFSICN OF AN OPTICAL CLOSED BOMB (OCB) Final6 PERFORMING ORG REPORT NUMBER

7 AL THOR(a) 8 CONTRACT OR GRANT NUMBER(a)

Didier Oevvnck*

9 PERFORMING ORGANIZATION NAME AND ADDRESS 10. PROGRAM ELEMENT. PROJECT.. TASK

ITS Army Balli;tir Pfesearch Laboratory AREA & WORK UNIT NUMBERS

ATINT: \MXBR-IBD 1L161102AH43\¾erdeen Proving Ground, MD 21005-5066

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I1 SUPPLEMENTARY NOTES

*Societe Nationale des Poudres et Explosifs,Centre de Recherches du Bouchet, France

*Defense Exchange Scientist, DEA-F-126719 KEY WORCS (ContInue on reverse elde If necessary and identify by block rnumber)

4 20 ABSTRACT CC.rtfimue ,meroerse, sfi If rMfCe•1*Wt 2i1identify. by block number)

In order to provide information on the mechanical behavior of gun propellantsduring combustion, an Optical Closed Bomb (OCB) has been designed.This fixture is to be used in connection with various visualization techniquessuch as flash radiography and high speed cinematography. Therefore, the OCBincludes some parts made of fiber reinforced composite materials.

DD FORM , ..

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TABLE OF CONTENTS

Paze

LIST OF ILLUSTRATIONS ...................................... 5

I. 1ITRODUCTION ..................................................... 7

II. DESM F OF OPTICAL CLOSED BOiD ............................... 8

A. Design of the Cor.:bustion Chamber ................... 9

"P. Other Features ............................. .. 13

III. CPERATIO.',AL POCFDUPFE ................ 17

IV Cu 'CLJSIOTS i....................................................p

ACKNOITLFDGEIE?!TS .................... ............ .. lq

PF FERENCES ..................................................... 20

APPENDIX A ............................. ........................ 21

DISTRIR UTIOV LIST ............................................ 45

Acceesson Fo0

DICDTI T,3Ci4I~sP~c~t~ Unear.bt7 - -

JU -'..- •.t a .. __

Avaliabiltty C'Z 3-

S. . Avail 4,c -,#

K

Av,D4it S

LIST OF ILLUSTRATIONtS

Fiture Page

1 Assembly DrawinG of the Optical Closed i3orab ........... 10(OCB)

2 Uail Thickness vs. Maximum Hoop Stress for a ...... 12

Fiber Reinforced Cylinder of 40-rmm ID at aLoading Pressure of 200 MPa (30 Kpsi)

Scheuatic of Fiberglass Bomb Sectioue with Steel . . . . 14

End Caps

4 Igniter Housing Sleeve for OCGD... .................... 14

5 Fi-ring Electrode .............................. 16

FK5

I. INTRODUCTIOU

Closed bomb testings are u valuable an,' dependable i eanr, ofevaluating tne ballistic performances that can be expected frow, agiven propellant lot. ' oreovcr, when the propellant involved is aclassical tuuular or 7-, 19- or 37- perforation grain,reduction techniques using computers have been developed toprovide the experimentalists with additional information, such Esthe burninE rate as a functior of pressure, fror the datarecorded dur:.ng closed boub .irincs.

Such computations are based upon the fact that, forclassical propellants, it way reasonably be assumed that tiephcaormenon involved is that of parallel co:.bustion, tha.t is tosay, "he burning rate is the same, at a Liven tiu.•, on everypoint of the surface of every propellant Erain of the chargetested in the closed bor-b.

This hypothesis has been shown to give results that allow asatisfactory prediction of the results obtained in actual Lunfirings. However, the pdst few years have witnessed tnedevelopment of new generations of propellants involvin% newballistic concepts. Among others, consolidated charges and VeryH11Ln Burning Rate (VHBR) propellants 3 have shown proL.isinE.results for enhancing tne performance level of guns.Unfortunately, theoretical predictions of the ballistic behaviorof these propellants is difficult due to the fact that theprevious assumption of parallel corbustion is no longer suitable.

Indeed, a consolidated charge is formed by a con-lomer•,>Ž ofpropellant Frains held together by a binder. After such a char-eis ignitca, it is very likely that the tcrains will be separatedfrom each other and tnat the charge will then behave as -aconventional charre. But it is no.,t inprobable that thisphenomenon occurs right at the tioc the charge is ignited andthis means that the form function of 'he constituent grains isnot valid during at lea,- the first instants of the comoustion.

IC. Price, A. Juhasz, "A Versatile User-Oriented Closed Bomb DataReduction Prograr.. (CERED)," Ballistic Eesearch LaboratoryTechnical Report No. ARERL-TR-2018, September 1977, AD# A049465.

21. W. iay, A. A. Juhasz, "Combustion Processes in Consolida ed

Propellants," Ballistic Research Laboratory I eiiorandum Report No.ARBRL-MR-O31o8, May 1981, AD# A101163.

3A. A. Juhasz, I. W. May, W. P. Aungst, F. R. Lynn, "Combustion

Studies of Very High Burning Rate (VHBR) Propellants," BallisticResearch Laboratory Memorandum Report No. PRBP.L-IP.R-03152,February 1982, AD# A113029. 7

It is of great importance then to the modelers to determine thedifferent steps of the combustion process in order to establishan empirical form function to be used as code input.

The problem encountered when dealing with VHBR propellantsis of an analogous nature. In fact, a VHBR propellant is not ahomogeneous material, but rather a heterogeneous mixture of verysmall particles. To ensure a reproducible and dependablecombustion of such a material, it is essential that the surfaceregression be a controlled process, i.e. that the flame frontdoes not generate a bulk decomposition of the grain or thepellet of propellant but on the contrary proceeds through thegrain following a linear law so it can be considered thatparallel combustion is the process involved.

Closed bomb testings and weapon firings essentially provideinformation on the pressuLre development during propellantcombustion. Although a press- s signal can occasionally carrysome information concerning tk.h mechanical behavior of thepropellant tested, this informat-.on is too limited to allow afull understanding of the phenomena involved.

Therefore, an experimental fixture has been designed toallow a visual observation of the combustion process, using flashradiography or high-speed cinematography. This Optical ClosedBomb (OCB) includes some parts made either of fiber-reinforcedmaterials that are translucent and X-ray transparent or simply ofoptically transparent plastic. This report presents the designrequirements and the solutions adopted to meet them. Alsopresented in the report is the operational procedure for usingthe fixture.

II. DESIGN OF OPTICAL CLOSED BOMB

The basic requirements for the design of the fixture werelisted as followsf

1. Fixture must be composed of a combustion chamber and asurge tank, the volume of which must be large comparedto that of the chamber to allow gases to expand and toavoid excessive pressurization of the fixture.

2. Fixture must be capable of accepting a blowout diskbetween the chamber and the surge tank.

3. Fixture must stand a maximum pressure of 100 MPa (about

15 kpsi) when used with a fiber-reinforced chamber.

4. Chamber must be transparent or translucent for use withhigh-speed cinematography, and/or X-ray transmitting for

use with flash radiography.8

•. Fixture must accept at least piezoelectric pressuretransducers and the possibility of sidewall mounted

strain gap-es.

6. Fixture must be capable of functioning either as aclosed boub or as a strand burner, i.e. gre-pressurization of fixture rust be possible.

7. Fixture rust be usable with a variety of propellants and

lrnition systems.

3. Fixture i:ust include a nozzle between the chambcr ancthe surge tank. Nozzle rust be rernovable so nozzles ofvarious sizes ray be inserted in order to perruit thepressurizatien rate to vary froth one experirient toa nother.

9. Fixture must accor~odate sample diameter variation,. i.e.fixture must be capable of accepting chambers of varioussizes.

4 10. Safe venting of combustion gases must be possibleafter experim emts.

An assembly drawing of the OCId is given in Figure 1 to beused as a reference in the following sections of this report.

A. Dcsiý-n of the Combustion Chamber

Consolidated charges and VIPBR propellant grains are ofcylindrical shape and two diarmeters are currently available:12.7 nr. (0.5 in.) and 36.6"mm (1.44 in.). Therefore, twodifferent diameters have been selected for the chamber: 15 mm(0.59 in.) and 40 mm (1.57 in.). However, manufacturingconstraints may lead to slightly different values. For the birLr•erdiameter chamber, the length-diameter ratio has deliberately beentaken equal to 2. This gives a chamber height equal to 80 mm anda volume of about 100 cm3. The chamber of smaller diameter shouldhave the same height so the adjustment required for using X-rayswith either chamber can be maintained at a minimum level.

Once the inside diameter of the chamber has been deterr ined,it is possible to calculate the outside diameter using the thickwall pressure vessel formula:

+2bý + a

%,ax= p (1I)whee -- a 2

where a mr-ax is the maximuri value of the hoop stress,p is the pressure inside the vessel,a is the inside diameter,b is the outside diameter.

IQNTIM lfVIcE 7-

SLEV

* KN~<Ž<\c\ \V\ \ \WA> '

Figure 1. Assembly D~rawing of Optical rl-oseeI Bomb- (ocr:)

10

The hoop stress is a maximum on the inside wall of thechamber. It should also be noted that Eq. (1) is used with tneiiplicit assumption that the wall is composed entirely of asingle material. This hypothesis is not quite right in the casepresented here since the requirement of X-ray transparencyimzposes a fiber reinforced composite material as the mostsuitable solution. Such a material is typically composed of about755 glass, Kevlar or carbon fibers held by a binder whichconstitutes the remaining 25% of the material. However, despite ascercity of experimental data to support this, it is usuallyconsidered that the binder plays no significant role in themecnanical strength of the material which is hence treated intheoretic-l predictions as being only composed of the fibermaterial. .

The curve presented in Figure 2 shows the value of wallthickness as a function of the maximum hoop stress of the fiberi;:aterial for a given pressure (30 kpsi or about 200 N.!Pa) and aninside diameter of 40 mm.

The maximum stress that can be expected from a filament-wound naterial depends on the winding angle. A 54-degree wind isthe optimum orientation for a thin wall closed pressure vesselwhere the value of the hoop or circumferential stress is twicethat of the longitudinal or axial stress.5 Although the chamberhas already been considered as a thick wall vessel, and becauseof an extreme lack of data, the values of the ultimate hoopstress used in the calculations are those obtained for a thinwall vessel and the 54-degree angle by computation from theultimate tensile properties of the composite in the fiberdirection using netting analysis theory. 5 Those values are;,193,000 psi (1330 EPa) for an S-glass composite and 123,000 psi(850 flPa) for a Kevlar composite.

In these conditions, the chamber wall thickness should beequal to 0.13 in. for a fiberglass chamber and to 0.23 in. whenusing Kevlar.

In fact, experiments made at the Societe Nationale desPoudres et Explosifs (France) show that a fiberglass chamber, thewind angle of which is 450, can resist a pressure close to 100M4Pa (15 kpsi) with an inside diameter of 30 mm (1.2 in.) and a

4 H. L. Perritt, "Design and Fabrication of a Kevlar FiberComposite 30-mm Gun Tube," Nlaval Surface Weapons Center, DahlgrenLaboratory Technical Report No. NSWC TR 79-251, July 1979.

5 A. Shibley, H!. L. Perritt, M. Fig, "A Survey of Filament WindingPLASTEC," Plastics Technical Evaluation Center, Dovcr, N.J.Report# 10, May 1962.

11

thickness (mm)

15

10

51

(lmax

0 '(ksi)60 90 120 150 180 210

Figure 2. Wall Thickness vs Maximum Hoop Stress for a Fiber ReinforcedCylinder of 40-mm ID at a Loading Pressure of 200 MPa (30 Ypsi)

12

thickness of 2.35 rLm (0.1 in.). 6 This corresponds to a value of

about 700 HMPa (100 kpsi) for the maximrum stress. This seems tojustify the use of the values given above in the calculations.

The ends of the chamber are a very critical point in thedesign of the chamber. The chamber itself is made of a compositematerial and sealing has to be accomplished along the surfaceswhere the composite tube is in contact with the other parts ofthe chamber. Since the surface of a composite raterial is ratherrough, such a sealing is difficult to achieve.ý Therefore,metallic end caps are affixed to the ends of the fiberglass tube""y usinL an epoxy resin which not only holds the caps and thetube togethier cut also prevents leaks (Figure 3). A compressiveload on the end caps and the chamber after assembly insures thatthu epoxy bond is not overstrained. The end caps make possibleLe use 01 O-rings to seal the chamber. Horeover, under normal'reebody assumptions, the stress at the ends of the chamber would

be twice as high as the stress along the chamber sidewall. Withthis respect, the end caps ensure a clamping of the chamber endsand thus prevent failures due to the end effect.

Once riounted in place, the chamber is squeezed between abottorm plate anu the surge tank through four bolts. This numberwas selected because this configuration is the one which makeseasiest the simultaneous use of X-ray and cinematography withouthaving the bolts spaced on a circle of excessive diameter, as itwould be the case if a larger number of bolts were used.

B. Other Feqture§

The bottom plate was designed so it is "universal," that isto say, that it can be used with chambers of small or largediamLeter simply because the end caps are also meant to beadapters. But this design requires that the central part of thebotton plate be of a small diameter and, as a result, there isonly roor for a pressure transducer on the bottom plate. Tc houseanother essential feature, the ignition system, it was thennecessary to include in the OCB a sleeve between the chamber andthe surge tank (Figure 4). This sleeve is in fact merely anadditional portion of the combustion chamber and therefore maynot be "universal" since the inside diameter of the sleeve must

the same as that of the cnaniber.

L4

6R. Gerbet, I1. Nicolas, T-L. Paulin, "Simulateur pour

Visualisation Ge-9 Phenomenes de Balistique Interieure-ContratDRE- No. 80/178-Sujet d'Etude No. 2-Note de Synthese," NoteTechnique No. 167/'81/CRB/NIP, Societe Nationale des Poudres et

Explosifs (France), 22 octobre 1981.

13

*--TOP END CAP

FIBERGLASSTUBE

A.Z

BOTTOM END CAP

Figure 3. Schematic of Fiberglass Bomb Section with Steel End Caps

!1n

Figure 4. Igniter Housing Sleeve for OCB

"14

The firing electrode has to be electrically isolated fromthe grounded sleeve and, at the same time it has, of course, tooffer a secure sealing of the chamber. The solution selected tomeet both of these requirements is illustrated in Figure 5. Theelectrode fits tightly into a Teflon seal which is double-coneshaped so it gets tighter around the electrode when it issqueezed between the housing in the sleeNe and a beryllium-copperring which is pushed against the seal by a threaded plug. Thefunction of the Teflon seal is then double: not only does itensure isolation and sealing but it also retains the electrode.But, as an additional safety feature, the electrode is dividedinto an internal and an external part. The two parts are incontact with each other through larger cross-section portions inorder to make impossible an accidental ejection of the electrode.

The ground electrode is simply a 1/8-in. diameter metallicwire held in the sleeve by a Swagelok high-pressure fitting.

Also machined in the sleeve are a pressure port designed tofit a 607C-type Kistler gage and a Harwood 4-L recess so aventing valve may be installed. This last feature is intended toallow the venting of the chamber when used with a blowout disk incase neither the chamber nor the disk yield after combustion ofthe charge, a situation which would result in a dangerousconfinement of combustion gases under pressure in the chamber.

As indicated in the list of requirements, and as can be seenon the assembly drawing presented in Figure 1, a nozzle isinserted between the chamber and the surge tank. Along with thebottom plate, the chamber and the sleeve, it is fastened throughthe four bolts previously mentioned.

Finally, the surge tank itself is but a relief device. Apartfrom the fact that it must be capable of withstanding the maximumallowable pressure designated for the OCB, its volume must havethe proper value to allow a sufficient expansion of thecombustion gases. In a closed bomb, a pressure of 15 kpsi isattained for a loading density of about 0.1 g/cm . Hence this isthe maximum allowable loading density for the OCB. Consolidatedcharges with a diameter of 36.6 mm weigh approximately 75 g.(2.65 oz.), which implie5 that the total volume of the OCB mustbe equal to about 750 cm when used with the 40-mm diameter (100cm3) chamber.

Therefore, considering that some additional volume isgenerated by the sleeve and the nozzle, a value of 550 to 600 cm3

has been selected for the surge tank itself. The final insidedimensions for the tank are as follows: 96.5 mm (3.8 in.) ind.**Lameter, 78.7 mm (3-1 in.) in height and a 12.7-mm (0-5 in.)radius round edge at the lower pfrt of the tank. These valuesyield an inside volume of 560 cm (see Figure 1).

15

EXTERNAL

-SLEEVE ELECTRODE

RETAINER

//

* COPPERRING

* TEFLON'SEAL

INTERNAL

INSULATINGELCRDWASH ERS

Figure 5. Firing Electrode

16

0

The tank is made of 4340 steel which, under given heattreatient conditions, exhibits a yield stress of 225,000 psi(1550 ?hPa). Using Eq.(1), this value can be used to determine therminimuM possible tank wall thickness. The result of such a"calc'ulation is 6.6 nm (C.26 in.). In fact, due to practical

* ccnsiderations, a far larger average wall thickness was used (seebe low).

--. The. tanL is closed at the upper end by a lid which uust berctaincc by screws. The sealing is achieved by a 5-in. (127 rnm)r.-ean diameter Viton O-rinL. At a pressure of 15 kpsi, the forceexerted on the lid is then 2914,500 lbs. (13,617 !). Because of

practical design consioerations, the number of screws used vuztnot exceed six. A safety factor of about 2 was taken into accountand tlis leads to the use of six 7/8-in. Allen fine-thread screwswh:ch have a total yield strength of 459,000 lbs. (21240 N). Thc

imatiný threaded holes are machined in the sideoal].

I'creover, t-rec iHarwood 4-L recesses are machined in the"tank wall so K:arwood fittings may be used to vent the combustiongases or to connect the fixture to various devices in order to

Sachieve pre-prcssurization and to check the pressure during thisoperation.

Finally, the OCB is supported by a frame and, to allow the"OCB to be used in the horizontal or vertical position, trunnionsare used between the fixture and the frame. These trunnions areaffixed on the outside tank wall and threaded holes must then bemachined in this wall (see Figure 1).

For all those reasons, the tank wall thickness is muchlarlger than that obtained by the above calculation and the finaltank outside diameter is 9 in. (228.6 mm).

A complete set of manufacturing drawings for the OCE isreproduced in Appendix A.

"T Il. OPERATIONAL PROCEDURE

Presented in this section are the steps that should befollowed for easy and safe handling of the OCE. It must first benoted that a careful cleaning of the whole fixture is absolutelynecessary after each experiment and the design was conducted tomake it easy.

The fýrst step consists of assembling the chamber. To makethis possible, the end caps are previously machined to fit the"fiberglass or plastic tube which constitutes the sidewall. Thecaps may then be affixed to the tube by using an epoxy resin as aglue and by squeezing the assembly between two parallel surfacesduring the time necessary for the resin to polymerize.

"17

0•)

The assembled chamber is then placed on the firing plate and"* is thus ready for loading. If the propellant involved in the test* exhibits a very high sensitivity to static electricity, as is the

case for Hivelite, a thin metallic liner may be inserted alongthe inside wall of the chamber without any significantconsequence on the resulting X-ray picture.

The ignition device is then mounted on the sleeve. In somecases, the propellant grains are packed in a plastic bag and theigniter (electric match + black powder for example) is imbeddedin the charge; the whole charge is then mounted on the sleeve.But, when the igniter and the charge are not joined, the chargeis placed first in the chamber and the sleeve on top of thechamber if the ignition is desired above the charge. Otherwise,the sleeve is installed first so the '.gniter is underneath thepropellant and the ignition occurs then at the bottom of thecharge.

The chamber is then corplete and may be mounted at thebottom of the surge tank after tr.e desired nozzle has beeninserted in its housing in the tank. The loaded chamber miust ofcourse be carried very carefully and the use of a small jack maybe helpful to bring smoothly the chamber to its location beneaththe tank. The screws or threaded rods are then fastened in the..ating threaded holes in the tank and tightened to hold theasserbly. If a rupture disk is used, it is important to keep innind that the venting valve on the sleeve must be kept open whenassembling the OCB for firing.

Finally, the OCB is closed by fastening the surge tank lidand the above precaution must still be observed, i.e. the ventingvalve, on the tank this time, must be kept open during thisoperation. The final steps of the procedure consist of connectingthe ignition device to the firing line and closing the OCD byshutting the valves.

Once the OCB is closed, all operations, namely, pre-pressurization of the OCB (if desired), firing, and venting ofthe combustion gases, must be remotely conducted until the beribhas been vented after the firing.

IV. CONCLUSIONS

The OCB has been designed to meet a large number ofrequirements and to be as versatile as possible. It is thereforereasonable to expect that it will be widoly used to provide dataon the behavior of a propellant during the combustion.

The use of composite materials in the design of the OCBmakes possible experiments involving such techniques as flashradiography and high speed cinematography. Since information onthis kind of material is very scarce, it is difficulttheoretically to predict the performances that can be expected

18

fron the fixture. Only experimental testing will provide theinformation needed in order to determine the fabricationparameters of the parts made of composite material.

"A CKNOWLEDGE14ENTS

The author wishes to thank Dr. A. A. Juhasz who proposed thebasic idea for the device. Further thanks go to Dr. Juhasz andDr. K. J. Vlhite for helpful suggestions during numerous valuablediscussions. Additional thanks go to Mr. W. F. Donovan, whosetechnical expertise was a priceless help in the achievement ofthis project. Support and assistance for the completion of thiswork were also provided by the Societe Nationale dez Poudres etExplosifs (France) and the Direction des Recherches Etudes etTechniques (France) by making possible the stay of the author atthe Ballistic Research Laboratory.

19

REFERENCES

C. Price, A. Juhasz, "A Versatile User-Oriented Closed Bomb DataReduction Program (CBRED)," Ballistic Research LaboratoryReport 'No. BRL-R-2018, September 1977, AD# A049465.

"2I. W. I'ay, P. A. Juhasz, "Combustion Processes in Consolidated.. Propellants," Ballistic Research Laboratory Ilemorandum Report No.

ARABRL-INE-03108, fay 1981, AD# A101163.

3 A. A. Juhasz, I. U. May, W. P. Aungst, F. R. Lynn, "CombustionStudies cf Very High Burning Rate (VHBR) Propellants," BallisticResearch Laboratory Memorandum Report No. ARBFL-IIR-03152,February 1982, AD# A113029.

r4. L. Perritt, "Design and Fabrication of a Kevlar FiberCoidposite 30-mni Gun Tube," :'aval Surface Weapons Center, DahlgrenLaboratory Technical Report N.o NSWC TR 79-251, July 1979.

"5 A. Shibley, H. L. Perritt, H. Fig, "A Survey of Filament WindingPLASTEC," Plastics Technical Evaluation Center, Dover, N.J.

* Report# 10, flay 1962.

"6 R. Gerbet, IN. Nicolas, J-L. Paulin, "Simulateur pour

Visualisation des Phenomenes de Balistique Interieure-ContratDRET No. 8 0/178-Sujet d'Etude No. 2-Note de Synthese," Note

S-.. Technique No. 167/81/CRB/NP, Societe Nationale des Poudres etExplosifs (France), 22 octobre 1981.

02

1-,

•]" 20

APPEHDIX A

IANUFACTURIIUG DRAWINGS

OF THE OCB

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