ACKNOWLEDGEMENT

We express our sincere thanks to the CIPET (Central Institute Of Plastics Engineering
And Technology) for providing all facilities, which were required to complete this project
successfully.
We would like to thank sincerely to Mr.Ravikanth(Manager-projects)who has the
main role in the project activities, guidance and encouragement as well as help given for
the completion of the project.
We are thankful to all other CIPET staff and colleagues for their timely
encouragement throughout project.
Last but not least ,we are also thankful to our faculty of our college for guiding
us in all aspects directly and indirectly for the completion of this project.

Yours sincerely

ABSTRACT

Design development of an ammunition box for impact resistance. In

present Scenario lot of research are going on to reduce the impact load with flexible
design concepts.
The projects aim is that to design an ammunition box of a particular load. The
explosives are kept in an enclosure and dropped from a particular height. The explosives
should not be exploded because of impact load acting on it hence the aim of this project
is to reduce the impact with plastic product design concepts and best suitable plastic
material with flexibility of mold manufacturing.

Curriculum:

Production drawing concepts.

Plastic product design concepts.

Plastic materials.

Exposure design with the help of PRO-E & 3D-MODELLING

concepts.

Analysis by using ANSYS.

Mould design process.

CONTENTS
ABSTRACT
LIST OF FIGURES
LIST OF TABLES
LIST OF SCREENS
SYMBOLS AND ABBREVATIONS
INTRODUCTION
ABOUT COMPANY
DESIGN
CAD MODELLING
PRO E
PRODUCT DESIGN
MATERIALS USED
ANALYSIS
COCNCLUSION
BIBILOGRAPHY

LIST OF FIGURES /TABLES AND SCREENS

INTRODUCTION
An ammunition box is a container designed for safe transport and storage of ammunition.
It is typically made of metal and plastic and labelled with caliber, quantity, and
manufacturing date or lot number. A rubber gasket is commonly found in the hinged lid to
protect the ammunition from moisture damage.
Due to their durable construction, metal ammunition boxes are popularly re-used for
general storage and other purposes.Players in the sport of geocaching commonly use
ammunition boxes as the containers to hide logbooks and treasures. Used boxes are often
sold at military surplus stores.
The resealing ammunition box is largely a NATO tradition. Warsaw Pact nations typically
stored and transported ammunition in single-use "spam cans". In World War II, Duct tape
was used to seal ammo boxes.
Not all ammunition boxes are metal, however Wood,plastic and paper have also
historically been used as a method of packaging and selling ammunition. Some
enthusiasts and investors collect historical ammunition boxes.
Presently conventional metal ammunition boxes are replaced by plastics because of their
superior properties over metals such as reduced weight, low cost, feasibility. Molding
flexibility permits designs that deliver outstanding sound-absorption properties. Plastics
have sound-absorption properties. Plastics enable ammunition box to be manufactured
simply, cost-effectively and quickly. Time-consuming machining steps such as turning,
milling, and drilling are eliminated because injection-molded plastic ammunition box
modules come out of the machine in their final shape.plastic reduces processing and
logistics costs because the granulated raw material is easily transported and stored. Once
the mold has been made, manufacturing of ammunition box can be started quickly and

without hitches anywhere in the world..plastics in the market are even comparable. The
advantages offered by plastics must be based on a solid technical foundation.

ABOUT COMPANY

CENTRAL INSTITUTE OF PLASTIC ENGINEERING AND TECHNOLOGY is

an autonomous institute under the ministry of chemicals and fertilizer(govt. of India) was
firstly established in 1968 at Chennai.
Later in 1987 CIPET was established for providing training and technical services to te
plastics and allied industries . CIPET is well equipped with the state of art facilities
inDesign CAD/CAM/CAE tooling plastics processing testing departments in order to
meet the customer requirements by providing quality training and technical services.It
undertakes various types of job works development assignments related to following
areas :

Training

Designing and Tooling

Processing and quality assurance

New unit establishment

CAD/CAM/CAE Centre
The CAD/CAM/CAE Centre in CIPET was equipped with latest hardware and
software and it undertakes design and development projects various courses like
Mechanical and master program in CAD/CAM/CAE and Mould design, CAD/CAM for
injection moulds.
Processing department
In procressing department it imparts training and renders the technical services.
It has machinery of all kinds like Arburg injection moulding maching ,EPM injection
moulding,PVC pipe plant,AXON ab extruder, e.t.c.,
Testing Department
IN testing department , Laboratories are well equipped with machineries and
equipments for testing plastic materials and products as per national and international
standards.CIPET testing services are utilized by Bureau of Indian standards municipal
corporations, defence establishment and another government agencies procuring plastic
products

OBJECTIVE

Now a days plastic was the major material used in all type of industries.It dethhrowned
the usage of conventional metal. Around 20 kg of plastic is used per head as for plastic
standards.Our main objective was to design an ammunition box with the plastic material
at low cost with the best storage and carrying style.
.
The word plastic is derived from the Greek word , plastikos
meaning capable of being shaped or molded from plastos meaning molded.
Plastic is the common term for a wide range of synthetic or semi synthetic organic
amorphous solid materials used in the manufacture of industrial products plastics are
typically polymers of high molecular mass and may contain other substances to improve
performance and reduce cost. It is available in some resin form or some derived from
trhe basic polymerized resin.
In olden days for the design of ammo wood were used first.Later
wood was replaced by metal.Though metal has long durability and stiffness , the
designing was little cumbersome.But plastic which is easy to carry and its stiffness
properties were attracting all type of industries for high production at low cost.Our
project aim was to design ammo with the plastic with all round requirements

LITERATURE SURVEY

M2 .50CAL AMMO BOX:

The M2 was primarily used for .50 caliber ammunition. It is opened on one side and had
a rubber gasket. The closing clamp was secured with a cotter pin or seal. The need for a
pin to secure the clamp was a major failing of this design. This ring on this one is original
and is held in a slot in the closing clamp. Some makers used this style of ring retention
but may lack the slot. Some makers were known to use both styles. This one was made by
MODERN.

Disadvantages of M2 .50 Caliber ammo box:

1. The M2 .50 caliber ammo box is made of metal which increases the weight of the
ammo box.
2. One side opening cap is provided with a clamp on other side for fixing. This clamp
may get opened when dropped from higher heights due to impact force acting on it when
it reaches the ground.
3. Since it is made of metal, dents can be formed when dropped on terrain ground.
4. Due to the impact force acting on the ammunition box it may damage the ammunition.

Proposed System:
To overcome these disadvantages, the weight of the ammunition box must be
reduced, so that when dropped from higher heights the impact force acting on it is
reduced. Using plastics will reduce the cost. The ammunition inside the box must be
fixed so that there will be no chances of damage.

Conclusion:
Reducing the weight of the ammunition box reduces the damage of the ammunition
when dropped from higher heights.

MATERIALS FOR AMMUNITION

The word plastic is derived from the Greek word ,
plastikos meaning capable of being shaped or molded from plastos meaning molded.
Plastic is the common term for a wide range of synthetic or semi synthetic organic
amorphous solid materials used in the manufacture of industrial products plastics are
typically polymers of high molecular mass and may contain other substances to improve
performance and reduce cost. It is available in some resin form or some derived from
trhe basic polymerized resin.
There are two types of plastics:
1.Thermo plastics
2.Thermo sets.

Thermoplastics:
These are the plastics that do not undergo chemical change in their
composition when heated and can be molded again and again.
Examples are polyethylene,polyskiktyrene,polyamide,poly tetra flouro ethylene etc..

Thermosets:
These can melt and can take shape once after they have solidified
once.The raw materials used to make plastics come from petroleum and natural gas.Due
to their low cost,ease of manufacturer ,plastics are enormously used.Thus it has displaced
conventional metal.
Examples are phenylformaldehyde,melamine formaldehyde,apoxy etc..

Plastic Processing
Plastic processing can be defined as the process of converting the plastic raw
materials into semi-finishing or finished products.

Methods of plastic processing

The processing of plastic can be classified into following types:

Injection molding

Compression molding

Extrusion

Blow molding

Reaction injection molding

Transfer molding

Thermoforming

Injection molding
The main method used for processing plastic is injection molding. With this
process, the plastic is placed into a hopper. The hopper then feeds the plastic into a heated
injection unit, where it is pushed through a long chamber with a reciprocating screw.
Here, it is softened to a fluid state.
A nozzle is located at the end of the chamber. The fluid plastic is forced through
the nozzle into a cold, closed mold. The halves of the mold are held shut with a system of
clamps. When the plastic is cooled and solidified, the halves open and the finished
product is ejected from the press.
Thermosetting materials usually are not processed with injection molding because
they will soften, they harden to an infusible state. If they are processed with injection
molding, they need to be moved through the heating chamber quickly so they do not set.
Types of Injection molding machines:

Plunger type Injection molding machine

Screw type Injection molding machine

Plunger-Plunger Injection molding machine

Screw-Plunger Injection molding machine

Compression molding
Compression molding is a method of molding in which the plastic, generally
preheated is first placed in an open heated mold cavity. They are four steps in
compression molds as;

Load charge

Compression of charge

Cured the charge

Ejecting process

The main construction is Punch (cavity side), core molds and ejection system.

Extrusion
The process of extrusion is usually used to make products such as film,
continuous sheeting, tubes, profile shapes, rods, coat wire, filaments, cords, and cables.

As with injection molding, dry plastic material is placed into a hopper and fed into a long
heating chamber. At the end of the chamber, however, the material is forced out of a small
opening or a die in the shape of the desired finished product. As the plastic exits the die, it
is placed on a conveyor belt where it is allowed to cool. Blowers are sometimes used to
aid in this process, or the product may be immersed in water to help it cool.

Blow molding
Blow molding is used when the plastic item to be created needs to be hollow. A
molten tube is created with blow molding by using compressed air, which blows up the
tube and forces it to conform to the chilled mold. Variations of blow molding include
injection, injection-stretch, and extrusion blow molding.
With injection blow molding uses a pre form, which is taken to a blow mold and
filled with compressed air. As a result, it conforms to the interior design of the blow
mold. With injection-stretch blow molding, the plastic is stretched prior to being formed.
Otherwise, it is essentially the same as the injection process.
With continuous-extrusion, a molten plastic tube is continuously created. At the
appropriate times, the tube is pinched between two mold halves. Then, a needle or a blow
pin is inserted into the tube and blows compressed air up the part in order to force it to
conform to the mold interior. With accumulator-extrusion, the molten plastic material is
gathered in the chamber before it is forced through a die in order to form a tube.

Reaction injection molding

Reaction injection molding, or RIM, is one of the newer processes used in the
plastics industry. It differs from liquid casting in that the liquid components are mixed
together in a chamber at a lower temperature of only about 75 to 140 degrees Fahrenheit
before it is injected into a closed mold. Here, an exothermic reaction occurs. As a result,
RIM requires less energy than other injection molding systems. Reinforced RIM, or RRIM, involves adding materials such as milled or chopped glass fiber in the mixture in
order to increase the stiffness.

The materials used for ammunition box are:1. Acetal (Derlin)

2. polycarbonate

Acetal (Derlin):- Acetal is a crystalline thermoplastic polymer with a high melting point.
It offers a high modulus of elasticity combined with great strength, stiffness and
resistance to abrasion. Moisture has little to no effect on acetal resin, and because of this,
the dimensional stability of close tolerance fabricated items is excellent. It is suitable for
mechanical parts or electrical insulators that require structural strength at above normal
temperatures.

Properties:

High modules of elasticity.

High strength and stiffness.

Low coefficient of friction.

Easily fabricated with hand tools and automatic production machinery.

Good abrasion and impact resistance.

Low moisture absorption.

Excellent machineability.

Natural lubricity.

Resistant to gasoline, solvents, and other neutral chemicals.

Useful in air temperatures of -60 to +320.

Grades:

Delrin 100 series: High viscosity grade of resin for production of rod, slab and
tubing to be machined.

Delrin 500 series: General purpose resin used in production of rod and slab.

Delrin 570 series: Resin containing glass fibers. Used where high stiffness,
creep resistance and better dimensional stability are required.

Delrin AF: Resin containing TEFLON fibers. Used where low coefficient of
friction, high resistance to abrasion and wear are required.

Applications:
Delrin's overall combination of physical, tribological and environmental properties
make it ideal for many industrial wear and mechanical applications such as: Pump and
Valve components, Gears, Bearings, Bushings, Rollers, Fittings and Electrical insulator
parts.

Product Description And Specification:

Acetal Homopolymer, Natural ASTM D-4181 POM111Acetal
Black ASTM D-4181 POM111 w/Black Acetal

Homopolymer,

Homopolymer, 20% Glass-filled

(570)ASTM D-4181 POM110G20A39(4200)170Acetal Homopolymer, AF Blend ASTM

D-4181 POM110L13A00000

AGENCY APPROVALS OR LISTING : FDA, NSF, USDA

BASE RESINS TRADE NAMES : Delrin

MECHANICAL PROPERTIES:
Specific gravity
Tensile strength, Ultimate
Elongation at break
Tensile modulus
Rockwell hardness
Impact strength (73 F)
Flexural strength
Flexural modulus
Wear factor against steel 40 psi

(ASTM D 792)
(ASTM D 638)
(ASTM D 638)
(ASTM D 638)
(ASTM D 785)
(ASTM D 256) (notched)
(ASTM D 790)
(ASTM D 790)

1.42
10,000 p.s.i.
75%
4.5x10~5 p.s.i.
R120,M94
2.3 ft-lb/inch
14,300 p.s.i.
3.8x 10~5 p.s.i.
55x10~10

50fpm
Coefficient of friction 40psi

0.20 Dynamic

50fpm

THERMAL PROPERTIES:
Melting point
Heat deflection at 66 psi
(ASTM D 648)
Heat deflection at 264 psi
(ASTM D 648)
Maximum serving temperature
for short term
Maximum serving temperature
for long term
Thermal conductivity
Specific heat
Coefficient of linear thermal
expansion
Applicable temperature range

347 F
342 F
277 F
300 F
185 F

(ASTM C 177)

2.60 Btu-inch/hr-ft~2- F
0.35 Btu/lb- F

(ASTM D 696)

6.8x10~5
85-140 F

for thermal expansion

ELECTRICAL PROPERTIES:
Dielectric constant at 60Hz
Dissipation factor at 60Hz

(ASTM D 150)
(ASTM D 150)

(73 F, 50% RH) 3.7

(73 F) 0.005

Volume resistivity
Dielectric strength

(ASTM D 257)
(ASTM D 149)

10~15 ohm-cm
500 v/MIL

MISCELLANEOUS:
Water absorption - 24 hours
Water absorption saturation
Density
Flammability
Weathering Resistance

(ASTM D 570)
(ASTM D 570)
(ASTM D 792)
(UL 94)

0.25%
0.90%
0.0513 lb/inch~3
HB
Limited (UV sensitive)

DESIGN
Small buisiness innovation research(SBIR) addressed the development of advanced
ammunition contain system for the advacnced Amphibious Assault Vehicle(AAV).The
objective of phase I was to develop a containment design concept for the ready
ammunition container and feed system which provides armor protection against

impacting threats and contains the overpressure and toxic gases generated from an
overmatching threat.Compatibility with the provided AAAV ammunition container and
feed system design and operational requirements was established as a critical design
constraint.since specific cost and weight constraints were not provided until the phase I
design and feasibility study were concluded, the design approach taken in phase I was to
develop an ammunition containment system which provides the maximum level of
performance against the worst case threat condition.Each component of the system was
sized to withstand the maximum loading conditions expected with high positive margins
of safety.Given specific cost and weight goals, a much lower cost, lighter weight system
could be designed to meet acceptable,although less stringent,performance criteria.
Design development and analyses were performed in phase I to establish a prototype
design concept and demonstrate performance in accordance with the program
objectives.Specifically ,analyses were performed to define the loading environments
associated with medium level and higher level threat engagements for the provided
AAAV ammunition configuration;establish armor thickness requirements and evaluate
armor

protection;define

and

evaluate

performance

of

burst-open

venting

system;evaluate energy absorption capability of the proposed wall configuration;and

identify materials and thickness and evaluate the structural performance of a composite
containment

wall design.In addition to the analyses ,solid models of the prototype

containment system design were generated for design presentation and for estimating
volume and weight.
The desisgn of the ready ammunition box and feed system containment
structure employs a multi-layer,armored composite wall that provides multi functional
capabilities of armor protection,energy absorption,blast protection,sealing and pressure
retention.Although the ammunition ready container was of primary concern for the phase
I effort,conceptual designs were also developed for the feed system containment in a
manner consistent with the design approach for the ready container.Since specific weight
and cost constraints were not provided during the phase I program,a generally

conservative approach using only currently demonstrated materials and technologies was
used to determine the most appropriate solution.
The design of the ammunition containment system was divided into two
tasks,armor design and pressure containment.The armour design effort focused on
fragment protection and energy absorption.The pressure containment effort focused on
the selection of materials and composite lay up required to contain the quasi static
pressure loading.Hydrocode analysis was performed to determine foam densities and
thickness for energy absorption.Three dimensional finite element analysis of the
ammunition ready container pressure wall were performed to evaluate different wall
thickness and structural reinforcement configurations.
The recommended containment wall design resulting from the phase I
analysis is as follows:-0.25 inch Armor steel(interior)/0.125 inch EPDM Rubber seal
layer/0125 inch S-2 glass/epoxy/0.5 inch Foam(20pef)/0.50 inch S-2 glass/epoxy.An
external steel frame was used to provide localized reinforcement to the composite wall
and allow attachment locations for the doors and access ways.

PRODUCT DESIGN

Product design is the process of creating a new product to be sold by a buisiness to its
customers.It is the effective and efficient generation and development of ideas through a
process that leads to new products.

Product designers conceptualize and evaluate ideas turning them into

tangible products.There are various product design processes and they are all focused on
different aspects.The design process follow a guideline involving three main sections:

Analysis

Concept

Synthesis

Product designers will have greater benefits like:

Greater design freedom, e.g., part complexity

Fewer assembly operations

Reduced secondary finishing, e.g., machining

Weight reduction

Reduction in total per-part cost.

Broad range of properties tailored to specific applications

Ability to withstand most chemicals and corrosive environments

CONCEPTS OF PRODUCT DESIGN

Research & development:
Basic research is a search for new knowledge. It does not have any immediate
application, but based on the basic research new product can be developed in future.
Applied research has objective of developing commercial products.
Concurrent engineering (CE):
CE is different than conventional approach of design. In CE, different co-related
are formed, which perform different activities for developing a product. For

teams

example,

development of market concept, design of product, development of manufacturing

process, selection and arrangement of material for new design is performed by different
teams at the same time. It reduces considerable amount of time to develop a new product.

In practice different concepts are combined and applied together to design a new
product.

Reverse engineering:
Reverse engineering is the process of carefully dismantling a product,
understanding its design and developing a product which is better than the
existing one.

CAD-CAM:
By using 3D modeling software system, designers develop a computerized model
of a new product and analyze its design parameters. After computer aided design
(CAD), computer aided manufacturing (CAM) system produce the product by
using CNC facility

OBJECTIVES OF PRODUCT DESIGN

To ensure growth of the organization

To utilize the surplus capacity of the organization, such as physical facility, man
power, etc.

To utilize the surplus fund of the organization

To meet new requirement of the customers

To increase companys market share and to target new market segment

To ensure complete product range in companys portfolio

STEPS OF PRODUCT DESIGN

Synthesis: Try to develop different alternatives

Sketching: Draw sketches in exact scale for different alternatives

Analysis:

Analysis

different

alternatives

with

respect

to

operability,

maintainability, inspection, assembling and dismantling issues, cost parameters,

production methos, etc.

Selection: Select the best alternative

Basic engineering: Prepare layout in exact scale, calculate strength of

components, select proper cost effective material.

Detail design: Prepare detail engineering drawing for each component

Prototype: If option is there, then prepare prototype and test it

Manufacturing: If prototype is not made, then follow manufacturing steps and

solve manufacturing problems and assembly problems, if any.

Operation: collect feedback during actual operation of the new product. If any
problem exists, try to provide design based solution. Also, implement lessons in
the future design.

Product development: If any modification can be done, implement the same in the
next generation product.

In product design the important elements are material

selection, part design, tool design,fabrication processes like injection moulding, blow
moulding, extrusion etc..

Examples of some injection mould parts:

Features of Product Design

PRODUCT SHAPES
PARTING SURFACES
SHRINKAGE
UNIFORM WALL THICKNESS
SHARP CORNERS
RIBS, BOSSES
TAPER
HOLES
HINGES
THREADS
SNAP FITS
DFA
INSERTS
METAL TO PLASTICS

Product shape
Product shape provide adequate strength for its use.They must be designed that it can be
produced readily by the method intended for its manufacture.They must be designed for
aesthetics.It includes as many features and functions as possible to make the product
attractive for use,easy to mould, for further steps in the manufacture and to reduce costs.

Parting surfaces

Parting line /surface

Shrinkage
Crystalline polymers shrink more than the amorphous polymers due to the
regular arrangement of chains.Nylons absorb moisture due to their hydrophilic nature. In
such

cases,accounting

for

post-molding

shrinkage

becomes

complicated

e.g

Polyaceta,Nylon. For Post molding Shrinkage Design Allowances are 0.005 to 0.006
mm/mm .Ways of controlling PMS are Air annealing parts are heated anywhere between
100 C to 120 C for 30 minutes to 3 hours in a hot air oven.Oil annealing160 3 C for
15 to 20 minutes for a nominal wall thickness of 1mm (plus 5 min/mm for additional
thickness).

RIBS AND OTHER PROJECTIONS

Typical projections are ribs, studs, mounting, support, hubs, flanges, threads.,undercuts
and ejector pin extensions.The projections create

problems like more material

concentration ,thickening, more cooling requirements, less homogeneity.

Boss

Pad

Boss
at
wall
Boss with
ribs

For a given stiffness, it is better to increase the number of ribs, not the height .Rib
thicknes should be less than wall thickness.A rib thickness of 60% to 80% of nominal
thickness recommended.

COMPUTER-AIDED DESIGN (CAD):

Computer Aided Design utilises the computer as a tool for all functions that are involved
in the design process. The main functions that would utilise the computer are

Layout design for the component modeling

Individual component modelings

Assembly modeling

Interference and tolerance stack checking

Engineering drawings

Todays CAD technology can provide the engineer/designer the necessary help in
following ways:

Computer Aided Design (CAD) is faster and more accurate than conventional
methods.

The various construction facilities available in CAD would make the job of
developing the model and associated drafting a very easy task.

In contrast with the traditional drawing methods, under CAD it is possible to

manipulate various dimensions, attributes and distances of the drawing elements.
This quality makes CAD useful for design work.

Under CAD, you will never have to repeat the design or drawing of any
component. Once a component has been made, it can be copied in all further
works within seconds, including any geometric transformation needed.

You can accurately calculate the various geometric properties including

dimensions of various components interactively in CAD, without actually making
their models and profiles.

With the constraint based modelling methods that are prevalent in most of the
commercially available CAD systems, it is possible to capture the design intent
into the product model beyond the simple geometry. This will help in actually
making modifications easily. Also, it is possible to try various options, thereby
optimizing the whole design process. Thus, the geometric modelling process can
be driven buy the physics of the process.

Modification of a model is very easy and would make the designers task of
improving a given product simple to take care of any future requirements.

Use of standard components makes a very fast model-development work. Also

large number of components and sub-assemblies may be stored in part libraries to
be reproduced and used later.

Professional CAD packages provide 3D visualization capabilities so that the

designers can see the products being designed from several different orientations.
This eliminates the need of making models of product for realization and
explaining the concepts to the team.

Elements of computer-aided design systems

The design process in a CAD system consists of four stages.
Geometric Modeling: In geometric modeling, a physical object or any of its parts is
described mathematically or analytically. The designer first constructs a geometric model
by giving commands that create or modify lines, surfaces, solids, dimensions, and text
that together, compose an accurate and complete two-or three-dimensional representation
of the object. The results of these commands are then displayed; the images can be
manipulated on the screen, and any section can be magnified in order to view its details.
Design analysis and optimization: After its geometric features have been determined,
the design is subjected to an engineering analysis, a phase which may, for example,
consist of analyzing stresses, strains, deflections, vibrations, heat transfer, temperature
distribution, or dimensional tolerances.

Design review and evaluation: An important stage is review and evaluation to check for
any interference among various components. This step is necessary to avoid difficulties
during assembly or use of the part and to determine whether moving members will
operate and function as intended.
Documentation: After the preceding stages have been completed, a paper copy of the
design may be produced, for documentation and reference. At this stage detail and
working drawings are also developed and printed. The CAD system is also capable of
developing and drafting sectional views of the part, scaling the drawings, and performing
transformations in order to present various views of the part.
Database: Many components in products are either standard components that are mass
produced according to a given design specification or are identical to parts used in
previous designs. CAD systems now have a built-parts from a library of stock parts.
These parts can be parametrically modeled to allow cost-effective updating of the part
geometry.

COMPUTER-AIDED ENGINEERING (CAE)

Computer-aided engineering (CAE) is the broad usage of computer software to aid
in engineering tasks. It

includes computer-aided

analysis (CAA), computer-integrated

design (CAD),computer-aided

manufacturing (CIM), computer-aided

manufacturing (CAM), material requirements planning (MRP), and computer-aided

planning (CAP).
Software tools that have been developed to support these activities are considered
as CAE tools. CAE tools are being used, for example, to analyze the robustness and
performance

of

components

and

assemblies.

The

term

encompasses

simulation, validation, and optimization of products and manufacturing tools. In the

future, CAE systems will be major providers of information to help support design teams
in decision making.

In regard to information networks, CAE systems are individually considered a

single node on a total information network and each node may interact with other nodes
on the network.
CAE systems can provide support to businesses. This is achieved by the use of
reference architectures and their ability to place information views on the business
process. Reference architecture is the basis from which information model, especially
product and manufacturing models.
The term CAE has also been used by some in the past to describe the use of
computer technology within engineering in a broader sense than just engineering
analysis.
CAE areas covered include:
Stress analysis on components and assemblies using FEA (Finite Element Analysis)
Thermal and fluid flow analysis Computational fluid dynamics (CFD)
Kinematics
Mechanical event simulation (MES)
Analysis tools for process simulation for operations such as casting, molding, and die
press forming.
Optimization of the product or process.
In general, there are three phases in any computer-aided engineering task:
Pre-processing defining the model and environmental factors to be applied to it.
(typically a finite element model, but facet, voxel and thin sheet methods are also
used)
Analysis solver (usually performed on high powered computers)
Post-processing of results (using visualization tools)
This cycle is iterated, often many times, either manually or with the use of commercial
optimization software.

Production Engineering (PRO E):

Pro / ENGINEER is based on a single database, parametric, and modular processoriented PLM system. Today, all over the world as businesses, small, SMEs and large
industrial companies from all sectors to all types of design processes and product
development, production machinery, molds, household appliances, automotive,
agricultural machinery , shipbuilding, electrical / electronics, medical products,
telecommunications, household appliances, metal products, heating and cooling, and the
manufacturing sectors such as defense and aerospace design and product development
processes of all types of collateral industries, universities , institutes of technical
education institutions and R & D is the software used. This is the result of the different
sectors to respond to the modular structure. All types of design, production, analysis and
data management needs of these modules for the modules are available and working
under a single database.

This is becoming increasingly complex with the emergence of

sophisticated, production methods and control systems production engineering is a
combination of manufacturing technology with management science. A production
engineer typically has a wide knowledge of engineering practices and is aware of the
management challenges related to production.The goal is to accomplish the production
in the smoothest,most judicious and most economical way.
In industry once the design is realized,production engineering
concepts

regarding

work

study,ergonomics,operation

research,

manufacturing

management, materials management,production planning etc.,play an important role in

efficient production processes.These deal with integrated design and efficient planning of
the entire manufacturing system,which is becoming increasingly complex with the
emergence of sophisticated production methods and control systems.
The Production Engineer possesses a wide set of skills,compertences and attitudes based
on market and scientific knowledge.These abilities are fundamental for the performance
of coordinating and integrating professionals of multidisciplinary teams.

Some Typical Work Activities:

These are some typical work activities of production engineer:

Dimensionate and integrate resources.Usually required to consider

physical,human and financial resources at high efficiency and low cost,yet
considering the possibility of continuous further improvement

Make proper use of math and statistics to model production systems during
decision making process.

Design,implement and refine products,services,processes and systems taking in

consideration constraints and particularities of the realated communities

Conducting process developments to scale in the laboratory.

Assesing the availability of raw materials and the safety and environmental
impact of the plant.

Managing the cost and time constraints of projects.

Selecting and working with sub contractors.

Supporting the conversation of samall scale processes into commercially viable

large scale operations.

Stay up to date with technological developments,enabling them to enterprises and

society.

Manage and optimize flow(information and production flow).

Roles and Capabilities of Production Engineering:

Must be capable of planning and introducing efficient production methods to

maximize company output.

Should coordinate with the all other dependent and independent departments of
the organization like the shop and the office.

Must develop and introduce methods to increase productivity at the production

line.

Should take the responsibility of making sure the production is cost effective and
feasible to the organization.

Should have excellent communication skills as production engineers are

responsible for instructing the production department.

Conduct PA work following Advanced Product Qualification plan (APQP)Spec

Responsible for deliberative package development,major tool change to improve

quality and in sourcing project that is new.

Holding technical leadership for process development working with project

members

such

like

industrial

Engineering,SCM,Purchasing,Process

Engineering,QA,Program Management.

Study and understand customer requirements,application,EHS and design those

things to the process development.

Supporting development

engineers to generate and create documents

delieverables

control

such

as

plan,process

FMEA,LAR

plan,project

charter,Quality function development,project schedule,line certification plan,to

identify process development cost etc.

To

plan

and

execute

process

optimization,failure

analysis,process

characterization,samples build for the development.

To lead project team members related with process development.

To

find

technical

and

systematic

solution

for

failures

of

reliability,quality,manufacturability,cost,and cycle time that are related with

process.

Track team member performance and report to origination manager.

Must keep a check on all machines involved in production and utilize technical
knowledge effectively to maximize productivity and profit.

To share and update project progress ,risk of delay,constraints,weekly at

designated day with stake holders,project team,sponsors.

Ammunition Box
The following Ammunition Box is designed as per the Product Design
Concepts using ACETAL also called DELRIN as the Product material. The Procedure of
the Ammunition box Design is carried out through the PRO-E software. The step by step
procedure photographs are as displayed below.
Ammunition Box Container Procedure:

Using Extrude Command the size of the container is defined as 600x400x500.

A 1 degree Draft is provided to the container for the feasible extraction of the core
cavity.

A 70x90x10 box is cut at the bottom of the box at all the four sides, this act as a
stopper for the ammo tray which is being inserted in the container.

A rectangular cut is made at the bottom.

A vertical cut is made on all the four sides of the container as shown below, these
act as guide ways for the ammo tray.

Shell command is used to make the solid model to a container opening one side.

The head of the container is made for fixing the lid using Protrusion command.

Ribs are provided in order to give strength to the container as shown below.

The entire engineering product is provided with a radius at the edges and corners.

A provision is made on the head for fixing bolts.

Ammunition Box Lid Procedure:

A 10mm Thickness plate is designed as per required size.

A semi circular cut is provided on the top.

Two rectangular cuts of 4mm are made in the middle.

The provision is provided at the edges for fixing the lid to the container.

Some clearance is provided for the provision in order to insert a rubber seal to
make it water proof.

Two handles are provided at the middle in order to withstand the total weight and
to avoid deformation of the Ammunition Box.

Ammo Tray Procedure:

Tray is designed as per the internal dimensions of the container.

A curved surface is provided as per the required dimensions of the Ammo.

ANALYSIS THROUGH ANSYS AND TESTS:

ANSYS is a general purpose software, used to simulate interactions of all disciplines of

physics, structural, vibration, fluid dynamics, heat transfer and electromagnetic for
engineers.So ANSYS, which enables to simulate tests or working conditions, enables to
test in virtual environment before manufacturing prototypes of products. Furthermore,
determining and improving weak points, computing life and foreseeing probable
problems are possible by 3D simulations in virtual environment.

ANSYS software with its modular structure as seen in the table below gives an
opportunity for taking only needed features. ANSYS can work integrated with other used
engineering software on desktop by adding CAD and FEA connection modules.

ANSYS can import CAD data and also enables to build a geometry with its
"preprocessing" abilities. Similarly in the same preprocessor, finite element model (a.k.a.
mesh) which is required for computation is generated. After defining loadings and
carrying out analyses, results can be viewed as numerical and graphical.
ANSYS can carry out advanced engineering analyses quickly, safely and practically by
its variety of contact algorithms, time based loading features and nonlinear material
models.
ANSYS Workbench is a platform which integrate simulation technologies and parametric
CAD systems with unique automation and performance. The power of ANSYS
Workbench comes from ANSYS solver algorithms with years of experience.
Furthermore, the object of ANSYS Workbench is verification and improving of the
product in virtual environment.

ANSYS Workbench, which is written for high level compatibility with especially PC, is
more than an interface and anybody who has an ANSYS license can work with ANSYS
Workbench. As same as ANSYS interface, capacities of ANSYS Workbench are limited
due to possessed license.

WATER SPRAY TEST

Conditioning phase meant to prepare for subsequent tests.
Water must spray from 4 different directions for a duration of 1 hour
Leakage observed visually and by measuring change in weight.

DROP TEST
Dropped from 4 ft onto various facets of the can: lid, latch, side, base, and corner
Must fall onto horizontal flat surface
Pass/fail: No leakage of inner components or significant damage to outer
packaging

PENETRATION TEST
Must use a bar of 3.2 cm in diameter with a hemispherical end and a mass of 6
kg

Dropped from 1meter above the target which rests on a rigid horizontal surface
Pass/fail: interior packaging must remain intact.

COMPRESSION TEST
Compressive load must be 5 times the weight of the package
Duration of 24 hours
Pass/fail: No significant deformation which would result in stack instability

30 FOOT DROP TEST

Specially required for liquid or gaseous RAM packages

Same conditions as the previously described drop test except the increased drop
height

 Pass/fail conditions also the same

CONCLUSION AND RECOMMENDATIONS

The research programe has demonstrated the technical feasibility
of developing a multi-layer armored composite ammunition containment system.The
results of the design development and analysis performed shown that a contain syetem
including plastic armor,energy absorbing foam and S-2 glass epoxy composite pressure
retention layers can be designed to provide the desired

armor protection against

impacting threats and reduce the response of the stowed ammunition to an acceptable
level when encountering an overmatched threat.The following conclusions are drawn
from the results of research:

The

multi layer,armored composite ammunition containment system

provides multi functional performance capability:

Armor protection

Energy Absorption

Pressure containment

Structural and Pressure Retention

An inner steel armor layer thickness of 0.25 inches is required to contain reacting
30 mm ammunition debris associated with an overmatch threat engagement.
A high elongation,low permeability elastomeric material layer is needed to
provide self sealing capability.
A 20 pcf density foam layer is required to absorb energy associated with internally
generated blast loading.
A 7 in vent area located on the underside of the turtet provides effective venting
of internal gas pressures.
A 0.50 inch S-2 glass/epoxy composite pressure wall provides sufficiently high
margin of safety of 300 psi international pressure containment.

 A 0.250 inch steel frame is required to locally reinforce composite wall and
provide interface for lid and acess door attachments.
The following recommendations are made to build on the results of research and
demonstrate manufacturability and performance of the prototype ammunition
containing system: Specific requirements must be established in coordination with

USMC and

General Dynamics to identify weight,space and cost constraints for the

containment system.
Loading and structureal conditions of the turret shelf and gun feed system require
further analysis prior to development of final design details.
Further development and testing is recommended to size the steel,composite and
foam wall thickness and demonstrate the performance of the elastomeric seal
layer.

Development of an optimized integral armor/composite wall design should be

investigated if significantweight and cost reductions are desired.

Manufacturing of a prototype HE/AP ready container at the onset programme is

recommended to demonstrate manufacturing feasibility.
Sub scale testing is recommended to validate the armor concept for blast and
fragment protection.
Full scale controlled pressure tests are required to validate the structural integrity
of the S-2 glass epoxy.
A full scale test of the burst open venting system is recommended.
Further development of the ammunition feed rail and gun feed containment is
required .
Integration and concurrent design should be established in co ordination with
overall feed rail and gun feed system design approach.

REFERENCES
MacCrehan WA, Reardon MR, Duewer DL. Associating gunpowder and
residues from commercial ammunition using compositional analysis. J
Forensic Sci 2002;47(2):260266.

www.dtlc.mil/cgi-bin/GetTRDoc?AD=ADA373847
Hpschapters.org/northcarolina/fall2007/DOT%20Testing-AndersonEvans.pdf

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