Advanced Sabot System Design Navy SBIR FY2008.1 Sol No.: Navy SBIR FY2008.1 Topic No.: N08-053 Topic Title: Advanced Sabot System Design Proposal No.: N081-053-0413 Firm: Simulations, LLC 9 East Tomstead Simsbury, Connecticut 06070-2005 Contact: Jeffrey Kezerian Phone: (860) 978-0772 Web Site: www.SimulationsLLC.com Abstract: Simulations, LLC, a privately held small-business engineering company, and team members DR-Technology, the U.S. Army Research Laboratory (ARL) and Douglas Elder, proposes to develop the material and fabrication methodologies to produce a lightweight, high-strength, low-cost composite sabot based on innovative configurations. Simulations will springboard from: (1) the current ONR Projectile IPT sabot subsystem concept; (2) two proven ARDEC SLEKE, Area I, four-petal, ribbed, aluminum sabots; (3) the Army D2 six-petal, uniaxial graphite-epoxy composite sabot development efforts, and; (4) the ILP design experience of the Simulations team. Simulations will innovate geometries, perform structural analyses and optimize configurations, materials and fabrication methodologies. The approach will use lessons learned from a collage of conventional and electromagnetically launched sabots, while utilizing Simulations parametric finite-element-analysis code FATE. FATE is a proprietary customized code, developed by Simulations for the ARL. FATE is used for analytically designing integrated launch packages, thus making it immediately idyllic for the Navy's Advanced Sabot System Design. FATE is the core structural analytical tool supporting ARL's F5 double-tapered sabot-armature designs. Based on F5 and FATE successes, Boeing contracted Simulations to size, design and analyze the Navy's Phase I base-push and mid-ride topologies in 2006. Consequently, Simulations showed parasitic ILP masses approaching 30%. Benefits: The U.S. Navy is in the process of developing a shipboard electromagnetic railgun (EMRG) under an Office of Naval Research (ONR) Innovative Naval Prototype (INP) initiative, which will use high-power electric current to launch precision guided projectiles at hypersonic speeds (i.e., > 2 km/s). The EMRG has the potential to substantially improve strategic and tactical strike capabilities, particularly the barrage-type naval surface fire support, accurate long-range land-attack capabilities, and force protection (self-defense) at a fraction of the cost of alternate munitions. With recent progress in shipboard integrated power systems (e.g., all electric ships), these objectives place EMRG technology at the forefront to achieve gun-like capabilities at missile-like ranges. In 2005, the baseline projectile performance goals were: (1) survive 40 kGee of launch acceleration from a 64 MJ EMRG; (2) reach ranges in excess of 250 nmi; and (3) maximize lethality on target. To achieve these goals, the ILP has to weigh approximately 20 kg with a launch velocity on the order of 2.5 km/s. To date, the ONR Projectile IPT effort continues to strive for the 20 kg mass budget, and until it is achieved the EMRG must supply larger gun energies to attain 2.5 km/s. Thus, to maximize range and lethality, focused efforts to minimize parasitic mass continue for the three major subsystems: (1) armature; (2) sabot; and (3) projectile (i.e., aeroshell, thermal protection, and guidance & control). The purpose of the proposed Advanced Sabot System Design (ASSD) program is to develop a low-cost, lightweight, high-strength sabot subsystem for use in high acceleration (40 kGee) gun launches. It is in this exact application that Simulations structural expertise applies and its FATE code can be applied effectively to meet the ONR ASSD goals. The current/primary ONR Projectile IPT ILP concept is a base-push topology comprised of a lightweight, high-strength composite material sabot with a forward bore-rider/aerodynamic scoop, a center bore-rider and an aft bore-rider. Many variables will govern the final design, yet convergence on a solution is critically governed by the complex in-bore, multi-disciplined physics, the projectile's operational functionality, and actual target missions. From this, a minimum mass, base-push sabot subsystem will evolve capable of surviving 40 kGee. The Simulations Team understands the ASSD goal to perform a feasibility study that will ultimately provide Phase III sabots to launch projectiles currently under development by the ONR Projectile IPT. The development and success of this next-generation lightweight ASSD offers enormous EMRG technological advancements as well as logistical military application advances. Creating innovative, minimum mass sabots will: (1) increase range and lethality capabilities; (2) enhance useful payload mass (e.g., warhead, guidance and controls, terminal seekers); and/or (3) lower prime/pulse power requirements. Thus, creating an advanced sabot system springboards today's conventional EM ILP laboratory sabots to that of sabots ready for fieldable military, defense and space applications. The Department of Defense and NASA are pursuing the development of EM gun systems as the natural replacement for conventional powder guns and certain missiles. The fundamental rationale for employing EM guns is the exploitation of hypersonic (velocity > 2 km/s) flight. However, to achieve hypersonic velocities requires either large muzzle energies within reasonable platform volume and pulse power constraints, or smaller launch packages. From simple system studies, it becomes obvious that delivering meaningful payload mass on target or into orbit/space is the single greatest engineering challenge of exploiting EM gun capabilities and hence, hypersonic flight. In turn, maximizing useful flight mass dictates parasitic mass (sabots, armatures, and aeroshell). Commercial application spin-offs will include: advanced fiber orientation, composite survivability, hybrid fiber/resin coatings to manage thermal loads, co-molding techniques for metallic and non-metallic inserts, and 2.5 and 3 dimensional text-tiling, all augmenting the industry's database of the successfully launched materials. Commercial applications will benefit from the ASSD since high-speed ILPs inherently require minimum flight vehicles and increased stiffness. Sharing the lessons learned from the ASSD program could call for modified and improved sabots throughout the DoD services and NASA. Thus, Simulations envisions itself as becoming an industry innovator in reducing parasitic mass by the employment of unique structural designs and high-strength materials, and advancing the commercial application success of FATE (Forces Applied To Elements). In turn, applications of interest to Simulations include: - Ground and sea-based long range artillery that can achieve from several hundred kilometers to intercontinental ranges - Upgrading gun ships, arsenal and long-range strike aircraft, unmanned aircraft, ships and ground vehicles, from troop carriers to main battle tanks - Ground, sea and airborne-based air & missile defense systems capable of engaging tactical and strategic ballistic missiles, cruise missiles, unmanned aircraft, and fixed and rotary winged aircraft - Placement of rugged payloads, such as fuel, water and materials, into orbit THE SIMULATIONS TEAM Simulations and its team members are pleased to respond to the Office of Naval Research's SBIR proposal request for Advanced Sabot System Design, N08-053, of the Acquisition Program: ACAT II, "Gun Weapon Systems Technology Program, Naval Surface Fire Support." The primary objective of Simulations' proposed effort is to develop a low-cost, lightweight, high-strength sabot subsystem for use in high-acceleration (>40 kGee) electromagnetic railgun launch. Proven capabilities of Simulations' team include: - A team consisting of three members (Jeffrey M. Kezerian, Alex E. Zielinski and Douglas J. Elder) instrumental in the successful conduction of ONR/Boeing's Phase I Armature Accelerated Smart Projectile (AASP) program, N00014-06-D-0181. In addition, Mr. Zielinski and Mr. Elder (who has had a close, professional working relationship for over 20 years) were responsible for the development of most all projectiles of tactical mass and flight configuration successfully launched from Green Farm, CEM-UT, ARDEC and Kirkcudbright 90-mm EMRG; ARDEC / Marine Corp 17- x 39-mm CCEMG; and all current laboratory railguns at ARL, IAT and Kirkcudbright. - A team composed of the leading experts in all key critical technology areas for the proposed effort, including materials; projectile, armature and sabot development and integration; in-bore ballistics and structural mechanics (dynamics and transition), electrodynamics (thermal and electromagnetic); and bore disengagement. SIMULATIONS PROPOSED PROGRAM In Phase 1, Simulations will focus on innovative configurations and optimized features, materials and fabrication methodologies to produce a lightweight, high-strength composite sabot. Low-mass, high-strength material properties and samples will be obtained from potential vendors, structural analyses will be conducted, and preliminary designs will be produced. In Phase II, Simulations will provide final sabot design, conduct prototype fabrication and demonstration of EMRG survivability through drop tests and powder gun tests. In Phase III, Simulations will provide sabots throughout the projectile test series. This development approach thus insures that the optimum launch topology "will facilitate transition into the follow-on System Development & Demonstration Application Program sponsored by NAVSEA JWS3C." [email protected] Return