Summer Training Report

On
DESIGN OF LIGHT WEIGHT FIRE EXTINGUISHER

Centre For Fire Explosive and Environment Safety

Defence Research and Development Organization
Brig SK Mazumdar Road Timarpur, Delhi -110054

in partial fulfillment of the degree

 
Bachelor of Technology

In

Mechanical engineering

Mahavir Swami Institute of Technology

Guru Gobind Singh Indraprastha University,
Delhi
Submitted By
Vishal
00455108220

Under the Guidance of

Vishal Dwivedi (SCIENTIST F)

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 DECLARATION

This is to certify that summer training report entitled Design of light

weight fire extinguisher which is submitted by Vishal in partial fulfillment
of the requirement for the award of degree B.Tech in Department of
Mechanical Engineering of Guru Gobind Singh Indraprastha University,
is a record of the candidate on work carried on by him under my
supervision. The matter embodied in this report is original and has not
been submitted for the award of any other degree. This report contains
no secret matter pertaining to CFEES, DRDO .

SIGNATURE

VISHAL DWIVEDI
(SCIENTIST F )

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 ACKNOWLEDGEMENT

The facts about the organization expressed in this report is a manifestation of a

learning process that began for me the day I entered the organization six
weeks ago. During the training period I have come across some wonderful
people from whom I have learnt immensely.
We would like to express our gratitude to Mr. Vishal Dwivedi Scientist-‘F’
our project in charge who explained us how to perform better in this
organization. He has told us the way to get the job done, not only providing the
exact way to do it, but also the concept behind. Where we could not find the
solution or were unable to adopt the better solution our self he taught us how
the work is to be done in an efficient and best manner and provided with
explored details about the problem and the solution.
It’s our great honor to express our gratitude to those who have been kind
enough to us so as to help us initiate our training and project. We would like to
thank Dr. Meenakshi Gupta, Scientist-‘G’, Additional Director FSEG, CFEES.

We would like to give our gratitude to Shri Rajiv Narang , OS & Director who
have given us the opportunity to join this prestigious organization.

Vishal
Mahavir Swami Institute of Technology 
Affiliated with Guru Gobind Singh Indraprastha University
Near O.P. Jindal University, Jagdishpur ,Haryana- 131030

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 About DRDO

Defence research and development organization( DRDO )works under

department of Defence research and development of ministry of defence. DRDO
dedicatedly working towards enhancing self- reliance in defence system and
undertakes design & development leading to production of world-class weapon
systems and equipment in accordance with the express needs and the qualitative
requirements laid down by the three services.

DRDO is one of the prestigious organisation of the country in the field of science and
Technology which could transform our country's Defence force into one of the most
modern and powerful force in the world .It was established by merging together the
Scientific and Technical development stablished under three services headquarters
in 1958, with the aim of creating an organisation that can take up the challenges of
developing and delivery in the high technology in the field of Modern Warfare ,
weapon system, avionics and other scientific aspect of nation,s defence . It has also
got mandate to modernize Defence Technology .

DRDO is working in various areas of military technology which include aeronautics,

arnaments, combat vehicles , electronics , instrumentation engineering systems,
missiles ,materials, naval systems, advanced computing ,simultation and life
sciences. DRDO while striving to meet the cutting edge weapon technology
requirements provide ample spin-off benefits to the society at large thereby
contributing to the nation building .
 
Vision
 
Make India prosperous by estabilising world- class science and technology based and
provide our Defence Services decisive edge by equipping them with internationally
competitive system and Solutions.

Mission

 Design, develop and lead to production state-of-the-art sensors weapon system,

platforms and allied equipments for our Defence Services.
 Provide technological solution to the Defence Services to optimise combat
effectiveness and to promote the well-being of the troops.
 Develop infrastructure and committed quality manpower and build strong Technology
base.
 Core competence.
 Dept of defence research and development (R&D) is working for indigenous
development of weapons, sensor and platforms required by the three Wings of the
armed forces .To fulfill this mandate department of Defence research and
development (R&D),is closely working with academic institution, research and
development( R&D) centres and production agencies of Science and
Technology(S&T) ministries /department in public and civil sector including defence
public sector undertakings & ordnance factories .

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 Table of Content

S. No. Description Page No.

1. Problem Definition & Introduction To 6

IFDSS
2. Composition Of The Material 7

3. Considering Material and Properties 8-12

4. Design Calculations as per IS 7285 13

5. Calculations with Existing Material 14-17

6. Manufacturing Method of Steel cylinder 18-22

from tubes
7.  Steel cylinders from billets 23-27

8. Conclusion 28

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Problem Definition
To achieve weight reduction for cylinder used for automatic fire extinguisher
used in IFDSS (Instant Fire Detection & Suppression System) applied in
combat vehicles, aircrafts, and warships for fire suppression.

Introduction to Instant Fire Detection & Suppression System (IFDSS):

Instant Fire Detection & Suppression System (IFDSS) is a microcontroller
based fire detection and suppression system for vehicle/tanks. The equipment
automatically detects the fire and suppression of fire is carried out either
automatically or by pressing manual override switch in crew as well as in
engine compartment of the tank.

Components:

I. IR sensors: These sensors detect the fire in crew compartment and

send the conformation signal of fire to main control unit (MCU). The
MCU further takes the necessary action.

II. Fire Wire: It is a flexible heat detecting wire, having one or more
elements joined in series by means of various connector accessories.
Its logic is designed for detection “over heat”, “fire”, “open circuit”, &
“short circuit” condition.

III. The system has features of continuous health monitoring of Detector

units, Alarm & Flasher unit, Fire wire & Fire Extinguishers associated
with it.

The existing fire extinguisher cylinder used in IFDSS is made up of Si-Mn

steel and has a tare weight of 6.41 Kg. these cylinders contain 3.5 Kg of halon
gas. So after charging the cylinder, the total weight of the cylinder becomes
12-13 Kg (including weight of assembly valves).

Thus the objective of our project is to reduce the tare weight of the cylinder by
substituting the existing material with a suitable low weight and high strength
characteristic materials with minimum change in dimensions.

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Composition Of The Material:
Percentag
Element e
Carbon : 0.54 max
Manganes
e : 1.30-1.70
Silicon : 0.10-0.35
Sulphur : 0.040 max
Phosphoru
s : 0.040 max

Specifications Of The Existing Cylinder Are:

Material : Silicon Manganese steel STH 70 (acc. to IS 7285)

Tare Weight : 6.41 Kg

Weight Of Halon Gas : 3.5 Kg

Total Weight : 12-13 Kg (including weight of assembly valves)

Water capacity : 3.6 litres

Bottom : convex

Hydrostatic Test Pressure : 240 Kgf/cm²

Working Test Pressure : 140 Kgf/cm²

Yield Stress : 4700 Kgf/cm²

Light Weight Materials Considered

1. Titanium 6Al-4V (ASTM) alloy is one of the most common titanium
alloys.

It is the most widely used titanium alloy, e.g. for aerospace, marine and
chemical processing. Among its many advantages, it is heat treatable.

This is an excellent combination of strength, corrosion resistance, weld and

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fabric ability.

Its uses are numerous such as for military, aircraft or turbines.

Generally, it is used in applications up to 400 ºC.

It is as strong as steel but half the weight. Also, it is twice the weight of
aluminium but twice as strong.

Components

 Al (6)
 V (4)
 Ti (90)
 Fe (max 0.25)
 O (max 0.2)

Mechanical Properties
 Conditions 
Properties
T (°C) Treatment

Density (×1000 kg/m3) 4.43 25  

Poisson's Ratio 0.34200001 25  

Elastic Modulus (GPa) 113.8 25  

Tensile Strength (Mpa) 993 

Yield Strength (Mpa) 924 

25  Annealed
Elongation (%) 14 

Reduction in Area (%) 30 

Hardness (HRC) 36  25  Annealed

Impact Strength (J)

19  25  annealed  
(Charpy)

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Thermal Properties

 Conditions 
Properties
T (°C) Treatment

Thermal Expansion (10-6/ºC) 8.6  20-100  

2. Al 6061 T6

Here is a table of the AL 6061 T6 properties.

Properties Value

STRUCTURAL

Mpa Ksi

Ult. Tensile Strength 430 62.4

Yield Strength 320 46.4

Modulus of Elasticity 72000 10442

Shear Strength 205 30

Kg/m 2

Mass Density 2850

Hardness 95

1/16" 1/2"
thick thick

% Elongation 12 17

THERMAL

Btu/ft
W/m*K
*n*F

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Thermal Conductivity 167 97

1 0−6 /° C

Coeff. of Thermal Expansion 22.1

3. Aramid Fibers

Para-Aramid Structure

Aramid fibers are a class of heat resistant and a strong synthetic fibers.

They are used in aerospace and military applications, for ballistic rated body
armor fabric, and an asbestos substitute.

The name is a shortened form of “aromatic polyamide”.

They are fibers in which the chain molecules are highly oriented along the
fiber axis, so the strength of chemical bond can be exploited.

Polymer preparation

Aramids are generally prepared by the reaction between an amine group and
a carboxylic acid halide group

nNH2-Ar-COCl → -(NH-Ar-CO)n- + nHCl

The most well known aramids (Nomex, Kevlar,Twaron and New Star) are
AABB polymers.

Aramid fiber characteristics

General

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 I. Good resistance to abrasion
II. Good resistants to organic solvents
III. Non- conductive
IV. No melting point, degradation starts from 500 ºC
V. Low flammability
VI. Good fabric integrity at elevated temperatures
VII. Sensitive to acids and salts
VIII. Sensitive to UV radiations

Para-Aramids
I. Para-Aramid fibers such as kevlar and twaron provide outstanding
strength to weight properties
II. High young’s modulus
III. High tenacity
IV. Low creep
V. Low elongation at break (~3.5%)

4. Glass Fibers

Fiberglass (also called fiberglass and glass fiber), is material made from
extremely fine fibers of glass. It is used as a reinforcing agent for many
polymer products.

What is commonly known as "fiberglass" today, is a material to be used as

insulation.

It has very high strength and low weight.

Properties
I. High ratio of surface area to weight
II. More susceptible to chemical attack
III. Good thermal insulation, with a thermal conductivity of the order of 0.05
W/mK

The freshest thinnest fibers are strongest because the thinner fibers are more
ductile.
The more the surface is scratched, the less the resulting tenacity.
Moisture is easily absorbed and can worsen microscopic cracks and surface
defects, and lessen tenacity.

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 5. Ceramic Fibers

For High Temperature Applications 1800° F Continuous, 2300° F Maximum

Ceramic Fiber is an aluminosilicate based refractory fiber, white and odorless.

It resists temperature as high as 2300º F.

They are lightweight with very low thermal conductivity.

They provide excellent insulation at high temperature, and resist corrosive

chemicals such as commonly used acids and alkalis.

They are excellent substitutes for asbestos products in many insulation and
sealing applications.

Insulation Properties:

Working Temperature                Thermal Conductivity of Fiber

BTU/sq.ft. ºF/in)           ( W/m ºK)

          570 ºF                                  0.84                   (0.12)

          1100 ºF                             0.91                    (0.13)

          1800 ºF                               1.19                    (0.17)

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Design Calculations as per IS 7285

The thickness of the cylindrical shell can be calculated from any of the
following formulae :

pi ( Do−t )
f=
200 t

pi ( Di+t )
f=
200 t

pi ( 1.3 D o +0. 4 D i )
2 2
f=
100 ( D o −D i )
2 2

Where

f= maximum allowable wall stress at hydrostatic test pressure in Kgf/mm²

f = 5/6 Re, Re being the minimum value of the yield strength in Kgf/mm²

pi = hydrostatic test pressure above atmospheric pressure in Kgf/cm²

Do = outer diameter of the cylinder in mm

Di = inner diameter of the cylinder in mm

t = wall thickness of the cylinder in mm

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Calculations with Existing Material
Given Data:

Water capacity (V) = 3.6 litres (3600000 mm³)

Hydrostatic Test Pressure (Pi) = 240 Kgf/cm²

Outer dia (Do) = 139.8 mm

Si-Mn steel

Density (ρ) = 8.57 g/cc (8.57 x 10−6 Kg/mm³)

Yield strength (σ) = 47 Kgf/mm²

f = 5/6 x 4700 Kgf/cm²

pi ( Do−t )
putting values in f = and solving for (t)
200 t

we get

t = 4.156 mm

Now

Do = 139.8 mm

Ro = 69.9 mm

Di = 139.8 – 2t = 131.488 mm

Ri = 65.744 mm

Water capacity

2 4 3
3600000=πR i ∗L+ ∗πRi
3

Solving for length of cylinder (L) we get

L = 177.46 mm

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Volume of cylinder material

Vc = vol of cylindrical part + vol of spherical part

4
Vc=π ( R o −R i ) L+ π ( R o −R i )
2 2 3 3
3

Vc = 314287.043 + 240304.810

Vc = 554591.868 mm³

Weight = Vc x ρ

Wt. = 554591.868 x 8.57∗10−6

Wt. = 4.753 Kg

Calculations With New Considered Materials

1. Ti 6Al 4V

Density (ρ) = 4.5 g/cc (4.5 x 10−6 Kg/mm³)

Yield strength (σ) = 78.72 Kgf/mm²

f = 5/6 x 78.72 Kgf/mm²

pi ( Do−t )
putting values in f = and solving for (t)
200 t

we get

t = 2.511 mm

Now

Do = 139.8 mm

Ro = 69.9 mm

Di = 139.8 – 2t = 134.878 mm

Ri = 67.439 mm

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Water capacity

2 4 3
3600000=πR i ∗L+ ∗πRi
3

Solving for length of cylinder (L) we get

L = 177.46 mm

Volume of cylinder material

Vc = vol of cylindrical part + vol of spherical part

4
Vc=π ( R o −R i ) L+ π ( R o −R i )
2 2 3 3
3

Vc = 192190.8928 + 148701.8915

Vc = 340892.7843 mm³

Weight = Vc x ρ

Wt. = 554591.868 x 4.5¿ 10−6

Wt. = 1.5340 Kg

Weight reduction

( Initialinitial
wt – final wt
wt )∗100
4.753 – 1.5340
= ∗100
4.753

= 67.72 % reduction

2. Al 6061 T6

Density (ρ) = 2.7 g/cc (2.7 x 10−6 Kg/mm³)

Yield strength (σ) = 22.85 Kgf/mm²

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f = 5/6 x 22.85 Kgf/mm²

pi ( Do−t )
putting values in f = and solving for (t)
200 t

we get

t = 8.285 mm

Now

Do = 139.8 mm

Ro = 69.9 mm

Di = 139.8 – 2t = 123.33 mm

Ri = 61.665 mm

Water capacity

2 4 3
3600000=πR i ∗L+ ∗πRi
3

Solving for length of cylinder (L) we get

L = 177.46 mm

Volume of cylinder material

Vc = vol of cylindrical part + vol of spherical part

4
Vc=π ( R o2−R i 2 ) L+ π ( R o3−R i 3 )
3

Vc = 607529.353 + 450830.254

Vc = 1058359.608 mm³

Now Weight = Vc x ρ

Wt. = 1058359.608 x 4.5¿ 10−6

Wt. = 2.8576 Kg

Weight reduction

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( )
Initial wt – final wt
initial wt
∗100

4.753 – 2.8576
= ∗100
4.753

= 39.88 % reduction.

Manufacturing Method of Steel cylinder from tubes

Tube technological route of seamless cylinder production

Traditional method of rotary forging with additional induction heating during

closing is applied for closing the tube end = cylinder bottom.

Special technology of rotary forging is used to close the other tube end =
cylinder neck, developed by engineers from the company.
 
During the production of steel cylinders on the small cylinders line (where
cylinders up to diameter of ø140 mm are produced), the tube end is closed in
a modern, fully automated workplace.

1. Storing 2. Cutting

Bottom forming Bottom calibration

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Neck forming Squaring up and preboring

Heat treatment Outside shot blasting

 
Identification Hardness testing

Neck machining and threading Thread inspection

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 Neck inspection by MT Inside cleaning

Volume measurement Hydraulic testing

 
Drying Eddy current test / Eddy current test of
necks

Pressing-in of the neck ring Pressing-in of the foot ring

 
Weighing and marking Inside shot blasting

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Visual inspection Visual inspection of cylinder necks

 
Ultrasonic testing Outside shot blasting

Overall inspection Primer anticorrosion painting

  

  Drying Top painting

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Drying Colour marking

 
Equipment assembly Final inspection

Packing Expedition

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 Steel cylinders from billets

Billet technological route of seamless cylinder production

Steel cylinders are produced by applying reverse extruding and broaching,

where a hot rolled billet is used as a raw material.

Unique rotary forming technology is being used for closing the semi-product
and form the neck.

Hot forming and heat treatment processes are followed by machining

operations and various types of testing procedures according required
cylinders standards.
 
Storing Cutting

  Induction heating Backward extrusion

Hot drawing and bottom forming Ultrasonic inspection

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Squaring up Neck forming

 
Squaring up and preboring Heat treatment

Outside shot blasting Identification

 
Hardness testing Neck machining and threading

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Thread inspection Neck inspection by MT

 
Inside cleaning Volume measurement

Hydraulic testing Drying

Eddy current test / Eddy current tests of necks Pressing-in of the neck
ring

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weighing and marking Inside shot blasting

 
Visual inspection and repair of surface defects Ultrasonic inspection

Outside shot blasting Visual inspection of cylinder neck

  Overall inspection Primer anticorrosion painting

Drying Top painting

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Drying Colour marking

 
Equipment assembly Final inspection

Packing Expedition

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Conclusion:

The Existing cylinder is made up of Si-Mn, which is currently having tare

weight of 6.41kg .In order to reduce the weight of cylinder we have worked on
application of different materials and their combinations. By analyzing the
combination of different materials up to 65.7% weight reduction is achievable.

First material is Titanium alloy, Ti-6Al4V.  It is lighter and weaker than good
steel, but heavier and stronger than good aluminum.  Many titanium alloys
have higher tensile strength to weight ratios than any aluminum or steel. . 
Since it is denser than aluminum, to reduce weight, a titanium alloy would
have to be thinner than its aluminum rival.  But reducing the cross-sectional
area makes the component prone to accidental damages easily.  Therefore,
titanium alloy have a tough time in the weight-loss competition.  Thus this
makes aluminum a great choice.   Because titanium is hard to manufacture
and expensive on top of that, steel is a great choice if weight is not of that
much of a concern. Since our main concern is of weight reduction, so we may
look for some other alternative.

The second material used to design cylinder of low weight is Aluminium alloy
Al 6061-T6 because of its high strength to density ratio than the existing one.
Moreover machinability of this grade of alloy is good as compared to other
high strength alloy of Al. Reduction of weight comes out to be 29.07 % which
is not a great deal. Since the material is not so costly so it can also be used
for weight reduction. If corrosion is a concern, aluminum may not be a good
choice to begin with. So some internal polishing of some anticorrosion
material would be needed which would add to the cost.

In compound cylinder Maximum weight reduction is achieved by taking the

combination of Al and Titanium alloys. Up to 65.31% weight reduction is
possible while taking Titanium alloy inside and Al alloy outside. This
combination is able to withstand the given working pressure and stress.

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