Hexagonal Embossment Pattern for Drawn Cup Warhead Fragmentation
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Solution Overview
Problem
Current fragmentation munitions face challenges with irregular fragment distribution and energy transfer efficiency, particularly in cylindrical warheads with domes, where traditional scoring methods lead to suboptimal spread and size consistency, and machining or additive manufacturing are costly and impractical.
Innovation Solution
A frangible munitions device with a combined embossment pattern featuring inner regular hexagonal embossments on the dome and outer pre-deformed hexagonal shapes on the cylinder, which distort to produce regular hexagonal fragments upon explosive rupture, optimizing fragment distribution and energy transfer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional scoring methods (stamped or machined shapes) are used in cylindrical warheads with domes, then manufacturing is simplified, but fragment distribution becomes irregular and energy transfer efficiency decreases
Solution Approach 1:
The warhead case is segmented into multiple embossed regions with different geometric patterns (hexagonal, triangular, quadrangular, octagonal, circular) distributed across the cylindrical and domed surfaces. Each embossed region acts as a independent fragmentation zone that controls the formation and distribution of fragments with specific shapes and sizes, ensuring uniform fragment distribution while maintaining manufacturing simplicity through stamping processes.
Solution Approach 2:
Different embossed patterns and geometries are applied to different local regions of the warhead case - hexagonal patterns in certain zones, triangular in others, quadrangular, octagonal, and circular patterns in remaining zones. This local variation in embossment quality and geometry optimizes fragment characteristics for specific directional distributions, improving overall fragment uniformity while using standard stamping manufacturing methods.
2Manufacturing precision
If embedded projectiles are used, then fragment mass and size consistency is improved, but energy transfer efficiency from explosive to fragments decreases
Solution Approach 1:
The invention extracts and eliminates the embedded projectile component from the warhead design, using only a solid case construction. The case itself is embossed with various geometric patterns that directly form the fragments upon explosive rupture. This removal of the embedded projectile eliminates the energy loss associated with breaking the case, improving energy transfer efficiency while the embossed patterns ensure consistent fragment mass and size.
Solution Approach 2:
The embossed patterns are pre-formed into the case during manufacturing before the explosive is installed. These pre-formed embossed regions create predetermined weak planes and stress concentration zones that guide the fragmentation pattern upon explosive rupture. This preliminary structuring of the case ensures consistent fragment characteristics without requiring embedded projectiles, thereby improving energy transfer efficiency.
3Use of energy by moving object
If solid warhead cases with welding assembly are used, then energy transfer efficiency is improved, but production flexibility and explosive filling options are limited
Solution Approach 1:
The invention merges the case construction into a single solid piece with embossed patterns, eliminating the need for welded assembly of multiple components. This unified solid case structure maintains high energy transfer efficiency while the embossed geometric patterns provide the necessary fragmentation control. The solid construction allows for greater flexibility in explosive filling options compared to welded assemblies, as it removes welding-related constraints on explosive selection and placement.
4Manufacturing precision
If Pearson Notches are machined into cylindrical walls, then fragment pattern is optimized, but manufacturing cost and complexity increase significantly
Solution Approach 1:
The invention replaces the complex mechanical machining process required for Pearson Notches with a simpler embossing or stamping process. Instead of machining precise notches into the cylindrical wall, geometric patterns (hexagonal, triangular, quadrangular, octagonal, circular) are embossed onto the case surface. This substitution maintains fragment pattern optimization while dramatically reducing manufacturing complexity and cost, as embossing is a more straightforward forming process than precision machining.
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 solution achieves a consistent and regular pattern of fragments with improved energy transfer, enhancing the munition's effectiveness in dispersing fragments of consistent mass and size, thereby increasing the probability of hitting a target within the effective radius.
Implementation Method 1
yields a plurality of fragments having shapes corresponding to a predetermined embossment pattern upon explosive rupture
Data Source
AI summary
Provided is a frangible munitions device optimized for a dome and cylinder that yields fragments having shapes corresponding to a predetermined embossment pattern upon explosive rupture. The embossment pattern includes a first set of inner regular hexagonal embossments formed into the dome and cylinder that are aligned with the axis of the cylinder, and a second set of outer pre-deformed hexagonal shapes that distort to produce regular hexagonal shapes after drawing into the cylinder wall. The second set of shapes are separated by sharp transition regions. The shapes are embossed in a repeated pattern around the hollow cylinder and the dome top. The dome yields a plurality of fragments having shapes corresponding to the first set of inner regular hexagonal embossments upon explosive rupture, while the cylinder yields a plurality of fragments having shapes corresponding to the second set of outer pre-deformed hexagonal embossments upon explosive rupture.