Composite Sabot Manufacturing via Stitched Fiber Lamination and VARTM
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Solution Overview
Problem
Conventional aluminum sabots for APFSDS systems are heavy, leading to reduced propulsion efficiency and penetration strength due to low adhesive strength in radial directional lamination and susceptibility to delamination under bending stress, which increases production costs and material costs with high-strength resin use.
Innovation Solution
A method involving the lamination of fiber mats with various orientations, followed by stitching with long fiber bundles to enhance circumferential shear strength, and subsequent resin-injection vacuum-assisted resin transfer molding (VARTM) to produce a lightweight, 3-dimensional fiber-reinforced composite sabot.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If radial directional lamination with prepreg ply is used to improve shear strength, then circumferential shear strength is improved, but adhesive strength in the lamination direction deteriorates causing delamination susceptibility
Solution Approach 1:
The patent combines two different lamination methods (radial directional lamination and axial/circumferential lamination) to create a composite structure that leverages the strengths of each approach while compensating for their weaknesses, achieving both high shear strength and adequate adhesive strength
Solution Approach 2:
The patent introduces a third dimension by stacking multiple layers with different lamination orientations (radial, axial, circumferential) to create a three-dimensional fiber architecture that simultaneously provides shear strength and resistance to delamination
2Reliability
If aluminum alloy is used for sabot manufacturing to ensure endurance against shearing stress, then reliability is improved, but weight increases reducing propulsion efficiency
Solution Approach 1:
The patent replaces aluminum alloy with fiber-reinforced composite materials that provide comparable or superior mechanical properties while significantly reducing weight, thereby improving propulsion efficiency without sacrificing reliability
Solution Approach 2:
The patent changes the material composition parameters by using high-strength fibers (carbon, glass, or aramid) combined with resin matrices to achieve the required mechanical properties at lower density compared to aluminum alloy
3Strength
If high-strength resin is used to improve material properties, then strength is improved, but manufacturing cost increases
Solution Approach 1:
The patent applies high-strength resin only in specific critical areas where maximum strength is required, while using standard resin in non-critical areas, thereby achieving the required material properties while controlling manufacturing costs
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The method reduces sabot weight by 30% compared to aluminum sabots, improves adhesiveness, and enhances durability against expansion pressure, enabling efficient propulsive force delivery and stable flight while reducing production time and costs.
Implementation Method 1
resin-injection vacuum assisted resin transfer molding
Implementation Method 2
forming composite material by inserting the pre-formed fabric object into resin-injection VARTM apparatus and performing resin-injection VARTM
Data Source
AI summary
Disclosed is a method for manufacturing a fiber-reinforced composite sabot for use in APFSDS (Armor. Piercing Fin Stabilized Discarding Sabot) wherein a plurality of fiber mats are laminated instead of one-directional prepreg ply and whole part is reinforced by stitching through long fiber bundle in order to enhance circumferential shear strength, and high quality fiber-reinforced composite sabot is manufactured in a short time using resin-injection vacuum assisted resin transfer molding after stitching.