Impact of an Additively Manufactured Projectile

A projectile has been designed and experimentally impacted against a concrete structure taking into account the viscoplasticity of an additive manufactured stainless steel. To ensure material survival, a topology-optimized interior structure capable of providing necessary stiffness to the projectile was incorporated. Loads applied to the topology optimization were resolved using an impact simulation calibrated to match test results of previous research in the field. Two designs were created by this method, and the survivability of each design was evaluated using finite element analysis (FEA) to determine the stress responses generated against a load simulating impact. Scaled test articles consisting of control and optimized designs were manufactured via Direct Metal Laser Sintering (DMLS) in 15-5 stainless steel and tested against monolithic concrete surfaces. Test results validated the project concept, the design methodology used to determine the structural layout. A static Finite Element analysis was performed of the completed design to determine if the stress field exceeded certain limitations. Results of this research prove thin-walled, internally-supported, additively manufactured penetrators are capable of surviving high energy impacts. Also, this work shows the potential for design and production of projectiles tailored uniquely to their intended impact. © 2017, Society for Experimental Mechanics, Inc (outside the US).