A

PROJECT REPORT

ON

VALUE ENGINEERING ANALYSIS OF

TURBO-GENERATOR IN ELECTRONIC FUZE

BY

ANIKET CHAUDHARI

AAKASH BORUDE

SANJOG GAWADE

NEIL FERNANDES

UNDER THE GUIDANCE OF

DR. A.P.PANDHARE

DR. VIRENDRA KUMAR

SPONSORED BY: A.R.D.E., PASHAN, PUNE

DEPARTMENT OF MECHANICAL ENGINEERING

SMT. KASHIBAI NAVLE COLLEGE OF ENGINEERING

Vadgaon(BK), Pune – 411 041

SAVITRIBAI PHULE PUNE UNIVERSITY

2014 – 2015
 CERTIFICATE

Sinhgad Technical Education Society’s

Smt. KashibaiNavale College of Engineering, Pune- 411041

This is to certify that

Aniket Chaudhari B80360838

Sanjog Gawade B80360869
Aakash Borude B80360835
Neil Fernandes B80360862
have successfully completed the project work titled ‘Value Engineering
Analysis of Turbo-generator used in Electronic Fuze ’ during the
academic year 2014-2015. This report has been approved as per the
syllabus described by the University of Pune for the academic year 2014-
2015
Date:
Place: Pune

Dr. A .P.Pandhare Dr. A.P.Pandhare

Project Guide Head of Department

Dr. Virendra Kumar

External Guide Examiner
 ACKNOWLEDGEMENT

This project would not have been possible without the support and help of
many individuals and organizations. We would like to extend our sincere thanks
to all of them.

We are highly indebted to Dr. Virendra Kumar, ‘Armament Research&

Development Establishment’, Pashan, Pune for his guidance, constant supervision and
support in completing the project.

Also we would like to thank our project guide Prof. Amar Pandhare,
Smt.Kashibai Navale College of Engineering, Pune for his constant encouragement
and valuable guidance during the course of this work.

We also thank and appreciate our colleagues for help with few aspects of the
project and people who have willingly helped us out with their abilities.
 ABSTRACT

In this Project we deal with the Design & Analysis of turbo generator for Fuzes
used in missiles. This is a new technology in which power is generated within the
warhead fuze. The projectiles have been powered by storage batteries traditionally.
But due to number of drawbacks of these storage batteries such as short life, leakage,
fire hazard, etc., a new technology was required which overcame these shortcomings.
Deep research was carried out, which resulted in the development of wind driven
turbo generator that could fit inside the fuze ogive.
The advantages of such a power source were long life, nonhazardous storage &
greater reliability. So, it has become the most preferred choice for use in artillery
munitions etc.
Very few countries such as US & Israel have been able to successfully develop
& use this technology. India is also trying to develop it for it’s obvious advantages.
Turbo generator consists of a turbine impeller mounted on a shaft. High velocity
air rotates the impeller, which rotates the shaft. A multi-pole permanent magnet rotor
is mounted on shaft, which is made to rotate at 10,000 to 15,000 rpm. The PM rotor
comprises the field winding of the alternator whose stator coil or armature is fixed to
the casing. The alternator functions according to Faraday’s Law of Electromagnetic
Induction; the rotating magnetic field/flux produces an emf in the stator coil, which is
used to power Fuze electronics.
This project report includes broad information about the turbo generator
construction and working, along with detailed design of the turbo generator and
analysis of the critical components.
Table of Contents Page No.

1.1 Introduction 1
1.1.1 Types of Fuzes 1
1.1.2 Alternate power sources 3
1.1.2.1 Fluidic generator 3
1.1.2.2 Reserve battery 4
1.1.2.3 Thermoelectric power supply 4
1.1.2.4 Thermal battery 4
1.1.2.5 Piezoelectric power supply 5
1.1.3 Turbo-generator 5

1.2 Construction and working 6

1.2.1 Turbine/rotor 6
1.2.2 Electric generator 6
1.2.3 Shaft 6

1.3 Manufacturing drawings 8

1.3.1 Turbo-generator components 8
1.3.2 Air-intake valve components 14

1.4 Assembly procedure 19

1.4.1 Sub-assemblies 19
1.4.2 Main assembly 23
1.4.3 Air intake valve 24

1.5 Test plan for turbo generator 25

1.5.1 Introduction 25
1.5.2 Fuze power requirements 25
1.5.3 Test plan 26
1.5.3.1 Test on Turbine & Alternator (T/A) 26
1.5.3.2 Test on Bearing 28
1.5.3.3 Rain test on Alternator 30

1.6 Design calculation 32

1.6.1 Shaft design check 32
1.6.2 Turbine design check 36
1.6.3 Calculation 37
1.6.4 Magnet selection 40

1.7 Results 41

1.8 Documentation 42

1.9 Conclusion 56

1.10 Future Scope 57

1.11 References 58
List of Figures Page No.
Figure 1: Different type of activation in fuzes 2
Figure 2: Section view of electronic FUZE 3
Figure 3: Next Generation Proximity Fuze 8
Figure 4: Laboratory test arrangement for measuring 27
operating characteristics
Figure 5: Experimental arrangement for studying 28
effect of temperature on Alternator output
Figure 6: Laboratory test arrangement for measuring 29
Alternator start-up
Figure 7: Pressure availability curve above Stop 34
Pressure line means continuous operation
during full projectile flight path
Figure 8: Von-Mises Stress of shaft 35

Figure 9: Total Deformation of shaft 35

Figure 10: Strain Energy of shaft 35

Figure 11: Von- Mises Stress of turbine 39

Figure 12: Maximum Principal Stress of turbine 39

Figure 13: Total Deformation of turbine 40

Figure 14: Equivalent Elastic Strain of turbine 40

List of Tables Page No.

Table 1: Properties of BS 970 Gr 30 32

Table 2: Physical Properties of Turbo 33

Generator Component
Table 3: Properties of NYLON6-6 36

Table 4: Pressure & Temperature variation 38

due to Projectile velocity

Table 5: Stress induced in Turbine for 38

various Projectile Velocities

Table 6: Properties of Magnetic material 41

Table 7: Stress induced in turbine 41

Table 8: Structural analysis results for shaft 42

List of Components Page No.

Component 1: Assembly of Turbo-generator 8

Component 2: Sectional view of Turbo-generator 9

Assembly

Component 3: Rotor 9

Component 4: Cover plate 10

Component 5: Thrust Ball Bearing 10

Component 6: Shaft 11

Component 7: Stamping plate 11

Component 8: Housing 12

Component 9: Shaft & Magnet Assembly 12

Component 10: PCB Assembly 13

Component 11: Stamping plate Assembly 13

Component 12: 2D Sectional view of Turbo-generator 14

Assembly
Component 13: 3D Air intake valve Assembly 14

Component14: Cut section of Air-Intake valve 15

Component 15: Air-intake Tube 15

Component 16: Valve Housing 16

Component 17: Air flow valve body 16

Component 18: Valve Plunger 17

Component 19: Valve body 17

Component 20: Adapter 18

Component 21: 2D Sectional view of Air-intake valve 18

Assembly
1. 1 INTRODUCTION

1.1.1 Fuze:

 A cord of readily combustible material that is lighted at one end to carry

a flame along its length to detonate an explosive at the other end.
 Often FUZE is a mechanical or electrical mechanism used to detonate an
explosive charge or device such as a bomb or grenade.
(International Defense Review).
 A fuze is a device used in munitions which is designed to detonate, or to set forces
into action to ignite, detonate or deflagrate, the charge (or primer) under specified
conditions. In contrast to a simple pyrotechnic fuse, a munitions fuze always has some
form of safety/arming mechanism, designed to protect the user from premature or
accidental detonation

Fuze categorization by munitions type:

a) Artillery fuzes.
b) Hand grenade fuzes.
c) Aerial bomb fuzes.
d) Landmine fuzes.
e) Naval mine fuzes.

Fuze categorization by activation mechanism :

a) Time fuzes :
Time fuzes detonate after a set period of time by using one or more
combinations of mechanical, electronic, pyrotechnic or even chemical timers. Early
artillery time fuzes consisted of hole filled with gunpowder leading from the surface
to the centre of the projectile. The burning gunpowder flame ignites this "fuze" on
firing and thus igniting or exploding whatever the projectile may have been filled
with.

1
b) Impact fuzes :
Impact or contact fuzes detonate when their forward motion rapidly decreases,
typically on physically striking an object such as the target. An instantaneous
"Superquick" fuze will detonate instantly on the slightest physical contact with the
target. A fuze with a graze action will also detonate on change of direction caused by
a slight glancing blow on a physical obstruction such as the ground. Impact fuzes in
artillery usage may be mounted in the shell nose ("point detonating") or shell base
("base detonating").

c) Proximity fuzes :
Proximity fuzes cause a missile warhead or other munition to detonate when it
comes within a certain pre-set distance of the target, or vice versa. Proximity fuzes
utilize sensors incorporating one or more combinations of the following: radar,
active sonar, passive acoustic, infrared, magnetic, photoelectric, seismic or
even television cameras.

d) Remote detonators :
Remote detonators use wires or radio waves to remotely command the device
to detonate Barometric fuzes cause a bomb to detonate at a certain pre-set altitude
above sea level by means of a radar, barometric altimeter or an infrared range finder.

Figure 1: Different activation type in FUZE.

2
The main components that make up a fuze are:
1. Electronic circuitry to initiate warhead,
2. Power supply for the electronic circuit,
3. Safe & arm unit
4. Detonator & lead charge.
The power supply unit is a very critical component of a fuze. It fulfils the power
requirements of the electronic circuit, which controls the warhead detonation.

Figure 2: Section view of electronic FUZE

1.1.2 The various power sources previously used in fuzes are:

1.1.2.1 Fluidic generator :

It comprises an air inlet means and a helmoltz resonator. The resonator consists
of a resonating cavity, a diaphragm and a metallic reed set in a magnetic field. The air
entering the resonating cavity produces acoustical vibrations. These vibrations cause a
diaphragm, which is mounted in the resonant cavity, to oscillate. The oscillating
diaphragm drives a metallic reed set in a magnetic field. This induces a current in the
coil, which is used to power electronics. At high flight velocities there is large mass
flow of air. As a result the diaphragm experiences large displacement, which in effect

3
causes the metallic reed to bang against the pole pieces. This leads to reel fatigue and
eventual failure, causing power loss.

1.1.2.2 Reserve battery :

They have been primarily lead/lead dioxide/fluboric acid based batteries.
Further they may be either dry cell based or wet cell based. Dry cell batteries have
limited useful lives. Wet cell batteries are used such that the electrolytic fluid is
injected automatically into the electrodes, as a result of shell spin after leaving the
gun. Batteries may not be stored separately from the electrical portion of the fuse,
which they are to power, but must be preassembled with the fuzes, for logistic and
ready available reasons.
Drawback:
Some types of battery-equipped fuzes have proven to be unreliable, as a result
of electrolyte fluid leakage. They have a low shelf life (5-10 years). Another problem
is that these batteries are difficult to manufacture so that at the onset of a national
emergency production levels are expected to lag requirements for several months,
thereby creating logistics problems. Also they are expensive.

1.1.2.3 Thermoelectric power supply :

Comprises of a plurality of junctions, which are coupled to the propellant for

sensing the temperature and means of generating a voltage in response to the
temperature sensed by the generator. It works on the thermocouple effect. Integrated
with a compatible impact sensor (triboluminescent) it will initiate the warheads
explosive warhead. The voltage generated by the thermoelectric power supply is
stored in a capacitor, which supplies it to the detonator when the warhead impacts the
target.
Drawback:
It requires the use of temperature sensitive elements/alloys, which makes the
unit costly.

4
1.1.2.4 Thermal battery :
Setback forces, which are generated when the round is fired, produce the
electric energy. A fuzed salt is released on setback, which subsequently causes an
electrical charge to be generated between two electrodes. This charge is stored in a
capacitor and used to set off the detonator upon of the warhead.
Drawback:
Requires a considerable volume of space, necessitating minimization of the
amount of explosive for a given warhead size. It also increases the weight of warhead.

1.1.2.5 Piezo-electric power supply:

The piezoelectric element has been placed in the nose of the fuze ogive to
produce electrical energy upon impact of the warhead. This produced energy is
allowed to pass through a detonator which is a thin wire surrounded by a sensitive
explosive, such as lead azide. Explosion of the lead azide causes the main explosive
charge in the warhead to detonate.
Drawback:
Piezoelectric elements located in the nose offer only a limited area of impact,
and the voltage output is a function of the impact angle, falling of as the angle
increases.

1.1.3 Turbo-generator:
It comprises an electric generator assembly housed within a projectile. The
assembly includes an air driven turbine and an electric generator. A common shaft
carries the turbine and the permanent magnet of the electric generator. The generator
rotor is a small permanent magnet and the stator a series of coils. The principle of
power generation is similar to the wind turbine-generator unit except that the turbo-
generator assembly is very compact and operates at substantial rotational speed.
The impellers used in prior art electrical generators were very inefficient in that
most of the air taken in by the turbine is diverted rather than used to drive the
impeller.
The prior art turbines were placed outside the fuze resulting in increased size of the
projectile. The new developments in the case of the turbo-generator have resulted in

5
reducing the size of the fuze by incorporating the unit inside the fuze. The next
generation turbo-generator power supply makes use of an efficient turbine (centrifugal
unit). The next generation turbo-generator has improved dynamic balance than the
prior art generators. Since it has a life span equal to that of the whole fuze, and other
advantages as mentioned above, it has turned out to be the choice for the next
generation electronic fuze.

1.2. CONSTRUCTION AND WORKING:

The assembly comprises of mainly:
1. Air-driven turbine /impeller
2. An electric generator, comprising
3. Rotor element
4. Stator element
5. Shaft

Description of the elements of the assembly:

1.2.1 Turbine:
Includes a cylindrical centrifugal impeller having a plurality of vanes. The
vanes are of air foil shape. Each vane is oriented at an angle to a radius of the
impeller. The vanes are uniformly spaced around the periphery of the impeller and are
separated by air conduits terminating in centrifugal discharge apertures from which
air leaves the impeller. The flow of air through the impeller imparts rotational motion
to the impeller, which drives the turbine.

1.2.2 Electric generator:

The generator includes a rotatable element comprising a generally ring-shaped
permanent magnet. The stationary element of the electric generator includes a coil
housing for containing a coil of wire in which an electric current is generated. Leads
from the coil are provided to supply electric current. The coil housing is generally
radially symmetric. The coil is wound on the coil housing by a conventional method
so that the coil is generally perpendicular to the axis of rotation of the turbine and the

6
magnet. Magnetic flux paths are provided between the rotating magnet and the coil
housing by an inner armature member and an outer armature member. In operation,
the rotating magnet creates a rotating magnetic field, which is conducted through the
armature members to the coil wherein it generates an electric current.

1.2.3 Shaft:
The turbine also includes a generally cylindrical elongated shaft member or
shaft preferably formed from a high strength material such as steel. The shaft carries
the abovementioned members.
Wind turbines operate on a simple principle. The energy in the wind turns two
or three propeller-like blades around a rotor. The rotor is connected to the main shaft,
which spins a generator to create electricity

• The wind stream in flight provides both the mechanical power needed to arm the
Safety & Arming (S&A) and the electrical power needed for the fuze electronics.

• In this system, the Air Inlet directs the wind stream into a converging-diverging
nozzle (Venturi tube) that limits the mass flow rate (choked flow).

• The axial flow then rams the center of a flat impeller and flows radially through the
blades. The curvature of the blades continuously redirects the flow and the net
pressure on the concave surface area generates a torque that rotates a drive shaft.

• The drive shaft is permanently connected to an alternating current generator called

the Turbine Alternator Assembly whose operating principles resemble an automobile
belt driven alternator miniaturized to provide 20 volts and withstand an acceleration
of 20,000g.

• The drive shaft is also engaged with the S&A mechanism at the time of launch, but
disengages after a specific number of shaft revolutions. This action unscrews a
Jackscrew locking device and enables the explosive train to snap into alignment,
thereby completing the second step in mechanical arming.

7
 Figure 3: Next Generation Proximity Fuze

1.3. MANUFACTURING DRAWINGS :

1.3.1. Turbo-generator components:

Component 1: Assembly of Turbo-generator.

8
Component 2: Sectional view of Turbo-generator assembly.

Component 3: Rotor

9
 Component 4: Cover Plate

Component 5: Thrust Ball Bearing

10
Component 6: Shaft

Component 7: Stamping Plate

11
 Component 6: Housing

Component 7: Shaft & Magnet Assembly

12
 Component 8: PCB Assembly

Component 9: Stamping Plate Assembly

13
 Comp No. Nomenclature
1. Rotor
2. Cover Plate
3. Housing
4. Washer
5. Thrust Ball Bearing
6. Foam Disc
7. Shaft and Magnet assy
8. Stamping Plate Assy
9. Bobbin Assy
10. Coil Assy
11. PCB Assy.

Component 10: 2D Sectional View of Turbo-generator Assembly

1.3.2. Air-intake valve components :

Component 11: 3D Air-intake valve Assembly

14
Component 12: Cut section of Air-intake valve

Component 13: Air-intake tube

15
 Component 14: Valve Housing

Component 15: Air flow valve body

16
Component 16: Valve Plunger

Component 17: Valve Body

17
 Component 18: Adapter

Component 19: 2D Sectional view of Air-intake valve Assembly

18
1.4. ASSEMBLY PROCEDURE

1.4.1 Sub-Assemblies:
a) Bobbin Assembly :
Parts required :
i. Bobbin
ii. Enamelled copper wire

Procedure:

19
b) Stamping plate Assembly:
Parts required :
i. Bobbin Assembly
ii. Stamping plates
iii. Rivet
iv. Connecting wire
v. Glass epoxy sheet

Procedure:

20
c) Shaft & Magnet Assembly :

Parts required:
i. Shaft
ii. Magnet
iii. In-situ moulding

Procedure:

Place

21
d) PCB Assembly :

Parts required:
i. PCB
ii. Strip
iii. Terminal pin
iv. Body
v. Holder

Procedure:

22
1.4.2 Main Assembly :

Parts required:
i. Washer
ii. Bearing
iii. Housing
iv. Cover plate
v. Rotor
vi. Foam disc
vii. PCB Assembly
viii Shaft & magnet Assembly
ix. Stamping plate Assembly

Procedure:

23
1.4.3 Air-intake valve Assembly:
Parts required:
i. Air-intake tube
ii. Valve housing
iii. ‘O’ Ring ‘A’
iv. ‘O’ Ring ‘B’
v. Air flow body
vi. Valve plunger
vii. Spring
viii. Valve body
ix. Locking spring washer
x. Ring ebonite
xi. Ring washer
xii. Adapter

Procedure:

24
1.5. TEST PLAN FOR TURBO-GENERATOR

1.5.1 Introduction :
An air-driven power supply has been developed for fuze for Mortars that
converts the ram-air energy available to a projectile in flight into electrical energy to
power the fuze. This power supply also furnishes an arming signature based on
projectile velocity.
The basic features of several alternator designs are discussed, including the
means of achieving various power levels, reducing alternator size, limiting rotational
speed, attaining velocity discrimination, and using improved magnetic materials.
Initial tests of this device with other fuze components showed that rotational
speed reduction and proper bearing lubrication were needed in order to achieve
successful field-test results. These studies are discussed in this report, which also
gives the characteristics of the alternator with these improvements.
To further reduce the cost of the alternator in production, a new design was
developed that incorporated cheaper bearings instead of costly miniature precision
bearings and eliminated machined parts.

1.5.2 Fuze power requirements :

For this reason, the portion of the trajectory over which the power supply is
required to function must be specified. For the concept-feasibility design it was
necessary to demonstrate that the generator produced the required power when fired at
the lowest charge, and that it could initiate during descent when fired at the steepest
angle of elevation (85°). Hence, the turbine must start at a threshold velocity of about
120" ft/sec or lower, so that the generator can provide power to the fuzing system.
The generator must supply electrical power to the fuzing circuit and also
provide a mechanical output from the generator shaft to the safing and arming (S&A)
system. For the mechanical output the spinning shaft drives a gear reduction system
that aligns the firing pin with the detonator at a specified safe distance from the gun.

25
The requirements for the power supply are:
i. It must generate 0.600W with a 600-Ω load at flight velocities varying from
150 ft/sec to about 850ft/s.
ii. It must fit into a space no greater than 1 cu in.
iii. It must retain its integrity when spinning at velocities greater than 100, 000
rpm for at least 40 sec.
iv. It must be simple to manufacture and to assemble.
v. If the alternator stops during the low-velocity phase of the flight, it must
restart during the high-velocity phase in time to power a fuze,
vi. The fuze drag must not adversely affect the range and stability of the round.
vii. The alternator must have a long storage life and be rugged enough to
withstand the gun environment.
viii. It must not be adversely affected by flight through rain.

1.5.3 Testing plan:

1.5.3.1 Test on Turbine & Alternator (T/A):
Initial tests of the alternator mated with the S&Ashowed that the alternator
rotational speed was too high, which caused the S&A to arm below the required
arming distance. This indicated that limitation of the alternator-shaft rotational speed
was needed.
To attain speed limitation, the turbine blade tips were undercut to obtain radial
flexure of the tips from centrifugal force, at the higher turbine speeds, thus reducing
the turn angle of the air flow through the blades.
To determine the optimum speed reduction from blade tip undercut, a series of
tests at room temperature (700F, 210° C) were conducted in the lab. Turbine speed
versus input pressure was measured with turbines moulded of Type 66 nylon.

26
 Figure 4: Laboratory test arrangement for measuring operating characteristics

The test item with instrumentation for these tests is shown in figure 1.
Regulated air from a settling chamber enters directly into the inlet of a fuze ogive,
which houses the T/A. The output frequency of the T/A is measured across a 600-ohm
resistor. Stagnation pressure in the settling chamber is monitored with a strain-gage
pressure transducer. Alternator frequency versus inlet stagnation pressure is then
recorded on an X-Y recorder. The turbine rotational speed may be obtained directly
from the alternator frequency by multiplying the alternator frequency by 20.
This turbine was tested over the required operating temperature range (-60°to
160°F, -51 to 71°C). Figure 2 shows the instrumentation preconditioning coils were
located within a temperature conditioning chamber. For these tests, dry nitrogen was
used as the working fluid. The nitrogen is temperature conditioned as it passes
through the copper coils to the T/A, so that its temperature is nearly identical to the
conditioning chamber temperature when it enters the T/A inlet.

27
 Figure 5: Experimental arrangement for studying effect of temperature on alternator output

When conducting these tests, the test unit is temperature conditioned for a
minimum of two hours; then the inlet pressure to the T/A is set to correspond to the
expected maximum flight velocity. The unit is then operated at this pressure for 60 s,
and its frequency is recorded as a function of inlet pressure. Each unit is tested at
temperatures of -60, 70, and 160 F (-51, 21, and 71°C). Although turbine speeds at a
given inlet pressure varies with temperature, the power delivered at the temperature
extremes is sufficient to operate the fuze.

1.5.3.2 Tests on Bearings:

During cold temperature firing of fuzes during the engineering development
phase of the test program, it was discovered that the S&A's were not arming when
they were fired at charge 0. Test units employed for these tests were conditioned at -
40F (-400°C) and then fired at ambient temperature. Because of change in lubricant
viscosity with temperature, bearing lubrication was suggested as a possible cause of
this problem. A study was undertaken to investigate the effects of bearing lubrication

28
on cold-temperature T/A operation. Three methods of bearing lubrication were
investigated to identify whether or not bearing lubrication contributed to the arming
problem, and to select an alternate method of lubricating the bearings if necessary.
The three lubrication methods investigated consisted of
a. soaking the bearings in oil (as supplied by the manufacturer)
b. lubricating the bearings with a film of Anderoil 501, obtained by dipping bearings
in a 96-percent Freon, 4-percent Anderoil 501 mixture
c. removing all lubrication so that the bearings were dry
Test units were assembled with bearings lubricated as described, and start-up
characteristics were obtained, employing the instrumentation as shown in figure 3.

Figure 6: Laboratory test arrangement for measuring alternator start-up

Starting characteristics of the T/A were generated by first setting the inlet
pressure while maintaining the rotor stationary. The rotor was then released and
allowed to rotate, and the turbine speed was monitored as a function of time.
The previous method of lubrication adversely affected arming time, and an
improved lubrication method was needed.
The two alternate lubrication methods were further investigated. This
investigation consisted of subjecting four samples of T/A's assembled with bearings
lubricated with 4-percent Ander oil 501 and 96- percent Freon, and four test samples
of T/A's assembled with dry bearings to the testing procedure specified for turbine
validation in section 3.

29
 This test procedure consisted of pre-temperature-conditioning each unit at -60,
70, and 160 F (-51, 21, and 71°C) and then operating the unit at each conditioned
temperature for 60 s. The inlet pressure to the unit for each run was set to correspond
to the expected maximum flight velocity at that temperature. Alternator frequency
was recorded as a function of inlet pressure for each run. If each unit's performance
was not degraded as a result of these tests, then the probability of a similar unit
performing adequately during actual flight environments would be very high. All
samples exhibited satisfactory performance based on these tests. Bearing lubrication
with 4-percent Ander oil 501 and 96-percent Freon was selected for the XM734 T/A.
This light film lubrication is considered sufficient to protect the bearings during
storage. The increase in alternator start-up time at -40°F (-40°C) with this method of
lubrication was considered acceptable.

1.5.3.3 Rain test on Alternator :

a) Introduction :
To tests the functioning characteristics of the alternators under simulated rain
conditions of 24 in. hr. The alternators were mounted on a sled propelled by rocket
motors through a rain field 2000 ft.in length. The voltage output of each device was
monitored via telemetry. In the first tests, the sled accelerated from zero velocity,
entered the rain field at a velocity of 650 ft./sec, and left the rain field 3.83 sec later at
a velocity of 410 It/sec. In the second test, the sled entered the rain field at R velocity
of 430 ft/sec- and left at a velocity of 250 ft/sec 6.18 sec later.
The two runs together provided data from 10.0 sec in the rain field over the
velocity range from 250 to 650 ft/sec.

b) Test Hardware :
For the rain test, each alternator was housed in a fuze ogive having an entrance
port 0.380 in. in diameter and rectangular exit ports (0.500 in.x 0.130 in.) uniformly
spaced around the circumference. The entrance and exit ports were completely open
to simulate firing from a mortar. To monitor the alternator output during the sled run,
a special circuit was designed that would reduce the rectified alternator output by a
factor of 20 and supply 0 to 7 V de, the voltage limit of the telemetry system. The

30
circuits shown in figure 9. All alternators were mounted in fuze ogives and tested in
the laboratory.
Pressures corresponding to the flight velocity expected in a sled were supplied
to the alternators and the output voltage was recorded. The alternators were also
checked when mounted on the sled, to ensure that the telemetry recording equipment
was operating properly. Laboratory tests were conducted after the device had flown in
the rain to determine any damage to the alternator parts from passage through the rain
field.

c) Tests :
The Holloman test track is 37, 000 ft long, and the , rain-field section of the
track extends over some 2000 ft. Rain was simulated by forming water through a
series of nozzles on both sides of the track. The entry and exit points of the sled in the
rain field were located 25, 032 and 23, 032 ft from the end of the track, respectively.
Weather stations, located in the rain section of the track at intervals of approximately
1000 ft, provided information about wind speed and direction, the velocity of the sled
during the test was measured every 200 ft along the full length of the track. The
telemetered output of the alternators was recorded at a ground station on oscillograph
charts and on magnetic tapes. The time of entry and time of exit of the sled from the
rain field was marked on the oscillograph charts and magnetic tapes.

31
 1.6 DESIGN CALCULATION:

1.6.1. Shaft Design check :

Shaft diameter: 2.98 mm.

Shaft material: BS 970 Grade 304, cold worked (EN 58- )

Sr.No. Properties Value

1. Density(kg/m3) 7900
2. Young’s 200
Modulus(Gpa)
3. Specific Heat 500
Capacity(J/kg-K)
4. Ultimate tensile 680
strength(MPa)
5. Yield tensile 500
strength(Mpa)
6. Possion’s ratio 0.31
Table 1: Properties of BS 970 Gr 30

Using ASME code, we have:

Ʈ (permissible) = min (0.3* Syt, 0.18* Sut) = min (150, 122.4 = 122.4Mpa

a) Structural Analysis:
The total forces acting on the shaft can be categorized into 2 groups:
i) Direct forces: generated due to the weights of the individual components.
ii) Shear forces: due to the torque generated by rotation of turbine.

i) Direct forces:

Assuming the weights of the individual components acting at their individual centre
of gravity, the FBD can be represented as:

Cover
Magnet & In-
plate Washer
situ
Turbine Washer Bearing Moulding Bearing Housing

32
Sr.No Component Material Volume[3] Mass Weight
. Name Density (m3) (kg) (N)
(kg/m3)
1. Turbine 1140[4] 6.978*10-7 7.9549*10-4 7.8037*10-3
2. Washer 8450[8] 1.178*10-8 9.9541*10-5 9.7649*10-4
3. Cover plate 2770[5] 1.438*10-8 3.9833*10-3 0.03907
4. Magnet 6900[6] 5.223*10-7 3.6038*10-3 0.03539
5. In-situ 1140[4] 1.169*10-7 1.3326*10-4 1.3073*10-3
Moulding
6. Housing 2770[5] 4.869*10-6 0.013487 0.1323

Table 2: Physical Properties of Turbo-generator Component

ii) Shear forces:

For turbine the starting Torque value of the impeller is kept as low as possible
so that it can start early and most importantly can work at higher Altitudes (~30 km)
where atmospheric density drops to nearly 1.5% of MSL value and projectile speed is
least of the trajectory. From the graph obtained during testing of the Turbo-generator
we observe that the starting and hence the running pressure of the turbine can be
accounted close to 1 bar.

33
Figure 7: Pressure availability curve above Stop Pressure line means continuous operation during full
projectile flight path.

Hence the net force on the blade will be = pressure*area

here pressure=1 bar and area= 2.262*10-5 m2
Therefore force acting per blade=2.262N
Torque pre blade= force*radius= 2.262*10.41 =23.547Nmm
Total torque acting on shaft= 265.474Nmm

The above 2 forces are used to do a detailed analysis in ANSYS. The results are
obtained as:

34
 Figure 8: Von-Mises Stress

Figure 9: Total Deformation

Figure 10: Strain Energy

35
Therefore from the above results it is seen that the equivalent stress is
104.09MPa<122.Mpa.
By using Von-Mises stress criterion the design is safe.

b) Vibration analysis:
The angular speed corresponding to the first node is given by: ω = (g/δ) 0.5,
Where:
g=gravitational acceleration=9.81 (m/s2)
δ=total deformation (m) =1.4746*10-6 (m)
ω= angular speed (rad/s)
ω= (9.81/1.4746*10-6)0.5 =2579.273 rad/s.
N=60* ω/(2*π)=24630.247 rpm.
Thus to avoid the sudden failure of shaft due to node formation the speed of 24630
rpm must be avoided which is observed during the projectile speed of 580-620 m/s.

1.6.2 Turbine design check:

WORKBENCH module of ANSYS software is used to carry out the static
structural analysis of the turbine.
Specifications[9] :
Speed range: 125 to 700 m/s.
Altitude range: 6000 to 15000 m/s.
Material: NYLON6-6.

Material properties Value

Density 1.14 (kg/m3)
Young’s Modulus 3.1*109 Pa
Bulk Modulus 5.1667*109 Pa
Shear Modulus 1.107*109 Pa
Poisson’s ratio 0.4
Tensile yield strength 9.0e07 Pa
Compressive yield 9.2e07 Pa
strength
Shear Strength 6.89e07 Pa
Table 3: Properties of NYLON 6-6

36
1.6.3. Calculations :
When the projectile travels through the atmosphere at supersonic speeds, it sets
up a normal shock wave in front of it. The air pressure just in front of the projectile
and air entering in inlet is represented by P2. At subsonic speeds no shock wave is
formed & air pressure just in front of the projectile and air entering in inlet is equal to
P1.During supersonic operation the generator, inside the projectile ogive, is exposed
to a total pressure at the ogive air inlet equal to P2. Pressure P2 is determined by the
flight Mach number and altitude expressed by the equation:

Equation 1: (U.S. Patent No. 4,581,999)

Where:
P2 = free stream static pressure at a given flight altitude;
M=projectile velocity expressed in terms of the local Mach number;
k =1.4 (k is the ratio of specific heat capacities for air).
For a given flight Mach number and altitude, the corresponding pressures of P2
and P1 determine the amount of ram air mass flow that enters the generator, and thus
the amount of electrical energy generated.
Since the missile behaves like a projectile the missile will attain its maximum
velocity at the launch where P1 will be atmospheric pressure. Considering standard
atmospheric conditions from ISA chart we have:
Pressure=1.01325 bar
Temperature: 288.15K
Density of air= 1.225
Speed of sound=340.294 m/s.
The projectile with the increasing velocity and pressure build up at the launch will
also experience a temperature rise which is given by the equation :

Equation 2: Stagnation Temperature

37
 Using the above 2 equations we obtain the values of turbine rpm and pressure
experienced by turbine and temperature rise is given in tabulated from as:

Projectile Mach no. Turbine Angular Pressure Temperature

velocity rpm speed (bar) (°C)

350 1.02941 54314.43 5687.793 1.985 76.219

400 1.17647 48564.203 5085.631 2.37037 94.915
425 1.25 44492.59 4659.253 2.58999 105.196
450 1.32353 40843.973 4277.171 2.82623 116.102
500 1.47058 34526.547 3615.611 3.34621 139.783
575 1.69117 26823.814 2808.983 4.24022 179.976
650 1.91176 20613.068 2158.595 5.2666 205.779
700 2.0588 17094.709 1790.154 6.02322 259.424
Table 4: Pressure & Temperature variation due to Projectile velocity

The above parameters are used to carry a detailed analysis of the turbine in ANSYS.

Projectile Mach Turbine Angular Pressure Temperature Max principal

velocity no. rpm speed (bar) (°C) stress(Pa)
350 1.02941 54314.43 5687.793 1.985 76.219 2.27E+07
400 1.17647 48564.203 5085.631 2.37037 94.915 2.63E+07
425 1.25 44492.59 4659.253 2.58999 105.196 2.13E+07
450 1.32353 40843.973 4277.171 2.82623 116.102 3.06E+07
500 1.47058 34526.547 3615.611 3.34621 139.783 3.57E+07
575 1.69117 26823.814 2808.983 4.24022 179.976 4.47E+07
650 1.91176 20613.068 2158.595 5.2666 205.779 5.52E+07
700 2.0588 17094.709 1790.154 6.02322 259.424 6.30E+07
Table 5: Stress induced in Turbine for various Projectile Velocities

From the above results it can be seen that the maximum stresses obtained are for 700
m/s. Hence the results are shown for this value:

38
 Figure 11: Von- Mises Stress

Figure 12: Maximum Principal Stress

39
 Figure 13: Total Deformation

Figure 14: Equivalent Elastic Strain

From the above results the maximum principal stress and the von-mises stress
(4.7e7, 6.3e7)<9e07
Hence the design is safe

1.6.4 Magnet Selection:

To = 482.35 K
This is the maximum temperature rise during the projectile operation, which is
obtained at highest operating speed i.e. 700 m/s. The different components have to be
designed according to the above temperature constraint

40
 Material Maximum Residual Coercive Working
Energy Flux Force Temperature
Product Density Hc(Koe) °C
Bhmax Br(G)
(MGOe)
Ceramic 5 3.4 3950 2400 400

Sintered Alnico 5 3.9 10900 620 540

Cast Alnico 8 5.3 8200 1650 540

Samarium Cobalt 20 20 9000 8000 260

Samarium Cobalt 28 28 10500 9500 350

Neodymium N45 45 13500 10800 80

Neodymium 33UH 33 11500 10700 180

Table 6: Properties of Magnetic material

Based on above characteristics we have selected Sintered Alnico 5.

1.7 RESULTS :
The results of the analysis done in ANSYS are obtained as follows:

a) Stress induced in Turbine for various Projectile Velocities

Projectile Mach Turbine Angular Pressure Temperature Max principal

velocity no. rpm speed (bar) (°C) stress(Pa)
350 1.02941 54314.43 5687.793 1.985 76.219 2.27E+07
400 1.17647 48564.203 5085.631 2.37037 94.915 2.63E+07
425 1.25 44492.59 4659.253 2.58999 105.196 2.13E+07
450 1.32353 40843.973 4277.171 2.82623 116.102 3.06E+07
500 1.47058 34526.547 3615.611 3.34621 139.783 3.57E+07
575 1.69117 26823.814 2808.983 4.24022 179.976 4.47E+07
650 1.91176 20613.068 2158.595 5.2666 205.779 5.52E+07
700 2.0588 17094.709 1790.154 6.02322 259.424 6.30E+07
Table 7: Stress induced in turbine

41
 b) The maximum principal stress and the von-mises stress
(4.7e7,6.3e7)Pa<9e07Pa
Hence the design is safe

c) Static structural analysis of shaft give the following results:

Result Value
Equivalent (von-mises) stress 1.0409e8 Pa
Strain energy 4.9769e(-8)
Total deformation 01.4746e(-6) m
Table 8: Structural analysis results for shaft

d) Vibrational analysis of shaft :

To avoid the sudden failure of shaft due to node formation the speed of 24630
rpm must be avoided which is observed during the projectile speed of 580-620
m/s.

1.8 Documentation :
Production documentation is the organised collection of records that describe the
structure, purpose, operation, maintenance, and data requirements for easy and
efficient communication between designer and manufacturer. Following figures show
some features of Production Document.

42
43
GEN.TOL.MEDIUM/COARSE/FINE DRAWING CONVENTION
CLASS TO IS:2102 CONFORM AS PER JSG:0104
DIMS IN mm UNLESS
OTHERWISE STATED.

COMP. DESCRIPTION
NO
1 ROTOR
2 COVER PLATE
3 HOUSING
4 WASHER
5 THRUST BALL
BEARING
6 FOAM DISC
7 SHAFT AND
MAGNET ASSEMBLY
8 STAMPING PLATE
ASSEMBLY
9 BOBIN ASSEMBLY
10 COIL ASSEMBLY
11 PCB ASSEMBLY

APPROVED BY MATERIAL:

PROTECTIVE FINISH:
(Dr. Virendra Kumar)
Scientist ‘F’
FOR DIRECTOR
SCALE: EST. MASS TITLE:
1:1
DESIGN TURBO GENERATOR
AUTHORITY: ASSEMBLY

ARDE

44
GEN.TOL.MEDIUM/COARSE/FINE DRAWING CONVENTION CONFORM
CLASS TO IS:2102 AS PER JSG:0104 DIMS IN mm
UNLESS OTHERWISE STATED.

NOTE:- THE ANGLE BETWEEN BLADES MUST BE MAINTAINED.

APPROVED BY MATERIAL:
NYLON 66 TO SPEC IS:13464
PROTECTIVE FINISH:

(Dr. Virendra Kumar)

Scientist ‘F’
FOR DIRECTOR
SCALE: EST. MASS TITLE:
1:1
DESIGN ROTOR
AUTHORITY:

ARDE
DRG. NO.

45
GEN.TOL.MEDIUM/COARSE/FINE DRAWING CONVENTION CONFORM
CLASS TO IS:2102 AS PER JSG:0104 DIMS IN mm
UNLESS OTHERWISE STATED.

NOTE: ALL SURFACES SHOULD BE SMOOTH.

APPROVED BY MATERIAL:
AL ALLOY TO SPEC IS:733-
24345 WP
PROTECTIVE FINISH:
(Dr. Virendra Kumar) TO BE ANODIZED TO SPEC
Scientist ‘F’ IS:1868 Gd AC 10
FOR DIRECTOR
SCALE: EST. MASS TITLE:
1:1
DESIGN COVER PLATE
AUTHORITY:

ARDE
DRG. NO.

46
GEN.TOL.MEDIUM/COARSE/FINE DRAWING CONVENTION CONFORM
CLASS TO IS:2102 AS PER JSG:0104 DIMS IN mm
UNLESS OTHERWISE STATED.

NOTE: REMOVE ALL SHARP EDGES.

ALL SURFACES SHOULD BE SMOOTH.

APPROVED BY MATERIAL:
AL ALLOY TO SPEC IS:733-
24345 WP
PROTECTIVE FINISH:
(Dr. Virendra Kumar) TO BE ANODIZED TO SPEC
Scientist ‘F’ IS:1868 Gd AC 10
FOR DIRECTOR
SCALE: EST. MASS TITLE:
1:1
DESIGN HOUSING
AUTHORITY:

ARDE
DRG. NO.

47
GEN.TOL.MEDIUM/COARSE/FINE DRAWING CONVENTION CONFORM
CLASS TO IS:2102 AS PER JSG:0104 DIMS IN mm
UNLESS OTHERWISE STATED.

APPROVED BY MATERIAL:
BRASS TO SPEC IS 319 Gd 1
HALF HARD
PROTECTIVE FINISH:
(Dr. Virendra Kumar) TO BE CROMATE
Scientist ‘F’ PASSIVATED TO SPEC IS:1340
FOR DIRECTOR
SCALE: EST. MASS TITLE:
1:1
DESIGN WASHER
AUTHORITY:

ARDE
DRG. NO.

48
GEN.TOL.MEDIUM/COARSE/FINE DRAWING CONVENTION CONFORM
CLASS TO IS:2102 AS PER JSG:0104 DIMS IN mm
UNLESS OTHERWISE STATED.

APPROVED BY MATERIAL:
PROTECTIVE FINISH:

(Dr. Virendra Kumar)

Scientist ‘F’
FOR DIRECTOR
SCALE: EST. MASS TITLE:
1:1
DESIGN THRUST BALL(STD) BEARING
AUTHORITY:

ARDE

49
GEN.TOL.MEDIUM/COARSE/FINE DRAWING CONVENTION CONFORM
CLASS TO IS:2102 AS PER JSG:0104 DIMS IN mm UNLESS
OTHERWISE STATED.

APPROVED BY MATERIAL:

PROTECTIVE FINISH:

(Dr. Virendra Kumar)

Scientist ‘F’
FOR DIRECTOR
SCALE: EST. MASS TITLE:
1:1
DESIGN FOAM DISC
AUTHORITY:

ARDE
DRG. NO.

50
 GEN.TOL.MEDIUM/COARSE/FINE DRAWING CONVENTION
CLASS TO IS:2102 CONFORM AS PER JSG:0104
DIMS IN mm UNLESS
OTHERWISE STATED.

NOTE:- 1. ITEM 1,2 TO BE INSITU MOULDED

2. ALL FLARE SHOULD BE REMOVED AFTER MOULDING

APPROVED BY MATERIAL:

PROTECTIVE FINISH:
(Dr. Virendra Kumar)
Scientist ‘F’
FOR DIRECTOR
SCALE: EST. MASS TITLE:
1:1
DESIGN SHAFT AND MAGNET
AUTHORITY: ASSEMBLY

ARDE

51
 GEN.TOL.MEDIUM/COARSE/FINE DRAWING CONVENTION CONFORM
CLASS TO IS:2102 AS PER JSG:0104 DIMS IN mm
UNLESS OTHERWISE STATED.

APPROVED BY MATERIAL:
STAINLESS STEEL Gd 304S15
TO B.S. 970
PROTECTIVE FINISH:
(Dr. Virendra Kumar) NOT REQUIRED
Scientist F
FOR DIRECTOR
SCALE: EST. MASS TITLE:
1:1
DESIGN AUTHORITY: SHAFT

ARDE
PART NO. DS CAT NO. AHSP

52
GEN.TOL.MEDIUM/COARSE/FINE DRAWING CONVENTION CONFORM
CLASS TO IS:2102 AS PER JSG:0104 DIMS IN mm
UNLESS OTHERWISE STATED.

SPECIFICATION: - 700-800 GAUSS, 8 POLES

NOTE: - ALL SURFACES SHOULD BE SMOOTH.

APPROVED BY MATERIAL:
ALNICO-5
ALLOY MAGNETIC
MATERIAL
(Dr. Virendra Kumar) PROTECTIVE FINISH:
Scientist ‘F’
FOR DIRECTOR
SCALE: EST. MASS TITLE:
1:1
DESIGN MAGNET
AUTHORITY:

ARDE

53
GEN.TOL.MEDIUM/COARSE/FINE DRAWING CONVENTION COMP.N DESCRIPTION QTY
CLASS CONFORM AS PER JSG:0104 O
1 GLASS EPOXY SHEET 2
TO IS:2102 DIMS IN mm UNLESS
2 CONNECTING WIRE 2
OTHERWISE STATED.
3 STAMPING PLATE ASSY 1
4 BOBIN ASSY 4
5 INSITU MOULDING ON COIL ASSY 1
NOTE:- A PIECE OF COPPE

APPROVED BY MATERIAL:

PROTECTIVE FINISH:

(Dr. Virendra Kumar)

Scientist ‘F’
FOR DIRECTOR
SCALE: EST. MASS TITLE:
1:1
DESIGN COIL ASSEMBLY
AUTHORITY: STAMPING ASSEMBLY

ARDE

54
GEN.TOL.MEDIUM/COARSE/FINE CLASS DRAWING CONVENTION
TO IS:2102 CONFORM AS PER JSG:0104 DIMS
IN mm UNLESS OTHERWISE
STATED.
COMP. DESCRIPTION QT
NO Y
1 PCB 1
2 STRIP 1
3 TERMINAL PIN 1
4 BODY 1
5 HOLDER 1

APPROVED BY MATERIAL:
AMSI Gd FR4 TO
SPECN
DS:7409-1990
(Dr. Virendra Kumar) PROTECTIVE FINISH:
Scientist ‘F’ GLASS EPOXY
FOR DIRECTOR
SCALE: EST. MASS TITLE:
1:1
DESIGN PCB ASSEMBLY
AUTHORITY:

ARDE

55
 1.9 CONCLUSION :

The performance of fuze influences the successful operation of a warhead. In

the fuze, the power source is a critical element. A detailed study of various power
sources available for the fuze was carried out. From the study it was concluded that
the most efficient power source with many inherent advantages, is, the turbo-
generator.
A comprehensive study was done on the assembly procedure for assembling the
components and sub-assemblies, and tests to be done to ensure its quality.
The warhead may function under different conditions of flight velocity and
altitude. Thus the first aim of the project was to get a clear picture of all flight
operating conditions. Then the optimum conditions were chosen and under these
conditions analysis of various components of the turbo-generator was carried. This
includes the design of turbine impeller and shaft. As seen in the results section, the
design of these components is safe and within permissible limits.
Hence the overall design of the turbo-generator was found to be safe under all
operating conditions.

56
 1.10 FUTURE SCOPE :

This report contains information about the turbo-generator currently in use, and
already in production. Further changes can be made in design, manufacturing and
other aspects, so as to make it more reliable, more efficient and also cheaper.
For further increase in power generated, pressure is needed to be increased,
which would require redesign & reanalysis of turbine.
Turbine analysis has been done successfully up till 2.06 mach, and results show
that it can sustain much larger pressures.

A turbo-generator with reduced size has been designed by ARDE. Making it

more compact and also reducing the production cost. This miniature version has been
proposed, and is currently being developed so as to make it available for large scale
production.

57
 1.11 REFERENCES :

[1] Dr.Virendra Kumar, "Fuze Power Supply Systems" ARDE Technical Report No.
1127 of 2004 (unpublished).

[2] http://www.interlloy.com.au/our-products/stainless-steel/304-austenitic-stainless-
steel-bar

[3] Volume computed using CATIA V5.

[4] A project on ‘REVERSE ENGINEERING OF TURBO-GENERATOR’,

D.Y.PATIL College of Engineering, 2013-14 (unpublished).

[5] Material Density (kg/m3) of Aluminum alloy and Brass are computed using
ANSYS WORKBENCH 14.5 .

[6] http://www.magnetsales.com/alnico/alprops.htm

[7] Sudhir Dhamija, IJME, Volume 1, Spl. Issue 1 (2014), e-ISSN: 1694-2302 | p-
ISSN: 1694-2418, ‘CHARACTERIZATION OF TURBO-GENERATOR BASED
POWER SOURCE FOR ARTILLERY FUZES’, Ballistics Group, Armament
Research & Development Establishment, Pune, Maharashtra, India.

[8] pub-117---the-brasses_whole_web-pdf

[9] 'Turbo-generator for Electronic Fuze' by Virendra Kumar, DN Joshi, Sunil Kumar
Nema, Armament Research & Development Establishment, Pune, India.

[10]www.rare-earth-magnets.com/permenant-magnet-selection-and-Design-
Handbook.pdf

58