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Defence Technology 16 (2020) 432e438

Contents lists available at ScienceDirect

Defence Technology
journal homepage: www.keaipublishing.com/en/journals/defence-technology

A novel variable topology design for a multi-flexible ejection


mechanism
Hao Liu a, Jun Zhou a, *, Zong-lai Mo b, Shi-wei Zhang c
a
School of Astronautics, Northwestern Polytechnical University, Xi'an, 710072, China
b
School of Mechanical Engineering, Nanjing University of Science and Technology, Nanjing, 210094, China
c
Luoyang Opto-Electro Technology Development Center, 471009, China

a r t i c l e i n f o a b s t r a c t

Article history: The airborne missile launch mechanism often subjects to significant deformations induced by the large
Received 5 May 2019 ejection force during high-speed actuations in missile ejection process, leading to a substantial deviation
Received in revised form of separation parameters from designed values that threats safety of the carrier. This study proposes a
5 July 2019
novel variable topology design for launch mechanism, achieved via a Prismatic-Revolute-Revolute pair
Accepted 29 July 2019
Available online 29 July 2019
(PR-R) motion formed by the structural gap with a specific direction. It enables launch mechanism
variability during missile ejection process and optimizes the ejection force given by the front and back
ejection arms, and greatly optimizes the separation parameters during missile ejection. The kinetics
Keywords:
Variable topology
simulation analysis is conducted under working conditions of the original ejection mechanism and the
Gap dynamics novel mechanism with variable topology design, respectively. The results show that the novel variable
Multi-flexible body topology design is more befitting for the launch process in terms of system safety and controllability,
Flexible control effectively improving the separation posture, restraining the flexible effect of the mechanism, and ful-
Ejection mechanism filling the effectiveness of the design value of multi-rigid body.
© 2020 China Ordnance Society. Production and hosting by Elsevier B.V. on behalf of KeAi
Communications Co. This is an open access article under the CC BY-NC-ND license (http://
creativecommons.org/licenses/by-nc-nd/4.0/).

1. Introduction dramatically under the influence of complex airflow, leading to


hidden dangers to the carrier safety. By utilizing the overlapping
The embedded ejection technology of air-to-air missile is to grid technology, Zhang et al. [3] conducted a numerical simulation
provide the concealed shooting effect for the advanced fighter. comparison between the external hanging delivery and the
Before the missile launching, the carrier first opens the weapon embedded launching, and obtained the falling rules of the external
cabin door, and then the launching mechanism ejects the missile hanging delivery and the embedded launching body under the
with a certain downward velocity and angular velocity, and the conditions of subsonic velocity and supersonic velocity. It was
missile finally fires away after falling for a certain distance. During pointed out that the initial downward angular velocity of the
the ejection process, the safety of the missile separation is mainly missile was crucial for the purpose of the launching safety of the
associated with the separation speed and separation angular ve- embedded missile. Liu et al. [4] analyzed the impact of overload
locity of the missile, given by the launch mechanism. centrifugal force generated by large maneuvering of aircraft on the
In the last years, some researches on the launch safety of missile ejection separation parameters of air-to-air missile based on
have been carried out, and some good results have been achieved, Lagrange dynamic equation. Yan et al. [6] utilized the improved
including the influence of the pneumatic flow field [1e4], the delayed separation vortex-simulation method combined with the
ejection dynamics of separation [5e7], and the ground test verifi- dynamic grid technology to carry out unsteady calculation of the
cation techniques [8], etc. Merrick et al. [1] studied the free-fall three-dimensional flow field in the process of internal ejection
trajectory and attitude of the embedded missile under the action separation, and obtained the influence law of different inlet Mach
of airflow, and pointed out that the missile attitude changed number, projectile launching velocity, initial angular velocity and
other parameters on the trajectory of projectile body. Based on the
rigid-flexible coupling multi-body dynamics model, Wang [7]
* Corresponding author. studied the influence of structural parameters of the air-to-air
E-mail address: zhoujun@nwpu.edu.cn (J. Zhou). missile embedded catapult launching system on its catapult
Peer review under responsibility of China Ordnance Society

https://doi.org/10.1016/j.dt.2019.07.017
2214-9147/© 2020 China Ordnance Society. Production and hosting by Elsevier B.V. on behalf of KeAi Communications Co. This is an open access article under the CC BY-NC-
ND license (http://creativecommons.org/licenses/by-nc-nd/4.0/).
H. Liu et al. / Defence Technology 16 (2020) 432e438 433

separation parameters, and pointed out that the initial angular software, and then imported into ANSYS. This paper adopts the
velocity of the missile was “rise” due to the flexibility of the second method.
mechanism during the catapult launching.
In order to ensure the launch safety, the embedded missile 2) Material attribute input
needs a downward velocity and downward angular velocity relative
to the carrier. However, due to the large ejection force and the Input material properties, including material density, elastic
strictly lightweight design, the components of the ejection mech- modulus and Poisson's ratio.
anism suffer from serious flexible deformation, resulting in critical
deviation of the angular velocity of the missile from the designed 3) Grid generation
value, even leading to the “head-up” problem which threats the
safety of the carrier. Currently, there are two common methods to For 3D solid model, the Brick 8 node 185 mesh in ANSYS can be
solve the flexible deformation problem for high-speed motion selected, with the mesh side length smaller than 3 mm. For modal
mechanism: calculation, default Block Lanczos method is applied, which is often
used in solid grid, with many advantages such as wide application,
1) Increase the stiffness of the mechanism components. It can high precision and fast calculation speed.
reduce the flexibility deformation effect of the mechanism. But
it also significantly increases the weight and the volume of the 4) Output files to ADAMS
ejection mechanism, which is conflict with the lightweight
design requirement. The file output for ADAMS needs to set the order of the modal,
2) Passive control method using damping layer [9,10] and active which can be generally taken based on engineering experience. The
control method based on piezoelectric actuation [11e13]. The more orders, the greater the computational burden of the model.
airborne missile catapult launcher requires a stringent, light- Here, the first 15e30 orders of the modal are selected.
weight and compact design with large ejection force and short
actuation time (less than 0.15 s). The passive control method of 2.1. Mechanism configuration of the fixed topological launcher
damping layer and the active control method of piezoelectric
actuator are difficult to be implemented due to the limited The airborne missile launch mechanism is based on the
control effect and high engineering cost. configuration of the US AMREL mechanism, which has a double y-
shaped mechanism, with ejection power derived from the hy-
Variable topology design is a new method [14e17] used for draulic piston rod which can only move horizontally, as shown in
optimizing the mechanism function. Currently, the optimization of Fig. 1. The hydraulic power drives the piston of the horizontal piston
the dynamic behavior of the flexible mechanism is rarely reported. rod, pushing the horizontal piston rod (denoted as no. 4 in Fig. 1) to
This paper proposes a novel variable topology design to optimize slide forward horizontally. The front head of the missile is located at
the airborne missile ejection separation parameters by using the the left end of the missile shown in Fig. 1.
variable kinematic pair to realize the variable topological design. Each y-shaped mechanism constitutes two isosceles triangles
This method focuses on the suppression of the flexibility effect of for converting the horizontal thrust given by the hydraulic piston
the entire ejection mechanism instead of individual component. rod into a vertical downward thrust of the push arm, thereby
The variable topology design can also be used for the dynamic pushing the missile to move downwards at a high speed. After
performance optimization of other parallel high-speed flexible reaching a certain distance, the missile leaves the launcher at a
actuators. certain speed and attitude. The y-shaped mechanism at the front
end of the launch device is designed to be longer than the y-shaped
2. Dynamics model of the missile ejection based on a fixed mechanism at the rear end. The launch mechanism has an assembly
topological launcher height of 109 mm in initial contraction state and an ejection stroke
of 350 mm. Ejection stroke represents that the missile is separated
The dynamics model of the missile ejection process is based on from the launcher structure, after 350 mm downward of the mass
the combination of the finite element method and the multi-body center of the missile from the initial position.
dynamic Lagrange equation. Considering the complexity of the
mechanism model, the mechanical components that flexible pro-
2.2. Lagrange dynamic equation for multi-flexible mechanism
cessed in finite element software (ANSYS) are assembled according
to the actual motion constraint pair.
The multi-flexible dynamics is described by using the coordi-
Firstly, the modal analysis of each flexible component is carried
nate system as shown in Fig. 2, which consists of the inertial
out via the finite element software (ANSYS), and the modal neutral
file is generated, which is required by the multi-body dynamics
software (ADAMS) for multi-flexible body dynamics modeling. Af-
ter the components being assembled according to the actual mo-
tion constraint pairs, the ejection power is set up. Finally, the virtual
prototype simulation model of the ejection mechanism of airborne
missile is established.
The detailed flexible process of components can be divided into
four steps:

1) Three-dimensional (3D) modeling

Fig. 1. The configuration of the AMELT launcher in its initial stage: 1. Structure of the
Components with simple shapes can be directly modeled in ejection mechanism, 2. Front support arm, 3. Front push arm, 4. Horizontal hydraulic
ANSYS. But for those of complex shapes, the modeling can be built piston rod, 5. Rear support arm, 6. Hydraulic actuated cylinder, 7. Rear push arm, 8.
in software Unigraphics NX (UG) or other professional 3D modeling Missile.
434 H. Liu et al. / Defence Technology 16 (2020) 432e438

2) Potential energy W

Potential energy W includes two parts: gravity potential energy


and elastic potential energy, which can be expressed by Eq. (8):

1
W ¼ xT K x (8)
2

where K is the stiffness matrix of structural components, corre-


sponding to the modal coordinates of q.

3) Dynamic equation of Multi-flexible bodies

Lagrange equation for flexible bodies is described by:


8
>
>  
Fig. 2. Kinematic relations in the flexible body coordinate system. >
> h iT
< d vL  vL þ vG þ vJ l  Q ¼ 0
>
_
dt vx vx vx _ vx (9)
>
>
coordinate system (er) and the floating coordinate system (eb). The >
>
>
: J¼0
former does not change with time, and the latter is to describe the
movement and deformation of the flexible body, which is changed
with the deformation of the flexible body. among them: J is constraint equation; Q is generalized force
In the coordinate system er, the motion of any point P on the projected in defined generalized coordinates x ; l is Lagrange
flexible body can be decomposed into a rigid translation and a rigid multiplier corresponding to the constraint equation; L is the
rotation relative to the system origin, or a deformation motion Lagrange term, defined as L ¼ T-W. Then the final differential
relative to the floating coordinate system. The positional motion of equation is:
P relative to G can be expressed as:  
1 vM _ T _ vJT
  M€x þ M_ x_  x x þ Kx þ l¼Q (10)
r ¼ rB þ A sp þ up (1) 2 vx vx

where r for the vector of point P in the inertial coordinate system;


rB is the vector of the origin of the floating coordinate system in the
inertial coordinate system; A for the transformation matrix; sp is 3. Dynamics simulation analysis of ejection process of a fixed
the vector of point P in floating coordinate system when the flexible topological launch mechanism
body is not deformed; up for the deformation vector of point P,
calculated by the modal coordinates: The simulation and analysis are performed on missile speed, the
missile angular velocity and the vertical thrust, under the condi-
up ¼ Fp q (2) tions of multi-rigid ejection mechanism and the multi-flexible
ejection mechanism. As the missile ejection device is a high-
where FP for the assumed deformation modal matrix at point P that precision mechanism, the assembly clearance of each joint is not
satisfies the ritz basis vector requirement, q is the generalized co- considered in this study.
ordinate of deformation.
3.1. Main simulation parameters
1) Kinetic energy T
Table 1 shows the main simulation input parameters of the
The position, direction and mode of any node P before and after airborne missile ejection dynamics model. The front support arm,
deformation in the generalized coordinates of the flexible body are the front push arm, the rear support arm and the rear push arm are
defined as: made of aluminum alloy, with an elastic modulus of E ¼ 70  109
and the Poisson's ratio is 0.3. The missile is treated as a rigid body.
x ¼ ½x y z j q f qi ði ¼ 1; /; nÞT ¼ ½r j qT (5) The material of the piston rod is high-strength alloy steel, with an
elastic modulus of E ¼ 210  109, and the Poisson's ratio is 0.3.
The kinetic energy T of the flexible body is:
3.2. Simulation results
1 T
T ¼ x_ MðxÞx_ (6)
2 The dynamic simulation analysis of the ejection process is car-
The mass matrix MðxÞ is the 3  3 dimension matrix, which can ried out, under the assumption of the multi-rigidity ejection
be expressed as: mechanism and the flexible state of the mechanism, respectively. In
the flexible simulation model, the front support arm, the front push
2 3
arm, the rear support arm, the rear push arm, and the horizontal
6 M Ttt M tr M tm 7
piston rod are flexibly processed in finite element software.
MðxÞ ¼ 6
4 MTtr M rr M rm 7
5 (7)
Fig. 3 shows the ejection power generated by the horizontal
M tm M Trm M mm
hydraulic cylinder. The first 10 ms is the ejection power establish-
ment phase, with a peak value of 58367 N at 10 ms. After that, the
where t, r, and m are the translational, rotational and modal degrees ejection power gradually decreases. The missile and the launcher
of freedom, respectively. are separated at 110 ms, with a power value of 26788 N.
H. Liu et al. / Defence Technology 16 (2020) 432e438 435

Table 1
Main simulation parameters.

The main parameters Numerical value

Front support arm size/m3 0.29  0.08  0.03


Front push arm size/m3 0.58  0.08  0.03
Rear support arm size/m3 0.28  0.08  0.03
Rear push arm size/m3 0.56  0.08  0.03
Launcher initial height/m 0.109
Piston rod length/m 0.6796
Missile weight/kg 320
Pitch moment of inertia/(kg,m2) 210
Ejection stroke/m 0.35
The horizontal distance between the gravity center of the 0.2
missile and the lower end of the rear push arm/m

Note: The unit of length is m and the unit of weight is kg. The pitching moment of
inertia of the missile is relative to its center of gravity.

Fig. 5. Angular velocity of the missile during ejection process.

demonstrates that the angular velocity at separation time is 23


deg/s, while the value is þ3 deg/s at the time of ejection separation
for the flexible mechanism. It can be seen that the flexibility of the
mechanism has a great influence on the separation angular veloc-
ity. For the air-to-air missile, the ejection angular velocity range is
about 20 ± 10 deg/s.
For air-to-air missile ejection separation of angular velocity, to
ensure that a missile can rapidly away from the aircraft after sep-
aration, missiles should have certain downward angular velocity.
Normally, this downward angular velocity generally should be
greater than 15 deg/s. Therefore, it seems that a downward
angular velocity of 23 deg/s could well meet the requirements of
the multi-rigid design. However, Fig. 5 shows that the angular ve-
Fig. 3. Horizontal hydraulic ejection force. locity of the flexible mechanism is þ3 deg/s, which does not fit the
range of 20 ± 10 deg/s. It is already in the “head-up” angular
velocity state and may fly towards the carrier, giving a serious
Fig. 4 shows the separation speeds during the missile ejection
threat to launch safety.
process. It indicates that, under multi-rigid body conditions (black
The analysis of the vertical force on the missile induced by the
line in Fig. 4), the speed between the missile and the launching
push arms can better explain the reason of “head up” problem of
device is 7.7 m/s at the time of separation; the blue dotted line is the
the missile during ejection process. Fig. 6 is the downward force on
simulation result of the flexible mechanism, with a separation
the missile induced by the front and rear push arms, under multi-
speed of 7.85 m/s. As the difference between the two results is
rigid and multi-flexible simulation conditions, respectively.
small, the flexibility of the mechanism has little effect on the sep-
As shown in Fig. 6, the force from the front push arm is in a
aration speed.
continuously increasing state, and its value is 14057 N at the time of
Fig. 5 shows the angular velocity of the missile during ejection
ejection separation; while the rear push arm force is in a contin-
process. Among them, the simulation result of the multi-rigid body
uous increase state in the early stage but sharply reduced in the

Fig. 6. The downward force on the missile by the front and rear push arms under the
Fig. 4. Separation speed simulation during missile ejection. multi-rigid and multi-flexible body conditions.
436 H. Liu et al. / Defence Technology 16 (2020) 432e438

later period, with a force of 14631 N at the time of ejection mechanism continues to operate until the missile is separated from
separation. aircraft.
Simulation results demonstrate that after enabling the mecha- During the ejection process, the mechanism performs a topo-
nism flexibility, the vertical force results of the front and rear push logical transformation when the rotating shaft reaches the rear end
arms on the missile shows significant difference with that of the of the U-shaped gap. The front pushing arm is changed from the
multi-rigid dynamics model, especially at the end of the ejection, rotating and the sliding to the relative rotation with respect to the
where the force of the front push arm is decrease rapidly instead of piston rod, that is, the movement of the Prismatic-Revolute (PR)
continuously increasing. The force is 9732 N at the time of sepa- pair is changed to a Revolute (R) pair. Therefore, the U-shaped gap
ration; In contrast, for the rear push arm, its value continues topology design here is referred to as the Prismatic-Revolute-
increasing instead of decreasing at the end, reached 34072 N at the Revolute (PR-R) kinematic pair. After the topology of the mecha-
time of ejection separation. nism is changed, the ejection power is provided by both the front
Therefore, the huge force changes of the missile by the front and and rear push arms instead of only rear arm.
rear push arms could result in seriously deviating from the ideal
design value of the angular velocity of the missile at the moment of 4.2. Dynamic contact force model of the PR-R kinematic pair
ejection separation, even the occurrence of “head-up”, which
seriously threatens the safety of missile launch. Consequently, to In the case of the variable topology design, the rotation pair
resolve this problem, it is necessary to reduce the influence of adopted in the fixed topology mechanism is not fit as the motion
thrust force change caused by the front push arm and the rear push constraint of the front push arm, the horizontal piston rod and the
arm. Specifically, in the last stage of the ejection process, the force rotating shaft. Instead, the contact force between the rotating shaft
acted by the front push arm should be increased, while the force of and the horizontal piston rod is used to judge whether the rotating
the rear push arm needs to be decreased. shaft and the horizontal piston rod have the interaction force.
While considering the practical design of the structure, the front
4. Dynamics simulation analysis of ejection process using push arm and the rotating shaft continue to adopt the rotation
variable topological design constraint.
The model of normal contact force F of PR-R motion constraint
4.1. Variable topological design of ejection mechanism considers both the material stiffness at the contact location and the
damping effect in impact event. In this case, the classical Lankarani-
To prevent the angular velocity of the airborne missile from Nikravesh dynamics model [18] is used:
deviating from the designed value, it is necessary to suppress the
flexibility effect of the entire ejection mechanism. Considering that F ¼ K dn þ C d_ (11)
the ejection time is only 0.11 s and the ejection force reaches up to Among them: K for the contact stiffness of the rotating shaft and
several tons, the existing flexible suppression methods of various the horizontal piston rod at the gap, 5  107 N/mm is taken in this
mechanisms have great limitations. paper. C for the damping coefficient of the contact, d for embedding
Fig. 7 is the variable topology design of ejection mechanism. At depth, n for the index coefficient, take 2.2 in this paper. The rela-
the hinge of the shaft hole of the front main arm and the horizontal tionship between multiple groups of embedded depth d and con-
piston rod, a clearance having a specific direction and size is tact force F can be calculated according to the structural design
designed in the rotary hole, which is different from the random parameters at the hinge of the launching mechanism by using the
machining error generated during manufacturing. The clearance finite element method, and then K and n in Eq. (11) can be deter-
designed in this research is a horizontal U-shaped gap located mined by combining results of the least square method and engi-
behind the rotating shaft. In the initial state, the rotating shaft is neering experience.
located at the front of the U-shaped gap.
 
In the initial stage of ejection, due to the existence of horizontal 3 1  e2
U-shaped gap, the piston rod cannot apply force on the front push C¼ K (12)
4d_ 0
arm. The ejection power of the piston rod can only act on the
missile via the rear push arm. During the ejection process, the
where e is the material recovery coefficient of the horizontal plug
rotating shaft in U-shaped gap slips backward, reaching the rear
rod structure, take 0.8 in this paper; Pc5-
end of the U-shaped gap after the mechanism stretching a certain
Antarctica_JASTP_keywords_V2 is the initial relative velocity
distance. The horizontal piston rod then can generate horizontal
when the rotating shaft is in contact with the horizontal piston rod.
force on the rotating shaft, further pushing the front push arm
which acts on the missile in vertical downward direction. The
4.3. Simulation results and analysis

The simulation was conducted on the forces of the front and rear
push arm, and the ejection separation angular velocity of the var-
iable topological ejection mechanism after using the PR-R gap pair.
The PR-R gap in the simulation model is set to 2 mm.
Fig. 8 is a normal contact force at the PR-R gap pair. It shows that
the rotation axis of the PR-R gap pair begins to contact with the
piston rod at 6.7 ms, and the contact force is 18700 N. At this
moment, the topological form of the ejection mechanism changes.
Before that, the piston rod has no force applied on the front push
arm. While after that, the piston rod has a force on the front push
arm, and the force gradually increases, reaching a peak of
24542 N at 55 ms, and then the contact force gradually decreases
Fig. 7. Variable topology design of ejection mechanism. and approaches zero at 110 ms.
H. Liu et al. / Defence Technology 16 (2020) 432e438 437

Fig. 8. Contact force at the PR-R gap.


Fig. 11. Separation angular velocity simulations for different gap sizes.

Fig. 9 shows the missile displacement during ejection process.


At 6.7 ms, the missile is in the initial position of the ejection Before 6.7 ms, the vertical force of the variable topology ejection
compared with the entire ejection stroke of 350 mm, with only mechanism to the missile is 0; after about 50 ms, the variable to-
0.4 mm downward displacement. Therefore, the topology switch- pology design is adopted, and the force by the front push arm is
ing of the variable topology mechanism completes in the initial higher than that of the fixed topological mechanism, while the rear
startup phase. push arm has a smaller force on the missile than that of the fixed
The purpose of the clearance design is to change the acting force topology mechanism. Therefore, the variable topology mechanism
on the missile by the front and rear push arm at the last stage of the can generate a larger pitch down torque on missile in the late stage
ejection process, further to avoid the “head up” problem of the of the ejection, preventing the missile from “heading up” event.
missile. Fig. 10 shows the influence of clearance design on the Fig. 11 shows the separation angular velocities of missile with
vertical force acted by the front and rear push arms on the missile different sizes of PR-R gap pairs. It is simulated under the gaps of
during the ejection process. 0 mm, 0.5 mm, 1 mm, 1.5 mm, and 2 mm, respectively.
Results show that the larger the gap, the higher the angular
velocities. With the gap size of 2 mm, the missile achieves the same
separation angular velocity of 23 deg/s as in the condition of
multiple rigid bodies at the time of separation. It can be seen that
the PR-R gap pair can greatly adjust the ejection separation angular
velocity of the airborne missile ejection mechanism to ensure the
safety of the launch.

5. Discussion

In order to facilitate readers to reproduce the simulation process


and results, the mechanism in this paper is a simplified mechanism
of the original mechanism, and the members of the mechanism are
given in simple shape, namely rectangular members with holes,
without considering the mutual structural interference of the
members during the assembly of the mechanism and during the
Fig. 9. Missile displacement during ejection process. movement process. The fabrication and subsequent verification of
the experimental mechanism require cutting and grooving of the
interferential parts of the mechanism during assembly and move-
ment. However, the shape of such mechanism components is
relatively complex, which is not suitable for readers to simulate and
reproduce. Therefore, there is no experimental data of physical
prototype which is completely consistent with the virtual proto-
type state in this paper. However, this design has been verified by a
real object prototype and has a good effect of inhibiting the flexible
effect of the mechanism. After optimization design, the ejection
separation parameters consistent with the rigid hypothesis can be
achieved.
Readers can manufacture a physical prototype for experimental
verification based on the design parameters provided in the paper,
and the design parameters of the reader's physical prototype does
not need to be completely consistent with those in the paper. The
relevant design data of ejection mechanism given in this study is
Fig. 10. Effect of clearance design on ejection force of the front and the rear push arm. sufficient for readers to simulate and reproduce the results.
438 H. Liu et al. / Defence Technology 16 (2020) 432e438

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