A PROJECT REPORT ON

“REVERSE ENGINEERING OF
TURBOGENERATOR”

SUBMITTED BY:

AWAGHADE VINIT B80080838

PATEL TAHER B80080862
KARAN DHANANI B80080888
KULKARNI AMEY B80080947

UNDER THE GUIDANCE OF

DR.DHANANJAY PANCHAGADE,
DR. VIRENDRA KUMAR.
SPONSORED BY: ARDE, DRDO, PUNE

MECHANICAL ENGINEERING DEPARTMENT

D Y PATIL COLLEGE OF ENGINEERING,
AKURDI, PUNE -411044
2013-2014
 D Y PATIL COLLEGE OF ENGINEERING,
AKURDI, PUNE 411044

CERTIFICATE
This is to certify that

AWAGHADE VINIT B80080838

PATEL TAHER B80080862
KARAN DHANANI B80080888
KULKARNI AMEY B80080947

have successfully completed the project work entitled “REVERSE

ENGINEERING OF TURBOGENERATOR” under my supervision, in the
partial fulfillment of Degree of Bachelor of Mechanical Engineering under
University of Pune in the academic year 2013-2014.
Date :
Place :

Dr.D.R. Panchagade H.O.D.

Project Guide Mechanical Department

Dr.Virendra Kumar Examiner

External Guide
 ACKNOWLEDGEMENT

No herculean task can be completed without support and contribution from number of
individuals and the task is a very essence of success of any colossal scheme. These few lines
are an effort to epitomize our deep sense of gratitude towards all those who helped us to
complete our project successfully.

We wish to thank Prof. Dr. DhananjayPanchagade, our project guide, for his
continuous guidance, invaluable suggestions, co-operation and motivation in preparation of
this project. We sincerely thank our Project Co-OrdinatorProf. TaslimShikalgar for his
valuable suggestions.

We would like to express our profound vote of thanks to Dr. Virendra Kumar, our
project incharge from ‘ARDE, Pune’ for his valuable guidance and technical support. We
also thank all the people from ‘ARDE, Pune’ for providing us with homely environment in
the company.

Last but not least, we would like to thank our parents and friends for their constant love
and affection.

AWAGHADE VINIT
PATEL TAHER
KARAN DHANANI
KULKARNI AMEY
 INDEX
Topic Page No.

Abstract 1
1. Mortar Fuze 2
1.1 Mortar 2
1.2 Fuze 2
1.2.1 Types 3
1.2.2 Classification 3
1.2.3 Components 3
1.3 Fig. Sectional View 3
1.4 History 4
1.5 Working 5
1.6 Power Sources 6
1.6.1 Piezoelectric 6
1.6.2 Thermal 6
1.6.3 Reserve 7
1.7 New Developments 7
1.7.1 Thermoelectric power supply 8
1.7.2 Fluidic generator (helmholtz resonator) 8
1.7.3 Turbogenerator 8
2. Turbogenerator 9
2.1 Function: 9
2.2 Modern Turbogenerators: 9
2.2.1 Features of Modern Turbogenerator : 9
2.3 Construction: 10
2.4 Components of Turbogenerators: 11
2.4.1 Duct: 11
2.4.2 Turbine: 11
2.4.3 Electric generator: 11
2.4.4 Shaft: 11
2.5 Why Turbogenerator?? 12
2.5.1 Disadvantages of Battery: 12
2.5.2 Advantages of TG 12

3. Reverse Engineering 13
3.1. Reasons for reverse engineering 13
3.2. Reverse engineering for military applications 15
3.3. Steps Involved In Reverse Engineering 17
4. Scanning/Modelling 19
4.1. Functionality 19
4.2. ClassificationOf 3D Scanners 21
4.2.1. Contact Type 21
4.2.2. Non Contact Type 21
4.3. Reconstruction From Point Clouds 22
4.4. Benefits of 3D scanning 23
4.5. Modeling Of Some Turbo Generator Components 24

5. Material Testing 26
5.1 Introduction 26
5.2 Spectrochemical Analysis 26
5.3 Results of Material Testing 29

6. Design check of Shaft 31

7. ANSYS Analysis of Rotor 36
7.1 Calculations 36
7.2 Analysis 37
7.2.1 Material Properties of Nylon66 37
7.2.2 Maximum Deformations & Stresses Developed 38
7.3 Results 39
7.3.1 Maximum Normal Stress 39
7.3.2 Total Deformation 39
7.3.3 Equivalent Strain 40
8. Static Trial on Rotor 41
8.1 Aim of the test 41
8.2 Test facility: 41
8.3 Pitot static tube 41
8.3.1 Test conditions: 42
8.3.2 Model description 42
8.4 Analysis of Impeller unit 42
8.5 Results: 47
8.6 Conclusion of test results: 48

9. Documentation 49
10. Conclusion 51
11. Future Scope 53
References 54
 LIST OF FIGURES

FIGURE NO. FIGURE NAME PAGE NO.

1.1 Mortar and Mortar Fuze 2

1.2 Sectional View of Mortar 3

1.3 Working of Mortar Fuze 5

2.1 Turbogenerator Construction 10

3.1 Steps in RE 18

4.1 3D Scanner 20

4.2 Rotor 24

4.3 Turbogenerator Assembly 25

5.1 Spectroscopy Equipment 28

6.1 FBD 31

6.2 BMD 32

Ansys Results For

7.1 Maximum Normal Stress 39

7.2 Total Deformation 39

7.3 Equivalent Strain 40

8.1 Block diagram of wind tunnel 42

 LIST OF TABLES

TABLE NO. TABLE NAME PAGE NO.

5.1 Material Test Result for Cover Plate 29

5.2 Material Test Result for Shaft 30

7.1 Material Properties 37

7.2 Maximum Deformations and Stresses Developed 38

8.1 Results of Static Trial 47

10.1 Material Testing Results 51

Appendix Table 56
 NOMENCLATURE

SR NO. SYMBOL PROPERTY

1 P1 Atmospheric Pressure

2 T Ambient Temperature

3 R Universal Gas constant

4 𝜌 Density

5 C1 Projectile Velocity

6 C2 Velocity at the end of duct

7 C3 Relative Velocity

8 P2 Inlet Pressure of the duct

9 M Mach Number

10 a Sonic Velocity

11 𝑚̇ Mass Flow Rate

12 k Adiabatic constant

13 A Area of Duct

14 Sut, Syt Ultimate and Yield Strenght of Material

15 kb Combined shock and fatigue factor for

torsional moment

16 kt Combined shock and fatigue factor for

bending moment

17 τ Shear Stress

18 g Gravitational Acceleration

19 N Rotational speed of turbine

20 ΔP Pressure Drop
 ABSTRACT

This Project deals with Design & Development Of turbo generator for Fuzes
used in 120mm mortars. This is a new technology in which power is generated within
the warhead fuze. Very few countries such as US & Israel have been able to
successfully develop & use this technology. India is also trying to develop it.
Presently this development process is carried out by using Reverse Engineering route.
Turbo generator consists of a turbine impeller mounted on a shaft. High velocity air
rotates the impeller, which rotates the shaft. A multiple permanent magnet rotor is
mounted on shaft, which is made to rotate at 10,000 to 15,000 rpm. The PM rotor
comprises the field winding of the alternator whose stator coil or armature is fixed to
the casing. The alternator functions according to Faraday’s Law of Electromagnetic
Induction; the rotating magnetic field/flux produces an emf in the stator coil, which is
used to power Fuze electronics. This project report contains introduction to
turbogenerator used in mortar fuze and detailed information about processes involved
in Reverse Engineering.

1
 CHAPTER 1
MORTAR FUZE
1.1 Mortar
Mortars are generally smooth bore, muzzle loaded high angle fire weapons, which has
a nose fuze, high-explosive payload and tail fin assembly with ignition and propellant
charges attached. Mortar is fired using a firing device like cannon.

Fig. 1.1 Mortar & Mortar Fuze

1.2 Fuze:
A Fuze is that part of an artillery projectile which detonates the explosive
charge and ideally would detonate the shell in most optimum position to inflict
maximum damage to the target. The basic role of the fuze is not only to indicate the
presence of the target and initiate the explosive train but also to provide safety by
separating the detonator from the remainder of the explosive train until arming is
acceptable. The initiation process is achieved by an action resulting from pressure,
electrical energy, chemical action, impact, clock action or a combination of

2
theseFuzes have wide range of applications in military munitions. Fuzes are used in
Mortars, rockets, aircraft bombs, guided missiles, grenades and mines, projectiles
fired by guns, howitzers and some other direct fire cannon munitions. [1]

1.2.1 Fuzes can be classified in following types:

1) Contact Fuze 2) Time Fuze
3) Proximity Fuze 4) Command Fuzes etc.
1.2.1 Proximity fuzes can be further classified on the basis of Sensing principle:
1) Radio frequency sensing 2) Optical Sensing
3) Acoustic sensing 4) Magnetic sensing
1.2.3 Components of Fuze
1. Sensor
2. Electronic Circuit
3. Power source (Turbogenerator)
4. Safety & Arming Mechanism

1.3 Fig.1.2 Sectional View

3
1.4 History:

Before the fuze's invention, detonation had to be induced either by direct

contact, or a timer set at launch, or an altimeter but all of these have disadvantages.
This created the need of an automatic triggering device like Fuze.

Before WW II: By the end of 19th century Time fuzes were introduced. Early
artillery time fuzes were nothing more than a hole filled with gunpowder leading from
the surface to the centre of the projectile. In 1915, in WWI, spring operated fuzes
were used in Hand Grenades.

World War II: Around 1940, during World War II, many types of proximity fuzes
like acoustic, pressure, electrostatic, optical, and radio were investigated. Initially
‘AcousticFuzes’were used in high-speedapplication.During this same period,
considerable research was carried on ‘Electrostatic methods’ and ‘Optical Fuzing’
methods.‘PhotoelectricFuze’ was developed in 1942 by British army. In October
1943, the Radio proximity fuze working on the principle of Doppler Effect was
developed.

After WW II: After World War II,Higher power output and definite range cutoff
were obtained using ‘Pulsed Doppler Fuzes’.After Korean War (1960),the Microwave
FM and the Pulsed Radar fuze systems were developed for nuclear warhead and
ballistic missile applications. In recent times Transistors were improved to the point
where an all transistorized mortarfuze was developed.[2]

4
1.5Working:

DETONATOR
STIMULUS SENSOR (First Stage of
Amplification)

Fig.1.3 Working
TURBINE
Of MortarFuze
GENERATOR

BOOSTER
MAIN CHARGE (Final Stage of
Amplification)

The main function of fuze is Initiation. The fuze action starts with an input
signal such as target sensing, impact, or other stimulus. This signal then must be
amplified by a device such as ‘detonator’ (first stage of amplification) and a ‘booster’
(final stage of amplification). The booster has an explosive output of sufficient force
to function the main charge. The detonator contains explosives that are very sensitive
because it is required to respond to the initial weak signals. ‘Turbine Generator’ or
Battery satisfies the need of Energy for modern fuze operation. [3][4]

5
1.6 Power Sources:
The various power sources that have been used are: --
1. Piezoelectric power supply,
2. Thermal battery,
3. Reserve battery.
Among these the use of reserve battery has been more prominent.
A brief description of the above mentioned power sources:

1.6.1Piezoelectric power supply:

The piezoelectric element has been placed in the nose of the fuzeogive to
produce electrical energy upon impact of the warhead. This produced energy is
allowed to pass through a detonator which is a thin wire surrounded by a sensitive
explosive, such as lead azide. Explosion of the lead azide causes the main explosive
charge in the warhead to detonate.

Drawback:
Piezoelectric elements located in the nose offer only a limited area of impact, and the
voltage output is a function of the impact angle, falling of as the angle increases.
New developmentsin the use of piezoelectric based power supply include the
incorporation of one-shot high output piezoid power supply. It consists of a plurality
of extremely thin polarized piezo material, each layer positioned and electrically
connected to a corresponding positive electrode and corresponding negative electrode.
It also contains a diode, a storage capacitor, a DC/DC converter and a speed up
capacitor.
· The setback force actuates it as the projectile is fired.
· Cost of the unit is the main drawback.

1.6.2Thermal battery:
Setback forces, which are generated when the round is fired, produce the
electric energy. A fuzed salt is released on setback, which subsequently causes an
electrical charge to be generated between two electrodes. This charge is stored in a
capacitor and used to set off the detonator upon of the warhead.

6
Drawback:
Requires a considerable volume of space, necessitating minimization of the amount of
explosive for a given warhead size. It also increases the weight of warhead.

1.6.3Reserve battery:
They have been primarily lead/lead dioxide/fluoric acid based batteries.
Further they may be either dry cell based or wet cell based. Dry cell batteries have
limited useful lives. Wet cell batteries are used such that the electrolytic fluid is
injected automatically into the electrodes, as a result of shell spin after leaving the
gun. Batteries may not be stored separately from the electrical portion of the fuse,
which they are to power, but must be preassembled with the fuzes, for logistic and
ready available reasons.

Drawback:
Some types of battery-equipped fuzes have proven to be unreliable, as a result of
electrolyte fluid leakage. They have a low shelf life (5-10 years). Another problem is
that these batteries are difficult to manufacture so that at the onset of a national
emergency production levels are expected to lag requirements for several months,
thereby creating logistics problems. Also they are expensive.

1.7 New Developments:

New developmentsin the application of reserve batteries to fuzes are the use of
lithium anode primary cells. These are assembled in series/parallel connections to
meet the current and voltage requirements of the battery. However, they suffer from
capacity degradation over a period of time with self-discharge at the rate of 0.03-
0.05% per month at 20 degree centigrade. Also they make use of materials and
electrolytes, which may have an impact on the environment. To overcome the
drawbacks of the previously employed power supply sources, so as to avoid logistics
problems in case of a national emergency, new avenues in the case of power supply
source have been sought.

7
Some of these are: -
 Thermoelectric power supply,
 Fluidic generator (using Helmholtz resonator)
 Turbo generator

1.7.1 Thermoelectric power supply:

Comprises of a plurality of junctions, which are coupled to the propellant for
sensing the temperature and means of generating a voltage in response to the
temperature sensed by the generator. It works on the thermocouple effect. Integrated
with a compatible impact sensor (triboluminescent) it will initiate the warheads
explosive warhead. The voltage generated by the thermoelectric power supply is
stored in a capacitor, which supplies it to the detonator when the warhead impacts the
target.
 It is actuated by the burning of the propellant.
 It requires the use of temperature sensitive elements/alloys, which makes the
unit costly.
1.7.2 Fluidic generator (helmholtz resonator):
It comprises an air inlet means and a helmoltz resonator. The resonator consists of
a resonating cavity, a diaphragm and a metallic reed set in a magnetic field. The air
entering the resonating cavity produces acoustical vibrations. These vibrations cause a
diaphragm, which is mounted in the resonant cavity, to oscillate. The oscillating
diaphragm drives a metallic reed set in a magnetic field. This induces a current in the
coil, which is used to power electronics.
 At high flight velocities there is large mass flow of air. As a result the
diaphragm experiences large displacement, which in effect causes the metallic
reed to bang against the pole pieces. This leads to reed fatigue and eventual
failure, causing power loss.
1.7.3 Turbogenerator:
In turbogenerator the ram air passing through the duct in fuze is used to rotate
the turbine impeller coupled to the alternator to generate the electric power. Further
details of turbogenerator are explained in the next chapter. [5]

8
 CHAPTER 2
TURBOGENERATOR
2.1 Function:
It comprises an electric generator assembly housed within aprojectile. The
assembly includes an air driven turbine andan electric generator. A common shaft
carries the turbineand the permanent magnet of the electric generator. Thegenerator
rotor is a small permanent magnet and the stator is a series of coils. The principle of
power generation is similarto the wind turbine-generator unit except that the
turbogenerator assembly is very compact and operates atsubstantial rotational speed.

2.2 Modern Turbogenerators:

Conventional turbogenerators were were larger in size. Also they were usually
situated outside the fuze. Therefore size and weight of the fuze used to be high as
compared to modern Turbogenerators

2.2.1 Features of Modern Turbogenerator :

 The impellers used in prior art electrical generatorswere very inefficient in that
most of the air taken in bythe turbine is diverted rather than used to drive
theimpeller.
 The prior art turbines were placed outside the fuzeogive resulting in increased
size of the projectile.
 The new developments in the case of the turbogenerator have resulted in
reducing the size of the fuzeby incorporating the unit inside the fuzeogive.
 The next generation turbo generator power supply makes use of an efficient
turbine (centrifugal unit).
 The next generation turbo generator has improved dynamic balance than the
prior art generators.
 Since it has a life span equal to that of the whole fuze, and other advantages as
mentioned above, it has turned out to be the choice for the next generation
electronicfuze.

9
2.3 Construction:
The assembly (refer fig no. 3) comprises, mainly: -
1. Air-driven turbine /impeller,
2. An electric generator, comprising,
 Rotor element &
 Stator element.
3. Brake member,
4. Shaft, which carries the above members.

2.3.1 Fig.2.1Turbogenerator Construction:

1. Flow Conduit (Duct)

2. Casing
3. Turbine Rotor
4. Bearings
5. Shaft
6. Magnet
7. Supporting Plate
8. Sleeve
9. Stator Coil

10
2.4 Components of Turbogenerators:

2.4.1 Duct:
The ram air passing through the duct in fuze should rotate the turbine impeller
coupled to the alternator to generate the voltage.

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

2.4.3 Electric generator:

Includes a rotatable element comprising generally ring-shaped permanent
magnet. The stationary element of the electric generator includes a coil housing for
containing coil of wire in which an electric current is generated. Leads from the coil
are provided to supply electric current. The coil housing is generally radially
symmetric. The coil is wound on the coil housing by a conventional method so that
the coil is generally perpendicular to the axis of rotation of the turbine and the
magnet. Magnetic flux paths are provided between the rotating magnet and the coil
housing by an inner armature member and an outer armature member. In operation,
the rotating magnet creates rotating magnetic field, which is conducted through the
armature members to the coil wherein it generates an electric current.

2.4.4 Shaft:
The turbine also includes a generally cylindrical elongated shaft member or
shaft preferably formed from a high strength material such as steel. The shaft carries
the abovementionedmembers. [16]

11
2.5 Why Turbogenerator??
There are two methods used to satisfy Power requirement of TG.
1) Battery Storage
2) Turbogenerator

2.5.1 Disadvantages of Battery:

 short life
 leakage
 fire hazards

2.5.2 Advantages of Turbogenerator:

 long life
 nonhazardous storage
 greater reliability
 Electricity is Generated using atmospheric air
Traditionally the projectiles have been powered by storage batteries. R&D was
carried out, which resulted in the development of wind driven turbo generator that
could fit inside the fuzeogive. Now a day’sTurbogenerator is the most preferred
choice for use in artillery munitions like Mortarfuze.

12
 CHAPTER 3

REVERSE ENGINEERING

Reverse engineeringis the process of discovering the technological principles

of a device, object, or system through analysis of its structure, function, and operation
[8]
.It often involves disassembling something (a mechanical device, electronic
component, computer program, or biological, chemical, or organic matter) and
analyzing its components and workings in detail, just to re-create it. Reverse
engineering is done for maintenance or to create a new device or program that does
the same thing, without using original, or simply to duplicate it.

Reverse engineering has its origins in the analysis of hardware for commercial or
military advantage [9]. The purpose is to deduce design decisions from end products
with little or no additional knowledge about the procedures involved in the original
production. The same techniques are subsequently being researched for application to
legacy software systems, not for industrial or defense ends, but rather to replace
incorrect, incomplete, or otherwise unavailable documentation.[10]

3.1.Reasons for reverse engineering:

 Interfacing. Reverse Engineering can be used when a system is required to

interface to another system and how both systems would negotiate is to be
established. Such requirements typically exist for interoperability.
 Military or commercial espionage. Learning about an enemy's or
competitors’ latest research by stealing or capturing a prototype and
dismantling it. It may result in development of similar product, or better
countermeasures for it.
 Improve documentation shortcomings. Reverse engineering can be done
when documentation of a system for its design, production, operation or
maintenance have shortcomings and original designers are not available to
improve it. RE of software can provide the most current documentation
necessary for understanding the most current state of a software system
 Obsolescence. Integrated circuits often seem to have been designed on
obsolete, proprietary systems, which means that the only way to incorporate

13
 the functionality into new technology is to reverse-engineer the existing chip
and then re-design it.
 Software Modernization. RE is generally needed in order to understand the
'as is' state of existing or legacy software in order to properly estimate the
effort required to migrate system knowledge into a 'to be' state. Much of this
may be driven by changing functional, compliance or security requirements.
 Product Security Analysis. To examine how a product works, what are
specifications of its components, estimate costs and identify potential patent
infringement. Acquiring sensitive data by disassembling and analysing the
design of a system component.[11] Another intent may be to remove copy
protection, circumvention of access restrictions.
 Bug fixing. To fix (or sometimes to enhance) legacy software which is no
longer supported by its creators.
 Creation of unlicensed/unapproved duplicates, such duplicates are called
sometimes clones in the computing domain.
 Academic/learning purposes. RE for learning purposes may be understand
the key issues of an unsuccessful design and subsequently improve the design.
 Competitive technical intelligence. Understand what one's competitor is
actually doing, versus what they say they are doing.

14
 3.2.Reverse engineering for military applications

Reverse engineering is often used by people in order to copy other nations'

technologies, devices, or information that have been obtained by regular troops in the
fields or by intelligence operations. It was often used during the Second World War
and the Cold War. Well-known examples from WWII and later include:

 Jerry can: British and American forces noticed that the Germans had gasoline
cans with an excellent design. They reverse-engineered copies of those cans.
The cans were popularly known as "Jerry cans".
 Panzerschreck: The Germans captured an American Bazooka during World
War II, and reverse engineered it to create the larger Panzerschreck.
 Tupolev Tu-4: Three American B-29 bombers on missions over Japan were
forced to land in the USSR. The Soviets, who did not have a similar strategic
bomber, decided to copy the B-29. Within a few years, they had developed the
Tu-4, a near-perfect copy.
 V-2 rocket: Technical documents for the V2 and related technologies were
captured by the Western Allies at the end of the war. On American side led
reverse engineering via operation Paperclip to the development of the PGM-11
Redstonerocket[12].On Soviet side Soviet and captured German engineers had
to reproduce technical documents and plans, working from captured hardware,
in order to make their clone of the rocket, the R-1, which began the postwar
Soviet rocket program that led to the R-7 and the beginning of the space race.
 K-13/R-3S missile (NATO reporting nameAA-2 Atoll), a Soviet reverse-
engineered copy of the AIM-9 Sidewinder, was made possible after a
Taiwanese AIM-9B hit a Chinese MiG-17 without exploding. The missile
became lodged within the airframe, and the pilot returned to base with what
Russian scientists would describe as a university course in missile
development.
 BGM-71 TOW Missile: In May 1975, negotiations between Iran and Hughes
Missile Systems on co-production of the TOW and Maverick missiles stalled
over disagreements in the pricing structure, the subsequent 1979 revolution
ending all plans for such co-production. Iran was later successful in reverse-

15
 engineering the missile and are currently producing their own copy: The
Toophan.
 China has reversed engineered many examples of Western and Russian
hardware, from fighter aircraft to missiles and HMMWV cars.
 During the Second World War, Polish and British cryptographers studied
captured German "Enigma" message encryption machines for weaknesses.
Their operation was then simulated on electro-mechanical devices called
"Bombes" that tried all the possible scrambler settings of the "Enigma"
machines to help break the coded messages sent by the Germans.
 Also during the Second World War, British scientists analyzed and defeated a
series of increasingly sophisticated radio navigation systems being used by the
German Luftwaffe to perform guided bombing missions at night. The British
countermeasures to this system were so effective that in some cases German
aircraft were led by signals to land at RAF bases, believing they were back in
German territory.

16
 3.3.Steps Involved In Reverse Engineering

A typical workflow in reverse engineering could involve scanning an object and

recreating it. These steps are illustrated below[13].

Step 1: A cloud of points taken from scanned data using a

digitizer such as a laser scanner, computed tomography, or faro
arms.

Step 2: Convert the point cloud to a polygonal model. The

resultant mesh is cleaned up, smoothed, and sculpted to the
required shape and accuracy.

Step 3: Draw or create curves on the mesh using automated

tools such as feature detection tools or dynamic templates.

Step 4: Create a restructured spring mesh using semiautomatic

tools.

Step 5: Fit NURBS surfaces using surface fitting and editing

tools.

17
 Step 6: Export the resulting final NURBS surface that satisfies
accuracy and smoothness requirements to a CAD package for
generating tool paths for machining.

Step 7: Manufacture and analyze the part for physical, thermal,

and electrical properties.

Fig. 3.1 Steps in RE

18
 CHAPTER 4

3-D SCANNING/MODELING

As mentioned above, three dimensional scanning is the first basic step in Reverse
Engineering. A 3D scanner is a device that analyzes a real-world object or
environment to collect data on its shape and possibly its appearance (i.e. color). The
collected data can then be used to construct digital three-dimensional models.

Many different technologies can be used to build these 3D-scanning devices; each
technology comes with its own limitations, advantages and costs. Many limitations in
the kind of objects that can be digitized are still present, for example, optical
technologies encounter many difficulties with shiny, mirroring or transparent objects.
For example, industrial computed tomography scanning can be used to construct
digital 3D models, applying non-destructive testing.

Collected 3D data is useful for a wide variety of applications. These devices are used
extensively by the entertainment industry in the production of movies and video
games. Other common applications of this technology include industrial design,
orthotics and prosthetics, reverse engineering and prototyping, quality
control/inspection and documentation of cultural artifacts.

4.1.Functionality:-
The purpose of a 3D scanner is usually to create a point cloud of geometric samples
on the surface of the subject. These points can then be used to extrapolate the shape of
the subject (a process called reconstruction). If color information is collected at each
point, then the colors on the surface of the subject can also be determined.

3D scanners share several traits with cameras. Like cameras, they have a cone-like
field of view, and like cameras, they can only collect information about surfaces that
are not obscured. While a camera collects color information about surfaces within its
field of view, a 3D scanner collects distance information about surfaces within its
field of view. The "picture" produced by a 3D scanner describes the distance to a
surface at each point in the picture. This allows the three dimensional position of each
point in the picture to be identified.

19
For most situations, a single scan will not produce a complete model of the subject.
Multiple scans, even hundreds, from many different directions are usually required to
obtain information about all sides of the subject. These scans have to be brought into a
common reference system, a process that is usually called alignment or registration,
and then merged to create a complete model. This whole process, going from the
single range map to the whole model, is usually known as the 3D scanning pipeline[6].

Fig.4.1 showing a 3D Scanner used to create a 3D Model of an object.

There are a variety of technologies for digitally acquiring the shape of a 3D object. A
well establishedclassification [14] divides them into two types: contact and non-contact
3D scanners. Non-contact 3D scanners can be further divided into two main
categories, active scanners and passive scanners. There are a variety of technologies
that fall under each of these categories.

20
4.2. Classification Of 3D Scanners:-

4.2.1. Contact:-
Contact 3D scanners probe the subject through physical touch, while
the object is in contact with or resting on a precision flatsurface plate, ground and
polished to a specific maximum of surface roughness. Where the object to be scanned
is not flat or cannot rest stably on a flat surface, it is supported and held firmly in
place by a fixture. A CMM (coordinate measuring machine) is an example of a
contact 3D scanner. It is used mostly in manufacturing and can be very precise. The
disadvantage of CMMs though, is that it requires contact with the object being
scanned. Thus, the act of scanning the object might modify or damage it.

4.2.2. Non-contact:-
Active scanners emit some kind of radiation or light and detect its
reflection or radiation passing through object in order to probe an object or
environment. Possible types of emissions used include light, ultrasound or x-ray.

 Time-of-flight: -The time-of-flight 3D laser scanner is an active scanner that

uses laser light to probe the subject. At the heart of this type of scanner is a
time-of-flight laser rangefinder. A laser is used to emit a pulse of light and the
amount of time before the reflected light is seen by a detector is measured.

 Triangulation: -Triangulation based 3D laser scanners are also active scanners

that use laser light to probe the environment. With respect to time-of-flight 3D
laser scanner the triangulation laser shines a laser on the subject and exploits a
camera to look for the location of the laser dot. Depending on how far away the
laser strikes a surface, the laser dot appears at different places in the camera's
field of view. This technique is called triangulation because the laser dot, the
camera and the laser emitter form a triangle [15].

21
  Conoscopic holography:-In a conoscopic system, a laser beam is projected
onto the surface and then the immediate reflection along the same ray-path are
put through a conoscopic crystal and projected onto a CCD. The result is a
diffraction pattern, that can be frequency analyzed to determine the distance to
the measured surface. The main advantage with conoscopic holography is that
only a single ray-path is needed for measuring, thus giving an opportunity to
measure for instance the depth of a finely drilled hole.

4.3. Reconstruction From Point Clouds:-

The point clouds produced by 3D scanners can be used directly for measurement and
visualization in the architecture and construction world.

 Polygon mesh models: In a polygonal representation of a shape, a curved

surface is modeled as many small faceted flat surfaces. Polygon models—also
called Mesh models, are useful for visualization, and are relatively un-editable
in this form. Reconstruction to polygonal model involves finding and
connecting adjacent points with straight lines in order to create a continuous
surface.
 Surface models: The next level of sophistication in modeling involves using a
quilt of curved surface patches to model our shape. These might be NURBS,
T-Splines or other curved representations of curved topology. Surface models
are somewhat editable, but only in a sculptural sense of pushing and pulling to
deform the surface. This representation lends itself well to modeling organic
and artistic shapes.
 Solid CAD models: From an engineering/manufacturing perspective, the
ultimate representation of a digitized shape is the editable, parametric CAD
model. After all, CAD is the common "language" of industry to describe, edit
and maintain the shape of the enterprise's assets. In CAD, our sphere is
described by parametric features which are easily edited by changing a value
(e.g., center point and radius).

22
4.4. Benefits of 3D scanning

3D model scanning could benefit the design process if:

 Increase effectiveness working with complex parts and shapes.

 Help with design of products to accommodate someone else's part.
 If CAD models are outdated, a 3D scan will provide an updated version
 Replacement of missing or older parts
 Large cost savings when conducting as-built design services in Automotive
Manufacturing Plants.

23
4.5. Modeling Of Some Turbo Generator Components through 3D Scanning
4.5.1. ROTOR

Fig 4.2

24
4.5.2. Turbo Generator Assembly

Fig. 4.3

25
 CHAPTER 5

MATERIAL TESTING

5.1 Introduction

In reverse engineering it is very important to recognize materials of given

samples before manufacturing actual product. The process of material testing &
recognition is known as Deformulation.

Deformulation refers to a set of analytical procedures used to separate and

identify individual components of a formulated metal or chemical
substance. Deformulation applies methods of analytical chemistry and metallurgy to
determine materials in reverse engineering.

The method used for Testing of metal is Spectrochemical Analysis and the apparatus
used for testing is Vacuumed Emission Spectrometer

5.2 SpectrochemicalAnalysis

Spectrochemical analysis, methods of chemical analysis that depend upon the

measurement of the wavelength and the intensity of electromagnetic radiation. Its
major use is in the determination of the arrangement of atoms and electrons in
molecules of chemical compounds on the basis of the amounts of energy absorbed
during changes in the structure or motion of the molecules. In its restricted and more
common usage two methods usually are implied:

(1) ultraviolet (nonvisible) and visible emission spectroscopy and (2)

ultraviolet, visible, and infrared absorption spectrophotometry.

In emission spectroscopy, atoms are excited to energy levels higher than their
lowest normal levels (ground states) by means of electrical discharges (arcs, sparks)
or flames. Identification of the elemental composition of an unknown substance is
based on the fact that when the excited atoms return to lower energy states, they emit
light of characteristic frequencies. These characteristic frequencies are separated into
an ordered sequence (spectrum) by diffraction or refraction (deflection of the path of
the light by a grating or a prism) for observation in a spectroscope (visual),

26
spectrograph (photographic), or spectrometer (photoelectric). The process consists of
four interdependent steps:

(1) vaporization of the sample,

(2) electronic excitation of its atoms or ions,
(3)dispersion of the emitted or absorbed radiation into its component
frequencies, and
(4) Measurement of the intensity of the radiation, usually at wavelengths at
which the intensity is greatest.
Ordinarily, emission spectrochemical analysis is applied to the qualitative and
quantitative determination of metallic elements, but it is not restricted to them. The
method is among the most sensitive of all analytical methods: a few milligrams of a
solid sample usually suffice for the detection of metallic elements present to the
extent of a few parts per million or less. In addition, the method is capable of
detecting several atomic species simultaneously, thus obviating chemical separations.

Quantitative analysis by emission spectroscopy depends upon the fact that the
quantity of light (i.e., the intensity) emitted at a given wavelength is proportional to
the number of atoms vaporized and excited. The quantity of a given element is usually
determined by a comparative method—that is, the intensity of the radiation emitted at
a selected wavelength by the sample is compared with the intensity of the radiation
emitted by a standard of known composition. Other spectrochemical methods useful
in elemental analysis are atomic absorption spectrometry and atomic fluorescence
spectrometry. Both methods resemble the flame method of emission spectroscopy
(i.e., a method that uses flame as the energy source to excite atoms) in that a solution
of the sample is usually vaporized into a flame of hydrogen or acetylene in air or
oxygen. In addition, light of the same wavelength as that emitted by the desired
element is passed through the flame. A certain fraction of the light is absorbed by
atoms that are in their ground electronic state. The quantity of radiation absorbed is
proportional to the concentration of atoms in the flame in their ground state and,
because thermal equilibrium exists, to the total concentration of that atomic species.
Atomic fluorescence spectrometry makes use of the same basic instrumental
components as atomic absorption spectrometry; however, it measures the intensity of
the light emitted by atoms that have been excited from their ground state by the

27
absorption of light of shorter wavelength than that emitted. The atomic
absorptionmethod is particularly well adapted to the determination of the alkali and
alkaline earth metals.
Fig: Spectroscopy Equipment

Fig 5.1: Spectroscopy Equipment

28
5.3 Results of Material Testing

29
30
 CHAPTER 6

SHAFT DESIGN CHECK

Shaft diameter = 2.98 mm.
Approximately take d = 3 mm.

For shaft material i.e. BS 970 Gd 304, cold worked,

(From design data book)

Ultimate tensile strength,Sut = 803 Mpa,

Yield tensile strength ,Syt = 402 Mpa , [16]

We have to use ASME code,

(permissible) = 0.3 * Syt= 0.3 * 402 = 120.6 Mpa ,

Or (permissible)= 0.18 * Sut= 0.18 * 803 = 144.54 Mpa,

We select minimum value of (permissible)

(permissible)= 120.6 Mpa ,

Fig. 6.1 Shaft assembly

31
 Fig.6.2

Now, we have to calculate turbine weight Tw and Cw,

Turbine diameter = 15 mm, width = 6 mm,

Volume = ((/4)*d2) * width = 1.0603 * 10(-6) m3,

m = vol * 1.0603 * 10(-6) * 1140 = 1.2087 * 10(-3) kg,

m = 1.2087 kg

Approximately, m = 3 gm,

Hence,

Turbine weight Tw = 1.3gm,

Cw= weight of magnet and rubber support assembly,

Cw= 4gm,

32
FORCE ANALYSIS

Let,Rb = reaction at bearing at point b,

Rd= reaction at bearing at point d,

(as shown in the figure)

( Rb + Rd ) = (Tw + Cw ) * 9.81,

( Rb + Rd ) = ( 1.3 + 4 ) * 9.81

( Rb + Rd ) = 0.052 N

Now take moment about ‘D’

0.0013 * 9.81 * 15.58 + 0.004 * 9.81 * 4.58 = Rb * 2 * 4.58

Rb= 0.0413 N

Rd = 0.0107 N

Now we have to find BMD ,

Tw = 1.3 * 9.81 N

Cw= 4 * 9.81 N

Rb= 0.0413 N

Rd= 0.0107 N

BM at A = 0 ,

BM at B = (–6.42 * 0.0013 * 9.81) = – 0.0818 Nmm ,

BM at C = (–11.0 * 0.0013 * 9.81) + (0.00413 * 4.58) = 0.04887 Nmm ,

BM at D = (-15.58 *0.0013 * 9.81) + (9.16 * 0.0413) – ( 4.58 * 0.004 * 9.81 )

= –1.0294 * 10(-4)Nmm ,

33
Fig. 6.3

34
So BMmax , Mb = 0.0818 Nmm ,

Twisting moment or torque acting on the shaft is , T = 405.5 Mpa ,

So by applying ASME code , we have ,

[(Kt * T)2+ (Kb *Mb)2](0.5)= (d3 * ) / 16

For gradually applied load ,

Kt = 1.5 (Combined shock and fatigue factor for bending moment)

AndKb = 1.0 (Combined shock and fatigue factor for torsional moment) [16]

Putting all the values in the equation, we get ,

pa,

Since ,

104.762 Mpa< 120.6 Mpa

i.e.<(permissible) ,

Design of Shaft is safe.

35
 CHAPTER 7
ANSYS ANALYSIS
ANSYS software is used for Static structural analysis of Rotor subjected to
calculated pressure values.

7.1 Calculations:

When the projectile travels through the atmosphere at supersonic speeds, it

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

𝑘
𝑘+1
{[ ∗𝑀2 ]𝑘−1 }
2
P2 = 1 * P1
2𝑘 𝑘−1 𝑘−1
{ ∗𝑀2 − }
𝑘+1 𝑘+1

Where:
P2 = free stream static pressure at a given flight altitude;
M=projectile velocity expressed in terms of the local Mach number;
k =1.4
(k is the ratio of specific heat capacities for air).
For a given flight Mach number and altitude, the corresponding pressures of P2 and
P1 determine the amount of ram air mass flow that enters the generator, and thus the
amount of electrical energy generated.
(U.S. Patent No. 4,581,999) [10]
Considering velocity of fuze while launching since fuze achieves its maximum
velocity during launching at ground level. For calculating maximum air pressure
developed inside the duct,
Consider, V= 450 m/s, i.e. supersonic velocity.
Mach number is given by equation,
𝑉𝑒𝑙𝑜𝑐𝑖𝑡𝑦𝑜𝑓𝑎𝑖𝑟
M= 𝑉𝑒𝑙𝑜𝑐𝑖𝑡𝑦𝑜𝑓𝑠𝑜𝑢𝑛𝑑

36
Where,𝑉𝑠𝑜𝑢𝑛𝑑 = 340 m/s
450
∴ M = 340 = 1.3235

P1 = 1.013 bar = 1.013* 105 Pa

(Taking atmospheric pressure at ground level)
1.4
1.4+1
{[ ∗ 1.32352 ]1.4−1 }
2
∴ P2= 1 * 1.013* 105
2∗1.4 1.4−1 1.4−1
{ ∗1.32352 − }
1.4+1 1.4+1

∴P2 = 287067.49 Pa
This is the pressure generated due to air on turbine rotor.
Hence, checking the rotor under this pressure by analysis using software ANSYS.

7.2 Analysis
7.2.1 Material Properties of Nylon66:[7]
Material Properties Value

Density 1.14 kg/m^3

Young’s Modulus: 3.1e09 Pa

Bulk Modulus: 5.1667e09 Pa

Shear Modulus 1.107e09 Pa

Poisson’s ratio 0.4

Tensile yield strength 9.0e07 Pa

Compressive yield strength 9.2e07 Pa

Shear Strength 6.89e07 Pa

Table7.1: Material Properties

37
7.2.2 Maximum Deformations &Stresses Developed:

Results Value

Total Deformation 8.8483e-04 m

Equivalent Elastic Strain 3.46e-02 m/m

Max. Normal Stress 8.7324e07 Pa

Max. Shear stress 1.8694e07 Pa

Table 7.2: Maximum Deformations and Stresses Developed

38
7.3 Results:
7.3.1 Fig7.1 Maximum Normal Stress:

Max. Normal Stress = 8.7324e07 Pa < 9.0e07 Pa (Syt)

Hence Nylon66 rotor is safe
7.3.2. Fig.7.2Total Deformation

39
7.3.3 Fig.7.3Equivalent Strain:

40
 CHAPTER 8

EXPERIMENTATION FOR TESTING OF TURBOGENERATOR

8.1 AIM OF THE TEST

It is desired that one must compare the theoretical and practical values of impeller
RPM for different air velocity entering in the conduit of the Turbogenerator when the
exposed to wind tunnel. For this we use wind tunnel having at ground conditions at
ambient pressure and temperature.

8.2 TEST FACILITY:

The test as are carried out in the 2D wind tunnel 0.3M X0.3M. It consists of pipe of
above mentioned dimensions an electric operated centrifugal fan of varying speed
Fixed geometry replaceable nozzle blocks are available pressure condition. Flow
visualization (both Shadowgraph and schlieren), Pressure, Velocity and Force
measurement on model are carried out. Here velocity of the air in the wind tunnel is
directly measured with the help of PitotTube. Tunnel is directly measured by. Here
velocity of the air in the wind Pitot Tube in m/sec as the projectile velocity.[19]

8.3 PITOT STATIC TUBE: [1]

An outside view and a sectional view of Pitot-Static tube are shown in (Fig). It
consists of an internal L-shaped tube which forms the mouth of the instrument at M,
the other end B being connected to one of the limits of the suitable manometer. This
inner tube is surrounded by an L-shaped outer tube so that an air space is provided
between two tubes; a ring of holes in the outer tube at A admits the air to its space.
The static pressure of the air can thus be transmitted along the air space to its outlet at
C, which is connected to the other limb of the manometer. The instrument is placed
with its mount facing the air stream. The head measured in then the velocity head
only of the air stream, as its static pressure is transmitted to both limbs of the
manometer and is, eliminated. The velocity of air is given by,
V= k (2*g*h) 1/2

41
8.3.1 TEST CONDITIONS:
Temperature=ambient;
Pressure= ambient;

8.3.2 MODEL DESCRIPTION: [19]

The assembly drawing of alternator, nose holder adapter and string is shown in
(fig).Geometrical details of nose and holder are shown in fig. nose has a nozzle for
streamlining the air entered. The nozzle has internal threads for fastening the holder.
The outer profile of the nose is designed such that flow passes over the smoothly the
nose replicates the fuze of the artilary.The alternator holder accommodates the air
driven alternator. The holder has four legs with external threads for fastening the
nose. Appropriate gap is maintained between the nose and holder so that this gap
without accumulating. The threaded joints designed to withstand the tunnel starting
and stopping loads the holder is attached to the string with an adapter. The adapter is
made up of M.S.slot is provided on adapter flange for passage of electrical loads of
alternator.

Fig.8.1 Block Diagram for Static Trial

8.4 ANALYSIS OF IMPELLER UNIT TO CALCULATE THEOROTICAL

RPM:

The flow of gas is a more complex problem than the flow of liquids on account
of the great compressibility of former. The gas flow takes place isothermally,
adiabatically, or at constant total energy. The flow may be resisted by friction which

42
partially or wholly reheats the Gas; thus the loss of energy due to friction reappears in
the gas in the form of Internal Energy. If large changes of temperature occur during
the flow, the variation in the specific heats will be considerable and should be taken
into account. [1]

The type of flow is also affected by velocity. It may be subsonic, sonic or supersonic
depending on its relation to velocity of sound in the gas; the latter will vary according
to its temperature or its pressure and density. At speed above sonic speed compression
waves and shock waves are transmitted which affect the resistance to flow.

The above remarks also apply to bodies moving with high velocities I a stationary
gas; the resulting phenomena will depend on the relative velocity between the velocity
and gas. [1]

By applying the law of conservation of energy to gas flowing through any type of
duct an energy equation for flowing gasses can be obtained by adiabatic flow
neglecting reheating we know the flow of compressible fluid through horizontal pipe
is given by,[17]

C22 - C12 = (K/(K-1)) R.T1 [1-(ΔP/P2)((K-1)/K)] 2g

Where

C1 is the inlet velocity of air in pipe and C2 is the outlet velocity to get the relative
velocity of the air with respect to projectile C3 is addition of velocity of projectile and
C2. When the projectile travels through the atmosphere at supersonic speeds, it sets up
a normal shock wave in front of it. The air pressure in front of the projectile and
entering air inlet is represented by P2. At subsonic speeds no shock wave is formed &
air pressure just in front of the projectile and entering air inlet is equal to P1.

During supersonic speeds the generator inside the projectile ogive, is exposed to the
total pressure at ogive air inlet equal to P2. Pressure P2 is determined by flight mach
no and altitude expressed by equation [18]

𝑘
𝑘+1
{[ ∗𝑀2 ]𝑘−1 }
2
P2 = 1 * P1
2𝑘 𝑘−1 𝑘−1
{ ∗𝑀2 − }
𝑘+1 𝑘+1

During supersonic operation the generator, inside the projectile ogive, is

43
Exposed to a total pressure at the ogive air inlet equal to P2
Where,
P1= free stream static pressure at a given flight altitude;
M= projectile velocity expressed in terms of the local Mach number;
K = 1.4(ratio of specific heat capacities for air).

Sonic Velocity, a = [k*R*T]1/2

R= Universal Gas Constant, 287 j/kg k,
T= Absolute Temperature of inlet air
= ( 273+15) = 288 K
a = sonic velocity = 340.174 m/sec

Designing for 125 m/sec at ground level where the values of density, pressure and
temperature of air are maximum as compared to high altitude wart. ground for least
operating velocity is done so that constant electrical output is obtained under all
operating velocities.
Mach number M= c/a
M = 125 / 340.174=0.37

As M < 1, Shock wave is absent,

P2 = P1
And since c is less than 400 m/sec the loss due to flow deflector
L= (c*10)/ 400 = 3.125
So air velocity in conduit
C1= ((100 - L)*c)/ 100
C1 = ((100- 3.125)* 125)/100
C1 = 121.093 m/sec

Mass flow rate is given by, m = 𝜌 * A * C1

Where A= cross sectional area of conduit
= (𝜋/4)* d2 (diameter of conduit = 10 mm)
= 7.85 x 10-5 m2

44
𝜌= P2 / (R.T1)
= 1.032x105 / (287 x 288)
= 1.246 kg/m3

Mass Flow rate, m = 1.246 x 7.85 x 10-5 x 121.093

= 1.184 x 10-2 kg/sec

Considering the flow through the duct with 80 % loss energy equation with adiabatic
process flow,

C22 - C12 = (K/(K-1)) R.T1 [1-(ΔP/P2)((K-1)/K)] 2g

C22 = 3.5 x 287 x 288 x [1- (0.8)0.2857142] x 2 x 9.81 + 121.0932

C2 = 604.35 m/s

The relative velocity of air, C4

C4 = C1 + C2
= 121.093 + 604.35
= 725.44 m/s
Hence, total quantity of air in conduit in m3/s

Q = 7.85 x 10 -5 x C4
= 7.85 x 10-5 x 725.44
= 0.05694 m3/s

The quantity of the air directly incident or impinged on the air depends upon the
height of the blade and gap between the two blades. Also it depends upon the total
number of the blades. Hence it has to be calculated from the height and the number of
the blades.
Absolute velocity of jet at inlet of blade,
V = Q/A
= 0.05694 / 0.0339
= 1.6784 m/s

45
Tangential Velocity of the single blade is given by velocity triangle as shown in the
fig. and is given by ‘u’,
ut= v / tan41
= 1.6784 / 0.86928
= 1.9307m/s
Angular Velocity of the Impeller is given by,
𝜔 = 10 x u / r,
Where, r = Inner radius of impeller
Hence,
𝜔 = (10 x 1.9307)/ 0.006
= 3217.8 rad/s

Also we know that the rotating speed N (RPM) of turbine is given by,
N = (60 x 𝜔) / (2 x 𝜋)
= (60 x 3217.8)/(2 x 𝜋)
= 30728.04 rpm
Rotating speed,
N = 30728.04 rpm.

46
8.5 RESULTS:

Sr. No. Air velocity in Theoretical speed Practical speed of

wind tunnel of impeller impeller

m/sec (RPM) (RPM)

1 130 30700 26200

2 150 31950 27157

3 200 34430 28000

4 250 36900 30000

5 300 39500 31000

6 350 42050 34450

7 400 45123 36100

8 450 45500 38000

Table 8.1 : Test Results

47
8.6 CONCLUSION OF TEST RESULTS:

From the above results it is clearly found out that the practical values of impeller
speed is less than around 20 – 25 % they may be due to following reasons,

1. Frictional loss in the inlet conduit and over the blade is neglected.
2. Total air intake quantity may lose without passing over blades.
3. Friction in bearing is not considered.
4. Weights of the rotor, shaft, bearing, etc are not considered.

48
 CHAPTER 9

DOCUMENTATION

Production Documentation involves 3D drawings, 2D views with dimensions and

tolerances and other information like component name, component number, material
configuration, Surface finish, etc. It is tool for easy and efficient communication
between designer and manufacturer. Following figures show some features of
Production Document.

49
 1. ROTOR

APPROVED BY: MATERIAL:

(Dr. Virendra Kumar)
FOR DIRECTOR Scientist ‘F’ NYLON66 TO SPECIS:13464

DATE: PROTECTIVE FINISH:

TITLE:

ROTOR

DRAWING NO: 1203 01 01 00 00 001 00DA PART NO: 1

50
 2. COVER PLATE

APPROVED BY: MATERIAL:

(Dr. Virendra Kumar) AL ALLOY 64430W TO SPEC IS: IS733-

FOR DIRECTOR Scientist 24345WP
‘F’
DATE: PROTECTIVE FINISH:

ANODISED TO SPEC IS:1868Gd AC 10

TITLE:

COVER PLATE

DRAWING NO: 1203 01 01 00 00 002 00DA PART NO: 2

51
 3. HOUSING

APPROVED BY: MATERIAL:

(Dr. Virendra Kumar) AL ALLOY TO SPEC IS:733-24345 WP

FOR DIRECTOR Scientist ‘F’
DATE: PROTECTIVE FINISH:

ANODISED TO SPEC IS:1868 Gd AC 10

TITLE:

HOUSING

DRAWING NO: 1203 01 01 00 00 003 00DA PART NO: 3

52
 4. WASHER

APPROVED BY: MATERIAL:

(Dr. Virendra Kumar) BRASS TO SPEC IS 319 Gd 1 HALF HARD

FOR DIRECTOR Scientist ‘F’
DATE: PROTECTIVE FINISH:
TO BE CROMATE PASSIVATED TO SPEC IS:1340
TITLE:
WASHER

DRAWING NO: 1203 01 01 00 00 004 00DA PART NO: 4

53
 5. BEARING

APPROVED BY: MATERIAL:

(Dr. Virendra Kumar) BRASS TO SPEC IS 319 Gd I HALF HARD

FOR DIRECTOR Scientist ‘F’
DATE: PROTECTIVE FINISH:
PASSIVATION
TITLE:
BEARING

DRAWING NO: 1203 01 01 00 00 004 00DA PART NO: 5

54
 6. FOAM DISC

APPROVED BY: MATERIAL:

(Dr. Virendra Kumar) SILICON RUBBER DTD 818 L2

FOR DIRECTOR Scientist ‘F’
DATE: PROTECTIVE FINISH:

TITLE:
FOAM DISC

DRAWING NO: PART NO: 6

55
 7. SHAFT

APPROVED BY: MATERIAL:

(Dr. Virendra Kumar) STAINLESS STEEL TO SPEC BS 970 Pt4Gd 304

FOR DIRECTOR Scientist ‘F’
DATE: PROTECTIVE FINISH:

TITLE:
SHAFT

DRAWING NO: PART NO: 7

56
 8. MAGNET

APPROVED BY: MATERIAL:

(Dr. Virendra Kumar) ALNICO-5 ALLOY MAGNETIC MATERIAL

FOR DIRECTOR Scientist ‘F’
DATE: PROTECTIVE FINISH:

TITLE:
MAGNET

DRAWING NO: PART NO: 8

57
 9. STAMPING PLATE

APPROVED BY: MATERIAL:

(Dr. Virendra Kumar) SILICON STEEL TO SPEC ASTM A867-03

FOR DIRECTOR Scientist ‘F’
DATE: PROTECTIVE FINISH:

TITLE:
STAMPING PLATE

DRAWING NO: 1203 01 01 02 01 001 00DA PART NO: 9

58
 10. BOBIN

APPROVED BY: MATERIAL:

(Dr. Virendra Kumar) NYLON 66 TOP SPEC IS : 13464

FOR DIRECTOR Scientist ‘F’
DATE: PROTECTIVE FINISH:

TITLE:
BOBIN

DRAWING NO: 1203 01 01 02 02 001 00DA PART NO: 10

59
 11. PCB

APPROVED BY: MATERIAL:

(Dr. Virendra Kumar) AMSI Gd FR4 TO SPECN DS:7409

FOR DIRECTOR Scientist ‘F’
DATE: PROTECTIVE FINISH:

GLASSI EPOXY

TITLE:
PCB

DRAWING NO: 1203 01 01 03 01 000 15DA PART NO: 11

60
61
 CHAPTER 10

CONCLUSION

A comprehensive study of all possible power sources available for the fuze was
carried out. Some of these are in extensive use presently, while others have been
proposed for development. From the study it was concluded that the most suitable
power source with many inherent advantages is the turbo generator.

The focus of the project was on developing the turbogenerator by Reverse

Engineering.

Materials were determined by Material Testing: Table 10.1

Washer IS 319 Gd 1

 Cover Plate IS 733- 24345WP

Housing IS 733- 24345WP

Shaft BS970 Pt4 Gd 304

Magnet Alnico 5

 Material for rotor in the sample is a polymer. Hence in indigenous design,

selecting material l as Nylon-66 since
o Nylon-66 is easily available in India,
o Low Density,
o Low cost,
o Similar properties as that of sample polymer.
 As material of the rotor is changed, Nylon 66 is checked in ANSYS under
required conditions. Rotor is safe.

61
  Design of shaft is checked under actual loading conditions. Shaft is Safe.
 Theoretical values of impeller speeds found more than practical values, the
reasons are:
o Friction losses in inlet duct and over the blade is neglected
o Total air intake quantity may lose without passing over blades
o Friction in bearing is not considered.
o Weight of rotor, shaft, and bearing is not considered.

The values of practical impeller speeds are within acceptable limits, hence static trial
was successful.

62
 CHAPTER 11

FUTURE SCOPE

After analyzing the shape of vanes in turbine with certain properties like inlet
flow angle of incidence etc for the use the use of small power generation system as we
have used, one can try out for different shapes and properties for different power
generation attributes like different voltage and current output for the applications of
different types of projectiles.

The research is being carried out to control the speed of turbine impeller
which is function of height of projectile, air pressure, density and velocity of the air
stream, by introduction of flow deflector or spring operated valve instead of simple air
duct. These designs provide constant turbine speed and hence constant current and
voltage output from alternator.

Another proposal is that of introduction of Braking system to control turbine speed.

63
 REFERENCES

1. Proximity Fuzes: Theory and Techniques by V. K. Arora

ISBN: 978-81-86514-29-0, DRDO monographs/special publications series.

2. Engineering Design Handbook Ammunition Series Fuzes, Proximity, Electrical

Part One (U)Am (Ad389295)

3. Engineering Design Handbook Ammunition Series: Fuzes, Proximity, Electrical-

Part One (U) By US Army Material Command. AMCP 706-211, July 1963.

4. Military Handbook: Fuzes, Department of Defence, United States of America.MIL-

HDBK-757 (AR), 15 April 1994.

5. Report on Turbogenerator provided by DRDO.

6. US Patent No. 4581999: Supersonic high altitude flight simulator for air driven
generators.

7. ERTALON® 66 SA Nylon-66 Catalog by Quadrant Engineering Plastic Products

8. Eilam, Eldad & Chikofsky, Elliot J. (2007).

Reversing: Secrets of reverse engineering. John Wiley & Sons.Pg.3.

9. Chikofsky, E. J. & Cross, J. H., II (1990).

"Reverse Engineering and Design Recovery: A Taxonomy".

10. A Survey of Reverse Engineering and Program Comprehension. Michael L.

Nelson, April 19, 1996, ODU CS 551 – Software Engineering Survey. Furthermore,
reverse engineering concept is used to modify or change premade .dll files in an
operating systems

11."Redstone rocket" centennial of flight.net. Retrieved 2010-04-27.

12. http://www.npd-solutions.com/remethod.html

13. Fausto Bernardini, Holly E. Rushmeier (2002)

"The 3D Model Acquisition Pipeline" (pdf).Comput.Graph. Forum 21 (2): 149–172

64
14. Brian Curless (November 2000). "From Range Scans to 3D Models". ACM
SIGGRAPH Computer Graphics 33 (4): 38–41.

15. Roy Mayer (1999). Scientific Canadian: Invention and Innovation from Canada's
National Research Council. Vancouver: Raincoast Books. References:

16. “Design of machine Elements”,by V.B.Bhandari ,

TataMacGraw Hill , edition 2012

17. “Gas Turbines” V Ganesan, Tata Mcgraw Hill, 2th edition (2006)

18. “Gas Turbine Theory” H Cohen, GFC Rogers & HIH Saravanamutto, 5th Edition

19. Patent no 4953475 “Safety & Arming System for Launched Projectile”
United States Of America Patent Office, New York, 1994, 1-10

20. Engineering Design Handbook Ammunition Series Fuzes, Proximity, Electrical

PartTwo (U) AMCP 706-212(s)

21. Engineering Design Handbook Ammunition Series Fuzes, Proximity, Electrical

Part Five (U)AD389296

22. www.wikipedia.com

65
Appendix
International Standard Atmospheric Chart

66