KIRAN:March

DRDO Science Spectrum, LOW SHOCK STAGE

2009, pp. SEPARATION SYSTEM FOR LONG RANGE MISSILE APPLICATION
227-229
© 2009, DESIDOC

Low Shock Stage Separation System for Long Range Missile Application

Ch Surya Kiran
Advanced Systems Laboratory, Kanchanbagh, Hyderabad-500 058

ABSTRACT
Stage separation mechanism is very mission critical operation in long range missile systems. However the current
trend is to look for a very low shock system during stage separation transition. Since the explosive shock generated
will sometimes lead to the malfunctioning of the critical flight passenger packages in the mission.To tackle such a
situation a low shock stage separation mechanism has been designed, developed, qualified and deployed for a specific
missile application successfully. This new concept of stage separation system has been configured for upper stages
of AGNI variants.The same concept is going to be implemented in long-range missile systems due to the low shock
features incorporated in the mechanism. This paper deals with the journey of the mission critical mechanism from design
to development.
Keywords : Mission-critical system, stage separation mechanism missile application

NOMENCLATURE confidence level 90%. Redundancy in cartridge functioning

BM = bending moment
Fn = force in the bolt due to bending moment
PCD = pitch circle diameter of stage bulkhead
db = bolt diameter at neck
D 0 = outermost diameter of pyrobolt
JRC= joint rotation constant
Fc = force developed by pyro pressure on bolt head
μ = co-efficient of friction between contact surfaces
α = Engagement angle
1. INTRODUCTION
The separation mechanism consists of a pyrocartridge,
a round-head bolt, and a segmented (4 segments) ring with
arrestor. This assembly is kept locked, before operation
by a locking pin. Bolt head is designed to get engaged
into the collet. Radial movement of collet is restricted by
using the arrester. Arrester is locked with casing by locking
pin. Pyrocartridge is fired to exert pressure on to the bolt
head. Since the bolt is arrested from moving in the direction
of applied force, the arrestor itself starts moving (after
shearing the locking pin) due to the reaction force in the
opposite direction. This movement of the arrestor makes
the segmented ring to move radially outward, thereby clearing
the bolt head to move in the direction of the applied force.
The segments of the ring are held into the casing and the
stages are separated with very low shock.
2. FEATURES OF SEPARATION MECHANISM
Separation mechanism contains a double squib
Pyrocartridge. Pyrocartridge requires 4 amp. current for
15ms to operate. Reliability of pyrocartridge is 0.9997 with
is provided 100% by double bridge system. 2) The separation
mechanism is designed for 15 ton load. It has outer most
diameter 44 mm and contains flange to mount it on the
interstage-bulkhead of one of the stage. 3) Operational
separation mechanism shock is found 500g to 2000g for
25ms to 50ms duration. 4) The Gases after expansion remain
contained and segments are remains in separation mechanism
housing after function i.e. no fling debris at the time of
function. This ensures safety of nearby mountings.
3. DESIGN DETAILS
3.1 Loads at Separation Interface
Maximum axial force, bending moment and shear force
on the separation interface are predicted for static and
dynamic loading on missile.
Axial force 65kN
Bending moment 133kN-m
3.2 Estimation of Tensile Force on Bolt
Two stages of missile are joined together using pyrobolt
and nut. The intersection joint is subjected to bending
moment. This bending moment is transfer to the bolt as
tensile forces. These forces have been calculated in two
ways.
In the first method, it is assumed that the tension
in bolt developed due to the bending moment is proportional
to the distance of the bolt from the bottom edge of the
section. Assuming n (even number) number of bolts are
necessary and sufficient to withstand loads. All the bolts

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of the joint will be in tension and joint will try to open N Fn Ft db F1 Do JRC
about N-A axis Fig. 2. Bending moment (BM) at the joint KN KN mm kN M m Rad/N-mm
will be taken by bolts and is equal to Σ2Fixi . 6 26096.5 63113.69 11.2 25488.0 44 4.29 x 10 -13

BM = Σ 2F ix i, Where F i = tension in bolt no. 'i' 8 19072.7 45767.8 8.5 18272.8 38 8.7716e-010

xi = Perpendicular distance of bolt 'i' from N-A axis = ( r-

r.cosθ i ) Fo = Fc /4 . Sinα . Cosα ( 1- μ2 ) – 2.μ .Fc /4 . Cos2α
where r = pitch circle radius When arrester is released, Fo = 0,
Force acting on bolt is proportioned to its distance from So tanα = 2μ / ( 1-μ2)
N-A axis. Pyrocartridge develops 2500 kgf force. Friction coefficient
F i = K ( r-rcosθ i ) between bolt head and collet is taken 0.2 for steel to steel
contact. It is found that system is in equilibrium, when
Therefore, BM = 2Kr2 Σ (1-cosθi )2 α = 23 0. Taking engagement angle 60 o. Radial outward
force on collet Fo = 197.3 kgf and friction force against
= Kr2 . 3n/2 the movement of collet is F r= μ S + α R Cosα= 49.8 kgf.
Therefore, Fn = 2.BM.r / 3n r2 ( 1-cosθ n ) Force acting on collet is 3.9 times the friction force acting
against the movement of collet.
since cosθ n =-1
3.3 Bolt head-Collet Engagement Design
Fn = 8.BM/3.n.PCD
The second method assumes that the bolt develop Maximum load which separation mechanism can take
forces according to beam bending theory. The maximum is equal to the strength of the bolt at the neck i.e. (YS
force in bolt is given by x A b). The bolt head and collet engagement is designed
for this load. It is found with FEA and break load testing
F1 = (BMxPCDxAb)/(2xIsy) that bolt head diameter should be 1.25db and bolt head
where PCD= pitch circle diameter height should be 0.25d b-. Fig 4.

Ab = bolt cross-section area 3.4 Outermost diameter of separation mechanism

Isy = Ib + Ab Σ xi2
Ib = moment of inertia of the bolt
xi = distance from neutral axis
Force on the bolt is calculated with both the methods
for different number of bolts in joint and given in table.
F t =Total force at the bolt = F P+ k.F + F A
Where FP = pre-tightening force at bolt
= 20,000N
k = basic load factor = λp/λb+λp = 0.43
λp = co-efficient of pliancy of bolt
λb = co-efficient of pliancy of flange
FA = force on one bolt due to axial force at intersection
joint
Bolt material is selected En-24, heat-treated to35+2
HRC. Yield strength of the material is 100 kg/mm 2. With
factor of safety 1.3, Bolt Diameter is given in the above
Table.
Bolt - collet engagement angle:
In equilibrium, R = Fc / 4 Cosα , see fig.5
Σ FH = 0 = F1 + μR Cosα - Fc /4 . Cosα . Sinα ,
Σ FV = 0 = S - μ R Sinα - Fc /4 . Cos2α ,
S = μ Fc /4 . Sinα . Cosα + Fc /4 . Cos2α
Outermost diameter of bolt is inner diameter of casing
plus twice the thickness of casing. Inner diameter of casing
is critical and it should be greater than the sum of the bolt
head diameter and twice the collet width plus 2.EF (Fig.1).
Otherwise bolt can not come out of collets.
3.5 Joint Rotation Constant
The joint rotation constant is defined as the angular
separation of the joint in radians per unit moment. The
joint rotation constant is evaluated as JRC = θ/ BM = L b/
AbEbΣxi2).
3.6 Locking Pin Design
Locking pin is designed to take vibration and shock
loads. It can take 150 kgf load before it shears. Locking
pin material is En-24, hardness 35+2 HRC. The neck is
provided in pin for clean shear see fig.6. Clean shear at
the neck was observed when shear pin was subjected to
load and it shears at force of 151 to 157 kgf in all the 7
tests.
3.7 Tolerances
1). Close running tolerance is to be given between arrester
and casing. It is observed that when tolerance was
loose, arrester tilted and jammed in casing and did not
free the collets to move.
2). Light push fit tolerance should be given between arrester
and collets to achieve rigid engagement of bolt.
3). Locking pinhead should not press arrester after assembly.

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Otherwise locking pin required more force to shear.
4). Close tolerance on engagement angle should be given
to achieve surface contact between bolt and collets
rather than point contact.
4. TESTING OF SEPARATION MECHANISM
Following tests are done on a batch of separation
mechanism before its use.
4.1 Break load testing
Assembled separation mechanism is subjected to tensile
load on strength testing machine to confirm the load carrying
capacity. Bolt broke from its neck and no damage in other
components, i.e., collets, arrester and casing of separation
mechanism was seen. Three numbers were subjected to
this test and breaking load was 16 tons.
4.2 Functional test with air pressure
An adopter was placed in the threads for pyrocartridge
in place of pyrocartridge and air pressure was given to
pyro bolt cylinder with pressure regulator. Pressure was
increased with slow rate. It was found that at pressure 45
Pyro bolt (Before operation)
Low shock stage separation system (Before operation).
to 52 ksc locking pin shears and bolt is released. All the
separation mechanisms of the batch were tested with air
pressure.
4.3 Functional test with Pyrocartridge
Pyrobolt was mounted in fixture and subjected to load
of 26 ton. Pyro was fired with the supply of current. All
the Five tested separation mechanism functioned.
5. CONCLUSIONS
separation mechanism was designed, developed and
tested. The new concept indigenous low shock stage separation
system has been demonstrated successfully several times
during Full Scale Stage Separation System static test and
flight tests also. This innovative concept can be used for
many applications in various projects and programmes of
DRDO. This concept has been proved to generate very
low shock in the order of below 2000g very near to the
shock source. Presently this type of low shock stage
separation system has been configured for the upper stages
of Agni variants to take the full advantage of low shock
phenomena during stage separation.
Pyro bolt (After operation)
Low shock stage separation system (After operation).
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