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EXTENDED ABSTRACT
1.
This is
subjected to severe aerothermal environment during Re-entry Phase of Flight and its
performance governs the Vehicle accuracy and survival to a large extent. Excessive
erosion occurring on nosetip and other parts can effect Vehicle stability and
asymmetric erosion on these parts will generate control problems. Another significant
performance requirement is inside temperature of the structure should not rise beyond
60o C for smooth functioning of the electronic components placed inside. In order to
satisfy above requirements, nosetip is made out of Carbon-Carbon (C-C) material
using 4D-Preform structure. The 4-D structure offers quasi isotropic properties in a
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plane perpendicular to the Missile Axis, to have almost uniform erosion. Coming to
conical sections, two layer composite construction is employed to satisfy the two main
functional
requirements. The inner Carbon-Epoxy layer out of CNC filament winding takes care
of structural loads and the outer Carbon-Phenolic layer using tape winding satisfies
the thermal protection requirements.
Regarding design aspects, initially thermal analysis is carried out to determine
theoretically the temperature distribution and surface ablation for each component.
The problem is basically that of heat transfer in a solid domain with time dependent
heat flux at the outer surface and temperature dependent material properties. The
shape change due to ablation of surface adds complexity to the problem. A computer
code is developed for heat transfer calculations with convective boundary where
reaction occurs and 2-D ablation model using finite elements in space and finite
difference approximation in the time domain. Further FEM analysis, using ANSYS
package, is carried out for the following cases:(i)
(ii)
(iii)
(iv)
(v)
design parameters.
2.
CANISTERS
Canisters are used for storage, transportation, handling and launch of Missiles.
This forms an essential requirement of modern Missiles where the launcher has to be
highly mobile to minimize enemy threat. Different types of launch platforms such as
ground, ship and sub-marine are considered for usage and the sub-marine launch
becomes critical design consideration if same canister has to be used for all platforms.
It consists of a long Composite cylindrical tube with a metallic dome at the bottom and
a short metallic cylinder in the front. Critical area of Canister development turns out to
be leak proof joint between metal and composite portions of the tube. The joint not
only experiences large direct stresses, but also is subjected to large stresses due to
stiffness mis-match between the metallic and composite shells in both hoop and
longitudinal directions. Basically two types of joint concepts, namely, radial joint and
axial joint are tried out simultaneously to arrive at a positive conclusion. The axial joint
configuration certainly provides more effective hermetical sealing.
However, it
Launch Load
2)
3)
Thus, at any instant of time, gas generator pressure act on part of the
3.
Carbon Carbon Composites are the state-of-the-art materials for aircraft Brake
Discs. All most all the fighter and passenger aircrafts are using Carbon Carbon Brake
Discs in view of significant weight savings and cost with respect to landing per
overhaul (LPO) over the conventional metallic discs with ceramic pads. Higher levels
of heat absorption per unit mass is feasible with Carbon Carbon Brake Discs. Aircraft
Brake Discs have to absorb tremendous amount of heat energy generated in the
process of braking action due to friction between the rotors and stators.
The fibre architecture and the matrix micro structure have to be suitably
selected to meet the thermo-structural and tri-biological design considerations. High
specific heat, high thermal conductivity, low co-efficient of thermal expansion and
stable coefficient of friction over the temperature of operation with low wear are the
key characteristics of Carbon Carbon Brake Discs.
Carbon Carbon Brake Discs have been developed both for Airforce and Navy
versions of LCA. The key technologies developed include preforming with woven
fabrics, chopped strands, spun yarn fabrics, densification with high pressure liquid
pitch impregnation, carbonization, (HIP) and Graphitization.
Squeeze riveting of
metallic clips with Carbon Carbon rotors has been established. Non-rubbing zones of
Carbon Carbon Discs are protected with specially formulated ceramic paint for
oxidation resistance.
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4.
RADOMES
power transmission, side lobe level and bore-sight error are very stringent as in the
case of Light Combat Aircraft, it becomes necessary to go in for a variable thickness
radome, in place of uniform thickness radome, which is normally used. Also for large
size radomes, an Insertion Phase Delay (IPD) measurement and correction system
will be employed to make finer corrections after fabrication so that rejections are
almost eliminated on production requirements.
5.
Rocket Motor Casing is basically a pressure vessel with specially designed end
fittings namely polar bosses and skirts. The polar bosses are provided with matching
interfaces to igniter and nozzle assemblies on either side. The skirts take care of
attachment to the fore and aft end sections of the Missile. The polar bosses are
structurally designed by considering a cantilever configuration subjected to internal
pressure load and nozzle ejection load. A rubber encapsulation is provided between
the metal polar boss and the composite