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Transcript of Page 1 VS. CONVENTIONAL ROLLING – CONVENTIONAL PRESSING SHEAR ROLL MILL – TWIN SCREW EXTRUDER...
Page 1
VS.
VS.
CONVENTIONAL ROLLING – CONVENTIONAL PRESSING
SHEAR ROLL MILL – TWIN SCREW EXTRUDER
VS.
Page 2
ATK SRM / Indian Head TSE
I. Conventional vs. SRM/TSEII. HistoryIII. Motor Data – Conventional vs. SRM PelletsIV. SRM Installation
Page 3
CONVENTIONAL PROCESS FLOW
CONING
Rolled PowderSELECTIVE SAMPLINGREAL TIME REVIEW
SLITTING AND CARPET ROLLINGCARPET ROLL
PACK
EVENSPEED PASTE BLENDING
CHEMICALS
PASTE REST
METAL DETECTING
NITROCELLULOSE NITROGLYCERIN & CHEMICALS INTO PROCESSING WATER
SLURRY MIXING
CENTRIFUGEWRINGING
WEIGHING
ANNEALING
PRESSING
SAWING
END INHIBITING
DOWEL RODDING
SPIRAL WRAPPING
CUFF TRIMMING
END SLEEVING
UT/RTR 100% INTERNAL INSPECTION
IN PROCESS AGING
FINAL INSPECTION
LOTTING & PACKING
MAGAZINE STORAGE
Rocket Manufacturing
Nitroglycerin
PREROLL
Page 4
CONVENTIONAL PROCESS
Page 5
SRM / TSE PROCESS FLOW
CONING
Pellet Manufacturing
SHEAR ROLL MILL
PASTE BLENDING
PASTE REST
METAL DETECTING
NITROCELLULOSE, NITROGLYCERIN, & CHEMICALS INTO WATER SLURRY MIXING
CENTRIFUGE WRINGING
WEIGHING
TWIN SCREW EXTRUSION
CUT TO LENGTHNET O.D. EXTRUSION
END INHIBITING &END SLEEVING
SPIRAL WRAPPINGCUFF TRIMMING
RTR 100% INTERNAL INSPECTION
IN PROCESS AGING
FINAL INSPECTION
LOTTING & PACKING
MAGAZINE STORAGE
MK90 Grain Manufacturing
NG Area
PELLET STORAGE & CONDITIONING
UT INSPECTION
Page 6
SRM /TSE PROCESS
Page 7
SRM MILESTONESATK Funded/ATKMANTECH/ARDECESTCP/Indian HeadNot Funded
4/99 ATK Blended Paste for Germany11/99 ATK & IH Participated in SRM Trials in Germany4/00 ATK Rolled remaining paste into Carpet Roll6/00 N00174-00-C 0011 – ATK Shipped 100 Lbs. of Inert Simulant to IH7/00 IH TSE 1st Trials w/ Inert Simulant1/01 ATK Received AA-2 Pellets from Germany3/01 ATK Shipped AA-2 Pellets to IH4/01 N00174-01-C-0002 – ATK Shipped 200 Lbs. of Inert Simulant to IH5/01 ATK & ARDEC Participated in JA-2 SRM Modeling in Germany6/01 ATK Rolled Pellets into Carpet Roll7/01 ATK Extruded Grains from Conventional CR & SRM Pellet CR10/01 ATK Fired Grains from both Lots12/01 N00174-01-C-0002 – IH TSE 1st AA-2 runs1/02 ATK Shipped JA-2 Pellets to ARDEC
Page 8
SRM FUTURE GOALS
ATK Funded/ATKMANTECH/ARDECESTCP/Indian HeadNot Funded
10/02 ATK Installation of 200mm SRM at Radford11/02 DAE30-02-R-0810 – SRM Modeling Phase II – ATK installation of
Thermal Imaging Camera 12/02 ATK Completion of 200mm SRM Live Proveout1/03 DAE30-02-R-0810 – SRM Modeling Phase II – ATK SRM AA-2 Trials1/03 N00174-01-C-0002 – IH TSE AA-2 Grains w/ New Die3/03 N00174-01-C-0002 – ATK Process & Fire Grains from IH SRM/TSE
Grains6/03 N00174-01-C-0002 – Optimization of SRM & TSE Process1/04 N00174-01-C-0002 – ATK Complete Plan & Cost Estimate
for Full Scale SRM/TSE Production Facility
Page 9
SBR @ 165°F
0.6
0.65
0.7
0.75
0.8
0.85
Pressure
SB
R (
in/s
ec)
Conventional CR CR from Pellets
Page 10
SBR @ -65°F
0.4
0.45
0.5
0.55
0.6
0.65
0.7
1200
1600
2000
2400
2800
Pressure
SBR
(in/
sec)
Conventional CR CR from Pellets
Page 11
CHEMICAL ANALYSIS
Ingredient Conventional CR SRM CR
% NC 51.82 51.17
% NG 38.33 38.48
% TA 2.35 2.37
% DNPA 2.12 2.10
% 2-NDPA 2.01 1.99
% LC-12-15 3.33 3.59
Page 12
GRAIN DIMENSIONS
Measurements Conventional CR SRM CR
Length (in.) 31.379 31.380
OD (in.) 2.568 2.568
ID (in.) 1.270 1.272
Aft web (in.) 0.658 0.656
Forward Web (in.) 0.655 0.652
Weight (lbs) 7.600 7.600
Page 13
BALLISTIC RESULTS
Normal NormalParameter Production Normal Pellets Production Normal Pellets
Action Time(sec) 1.164 1.139 1.148 1.026 1.032 1.025
Impulse(lbf-sec) 1490 1480.3 1480.2 1538 1527.6 1528.5
Max Thrust(lbf) 1650 1651.5 1650.8 1951 1879.5 1901.7
Spec. Impulse(lbf-sec/lb) 213.3 213.0 213.0 220.2 219.7 219.9
SRM SRMCold Motors @ -50°F Hot Motors @ +150°F
Page 14
Shear Roll Mill Pilot Plant Layout
Page 15
SRM & PELLET CONVEYOR
Page 16
SRM & PELLETIZER
Page 17
PASTE CONVEYOR & LIW FEEDER
Page 18
PASTE HOPPER & CONVEYOR
Nitrocellulose Based Propellant Manufacturing Waste Minimization
Wayne Thomas
Naval Surface Warfare Center
Indian Head Division
PROGRAM OBJECTIVESAT INDIAN HEAD
• Produce a MK 90 propellant grain from SRM pellets and reduce the amount of waste generated at extrusion.
• Test fire grains in heavy weight hardware.
Continuous Processing of AA2 Pellets
• 4 processing runs on the 40 mm extruder have been carried out.
• The run objectives were to familiarize Indian Head with processing double base pellets in a safe manner on a twin screw extruder and to exercise our processing equipment with double base.
• Our first objectives were met and we have reached several conclusions.
AA2 EXTRUDED GRAINS
• The first double base grains extruded at Indian Head were extruded through tooling that was originally designed for extruded composite propellant. The grains were well consolidated and dimensionally stable.
FIRST GRAINS
• The grains from the first extrusion were smaller than the die diameter.
• For the next extrusion we changed extrusion parameters.
• We changed extrusion temperature and rate. Reducing temperature and increasing extrusion rate.
SECOND ATTEMPT
• We attempted to change extrusion parameters and we found that consolidation would be a problem as we attempted to change grain dimensions.
CONCLUSIONS
• We were unable to control grain dimensions. • This has led us to pursue the design of a MK
90 die. • We have procured hardware to help us with
collecting the rheological data that is needed for the design.
• At our current extrusion parameters we are operating safely.