etic actuator

which uses
which uses
aa
pulse of
pulse of
curr
curr
ent to
ent to
acac
cece
lerler
ate
ate
magn
magn
etic
etic
ally
ally
active
active
pro
pro
jecjec
tiles to
tiles to
high velocit
high velocit
y. y.
We derive an
We derive an
appr
appr
oximate close
oximate close
d form
d form
solution for the
solution for the
exit veloc
exit veloc
ity ity
of of
the
the
prpr
ojeoje
ctile
ctile
..
As As
aa
mor
mor
ee
acac
cur
cur
ate model, we
ate model, we
also derive
also derive
aa
non-
non-
line
line
ar ar
differ
differ
entia
entia
ll
eqeq
uation
uation
for
for
proje
proje
ctile
ctile
positi
positi
on on
from
from
first
first
principles.
principles.
We
We
validate
validate
these
these
analytica
analytica
ll
results
results
with
with
both
both
finite
finite
eleme
eleme
nt nt
momo
dels
dels
and
and
expexp
erimen
erimen
tal tal
resres
ults.
ults.
The
The
analyt
analyt
icaica
ll
caca
lculat
lculat
ions
ions
tend to
tend to
prepre
dict
dict
larlar
ger
ger
then
then
meme
asur
asur
ed velociti
ed velociti
es, es,
which is
which is
expexp
ecec
ted given
ted given
the
the
assumptio
assumptio
ns ns
made.
made.
FF
rom our
rom our
analytic
analytic
al al
resres
ults
ults
we show that the exit velocity is proportional to t
he magnetic susceptibility of the projectile
we show that the exit velocity is proportional to t
he magnetic susceptibility of the projectile
material.
material.
We found that
We found that
iron proje
iron proje
ctiles with
ctiles with
large cross sectional are
large cross sectional are
a produc
a produc
ed the highest
ed the highest
exit
exit
velo
velo
cities
cities
..
SteSte
el el
and hollow
and hollow
prpr
ojeoje
ctiles pro
ctiles pro
duc
duc
ed lower velocit
ed lower velocit
ies ies
and length
and length
was
was
found to
found to
not
not
matte
matte
rr
substa
substa
ntially.
ntially.
Over
Over
all,
all,
the
the
invest
invest
igatio
igatio
nn
was
was
sucsuc
cece
ssful and
ssful and
useful result
useful result
ss
wer
wer
ee
obtain
obtain
eded
..
11
In
In
tr
tr
odu
odu
ct
ct
ioio
nn
A coil gun is a device which uses electromagnets
A coil gun is a device which uses electromagnets
to to
accel
accel
erate magnetical
erate magnetical
ly ly
activ
activ
ee
projectil
projectil
es es
toto
high velocity. In a coil gun, a current is passed
high velocity. In a coil gun, a current is passed
through a solenoid, creating a magnetic field
through a solenoid, creating a magnetic field
which draws a projectile to the center of the
which draws a projectile to the center of the
coil. If the current is stopped quickly, it contin-
coil. If the current is stopped quickly, it contin-
ues out of the barrel at rapid speed. Many coil
ues out of the barrel at rapid speed. Many coil
guns involve multiple stages of coils which are
guns involve multiple stages of coils which are
triggered in series for maximum acceleration.
triggered in series for maximum acceleration.
Coil guns have many useful applications. For
Coil guns have many useful applications. For
example, orbital satellite launch with coil guns
example, orbital satellite launch with coil guns
has been proposed but has of yet been deemed
has been proposed but has of yet been deemed
impractical due to large stresses on the pay-
impractical due to large stresses on the pay-
lolo
ad.
ad.
CoCo
il guns ha
il guns ha
ve als
ve als
oo
bee
bee
nn
pro
pro
pose
pose
dd
asas
replacements for chemical firing weapons for
replacements for chemical firing weapons for
naval purposes, although the similar rail gun
naval purposes, although the similar rail gun
is generally preferred. Coil guns are relatively
is generally preferred. Coil guns are relatively
quiet, wear very well and can be used with a
quiet, wear very well and can be used with a
variety of ammunition types.
variety of ammunition types.
The goal of this project is to investigate the
The goal of this project is to investigate the
effect of varying projectile material and geom-
effect of varying projectile material and geom-
etry on
etry on
coicoi
ll
gun performa
gun performa
nce.
nce.
TT
oo
acco
acco
mpli
mpli
shsh
this goal, we built a working coil gun prototype
this goal, we built a working coil gun prototype
which served as a test platform for a variety of
which served as a test platform for a variety of
projectiles.
projectiles.
In this paper, we begin by deriving theoret-
In this paper, we begin by deriving theoret-
ical mod
ical mod
els for a coil gun
els for a coil gun
..
The desi
The desi
gn of our
gn of our
coil gun is then presented, followed by numer-
coil gun is then presented, followed by numer-
ical simulati
ical simulati
ons for
ons for
model validat
model validat
ion.
ion.
Finall
Finall
yy
,,
experime
experime
ntal results are
ntal results are
presen
presen
ted for
ted for
aa
num
num
ber
ber
of projectiles and the results are analyzed.
of projectiles and the results are analyzed.
22
CC
oi
oi
ll
Gu
Gu
nn
TT
hh
eo
eo
ry
ry
The coil gun works by quickly discharging a large
The coil gun works by quickly discharging a large
amount of energy from a capacitor through a
amount of energy from a capacitor through a
coil, creating a strong magnetic field through
coil, creating a strong magnetic field through
the coil. This strong field induces magnetization
the coil. This strong field induces magnetization
in the slug, causing microscopic dipoles to align
in the slug, causing microscopic dipoles to align
with the field in a lower energy state. Because
with the field in a lower energy state. Because
the coil is a solenoid of finite length, the pro-
the coil is a solenoid of finite length, the pro-
duced magnetic field decays in strength axially
duced magnetic field decays in strength axially
awaw
ay from the edg
ay from the edg
e of
e of
the coi
the coi
l. l.
The ali
The ali
gned
gned
dipoles feel a force proportional to the gradient
dipoles feel a force proportional to the gradient
in the magnetic field:
in the magnetic field:
FF
==
μμ
00

∇∇
((
MM
··
HH
)
)
((
11
))
Where
Where
MM
is the projectile magnetization and
is the projectile magnetization and
HH
is the applied field.
is the applied field.
If the current were sustained indefinitely, af-
If the current were sustained indefinitely, af-
ter being accelerated from one side of the coil,
ter being accelerated from one side of the coil,
the projectile
the projectile
wou
wou
ld ld
enco
enco
unte
unte
rr
an an
opposit
opposit
ee
gra-
gra-
dient on the other side which would apply a
dient on the other side which would apply a
force back towards the center of the coil. Thus,
force back towards the center of the coil. Thus,
a coil gun with constant current would simply
a coil gun with constant current would simply
cause the projectile to oscillate within the coil.
cause the projectile to oscillate within the coil.
If the slug reaches the other side of the coil while
If the slug reaches the other side of the coil while
significant current is still running in the coil, th
e
significant current is still running in the coil, th
e
slug will experience a force toward the center
slug will experience a force toward the center
11
of the coil, slo
of the coil, slo
win
win
g its motion.
g its motion.
This effe
This effe
ct is
ct is
commonly called suckback, and is undesirable
commonly called suckback, and is undesirable
for coil gun operati
for coil gun operati
on.
on.
How
How
eve
eve
r, if
r, if
all of the
all of the
charge is drained from the capacitors quickly,
charge is drained from the capacitors quickly,
before the projectile reaches the other side of
before the projectile reaches the other side of
the coil, there will be no repelling force and the
the coil, there will be no repelling force and the
projectile will continue on to exit the barrel.
projectile will continue on to exit the barrel.
Order of Magnitude Estimation
Order of Magnitude Estimation
We can get a rough estimate for the exit velocity
We can get a rough estimate for the exit velocity
of the slug by comparing the energy state of the
of the slug by comparing the energy state of the
slug outside and inside the coil. Before the coil
slug outside and inside the coil. Before the coil
fires, the magnetic field on the slug is negligible.
fires, the magnetic field on the slug is negligible.
We will make the assumption that the current
We will make the assumption that the current
in the coil is constant until the slug reaches the
in the coil is constant until the slug reaches the
cen
cen
ter, at which point it drops to
ter, at which point it drops to
zero
zero
..
Whe
Whe
nn
the slug is inside the coil, we can apply the
the slug is inside the coil, we can apply the
common Ampere’s law estimation of the applied
common Ampere’s law estimation of the applied
field
field
HH
and assume the slug is within a constant
and assume the slug is within a constant
magnetic field. This will have a lower potential
magnetic field. This will have a lower potential
energy state b
energy state b
ecaus
ecaus
ee
the induced
the induced
magnet
magnet
izatio
izatio
nn
MM
align with the applied field.
align with the applied field.
I
I
n
n
i
i
t
t
i
i
a
a
l
l
F
F
i
i
n
n
a
a
l
l
Figure 1:
Figure 1:
The two states of the slug considered
 The two states of the slug considered
in the order of magnitude estimation. The slug
in the order of magnitude estimation. The slug
starts in neglible field and when it reaches the
starts in neglible field and when it reaches the
final
final
state
state
the
the
field
field
complet
complet
ely
ely
cuts
cuts
off.
off.
We define the potential energy state of the
We define the potential energy state of the
slug outside the coil to be zero:
slug outside the coil to be zero:
EE
outside
outside
= 0J.
= 0J.
The magnitude of the applied field inside the
The magnitude of the applied field inside the
coil can be approximated by assuming an in-
coil can be approximated by assuming an in-
finitely long coil and applying Ampere’s law.
finitely long coil and applying Ampere’s law.
The well-kno
The well-kno
wn
wn
resul
resul
tt
isis
HH
==
nI
nI
ˆˆ
xx
(2)(2)
Where
Where
nn
is the turn count per length,
is the turn count per length,
II
isis
the current through the coil, and
the current through the coil, and
ˆˆ
xx
is an axial
is an axial
unit vec
unit vec
tor.
tor.
Assu
Assu
ming the slug
ming the slug
is comple
is comple
teltel
yy
within the uniform field and a linear model of
within the uniform field and a linear model of
magnetizat
magnetizat
ion
ion
with
with
magnetic susceptibilit
magnetic susceptibilit
yy
χχ
mm
,,
the induced magnetization in the slug will be:
the induced magnetization in the slug will be:
MM
==
χχ
mm
HH
==
χχ
mm
nI nI
ˆˆ
xx
(3)(3)
The energy per unit volume of a magnetized
The energy per unit volume of a magnetized
material in an applied field is
material in an applied field is
ρρ
ee
==
−−
μμ
00

MM
··
HH
..
In our case, the applied field and magnetization
In our case, the applied field and magnetization
are parallel, because the former creates the lat-
are parallel, because the former creates the lat-
ter, and thus the dot product can be rendered
ter, and thus the dot product can be rendered
as multiplication. The potential energy of the
as multiplication. The potential energy of the
slug inside the coil is thus:
slug inside the coil is thus:
EE
inside
inside
==
−−
μμ
00

MM
HH
==
−−
μμ
00

χχ
mm
nn
22

II
22

(4)(4)
This is a lower potential energy state than
This is a lower potential energy state than
the slug outside the coil. Assuming that all po-
the slug outside the coil. Assuming that all po-
tential energy is transferred into kinetic energy,
tential energy is transferred into kinetic energy,
the exit velocity is:
the exit velocity is:
vv
exit
exit
==



22
mm
VV
μμ
00

χχ
mm
nn
22

II
22

(5)(5)
Where
Where
VV
is the volume of the slug and
is the volume of the slug and
mm
is the mass of
is the mass of
the slug.
the slug.
Usin
Usin
g reasona
g reasona
ble va
ble va
l-l-
ues for our coil gun with a commercial grade
ues for our coil gun with a commercial grade
iron slug
iron slug
[[
33
]]
,,
μμ
00

==
44
ππ
××
1010
−−
77

,,
nn
= 500,
= 500,
II
= 50,
= 50,
χχ
mm
= 100,
= 100,
mm
==
..
03 and
03 and
VV
==
33
××
1010
−−
66

(all in
(all in
SI units) this approximation predicts an exit
SI units) this approximation predicts an exit
velocity of about 4m/s.
velocity of about 4m/s.
This order of magnitude calculation makes
This order of magnitude calculation makes
aa
num
num
ber
ber
of of
simplif
simplif
ying assumptio
ying assumptio
ns ns
whic
whic
hh
im-
im-
pair the accuracy of the model. The assumption
pair the accuracy of the model. The assumption
that the slug lies completely within a uniform
that the slug lies completely within a uniform
magnetic field in the final state overestimates
magnetic field in the final state overestimates
the amount of potential energy loss, and hence
the amount of potential energy loss, and hence
caus
caus
es a
es a
larlar
ger exit veloci
ger exit veloci
ty predi
ty predi
cticti
on.
on.
The
The
assumption that the current dies out instantly
assumption that the current dies out instantly
when the slug reaches the center of the coil ig-
when the slug reaches the center of the coil ig-
nores the effect of suckback, and causing a larger
nores the effect of suckback, and causing a larger
exit velocity prediction. Furthermore, all the po-
exit velocity prediction. Furthermore, all the po-
tential energy will not be transferred into kinetic
tential energy will not be transferred into kinetic
energy: much of it will go toward frictional work.
energy: much of it will go toward frictional work.
This too, will overestimate the exit velocity.
This too, will overestimate the exit velocity.
A More Complete Model
A More Complete Model
To improve the model, we will take into account
To improve the model, we will take into account
the effects of non-uniform fields and suck back.
the effects of non-uniform fields and suck back.
22
To do this we will derive the axial applied field
To do this we will derive the axial applied field
of a solenoid and use it to calculate the force on
of a solenoid and use it to calculate the force on
the slug.
the slug.
The Applied Field of a Solenoid
The Applied Field of a Solenoid
In the following analysis, we will use the system
In the following analysis, we will use the system
definition presented in Figure
definition presented in Figure
2. 2.
Our goal is to
Our goal is to
find the magnetic field at a test point
find the magnetic field at a test point
pp
which is
which is
a distance
a distance
xx
from the left face of the coil. The
from the left face of the coil. The
derivation will first be made in terms of
derivation will first be made in terms of
θθ
, the
, the
angle formed by the x-axis and a line from
angle formed by the x-axis and a line from
pp
to to
aa
point on the coil, as it proves to be algebraically
point on the coil, as it proves to be algebraically
easier. Later, we will convert this into a function
easier. Later, we will convert this into a function
of of
xx
, to create a differential equation of
, to create a differential equation of
xx
..
P
P
θ
θ
θ
θ
2
2
θ
θ
1
1
x
x
L
L
R
R
r
r
Figure 2:
Figure 2:
The system parameters used in the
The system parameters used in the
derivation of the force on the slug. Note that in
derivation of the force on the slug. Note that in
the figure the value
the figure the value
xx
, the position of point
, the position of point
pp
,,
is is
a negative value.
a negative value.
The applied field due to one loop of wire
The applied field due to one loop of wire
is[is[
1]1]
::
HH
((
θθ
)=
)=
II
sin
sin
θRθR
22
rr
22

==
II
sin
sin
θθ
33

22
RR
Where
Where
RR
is the radius of the loop and
is the radius of the loop and
rr
isis
the distance from
the distance from
pp
to the edge of the loop.
to the edge of the loop.
If we consider the coil to be made of many
If we consider the coil to be made of many
infinitesimal loops, we can use the equivalent
infinitesimal loops, we can use the equivalent
surface current density
surface current density
K K
==
nI
nI
to calculate the
to calculate the
current through those loops as a function of
current through those loops as a function of
θθ
::
dI dI
==
KK
dxdx
==
−−
KR
KR
csccsc
θθ
22

dθdθ
(7)(7)
The contribution to the applied field from
The contribution to the applied field from
one of these loops is thus, using equation
one of these loops is thus, using equation
????
::
dH
dH
==
−−
11
22
KK
sin
sin
θdθ
θdθ
(8)(8)
We can now integrate over the angles sub-
We can now integrate over the angles sub-
tended by the line from
tended by the line from
pp
to the coil to find the
to the coil to find the
total applied field due to all loops:
total applied field due to all loops:
HH
((
θθ
11

,,
θθ
22

)=
)=


θθ
22

θθ
11

−−
KK
22
sinsin
θθ
dθdθ
==
nI nI
22
(cos
(cos
θθ
22
−−
cos
cos
θθ
11

))
(9)(9)
This can then be converted into a function
This can then be converted into a function
of of
xx
::
HH
((
xx
)=
)=
nI nI
22
((
LL
−−
xx



((
LL
−−
xx
))
22

++
RR
22

++
xx
√√
xx
22

++
RR
22

) ˆ) ˆ
xx
(10)
(10)
The Force on the Slug
The Force on the Slug
Equation
Equation
11
00
can now be used to calculate the
can now be used to calculate the
mag
mag
nitnit
ude of
ude of
the for
the for
ce on
ce on
the slu
the slu
g. g.
WW
ee
wiwi
llll
consider the slug to be made up of many in-
consider the slug to be made up of many in-
finitesim
finitesim
ally thin
ally thin
disks, sliced axially
disks, sliced axially
..
WW
e will
e will
assume that the applied field on these disks is
assume that the applied field on these disks is
constant and equal to the field through the axis.
constant and equal to the field through the axis.
We can then calculate the force on each disk
We can then calculate the force on each disk
and integrate over the disks to find the total
and integrate over the disks to find the total
force. The force on a small volume object in an
force. The force on a small volume object in an
applied field is [
applied field is [
4]4]
::
dF
dF
==
μμ
00

∇∇
((
MM
··
HH
))
dV dV
==
μμ
00

∇∇
((
MM
··
HH
))
AA
dxdx
(11)
(11)
Where
Where
AA
is the cross sectional area of the
is the cross sectional area of the
slug.
slug.
FF
or our case, the magnetization and ap-
or our case, the magnetization and ap-
plied field are assumed to be parallel to the
plied field are assumed to be parallel to the
x-ax
x-ax
is. is.
If we also assu
If we also assu
me a
me a
linlin
ear model
ear model
, the
, the
force on a slice is:
force on a slice is:
dF
dF
==
μμ
00

dd
dxdx
((
χχ
mm
HH
22
))
AA
dxdx
==
μμ
00

χχ
mm
22
HH
dH
dH
dxdx
AA
dxdx
(12)
(12)
This infinitesimal equation parallels the em-
This infinitesimal equation parallels the em-
pirical formula for the force on a small object in
pirical formula for the force on a small object in
an applied field [
an applied field [
5]5]
::
FF
==
VV
χχ
mm
μμ
00

HH
dH
dH
dxdx
(13)
(13)
This similari
This similari
ty gives credence to
ty gives credence to
our derived
our derived
resu
resu
lt. lt.
WW
ee
can now integ
can now integ
rate ov
rate ov
er the
er the
slisli
ces
ces
to get the tota
to get the tota
ll
fofo
rce on our slug
rce on our slug
..
If If
xx
is the
is the
position of the right side of the slug, and
position of the right side of the slug, and
ll
is the
is the
length of the slug the total force is:
length of the slug the total force is:
33
FF
==


xx
xx
−−

ll
μμ
00

dd
dxdx
((
χχ
mm
HH
22

))
AA
dxdx
(14)
(14)
FF
((
xx
)=
)=
μμ
00

Aχ
Aχ
xx
((
HH
((
xx
))
22

−−
HH
((
xx
−−
ll
))
22

) )
((
11
55
))
This equation for the force on the slug gives
This equation for the force on the slug gives
a non-linear second order ordinary differential
a non-linear second order ordinary differential
equation. In the Simulation section, we submit
equation. In the Simulation section, we submit
this differential equation to numerical solution.
this differential equation to numerical solution.
While this model is more accurate than the
While this model is more accurate than the
estimation, there are still a number of simpli-
estimation, there are still a number of simpli-
fying assumptions. The assumption of uniform
fying assumptions. The assumption of uniform
field for a given x-position ignores the radial
field for a given x-position ignores the radial
dependence of the field. The field close to the
dependence of the field. The field close to the
wires would be larger than the center field, mean-
wires would be larger than the center field, mean-
ing the predicted velocity would be too small.
ing the predicted velocity would be too small.
This model still assumes frictionless travel of
This model still assumes frictionless travel of
the slug, although it would not be difficult to
the slug, although it would not be difficult to
include a frictional force in the simulation. The
include a frictional force in the simulation. The
linear model of magnetization is also not en-
linear model of magnetization is also not en-
tirely accurate, especially given the large fields
tirely accurate, especially given the large fields
we produce in the experimental setups: in fact
we produce in the experimental setups: in fact
we may be reaching saturation magnetization.
we may be reaching saturation magnetization.
This would mean the expect exit velocity is too
This would mean the expect exit velocity is too
high. Furthermore, the calculation of the field
high. Furthermore, the calculation of the field
assumes a thin solenoid - that is, the wires are
assumes a thin solenoid - that is, the wires are
infinitely thin and do not stack on one another.
infinitely thin and do not stack on one another.
This makes the expected field larger, and the
This makes the expected field larger, and the
exit velocity larger.
exit velocity larger.
RLC Analysis
RLC Analysis
In order to reduce suckback, the RLC system
In order to reduce suckback, the RLC system
defined by the capacito
defined by the capacito
r bank and
r bank and
coil should be
coil should be
tuned to provide the minimum discharge time.
tuned to provide the minimum discharge time.
The faster the discharge time, the lower the cur-
The faster the discharge time, the lower the cur-
rent will be when the slug exits the coil, giving
rent will be when the slug exits the coil, giving
it a higher exit velocity. We developed a math-
it a higher exit velocity. We developed a math-
ematical model of the RLC system in order to
ematical model of the RLC system in order to
tune the
tune the
param
param
eter
eter
ss
before creatin
before creatin
gg
it.it.
Resistor
Resistor
Inductor
Inductor
Capacitor
Capacitor
Figure 3:
Figure 3:
An RLC Circuit.
An RLC Circuit.
The RLC circuit shown in Figure
The RLC circuit shown in Figure
33
has a
has a
Kirchoff’s Voltage Law of:
Kirchoff’s Voltage Law of:
VV
RR
++
VV
CC
++
VV
LL
= =
0=
0=
II
RR
++
VV
CC
++
LL
dI dI
dtdt
(16)
(16)
This can be rewritten in terms of
This can be rewritten in terms of
V V
CC
only:
 only:
RC
RC
dV dV
CC
dtdt
++
VV
CC
++
LC
LC
dd
22

VV
CC
dtdt
=
=
0 0
((
11
77
))
The charact
The charact
eristic polynomia
eristic polynomia
ll
of of
this homo-
this homo-
geneous second order linear differential equation
geneous second order linear differential equation
is:is:
LCλ
LCλ
22

++
RCλ
RCλ
+ +
1 1
= =
0 0
((
11
88
))
Which gives eigenvalues of:
Which gives eigenvalues of:
λλ
11
,,
22

==
−−
RC
RC
∓∓
√√
RR
22

CC
22

−−
44
LC
LC
22
LC
LC
(19)
(19)
The solution to the equation is thus:
The solution to the equation is thus:
VV
CC
((
tt
)=
)=
cc
11

ee
λλ
11

tt
++
cc
22

ee
λλ
22
∗∗

tt
(20)
(20)
Applyi
Applyi
ng ng
the
the
initial condition
initial condition
ss
I I
(0) = 0 and
(0) = 0 and
VV
CC
(0) =
(0) =
V V
00

, we can solve for the constants:

, we can solve for the constants:
cc
22

==
V V
00

//
(1(1
−−
λλ
11

λλ
22

) )
((
22
11
))
cc
11

==
V V
00

−−
cc
22

(22)
(22)
The current through the inductor can then
The current through the inductor can then
be expressed as:
be expressed as:
II
((
tt
)=
)=
C C
∗∗
dV
dV
CC
dtdt
(23)
(23)
We used this equation to find a reasonable
We used this equation to find a reasonable
set of parameters for our RLC system in order
set of parameters for our RLC system in order
to create a relatively fast discharge time. This
to create a relatively fast discharge time. This
same analysis was also used in our dynamic
same analysis was also used in our dynamic
model to find the current though the coil as a
model to find the current though the coil as a
function of time.
function of time.
33
Pr
Pr
ot
ot
ot
ot
ype
ype
De
De
sisi
gn
gn
A prototype coil gun and projectiles were de-
A prototype coil gun and projectiles were de-
signed to allow us to test the effect of projectile
signed to allow us to test the effect of projectile
material on performance. The design, shown in
material on performance. The design, shown in
Figure
Figure
44
, was manufactured by team members
, was manufactured by team members
in the Olin Colleg
in the Olin Colleg
e machin
e machin
ee
shop
shop
..
The gun’s
The gun’s
transparent polycarbonate barrel has an inner
transparent polycarbonate barrel has an inner
44
diameter of
diameter of
55
⁄ ⁄
88

” and is one foot long. The bar-

” and is one foot long. The bar-
rel is mounted on a clamping support structure
rel is mounted on a clamping support structure
manufactured from black ABS plastic.
manufactured from black ABS plastic.
Figure 4:
Figure 4:
Coil gun prototype design.
Coil gun prototype design.
Projectiles
Projectiles
Eight different styles of projectile were manu-
Eight different styles of projectile were manu-
factured for test
factured for test
ing.
ing.
All projectiles are
All projectiles are
55
⁄ ⁄
88

””
inin
diameter and slide easily in the plastic barrel.
diameter and slide easily in the plastic barrel.
Iron projectiles, which we predict will shoot the
Iron projectiles, which we predict will shoot the
best, were made in three different lengths (1”,
best, were made in three different lengths (1”,
11
11
⁄ ⁄
22
” and 3”) as well as in hollow and solid con-
” and 3”) as well as in hollow and solid con-
figuration
figuration
s. s.
1” long solid projectiles were also
1” long solid projectiles were also
manufactured out of 6061-T6 Aluminum, A36
manufactured out of 6061-T6 Aluminum, A36
Steel, 1018 Steel and 4130 Steel.
Steel, 1018 Steel and 4130 Steel.
In addition to machined projectiles, a pur-
In addition to machined projectiles, a pur-
chased magnet and a rolled sheet of mu-metal
chased magnet and a rolled sheet of mu-metal
will be launched. Mu-metal is a very magneti-
will be launched. Mu-metal is a very magneti-
cally active material and is commonly used for
cally active material and is commonly used for
electromagnetic shielding. The purchased mag-
electromagnetic shielding. The purchased mag-
net has a surface field of 7157 Gauss
net has a surface field of 7157 Gauss
11

..
The sizes
The sizes
and masses of all projectiles are given in Table
and masses of all projectiles are given in Table
1.1.
MaMa
tete
riri
al al
StSt
ylyl
ee
DiDi
amam
etet
er er
LeLe
ngng
th th
MaMa
ssss
II
rr
oo
nn
SS
oo
ll
ii
dd
55
⁄ ⁄
88

” ”
11
” ”
33
0 0
gg
II
rr
oo
nn
HH
oo
ll
ll
oo
ww
55
⁄ ⁄
88

” ”
11
” ”
11
8 8
gg
II
rr
oo
nn
SS
oo
ll
ii
dd
55
⁄ ⁄
88

””
11
33
⁄ ⁄
44
” ”
55
1 1
gg
II
rr
oo
nn
SS
oo
ll
ii
dd
55
⁄ ⁄
88

” ”
33
” ”
99
3 3
gg
StSt
eeee
ll
A3A3
66
SoSo
lili
dd
55
⁄ ⁄
88

” ”
11
” ”
33
6 6
gg
StSt
eeee
ll
4141
30 30
SoSo
lili
dd
55
⁄ ⁄
88

” ”
11
” ”
33
6 6
gg
StSt
eeee
ll
1010
18 18
SoSo
lili
dd
55
⁄ ⁄
88

” ”
11
” ”
33
6 6
gg
MM
agag
nn
ee
tt
SS
oo
ll
idid
11
⁄ ⁄
22

” ”
11
” ”
22
4 4
gg
MuMu
-M-M
etet
al al
RoRo
llelle
dd
55
⁄ ⁄
88

” ”
44
” ”
11
8 8
gg
Alu
Alu
mimi
nunu
mm
SoSo
lidlid
55
⁄ ⁄
88

” ”
11
” ”
11
2 2
gg
Table 1:
Table 1:
Projectile Parameters
Projectile Parameters
It is important to note that the three differ-
It is important to note that the three differ-
ent steels were chosen for their iron content as
ent steels were chosen for their iron content as
well as their avail
well as their avail
abilit
abilit
yy
..
The iron content of
The iron content of
each of the steel alloys is given in Table
each of the steel alloys is given in Table
2. 2.
The
The
A36 steel, which is a hot-rolled alloy, has the
A36 steel, which is a hot-rolled alloy, has the
highest iron content of the three followed by the
highest iron content of the three followed by the
1018 and the 4130 on bottom, both cold rolled
1018 and the 4130 on bottom, both cold rolled
alloys.
alloys.
AllAll
oy oy
IroIro
nn
Con
Con
tenten
tt
AA
33
6 6
99
99
..
00
%%
1010
18 18
9898
.8.8
%%
--
9999
.3.3
%%
4141
30 30
9797
.0.0
%%
--
9898
.2.2
%%
Table 2:
Table 2:
Iron Composition of Steel Alloys
Iron Composition of Steel Alloys
[6 [6
] ]
Coil
Coil
The coil gun’s coil is made from 20 turns of 14
The coil gun’s coil is made from 20 turns of 14
AWG wire. The coil was designed to have a low
AWG wire. The coil was designed to have a low
resistance and inductance so that the capacitor
resistance and inductance so that the capacitor
would discharge quickly. The parameters for the
would discharge quickly. The parameters for the
coil are provided in Table
coil are provided in Table
33
. As shown, the resis-
. As shown, the resis-
tance of the coil is extremely low at .116 Ω and
tance of the coil is extremely low at .116 Ω and
the inductance is also quite low at 4.62
the inductance is also quite low at 4.62
××
1010
−−
33

H.H.
LL
ee
nn
gg
tt
h h
33
0 0
mm
mm
WW
ii
rr
e e
GG
aa
uu
gg
e e
11
4 4
AA
WW
GG
TT
uu
rr
nn
s s
22
00
II
nn
nn
ee
r r
DD
ii
aa
mm
ee
tt
ee
r r
11
9 9
mm
mm
OO
uu
tt
ee
r r
DD
ii
aa
mm
ee
tt
ee
r r
33
3 3
mm
mm
AA
vv
ee
rr
aa
gg
ee
II
nn
dd
uu
cc
tt
aa
nn
cc
ee
44
..
66
22
××
1010
−−
33

HH
Induc
Induc
tance
tance
Standa
Standa
rd rd
Deviati
Deviati
on on
3.74
3.74
××
1010
−−
55

HH
AA
vv
ee
rr
aa
gg
ee
RR
ee
ss
ii
ss
tt
aa
nn
cc
ee
11
..
11
66
××
1010
−−
11

ΩΩ
ResRes
istist
ance
ance
StaSta
nda
nda
rd rd
Dev
Dev
iatiat
ion ion
9.05
9.05
××
1010
−−
33

ΩΩ
SS
aa
mm
pp
ll
ee
s s
TT
aa
kk
ee
n n
77
Table 3:
Table 3:
Coil Parameters
Coil Parameters
Circuit Design & Characterization
Circuit Design & Characterization
The electrical components of our coil gun are
The electrical components of our coil gun are
shown in Figure
shown in Figure
5. 5.
We used a power supply to
We used a power supply to
charge the capacitors before firing and a large
charge the capacitors before firing and a large
block of metal with an insulated handle to dis-
block of metal with an insulated handle to dis-
cha
cha
rge the capaci
rge the capaci
tors for stor
tors for stor
age.
age.
Note that
Note that
while there is no resistor in this circuit, the in-
while there is no resistor in this circuit, the in-
ductor and capacitors provide some resistance.
ductor and capacitors provide some resistance.
This equivalent series resistance is omitted for
This equivalent series resistance is omitted for
simplicity here but is utilized in calculations
simplicity here but is utilized in calculations
elsewhere.
elsewhere.
11

K&J Magnetics Product #D8X0DIA

K&J Magnetics Product #D8X0DIA
55
ఀ밀ꐀ뀀ఀ밀ꐀ뀀
萀렀가 ఀࠀ萀쀀萀谀ꐀ퀀밀저
萀렀가 ఀࠀ萀쀀萀谀ꐀ퀀밀저
䰀ఀ䠀䰀ఀ䠀
�堀 䠀鐀鰀
�堀 䠀鐀鰀
䠀쐀䠀쐀
쐀 가Ω쐀 가Ω
䠀저䠀저
쐀 가Ω쐀 가Ω
倀저ꐀ鰀鰀鐀저
倀저ꐀ鰀鰀鐀저
倀倀
저저
ꐀꐀ
鰀鰀
鰀鰀
鐀鐀
저 저
ఀఀ
ꐀꐀ
저저
谀谀
퐀퐀
ꐀꐀ
퀀 퀀
ఀఀ
밀밀
ꐀꐀ
뀀 뀀
ᰀᰀ
퐀퐀
렀 렀
ఀఀ
ꐀꐀ
저저
谀谀
퐀퐀
ꐀꐀ
퀀퀀

Figure 5:
Figure 5:
Coil gun electrical system schematic
Coil gun electrical system schematic
Th
Th
ee
sysy
stst
em
em
is is
trtr
igig
gege
rere
dd
bb
yy
aa
sisi
lili
coco
n-n-
controlled rectifier (SCR). The SCR we are using
controlled rectifier (SCR). The SCR we are using
is triggered by the application of 1.7-5V refer-
is triggered by the application of 1.7-5V refer-
enced to the SCR’s anode. So the system would
enced to the SCR’s anode. So the system would
be self-contained, we wanted the triggering cir-
be self-contained, we wanted the triggering cir-
cuit to be driven off of the firing capacitors. We
cuit to be driven off of the firing capacitors. We
used a 6V voltage regulator which accepts input
used a 6V voltage regulator which accepts input
voltages between 7 and 40V and an additional
voltages between 7 and 40V and an additional
1000 Ω voltage divider to produce the desired
1000 Ω voltage divider to produce the desired
3V for the trigger. We attached the SCR to the
3V for the trigger. We attached the SCR to the
output of the voltage divider and use a linear
output of the voltage divider and use a linear
SPDT switch to control the voltage regulator
SPDT switch to control the voltage regulator
state and fire. By using a switch to connect and
state and fire. By using a switch to connect and
disconnect the voltage divider, we eliminated
disconnect the voltage divider, we eliminated
capacitor voltage bleed through the voltage reg-
capacitor voltage bleed through the voltage reg-
ulator which some other trigger circuits have.
ulator which some other trigger circuits have.
The system’s charge is stored in a bank of
The system’s charge is stored in a bank of
thirty two 18mF capacitors in parallel. The ca-
thirty two 18mF capacitors in parallel. The ca-
pacitors were characterized with a capacitance
pacitors were characterized with a capacitance
meter to
meter to
determ
determ
ine their
ine their
actual capacita
actual capacita
nce and
nce and
equiv
equiv
alent
alent
series
series
resistan
resistan
ce ce
(T(T
able
able
44
). ).
Duri
Duri
ngng
characterization, the capacitors were found to
characterization, the capacitors were found to
have capacitance much lower than rated. How-
have capacitance much lower than rated. How-
ever, each of the capacitors has a
ever, each of the capacitors has a
±±
20% toler-
20% toler-
ance so this lower capacitance is not unreason-
ance so this lower capacitance is not unreason-
able.
able.
NN
uu
mm
bb
ee
r r
oo
f f
CC
aa
pp
aa
cc
ii
tt
oo
rr
s s
33
22
RR
aa
tt
ee
dd
UU
nn
ii
tt
CC
aa
pp
aa
cc
ii
tt
aa
nn
cc
ee
11
..
88
00
××
1010
−−
22

FF
Rated Capacitor Tolerance
Rated Capacitor Tolerance
±±
20 20
%%
AvAv
erer
age
age
MeMe
asas
urur
ed ed
UnUn
it it
CaCa
papa
citcit
anan
ce ce
1.1.
5353
××
1010
−−
22

FF
CC
apap
acac
itit
anan
ce ce
SS
tata
ndnd
arar
dd
DeDe
vivi
atat
ioio
nn
8.8.
3333
××
1010
−−
44

FF
Unit
Unit
Capaci
Capaci
tance
tance
Measur
Measur
emen
emen
ts ts
TT
aken
aken
1010
Aver
Aver
age Me
age Me
asured
asured
equiv
equiv
alent
alent
Resista
Resista
nce
nce
8.35
8.35
××
1010
−−
22

ΩΩ
ReRe
sisi
stst
anan
ce ce
StSt
anan
dada
rd rd
DeDe
vivi
atat
ioio
nn
7.7.
1111
××
1010
−−
44

ΩΩ
SS
aa
mm
pp
ll
ee
s s
TT
aa
kk
ee
n n
77
Table 4:
Table 4:
Capacitor Parameters
Capacitor Parameters
As the capacitors discharge into the coil, the
As the capacitors discharge into the coil, the
circu
circu
it acts
it acts
as as
an RLC
an RLC
circui
circui
t. t.
TT
oo
cha
cha
racter
racter
izeize
the circuit, we measured its discharge curve with
the circuit, we measured its discharge curve with
an an
oscil
oscil
loscope (Figure
loscope (Figure
66
). After 50ms, 87% of
). After 50ms, 87% of
the charg
the charg
ee
had b
had b
een dissip
een dissip
ated
ated
;;
aftaft
er er
100m
100m
s,s,
ovov
er 98%
er 98%
of the charge was gone.
of the charge was gone.
This exper
This exper
--
imental data matched up with our theoretical
imental data matched up with our theoretical
calculations quite well.
calculations quite well.
Note that the values for resistance, induc-
Note that the values for resistance, induc-
tance and capacitance obtained via discharge
tance and capacitance obtained via discharge
char
char
acteri
acteri
zation do
zation do
not match up
not match up
perfectly with
perfectly with
the results from direct measurement. The char-
the results from direct measurement. The char-
acterization suggests that the values of resis-
acterization suggests that the values of resis-
tance, inductance and capacitance are .13 Ω,
tance, inductance and capacitance are .13 Ω,
11
××
1010
−−
55

H and .2 F, respectively. We suspect

H and .2 F, respectively. We suspect
this is because the properties of the elements
this is because the properties of the elements
change somewhat when run at such high cur-
change somewhat when run at such high cur-
rents.
rents.
The equival
The equival
ent series resistance, for ex-
ent series resistance, for ex-
ampl
ampl
e, may b
e, may b
e dependen
e dependen
tt
on curren
on curren
t. t.
WW
ee
are
are
not truly sure of the cause of this discrepancy
not truly sure of the cause of this discrepancy
but the characterization results presented here
but the characterization results presented here
reflect how the circuit will behave in practice.
reflect how the circuit will behave in practice.
Thus these are the values we use in simulation.
Thus these are the values we use in simulation.
−−
00
..
00
5 5
0 0
00
..
00
5 5
00
..
1 1
00
..
11
5 5
00
..
22
00
55
1010
1515
Time (s)
Time (s)
V V
o o
l l
t t
a a
g g
e e
( (
V V
) )
Measured
Measured
Theoretical
Theoretical
Figure 6:
Figure 6:
Capacitor Voltage Discharge Curve
Capacitor Voltage Discharge Curve
Experimental Test Setup
Experimental Test Setup
TT
oo
obtain results on
obtain results on
coil shooting
coil shooting
perform
perform
ance,
ance,
a Vernier system photogates was used to mea-
a Vernier system photogates was used to mea-
sure the time required for the projectile to pass.
sure the time required for the projectile to pass.
The known length of the projectile could then
The known length of the projectile could then
be used to calculate the exit velocity.
be used to calculate the exit velocity.
44
Si
Si
m
m
ul
ul
at
at
ioio
nn
In order to assist in field visualization, several
In order to assist in field visualization, several
computer simulations of the system were made.
computer simulations of the system were made.
We used two finite element modeling packages to
We used two finite element modeling packages to
66
calculate the field induced by the coil with and
calculate the field induced by the coil with and
without the slug. We used a MATLAB model
without the slug. We used a MATLAB model
to numerically integrate equation
to numerically integrate equation
15 15
, the force
, the force
on the projectile.
on the projectile.
Finite Element Models
Finite Element Models
First, to visualize the fields surrounding the coil,
First, to visualize the fields surrounding the coil,
a simple coil model was made in COMSOL. This
a simple coil model was made in COMSOL. This
model uses the peak discharge current which
model uses the peak discharge current which
was measured at 60 A. The resultant fields are
was measured at 60 A. The resultant fields are
shown in Figure
shown in Figure
7.7.
As shown, the fields vary,
As shown, the fields vary,
but not significa
but not significa
ntly
ntly
, off
, off
the axis of the coil.
the axis of the coil.
Our
Our
MATLAB simulation assumes the on-axis field
MATLAB simulation assumes the on-axis field
is constant through the projectile and because
is constant through the projectile and because
of this simulation result, we are confident that
of this simulation result, we are confident that
this assumption is not throwing off the results
this assumption is not throwing off the results
significantly.
significantly.
Figure 7:
Figure 7:
Simulated magnetic field around coil
Simulated magnetic field around coil
from
from
COMSOL
COMSOL
Next, a secondary model was created in Fi-
Next, a secondary model was created in Fi-
nite Element Method Magnetics (FEMM), a
nite Element Method Magnetics (FEMM), a
free
free
simu
simu
lation pack
lation pack
age
age
specifical
specifical
ly ly
design
design
ed ed
forfor
magnetic systems. FEMM is ideal for the coil
magnetic systems. FEMM is ideal for the coil
gun system because it is scriptable, allowing us
gun system because it is scriptable, allowing us
to calculate the work done by the coil on the
to calculate the work done by the coil on the
projectile as it moves through the length of the
projectile as it moves through the length of the
barrel.
barrel.
To validate our FEMM results, we replicated
To validate our FEMM results, we replicated
the magnetic field plot from COMSOL using
the magnetic field plot from COMSOL using
FEMM (Figure
FEMM (Figure
88
). The numerical value of the
). The numerical value of the
field is slightly different with the values from
field is slightly different with the values from
FEMM being lower than the COMSOL values
FEMM being lower than the COMSOL values
by a factor of
by a factor of
44
⁄ ⁄
33

..
How
How
ever, this is quite clos
ever, this is quite clos
e,e,
within less than an order of magnitude and the
within less than an order of magnitude and the
qualitative shape of the field is very similar be-
qualitative shape of the field is very similar be-
tween the two models so we are confident in the
tween the two models so we are confident in the
results obtained from FEMM.
results obtained from FEMM.
Figure 8:
Figure 8:
Simulated magnetic field around coil
Simulated magnetic field around coil
from
from
FEMM
FEMM
Next, the iron projectile was added to the
Next, the iron projectile was added to the
FEM
FEM
MM
model
model
..
The addit
The addit
ion of
ion of
the projecti
the projecti
lele
changes the fields significantly, with extremely
changes the fields significantly, with extremely
intense fields concentrated within the projectile
intense fields concentrated within the projectile
(Figure
(Figure
99
).).
Figure 9:
Figure 9:
Simulated magnetic field around coil
Simulated magnetic field around coil
with Iron Projectile Present from FEMM
with Iron Projectile Present from FEMM
Using the FEMM model, the force on the
Using the FEMM model, the force on the
projectile as it moves through the field gradient
projectile as it moves through the field gradient
was calculated at thirty five points through the
was calculated at thirty five points through the
field gradient of the coil. These forces were nu-
field gradient of the coil. These forces were nu-
merically integrated to derive the work done by
merically integrated to derive the work done by
the field on the projectile. When combined with
the field on the projectile. When combined with
the actual masses of the projectiles, the barrel
the actual masses of the projectiles, the barrel
exit velocity of each was calculated. Note that
exit velocity of each was calculated. Note that
this simulation assumes that the current is at
this simulation assumes that the current is at
77
its peak for the entire transit of the projectile
its peak for the entire transit of the projectile
and disregards friction in the barrel.
and disregards friction in the barrel.
The results of this FEMM simulation are
The results of this FEMM simulation are
given in Table
given in Table
55
..
Note tha
Note tha
t two of the chose
t two of the chose
nn
steels were not in FEMM’s material database
steels were not in FEMM’s material database
and were substituted with similar steels. “Hot
and were substituted with similar steels. “Hot
Rolled Low Carbon Steel” was used for A36 and
Rolled Low Carbon Steel” was used for A36 and
“Cold Drawn Carbon Steel” was used for 4130.
“Cold Drawn Carbon Steel” was used for 4130.
Furthermore, the Mu-Metal was modeled as a
Furthermore, the Mu-Metal was modeled as a
solid 1” Long Slug, which differs from the actual
solid 1” Long Slug, which differs from the actual
geom
geom
etry of
etry of
our projectile.
our projectile.
MaMa
tete
riri
al al
LeLe
ngng
th th
StSt
ylyl
ee
ExEx
it it
VV
elel
ocioci
tyty
II
rr
oo
n n
11
” ”
SS
oo
ll
ii
d d
00
..
99
88
88
mm
⁄ ⁄
ss

SS
tt
ee
ee
l l
AA
33
6 6
11
” ”
SS
oo
ll
ii
d d
00
..
22
44
55
mm
⁄ ⁄
ss

SS
tt
ee
ee
l l
44
11
33
0 0
11
” ”
SS
oo
ll
ii
d d
00
..
22
00
55
mm
⁄ ⁄
ss

SS
tt
ee
ee
l l
11
00
11
8 8
11
” ”
SS
oo
ll
ii
d d
00
..
99
88
99
mm
⁄ ⁄
ss

MM
uu
--
MM
ee
tt
aa
l l
11
” ”
SS
oo
ll
ii
d d
00
..
11
88
00
mm
⁄ ⁄
ss

AA
ll
uu
mm
ii
nn
uu
m m
11
” ”
SS
oo
ll
ii
d d
00
..
00
00
11
mm
⁄ ⁄
ss

Table 5:
Table 5:
Velocity Results in
mm
Velocity Results in
⁄ ⁄
ss

It is interesting to see that according to the

It is interesting to see that according to the
FEMM simulation, the 1018 steel ended with
FEMM simulation, the 1018 steel ended with
a higher exit velocity than the pure iron, an
a higher exit velocity than the pure iron, an
unexpected result. Furthermore, the two steels
unexpected result. Furthermore, the two steels
for which similar steels were substituted both
for which similar steels were substituted both
performed very poorly with vastly different re-
performed very poorly with vastly different re-
sults than the 1018 steel. As expected, because
sults than the 1018 steel. As expected, because
aluminum has low magnetization, the forces on
aluminum has low magnetization, the forces on
the aluminum projectile were very low and we
the aluminum projectile were very low and we
suspect that in experimental testing, it will not
suspect that in experimental testing, it will not
overcome friction and will remain stationary.
overcome friction and will remain stationary.
Finally, the exit velocity of the mu-metal was
Finally, the exit velocity of the mu-metal was
surprisingly low given the high magnetization
surprisingly low given the high magnetization
of the material.
of the material.
Dynamic Model
Dynamic Model
We submitted equation
We submitted equation
1515
to numerical inte-
to numerical inte-
gration in Matlab, using equation
gration in Matlab, using equation
2323
to find
to find
the current through the coil at each time-step.
the current through the coil at each time-step.
The results of a simulation with parameters that
The results of a simulation with parameters that
match our experimental setup are shown in Fig-
match our experimental setup are shown in Fig-
ure
ure
????
..
55
Ex
Ex
peri
peri
men
men
ta
ta
ll
Re
Re
su
su
lts
lts
Each of the ten projectiles was launched three
Each of the ten projectiles was launched three
times out of the coil gun barrel and its velocity
times out of the coil gun barrel and its velocity
measured by the sensors. For each test, the lead-
measured by the sensors. For each test, the lead-
ing edge of the projectile was aligned with the
ing edge of the projectile was aligned with the
tail edge of the coil. The velocity data is given in
tail edge of the coil. The velocity data is given in
Table
Table
6. 6.
Note that the aluminum projectile did
Note that the aluminum projectile did
not move at all in the barrel, as expected due
not move at all in the barrel, as expected due
to its extremely small magnetic susceptibility.
to its extremely small magnetic susceptibility.
MaMa
tete
riri
al al
LeLe
ngng
th th
StSt
ylyl
ee
AvAv
erer
agag
ee
StSt
..
DeDe
v.v.
II
rr
oo
n n
11
” ”
SS
oo
ll
ii
d d
11
..
77
2 2
00
..
00
44
II
rr
oo
n n
11
” ”
HH
oo
ll
ll
oo
w w
11
..
00
0 0
00
..
22
66
II
rr
oo
n n
11
..
77
55
” ”
SS
oo
ll
ii
d d
11
..
99
2 2
00
..
00
55
II
rr
oo
n n
33
” ”
SS
oo
ll
ii
d d
11
..
66
8 8
00
..
00
55
SS
tt
ee
ee
l l
AA
33
6 6
11
” ”
SS
oo
ll
ii
d d
11
..
44
9 9
00
..
11
22
SS
tt
ee
ee
l l
44
11
33
0 0
11
” ”
SS
oo
ll
ii
d d
11
..
22
3 3
00
..
33
55
SS
tt
ee
ee
l l
11
00
11
8 8
11
” ”
SS
oo
ll
ii
d d
11
..
22
4 4
00
..
11
22
MM
aa
gg
nn
ee
t t
11
” ”
SS
oo
ll
ii
d d
11
..
66
2 2
00
..
11
66
MM
uu
--
MM
ee
tt
aa
l l
44
” ”
RR
oo
ll
ll
ee
d d
11
..
33
7 7
00
..
00
22
AA
ll
uu
mm
ii
nn
uu
m m
11
” ”
SS
oo
ll
ii
d d
0 0
00
Table 6:
Table 6:
Velocity Results in
mm
Velocity Results in
⁄ ⁄
ss

A plot of the deviation of the data is shown

A plot of the deviation of the data is shown
in Figure
in Figure
10.
10.
For certain materials, the launch
For certain materials, the launch
velocities were rather inconsistent leading to
velocities were rather inconsistent leading to
wider than ideal spreads. We attribute this in-
wider than ideal spreads. We attribute this in-
consistency to poor surface finishes on some of
consistency to poor surface finishes on some of
the machined slugs, causing friction to vary sig-
the machined slugs, causing friction to vary sig-
nificantly depending on the orientation of the
nificantly depending on the orientation of the
slug in the barrel.
slug in the barrel.
Figure 10:
Figure 10:
Deviation of launch velocity results
Deviation of launch velocity results
for
for
differen
differen
tt
proje
proje
ctiles
ctiles
66
AA
nn
aa
ll
yy
ss
ii
ss
Comparison of Results
Comparison of Results
An analysis of ideal theoretical calculations, nu-
An analysis of ideal theoretical calculations, nu-
merical simulati
merical simulati
ons
ons
and
and
experimen
experimen
tal results
tal results
leads to some interesting conclusions.
leads to some interesting conclusions.
88
First of all, we see that the order of mag-
First of all, we see that the order of mag-
nitude theoretical calculation which was per-
nitude theoretical calculation which was per-
formed matches up surprisingly well with the
formed matches up surprisingly well with the
experi
experi
men
men
tal results.
tal results.
The results from
The results from
this cal-
this cal-
culation were off from the final results by a
culation were off from the final results by a
factor of about 3, quite close considering all of
factor of about 3, quite close considering all of
the assumptions that were made.
the assumptions that were made.
Furthermore, the FEMM numerically inte-
Furthermore, the FEMM numerically inte-
grated veloci
grated veloci
ty data lines up
ty data lines up
with the data
with the data
quite
quite
well and is off by less than a factor of two for
well and is off by less than a factor of two for
the iron slug. For some of the steels, however,
the iron slug. For some of the steels, however,
the results differ significantly from the FEMM
the results differ significantly from the FEMM
simulation, a fact which we believe can be at-
simulation, a fact which we believe can be at-
tributed to differences between the simulated
tributed to differences between the simulated
materials and the actual used materials.
materials and the actual used materials.
Our Matlab dynamics model predicts exit
Our Matlab dynamics model predicts exit
velocities on the order of 4m/s, about twice as
velocities on the order of 4m/s, about twice as
fast as our experimental results showed. The dy-
fast as our experimental results showed. The dy-
namic model makes several assumptions which
namic model makes several assumptions which
would increase the exit velocity. It assumes there
would increase the exit velocity. It assumes there
is no friction or air resistance in this system, th
at
is no friction or air resistance in this system, th
at
a linear model of magnetization holds true and
a linear model of magnetization holds true and
that the field is radially uniform and equal in
that the field is radially uniform and equal in
magnitude to the axial field. The finite element
magnitude to the axial field. The finite element
models showed that the radial uniformity ap-
models showed that the radial uniformity ap-
proximation was not a terrible, but the actual
proximation was not a terrible, but the actual
field generally decreases in the radial direction.
field generally decreases in the radial direction.
The Matlab model
The Matlab model
predic
predic
ts peak
ts peak
magnet
magnet
ic fields
ic fields
internal to the slug in excess of 3
internal to the slug in excess of 3
TT
using the
using the
linear model. The saturation magnetization of
linear model. The saturation magnetization of
most soft irons is around 1 or 2T. Thus the
most soft irons is around 1 or 2T. Thus the
actual magnetization may be much lower than
actual magnetization may be much lower than
the linear model predicts. The combination of
the linear model predicts. The combination of
these three phenomena could explain the dis-
these three phenomena could explain the dis-
crepancy between the dynamic model and the
crepancy between the dynamic model and the
experimental results.
experimental results.
Material Performance
Material Performance
Although the collected launch data for several
Although the collected launch data for several
of the materials had high standard deviation,
of the materials had high standard deviation,
some definite conclusions can be drawn from the
some definite conclusions can be drawn from the
data.
data.
First of all, it is quite clear that solid pro-
First of all, it is quite clear that solid pro-
jectiles
jectiles
perform
perform
better
better
than
than
their
their
hollow
hollow
coun-
coun-
terparts. Although the hollow projectiles have
terparts. Although the hollow projectiles have
less air resistance, the 1” long iron slugs clearly
less air resistance, the 1” long iron slugs clearly
demonstrate that the increased magnetization
demonstrate that the increased magnetization
from the extra material makes a significant dif-
from the extra material makes a significant dif-
ference. This demonstrates that cross-sectional
ference. This demonstrates that cross-sectional
area is quite important in projectile design
area is quite important in projectile design
..
The
The
1” long hollow slug reached an exit velocity of
1” long hollow slug reached an exit velocity of
1.00
1.00
±±
0.26
0.26
mm
⁄ ⁄
ss

, much lower the 1” long solid

, much lower the 1” long solid
slug which reached 1.72
slug which reached 1.72
±±
0.04
0.04
mm
⁄ ⁄
ss

. In fact, the
. In fact, the
hollow slug may have been the slowest of all
hollow slug may have been the slowest of all
of the projectiles tested. This much lower exit
of the projectiles tested. This much lower exit
velocity for the hollow projectile helps to corrob-
velocity for the hollow projectile helps to corrob-
orate our theoretical results: both the order of
orate our theoretical results: both the order of
magnitude and detailed calculations show that
magnitude and detailed calculations show that
the force is roughly proportional to the cross
the force is roughly proportional to the cross
sect
sect
iona
iona
l area of
l area of
the slug.
the slug.
ThTh
us a
us a
hol
hol
low slug
low slug
would be expected to have a lower exit velocity,
would be expected to have a lower exit velocity,
which we see in the experimental data.
which we see in the experimental data.
Subsequently, it is interesting that length of
Subsequently, it is interesting that length of
iron projectile did not significantly affect the
iron projectile did not significantly affect the
launch performance of the coil gun. This is be-
launch performance of the coil gun. This is be-
cause the
cause the
large
large
rr
projectil
projectil
es es
obtain higher levels
obtain higher levels
of magnetization but also have higher masses
of magnetization but also have higher masses
and normal forces in the barrel, leading to in-
and normal forces in the barrel, leading to in-
creased friction. This suggests that a coil gun
creased friction. This suggests that a coil gun
of a fixed design may be able to launch a large
of a fixed design may be able to launch a large
range of projectiles with good results. In fact, in
range of projectiles with good results. In fact, in
the order of magnitude approximation the mass
the order of magnitude approximation the mass
of the slug has no effect on the exit velocity,
of the slug has no effect on the exit velocity,
using equation
using equation
55
::
vv
exit
exit
==



22
mm
VV
μμ
00

χχ
mm
nn
22

II
22
==



22
ρρ
mm
μμ
00

χχ
mm
nn
22

II
22

(24)
(24)
That is, the exit velocity depends only on
That is, the exit velocity depends only on
the density of the object.
the density of the object.
Next, the data shows that the iron projectiles
Next, the data shows that the iron projectiles
perform
perform
ed ed
better than
better than
their steel counterpar
their steel counterpar
ts.ts.
This was expected because iron is a stronger
This was expected because iron is a stronger
ferromagnetic material than most steels. How-
ferromagnetic material than most steels. How-
ever, there is not a correlation between percent
ever, there is not a correlation between percent
iron content in a steel and the performance of
iron content in a steel and the performance of
the steel, leading us to believe that the solutes
the steel, leading us to believe that the solutes
of the alloy have a greater affect its magnetic
of the alloy have a greater affect its magnetic
susceptib
susceptib
ilitilit
y than the
y than the
iron conten
iron conten
t. t.
It is also
It is also
possible that the process by which the steel
possible that the process by which the steel
was formed affects its magnetic performance.
was formed affects its magnetic performance.
The data suggests that the hot-rolled A36 steel
The data suggests that the hot-rolled A36 steel
performed better than its cold-rolled 1018 coun-
performed better than its cold-rolled 1018 coun-
terpart. However, the data from the 4130 cold-
terpart. However, the data from the 4130 cold-
rolled steel is inconclusive.
rolled steel is inconclusive.
The both analytical results suggest that the
The both analytical results suggest that the
exit velocity is proportional to the magnetic
exit velocity is proportional to the magnetic
susceptibility of the material. This is the most
susceptibility of the material. This is the most
likely explanation for the
likely explanation for the
Finally, the launch performance of the rolled
Finally, the launch performance of the rolled
99
mu-metal and the permanent neodymium mag-
mu-metal and the permanent neodymium mag-
net raises interesting conclusions. In tests, the
net raises interesting conclusions. In tests, the
mu-metal performed about as well as the tested
mu-metal performed about as well as the tested
steels. However, in its rolled configuration and
steels. However, in its rolled configuration and
with half the mass of the steel projectiles, its
with half the mass of the steel projectiles, its
performance is nonetheless impressive. We pos-
performance is nonetheless impressive. We pos-
tulate that if
tulate that if
we had a
we had a
solid mu-m
solid mu-m
etal projectile,
etal projectile,
it would have performed better than both the
it would have performed better than both the
iron and
iron and
steel projectiles
steel projectiles
..
How
How
eve
eve
r, mu-metal is
r, mu-metal is
a rather rare material and is not commonly pro-
a rather rare material and is not commonly pro-
duced in forms other than sheets. Furthermore,
duced in forms other than sheets. Furthermore,
the p
the p
erfo
erfo
rmanc
rmanc
ee
of of
the permanent magnet was
the permanent magnet was
disappointing, with its launch velocities strug-
disappointing, with its launch velocities strug-
gling to keep up with the solid iron slugs. We
gling to keep up with the solid iron slugs. We
suspect this disparity is because of the high mag-
suspect this disparity is because of the high mag-
netization of the iron projectiles which, when
netization of the iron projectiles which, when
combined with an intense magnetic field, caused
combined with an intense magnetic field, caused
the projectiles to reach magnetic saturation, as
the projectiles to reach magnetic saturation, as
predicted by our dynamics model. The magnet
predicted by our dynamics model. The magnet
has a lower saturation magnetization of 1.3 T
has a lower saturation magnetization of 1.3 T
when compared to the Iron’s 2.3T
when compared to the Iron’s 2.3T
[[
33
]. Further-
]. Further-
more, the magnet had a smaller diameter than
more, the magnet had a smaller diameter than
the slugs and this decreased cross-sectional area
the slugs and this decreased cross-sectional area
may have affected the performance.
may have affected the performance.
77
Co
Co
nc
nc
lu
lu
sisi
on
on
In conclusion, we successfully built a coil gun
In conclusion, we successfully built a coil gun
and tested its performance with a wide variety of
and tested its performance with a wide variety of
projectiles. In the process, we used several meth-
projectiles. In the process, we used several meth-
ods to predict our gun’s performance including
ods to predict our gun’s performance including
the development of a custom, remarkably ac-
the development of a custom, remarkably ac-
curate mathematical model. Furthermore, con-
curate mathematical model. Furthermore, con-
clusive results were reached for a number of
clusive results were reached for a number of
differe
differe
nt classes of projectiles.
nt classes of projectiles.
It was found that
It was found that
solid iron projectiles perform very well in a coil
solid iron projectiles perform very well in a coil
gun and that projectile length is not very im-
gun and that projectile length is not very im-
portant to launch performance.
portant to launch performance.
FF
urthermor
urthermor
e,e,
permanent magnets perform well in a coil gun
permanent magnets perform well in a coil gun
but not substantially different from their iron
but not substantially different from their iron
count
count
erparts
erparts
..
Additio
Additio
nally
nally
,,
steel pro
steel pro
jectil
jectil
es es
can
can
perform well
perform well
, but not
, but not
as well as iron slugs.
as well as iron slugs.
How
How
--
ever, steel is a harder and stronger material
ever, steel is a harder and stronger material
and may be more useful than iron in real-world
and may be more useful than iron in real-world
applications.
applications.
88
FF
ur
ur
th
th
er
er
W
W
or
or
kk
Further work in the topic could be done in a num-
Further work in the topic could be done in a num-
ber of
ber of
area
area
s. s.
In order to
In order to
impr
impr
ovov
ee
the dynami
the dynami
cc
model, an expression for the off-axis field of a
model, an expression for the off-axis field of a
finite solenoid could be derived, and further in-
finite solenoid could be derived, and further in-
vestigation could be done into non-linear magne-
vestigation could be done into non-linear magne-
tization models. The experimental setup could
tization models. The experimental setup could
be improved by investigating barrel materials
be improved by investigating barrel materials
and lubricants to reduce friction. Furthermore,
and lubricants to reduce friction. Furthermore,
improved finish on the projectiles would help
improved finish on the projectiles would help
to reduce the exit velocity variance and reduce
to reduce the exit velocity variance and reduce
frifri
cticti
on.
on.
FF
urth
urth
er study could be
er study could be
done to
done to
ana-
ana-
lyze a wider class of projectiles. Attributes like
lyze a wider class of projectiles. Attributes like
projectile shape, a wider range of alloys, types
projectile shape, a wider range of alloys, types
of permanent magnets and projectile lengths.
of permanent magnets and projectile lengths.
Second, exploration could be done into how dif-
Second, exploration could be done into how dif-
ferent barrel materials affect performance and
ferent barrel materials affect performance and
possibly into lubrication as a method of decreas-
possibly into lubrication as a method of decreas-
ing barrel fricti
ing barrel fricti
on.
on.
Never
Never
theless, we feel that
theless, we feel that
even without includin
even without includin
gg
some of
some of
these addition
these addition
alal
fact
fact
ors, our
ors, our
result
result
ss
are conclusiv
are conclusiv
ee
and useful.
and useful.
References
References
[1][1]
Griffiths, David J.
Griffiths, David J.
Introduction to Electrody-
Introduction to Electrody-
namics
namics
(3rd Edition). Upper Saddle River,
(3rd Edition). Upper Saddle River,
New Jersey: Prentice-Hall, 1999.
New Jersey: Prentice-Hall, 1999.
[2][2]
Hanse
Hanse
n, n,
Barry
Barry
..
Bar
Bar
ry’s
ry’s
Coilg
Coilg
un
un
Desi
Desi
gns
gns
..
http://coilgun.info
http://coilgun.info
, 2012.
, 2012.
[3][3]
Miner, Douglas F. and John B. Seastone.
Miner, Douglas F. and John B. Seastone.
Handbook of Engineering Materials
Handbook of Engineering Materials
(1st Edi-
(1st Edi-
tion). New York: John Wiley & Sons, 1955.
tion). New York: John Wiley & Sons, 1955.
[4][4]
Livingston, James D.
Livingston, James D.
Electronic Properties
Electronic Properties
of Engineering Materials
of Engineering Materials
. New York: John
. New York: John
Wiley & Sons, 1999.
Wiley & Sons, 1999.
[5][5]
Hummel, Rolf E.
Hummel, Rolf E.
Electr
Electr
onic
onic
Pro
Pro
pertie
pertie
ss
of of
Materials
Materials
 (3rd Edition). New York: Springer-
(3rd Edition). New York: Springer-
Verlag, 2001.
Verlag, 2001.
[6][6]
MatWeb, Online Materials Information Re-
MatWeb, Online Materials Information Re-
source.
source.
http://matweb.com
http://matweb.com
,,
2012.
2012