Materials & Manufacturing Process Date: 26-01-2023

Problem statement:
Attacking Military robotics is an important field within computer-based military technology.
Future armed conflicts will be characterized by the increased use of, and reliance upon, military
robots. One of the distinctive features of ‘robo-wars’ is that, unlike previous conflicts, they will
be fought with unmanned or uninhabited weapons. Unlike a tank where a group of soldiers is
located inside the vehicle, there are no soldiers inside the robot. In some cases, soldiers may be
located thousands of miles away from the battlefield. In this respect, ROBOWAR is a combat
competition which is organized by different institute in Pakistan. The only way to win the fight is
that you have to pin down or destruct the opponent robot. The fittest one will survive in this
event. Robots may be equipped with mechanical weapons such as hammer and claws etc.

Robot Classes :
The combat robotics community spreads across the entire world, with major competitions
happening on almost every continent. Combat robots are divided into different weight classes
based on the robot’s overall weight, and within those classes an amazing number of weapon
types are possible. In this guide we’ll introduce you to all of the most important weight classes
and weapons.

1. Selecting Appropriate Materials:

(a) Structure:

Aluminum Alloy (6061-T6): Aluminum is lightweight and strong, making it suitable for the
robot's frame. The 6061-T6 alloy provides excellent strength-to-weight ratio and corrosion
resistance.

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Materials & Manufacturing Process Date: 26-01-2023

Steel (High Carbon): High carbon steel can be used for critical load-bearing components like
axles and joints due to its high tensile strength and durability.

(b) Attack Systems:

Hardened Steel:

For weapon components like hammer and claws, hardened steel offers superior durability and
sharpness.

Polycarbonate:

Clear polycarbonate can be used for armor or shielding, providing transparency while still being
impact-resistant.

Rubber or Urethane:

These materials can be used for shock absorbers and wheel tires to improve traction and absorb
impact.

2. Manufacturing Processes:
(a) S tructure:

CNC Machining:

For precise shaping and cutting of aluminum alloy components.

Welding: To join steel components, ensuring strength and stability.

Attack Systems:

Precision Grinding:

To shape and sharpen hardened steel weapon components.

Injection Molding:

For producing polycarbonate parts like shields.

3D Printing:

For custom-designed components like connectors or brackets.

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Materials & Manufacturing Process Date: 26-01-2023

3. Comparing Properties and Environmental Implications:

(a) Material Properties:

Aluminum Alloy (6061-T6):

Lightweight, corrosion-resistant, recyclable.

Steel (High Carbon):

High strength, durability, but heavier and less corrosion-resistant.

Hardened Steel:

Excellent durability, but not easily recyclable.

Polycarbonate: Impact-resistant, lightweight, recyclable.

Rubber/Urethane: Good shock absorption, may not be easily recyclable.

Available Properties Selected

Aluminum alloy Light weight Selected

Corrosion resistant

Good strength

Titanium Light weight Not selected

High strength

Corrosion resistant

Expensive

Carbon fibre Light weight Not selected

Corrosion resistant

High strength

high stiffness

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Materials & Manufacturing Process Date: 26-01-2023

Aluminum Characteristics
Aluminum is lightweight, durable, malleable and corrosion-resistant. This metal is widely used
for components in the aerospace, transportation and construction industries.

 Non-corrosive
 here to help 200Easily machined and cast
 Lightweight yet durable
 Non-magnetic and non-sparking
 Good heat and electrical conductor

Applications for Aluminum:

 Electronic casings
 Electrical transmission lines

(b) Manufacturing Processes:

CNC Machining:

Precise but can produce waste material.

Welding:

Effective, but consumes energy and may produce emissions.

Precision Grinding:

Efficient for shaping but may produce grinding dust.

Injection Molding:

High production efficiency but consumes energy.

3D Printing: Highly customizable, can reduce material waste when used efficiently.

(c) Environmental Considerations:

Choosing recyclable materials like aluminum and polycarbonate helps reduce environmental
impact.

Minimizing waste during manufacturing processes and optimizing designs can reduce resource
consumption.

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Materials & Manufacturing Process Date: 26-01-2023

Energy-efficient manufacturing processes and recycling efforts should be part of the production
plan to mitigate environmental effects.

Attacking Military Weapon Robot:

Anti-Tank Missiles:

These are designed to penetrate heavy armor and can be effective against heavily armored
UGVs. Examples include the TOW missile and the Javelin missile.

Rocket-Propelled Grenades (RPGs):

RPGs are portable and can be used against lightly armored UGVs. They are often employed by
infantry units.

Grenades and Explosives:

Hand-thrown grenades, as well as other explosive devices, can be used to damage or disable
robots if thrown or placed accurately.

Machine Guns and Automatic Rifles:

These can be used to target vulnerable points on the UGV, such as sensors or joints. It's
important to note that some military robots may have armor that is resistant to small arms fire.

Anti-Aircraft Weapons:

In some cases, anti-aircraft weapons like anti-aircraft guns or surface-to-air missiles may be used
against flying UGVs or drones.

Electromagnetic Weapons:

Directed energy weapons (DEWs) that use electromagnetic energy can disrupt or damage the
electronic components of UGVs, rendering them inoperable.

Explosive Ordnance Disposal (EOD) Robots:

These specialized robots are designed to neutralize explosive devices. They may use disruptors
or water cannons to disable other UGVs.

Hacking and Cyber attacks:

Cyber warfare techniques can be employed to hack into the control systems of military robots,
potentially taking over their operation or disrupting their communication.

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Materials & Manufacturing Process Date: 26-01-2023

Artillery and Mortars:

Larger UGVs may require heavy artillery or mortars to damage or destroy them. These indirect
fire weapons can be used to engage targets from a distance.
Method Required :
We mostly used casting for the manufacturing of all the part and and also using grinder to make
the sharp edges.

Casting
Casting is a manufacturing process in which a liquid material is usually poured into a mold,
which contains a hollow cavity of the desired shape, and then allowed to solidify. The solidified
part is also known as a casting, which is ejected or broken out of the mold to complete the
process.

Casting method:

Different Types of Casting Process

 Sand Casting Process.
 Gravity Die Casting.
 Pressure Die Casting.
 Investment Casting.
 Plaster Casting.
 Centrifugal Casting.
 Lost-Foam Casting.
 Vacuum Casting.

and we used the sand casting its make the difficult parts more easily.
Process
There are five steps in this process

 Place a pattern in sand to create a mold.

 Incorporate the pattern and sand in a gating system. Remove the pattern.
 Fill the mold cavity with molten metal.
 Allow the metal to cool.
 Break away the sand mold and remove the casting.
 Haandform-e.png

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