UNIVERSITI TEKNIKAL MALAYSIA MELAKA

THE USE OF SNAKEHEAD FISH BEHAVIOR IN ROUND NOSE

BULLET DESIGN

This report submitted in accordance with requirement of the Universiti Teknikal

Malaysia Melaka (UTeM) for the Bachelor Degree of Manufacturing Engineering

(Manufacturing Design) with Honours.

By

SITI ZULAIHA BINTI MOHD AZAM

B051110017

920626105464

FACULTY OF MANUFACTURING ENGINEERING

2015

DECLARATION

I hereby, declared this report entitled “A Study of Bullet’s Profile Design using

Snakehead Fish’s Aerodynamic Concept” is the results of my own research except as

cited in references.

Signature : …………………………………………………………

Author’s Name : …………………………………………………………

Date : …………………………………………………………

APPROVAL

This report is submitted to the Faculty of Manufacturing Engineering of Universiti

Teknikal Malaysia Melaka (UTeM) as a partial fulfilment of the requirements for the

degree of Bachelor of Manufacturing Engineering (Manufacturing Design) (Hons.).

The members of the supervisory committee are as follow:

…………………………………………………..

(Supervisor)

…………………………………………………

(Co-Supervisor)

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ABSTRACT

In this modern era, the conflicts and violence acts are increasing which give an

impact to the manufacturing of bullet due to the demand is high. Thus, the

manufacturing industry has to improve the performance and design efficiency of the

bullet in order to fulfil the market requirement. One of the issues that the

manufacturer has to face is the aerodynamic effects on the bullet. The shape of the

bullet will determine the impact and aerodynamic features of the bullet and the

effectiveness of bullet can be maximized by improving the shape of the bullet. The

concept of nature design of snakehead fish (BID) is then proposed to overcome this

effectiveness issue. Round Nose Bullet is chosen as an existing design due to have

the similar profile when compared to the snakehead fish. SolidWorks

SimulationXpress and ANSYS Fluid Flow (FLUENT) are the software utilized in

this research study. The results obtained in Linear Static Analysis depict that the

improvement design tends to be mushroom shape due to the greater deformation

while the Von Mises Stress is then small. Based on the computation of Newton

interpolation polynomial, the prediction of fatigue can be obtained. From the

computation, the existing design will experience the failure mode when the initial

pressure applied, x ≥ 300.921526× while for improvement design is x ≥

472.250888× . Besides that, consistency of bullet design is also measured by

employing Coefficient of Variation (CV). Based on the calculation of CV,

improvement design has the lowest percentage when compared to existing design.

Due to that percentage, this bullet design has increased in the number of the spin of

the bullet which makes the bullet more stable during trajectory. Therefore, the

snakehead fish profile design applied in improvement design is better than an

existing design due to the structural and dynamic analyses that are shown.

i

ABSTRAK

Pada zaman ini, konflik dan keganasan sering berlaku sehingga memberi kesan kepada pembuatan peluru kerana permintaan yang tinggi. Oleh itu, industri pembuatan peluru perlu mempertingkatkan prestasi and kecekapan rekabentuk untuk memenuhi keperluan pasaran. Salah satu isu yang dihadapi oleh pengeluar adalah kesan aerodinamik terhadap peluru. Rekabentuk peluru akan menentukan kesan dan ciri-ciri aerodinamik peluru itu dan keberkesanan peluru boleh ditingkatkan sehingga maksimum dengan cara mempertingkatkan rekabentuk peluru. Konsep rekabentuk semulajadi ikan haruan telah dicadangkan untuk menangani isu keberkesanan ini. Round Nose Bullet telah dipilih sebagai rekabentuk sedia ada kerana profil peluru ini serupa dengan profil ikan haruan. Perisian SolidWorks SimulationXpress dan ANSYS Fluid Flow (FLUENT) akan digunakan dalam kajian ini. Hasil kajian yang akan dapat dari analisis Statik linear adalah rekabentuk penambahbaikan cenderung menjadi bentuk cendawan kerana perubahan yang ketara manakala Von Mises Stress adalah kecil. Berdasarkan interpolasi polinomial Newton pengiraan, ramalan ‘fatigue’ boleh didapati. Pengiraan tersebut menunjukkan rekabentuk sedia ada akan berada dalam keadaan gagal apabila nilai tekanan awal yang telah diaplikasikan, x ≥ 300.921526× manakala untuk rekabentuk penambahbaikan nilai x ≥ 472.250888× . Selain itu, rekabentuk peluru yang konsisten diukur dengan menggunakan pekali variasi (CV). Berdasarkan hasil keputusan CV, rekabentuk penambahbaikan mempunyai peratus yang terendah berbanding dengan rekabentuk sedia. Oleh kerana peratus tersebut, rekabentuk peluru ini telah meningkatkan jumlah putaran peluru yang menyebabkan peluru lebih stabil semasa trajektori. Oleh itu, profil ikan haruan yang telah diaplikasikan sebagai rekabentuk penambahbaikan adalah lebih baik daripada rekabentuk sedia ada kerana disebabkan oleh struktur dan analisis dinamik yang telah ditunjukkan.

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DEDICATION

Specially dedicated to my father, Mr. Mohd Azam Bin Hj. Muzakir and my

mother, Mrs. Siti Rabunah Binti Talip who are very understanding, caring,

patient and supporting for help me mentally. Thanks a million to my lovely

siblings, honorable lecturers and dearest friends for the guidance, patient and

encouraging in my final year project. My prayers upon you will be embedded

in my lips whenever I go and whenever I think of you.

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ACKNOWLEDGEMENT

In the name of Allah, the Most Gracious and the Most Merciful.

Alhamdulillah, all praises to Allah, the Almighty, on whom ultimately we depend for

sustenance and guidance. I am grateful to Allah S.W.T for giving me enough

strength and His blessing in completing this thesis. For without the help He has given

along with His permission, all may not have been completed. Mr. Saifudin Hafiz Bin

Yahaya has been the ideal thesis Co-Supervisor. His sage advice, insightful

criticisms and patient encouragement aided the writing of this thesis in innumerable

ways. He inspired and motivated me to contribute tremendously to this project and

has given me a lot of innovative ideas in solving all the obstacles which rises. Once

again, I would like to thank him for all comments and amendments he has given me

with his patience towards my deficiency. Thanks a million to Mr. Baharuddin Bin

Abu Bakar whose faithful support of this thesis was greatly needed and deeply

appreciated. My acknowledgement also goes to all the technicians especially Mr.

Jazlan and Mr. Saiful which help me and teach me to use the software. Sincere

thanks to all of my classmates and to those who have been helping directly or

indirectly in completing this thesis. All of my hard work will mean nothing without

the inspirational and motivational from all of them. Lastly, I am forever indebted to

my beloved family, who understanding the importance of this thesis suffered my

hectic working hours. For they, has given me the strength to complete this report

entirely and I will always be grateful for having them as my family. ‘Gracias.’

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TABLE OF CONTENTS

Abstrak i

Abstract ii

Dedication iii

Acknowledgement iv

Table of Content v

List of Tables viii

List of Figures ix

List of Equations xii

List of Abbreviations, Symbols and Nomenclatures xii

CHAPTER 1: INTRODUCTION 1

1.1 Background of The Research Study 1

1.2 The Application of BID’s Concept 6

1.3 Problem Statement 10

1.4 Research Objectives 11

1.5 Research Scope 12

CHAPTER 2: LITERATURE REVIEW 14

2.1 History of The Bullet 14

2.2 Ammunition 15

2.3 Bullet Terminology 17

2.4 Types of Bullet 18

2.4.1 Round Nose Bullet 18

2.4.2 Hollow-point Bullet 19

2.5 Bullets Ballistic 20

2.5.1 Internal Ballistic 20

2.5.2 External Ballistic 22

2.5.3 Terminal Ballistic 23

2.6 Conclusion 24

vi

CHAPTER 3: METHODOLOGY 26

3.1 Method of Research 26

3.2 Bullet’s Profile Design 28

3.2.1 Improvement Design: Snakehead Fish Concept 29

3.2.2 Existing Design: Round Nose Bullet 31

3.3 Method of Analysis 34

3.3.1 Linear Static Analysis 34

3.3.2 Fatigue Analysis 37

3.3.3 Dynamic Analysis 41

CHAPTER 4: LINEAR STATIC AND FATIGUE ANALYSIS 44

4.1 Linear Static Analysis 44

4.1.1 Meshing Process 48

4.1.2 Boundary and Loading Conditions 53

4.1.3 Material Selection 56

4.1.4 Stress and Displacement Distributions 58

4.1.5 Safety Factor 62

4.2 Newton Interpolation Polynomial as a Fatigue Predictor 64

4.3 Design Efficiency of The Models 69

4.4 Conclusion 70

CHAPTER 5: DYNAMIC ANALYSIS AMONGST THE MODELS 72

5.1 Dynamic Analysis 72

5.1.1 Creating a Fluid Flow (FLUENT) Analysis System 76

5.1.2 Creating The Geometry in ANSYS DesignModeler for Fluid Flow

(FLUENT) 77

5.1.3 ANSYS Meshing in Fluid Flow (FLUENT) Package 79

5.1.4 Setting Up The Boundary Conditions amongst The Model 82

5.1.5 Velocity, Pressure and Coefficient of Variation amongst The Models 85

5.2 Conclusion 93

CHAPTER 6: CONCLUSION AND RECOMMENDATIONS 94

6.1 Conclusion 94

vii

6.2 Recommendations 95

REFERENCES 97

APPENDICES

viii

LIST OF TABLES

1.1 Several of biological models applied for Abalone Armor 8

1.2 Kevlar and Abalone types of vest 8

4.1 The mesh information of existing and improvement designs 52

4.2 The properties of Ti-6Al-4V Solution treated and aged (SS) 57

4.3 Stress and displacement results for existing and improvement designs 60

4.4 The results of stress and safety factor for both designs 65

4.5 The pressure applied and safety factor for both designs 67

4.6 Divided difference for Newton interpolation polynomial for existing

design 67

4.7 The initial pressure for both designs 68

5.1 The elements and nodes amongst the models 81

5.2 Mechanical Properties of Air 82

5.3 The results obtained in the ANSYS software for dynamic analysis 88

5.4 The statistical values in the models 90

ix

LIST OF FIGURES

1.1 The Dolphin 2

1.2 The ship that have a pear-shaped of bow protuberance 2

1.3 The Shark 3

1.4 The wing of aircraft 3

1.5 The viewing nature as a design model, measure and mentor 4

1.6 The process flow diagram of the problem-driven BID processes 5

1.7 The process flow diagram of the solution-driven BID processes 6

1.8 The Abalone Shell 9

1.9 The Kevlar Body Armor 9

1.10 The direction of the aerodynamic force 10

1.11 The example of snakehead fish 11

2.1 The major parts of an ammunition 15

2.2 Anatomy of an ammunition 16

2.3 The diagram of a projectile (Hendrick et al., 2007) 18

2.4 Round Nose Bullet 19

2.5 Hollow-Point Bullet 20

3.1 The overview of entire process flow diagram of the research study 27

3.2 The snakehead fish 29

3.3 The process flow diagram of 2D sketching and 3D design model for

bullet’s profile using snakehead concept design 30

3.4 The 2D sketch of bullet’s profile using snakehead fish design concept 31

3.5 The solid model of bullet’s profile using snakehead fish design

concept 31

3.6 Round Nose Bullet 32

x

3.7 The process flow diagram of 2D sketch and 3D design model Round

Nose bullet’s profile 33

3.8 The 2D sketch of Round Nose bullet’s profile design 33

3.9 The solid model of Round Nose bullet profile 34

3.10 The sample meshing of bike wheel hub for TET10 element 35

3.11 The process flow diagram of Linear Static Analysis for both existing and

improvement designs using SolidWorks software 36

3.12 The process flow diagram of fatigue analysis for existing and improvement

models 38

3.13 The process flow diagram of the detailed fatigue predictor using

Newton interpolation 40

3.14 The overall flow diagram of the simulation process using ANSYS

Software 41

3.15 The process flow diagram of dynamic analysis using ANSYS

software 43

4.1 Example mesh of Methane Carrier components 48

4.2 The unstructured mesh (left) and structured (right) of a model 49

4.3 The typical mesh elements 50

4.4 The example of meshing process of improvement (left) and

existing (right) design 51

4.5 The example of TET4 (above) and TET10 (below) on a shaft 52

4.6 The fixed boundary conditions such on improvement design 54

4.7 The example of mushroom shape on a bullet 54

4.8 The direction of force in improvement design 55

4.9 The pressure conditions in improvement design 56

4.10 The simulation of Von Mises stress, on existing (left) and

improvement (right) designs at P = 450× N/ 59

4.11 The simulation of displacement (d) on existing (left) and

improvement (right) designs at P = 450× N/ 60

4.12 The curvature of improvement (left) and existing (right) designs 70

5.1 The ANSYS DesignModeller interface in ANSYS software 77

xi

5.2 The geometry created in ANSYS Fluid Flow (FLUENT)

package (Improvement Design) 77

5.3 The types of surface element for 3D mesh 79

5.4 Axisymmetric solid elements 80

5.5 The meshing process in existing (left) and improvement (right) designs 81

5.6 The boundary conditions in ANSYS Fluid Flow (FLUENT) package 82

5.7 The example of reference value 83

5.8 Velocity contour for existing (above) and improvement (below) designs

at = 600 85

5.9 Pressure contour for existing (above) and improvement (below) designs

at = 600 86

5.10 The distribution of amongst the models 91

5.11 The distribution of pressure amongst the models 92

xii

LIST OF EQUATIONS

2.1 The equation of Kinetic Energy 22

3.1 The equation of factor of safety 37

3.2 The equation of linear interpolation polynomial 37

3.3 The Newton interpolation polynomial equation after substitution 38

4.1 The equation of force 46

4.2 The calculation of system equation in linear static analysis 47

4.3 The order of polynomial equation 66

4.4 The common simplified form of polynomial 66

4.5 The equation of design efficiency 69

4.6 The equation of curvature 70

5.1 The equation of linear dynamic equilibrium 72

5.2 Governing Equation for mass conservation 73

5.3 Governing Equation for momentum conservation 73

5.4 Governing Equation for momentum energy 74

5.5 The equation of Coefficient of Variation 89

xiii

LIST OF ABBREVIATIONS, SYMBOLS AND

NOMENCLATURE

3D – Three Dimensional

BID – Biolgically-Inspired Design

CAD – Computer-Aided Design

CFD – Computational Fluid Dynamics

CV – Coefficient of Variation

d – Displacement

DE – Design efficiency

FDM – Finite Different Method

FEA – Finite Element Analysis

FEM – Finite Element Method

FVM – Finite Volume Method

P – Pressure

PDF – Partial Differential Equation

– Safety factor

TET10 – Tetrahedral Elements

– Input velocity

– Velocity

– Von Mises Stress

1

CHAPTER 1 INTRODUCTION

This chapter contains the general ideas of the research study which provided four

main sections such as the project background and problem statement. Besides, the

research objective of this study is stated in this chapter. This chapter 1 ends with the

description of the research scope.

1.1 Background of The Research

In this era of globalization, designers and engineers have to solve problems by

searching for inspiration. In general, inspiration is defined as a force or influence that

inspires human by nature, person, place and many more. One of the alternatives of

inspiration that help designers and engineers are about the nature (Volstad and Boks,

2012). This inspiration by nature is an excellent source for designers and engineers

who want to inspire processes, functions, ideas, behaviours and structures to convert

from biological knowledge to engineering knowledge (Konez, 2011). It is because

the nature provides an important model to solve designer’s problem and engineer’s

problem (Denis and Carlos, 2014). For example, by using the nature as an

inspiration, the ship is innovating with the nose of the dolphin as the model

(Anonymous, 2005). As the result, the nose of the dolphin creates a pear-shaped of

bow protuberance that enables the ship to have less resistance of water while sailing

and give a lower of fuel consumption. Figure 1.1 and Figure 1.2 show the picture of

Dolphin’s nose and the picture of the pear-shaped on the ship.

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Figure 1.1: The Dolphin (Anonymous, 2010)

Figure 1.2: The ship that have a pear-shaped of bow protuberance (Anonymous, 2009)

Besides, the rough skin of the shark give the engineer an inspiration to develop a

striped foil coating for the wings of aircraft. This innovation give benefit to aircraft

which are the friction is low until six percents (Anonymous, 2005) and saving on fuel

consumption. Figure 1.3 and Figure 1.4 show the rough skin of the shark and the

picture of aircraft’s wing.

3

Figure 1.3: The Shark (Anonymous, 2008)

Figure 1.4: The wing of aircraft (Kuki, 2014)

Thus, the example stated on previous is known as biomimicry. At the 21st century,

this biomimicry method becomes more interest and challenging amongst the

engineer. It is challenging because it requires a breadth of knowledge in biology as

well as engineering to fit the biological to the engineering (Weissburg, 2014).

Moreover, Avinash (2014) said that biomimicry also recognized as Biologically-

Inspired Design (BID).

Chakrabarti (2014) noted that BID is the design with inspiration from nature and

developing a creative design to solve engineering problems. It is defined as a practice

of taking ideas and concepts from the nature and implementing them into various

fields such as design, engineering and architecture (Elmahdi, 2008). Since 1960s, the

4

BID has become important in improving the design and generating innovative ideas

(Freitas, 2013). Benyus (1997) claimed that the objectives of BID are looking to the

nature as a model, nature as a measure and nature as a mentor. Figure 1.5 depicts the

viewing nature as a design model, measure and mentor.

Figure 1.5: The viewing nature as a design model, measure and mentor (Curricula, 2009)

The nature as a model is referred to as the inspiration solution to solve such as the

human problem in the field of science and technology (Chang, 2012). While, nature

as a measure means to find out the accuracy of innovation in ecological and the

nature as a mentor is used as a source where the characteristic and behaviour of the

nature is imitated for science and technology purpose (Chang, 2012).

Moreover, the behaviour of BID can be employed in order to develop the related

solution, especially in engineering problem. For instance, the wind turbine is

redesigned by using whale fins as an inspiration. The researcher want lessen the

noise generated by wind turbine and to improve the reliability of the wind turbine

(Andy, 2009). Thus, this inspiration helps the wind turbine decreased the drag force,

doubled the performance at speeds of 17 miles per hour, reduce turbulence over the

surface and create more efficient of wind turbines (Anonymous, 2010). Benyus

(1997) said that BID is a vital and well-known application in design method that

fulfilled the environmental and sustainable development.

5

In general, this BID has two approaches of processes which are problem-to-solution

and solution-to-problem. The problem-to-solution recognized as the problem-driven

BID process needs to identify a problem, biologize the problem and the problem is

solved biological (Vattam et al., 2007). Specifically, problem-driven BID process

involves problem definition that need to define a specific or detectable problem of

human life and for problem decomposition, it require understanding properly the

meaning of the problem. While, biologize the problem means to innovate the

problem in biological terms. In biological search, it needs to develop a solution that

relate with the biological system. Continuously, understand the principles and

techniques that used by the biologist to solve the problem via observation and

experimentation. In principle extraction step, necessitates knowing the constraints of

the solution that acquire. Lastly, the possible principles such as Hooke’s Law will be

discovered and apply the principle in project research. Figure 1.6 shows the

procedures of the problem-driven BID process.

Figure 1.6: The process flow diagram of the problem-driven BID processes

On the other hand, the solution-to-problem or also known as solution-driven BID

process includes the application biologically inspired solution, principle extraction

Problem Definition

Problem Decomposition

Biological Search

Define the Problem

Principle Extraction

Principle Application

Biologize the Problem

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and principle application (Vattam et al., 2009). The process begins with the

biological solution identification which is observing the biological solution with the

casual study. In define the problem, it needs to understand the problem properly and

the principles that used to solve the problem. Then, implement the applicable

principles that must be suited to the engineering field.

In the problem search, it requires to know the constraint of the solution and define a

new problem or stay in the previous problem. The last procedure is principle

application which leads to apply the possible solution principle in the problem which

then solved smoothly. Figure 1.7 shows the procedures of the solution-driven BID

process. The next section will be explained about some of example that using BID

concept.

Figure 1.7: The process flow diagram of the solution-driven BID processes

1.2 The Application of BID’s Concept

This section will be described the design project that successfully used Biologically-

Inspired Design (BID) method. Abalone Armor is one of the examples of the

Biologically-inspired design project. Abalone Armor is a bullet-proof vest which

used material that combines the qualities of strength, toughness, and self-healing

Biological Solution Identification

Define the Problem

Principle Extraction

“Humanize” the Problem-Solution Pair

Problem Search

Principle Application

7

properties. This project had used solution-driven BID approach and problem-driven

BID approach to solve the problem. Firstly, the team for this project is determined to

use abalone shell or also known as nacre as their inspiration. Then, prepared and

organized the problem that could be solved by the impact-resistant nacre. The team

uses the abalone nacre to settle the problem of conceptualizing a bullet-proof vest.

By using the problem-driven approach, several characteristics in combination the

quality of material which are the strength, toughness and self-healing is chosen. For

the step of biologize the problem, search the organism that had the same

characteristic as mentioned above and investigated six alternative biological sources

of inspiration. Based on Table 1.1, there are six biological models that had been

considered in this project. This table shows the reason for considering and the reason

for rejecting. The first biological model is spider silk. The spider silk is considered

due to its strength per weight ratio and it is rejecting due to possible to manufacture

and not strength enough to avoid from knife wounds.

Then, the lobster exoskeleton is considered because it ability to blunt cracks by using

overlapping plates but the process requires water in order to be effective and would

not scale-up to level required by body Armor. Next, the reason for considering the

sea star is its ability to generate entire structure from a small fraction of its original

mass. While, the reason for rejecting is the process of regeneration is only available

to bring organism and cannot be replicated in inorganic materials. The rhino horn is

considered because the strength and it is able to regrow, but it had been rejecting due

to unknown rejecting. Besides, human bone is being considered because the strength,

ability to regrow and modestly flexible. It has been rejected due to healing properties

of bone are not viable under normal circumstances and requiring a suspension in a

solution of calcium.

The Abalone shell has been chosen as a source of inspiration due to the toughness,

strength, and ability to reform itself. Then, focused on how abalone nacre reacted

when it was applied on the forces at variety of time scales including the fracture

characteristic on the bullet impact like fracture stress, minimum of initial crack size,

strength intensity and surface energy. Table 1.1 depicts the biological models that

considered in Body Armor design.

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Table 1.1: Several of biological models applied for Abalone Armor (Vattam et al., 2007) BIOLOGICAL

MODEL REASONS FOR CONSIDERING

REASONS FOR REJECTING

Spider Silk Strength to weight ratio. Manufacturing on the industrial scale is not currently possible and not resistant to knife wounds.

Lobster Exoskeleton Ability to blunt cracks (dampen fractures as occur) using overlapping plates.

This process requires water in order to be effective and would not scale-up to level required by body armor.

Sea Star Ability to generate entire structure from a small fraction of its original mass.

The regeneration process (through cell division) is only available to living organism and cannot be replicated in inorganic materials.

Rhino Horn Strength and its ability to re-grow (the same way that finger nails re-grow).

Unknown.

Human Bone Strength and its ability to re-grow. Also, it is modestly flexible.

Healing properties of bone are not viable under normal circumstances, requiring a suspension in a solution of calcium.

Abalone Shell Toughness, strength, and ability to reform itself.

Accepted

The analysis (as shown in Table 1.2) showed that body armor made from abalone

shell would be one hundred times powerful to stop a bullet. The characteristic of self-

healing mechanism was excluded from the criteria due to the mechanism was not

well understood. In addition, Abalone Body Armor would ten times heavier than

Kevlar Body Armor. Despite there is a light-weight characteristic, the problem

definition does not state about the weight characteristic. Thus, the team had chosen

Abalone Body Armor as their biological inspiration for bullet-proof vest problem.

Table 1.2 depicts the different between Kevlar and Abalone Vest. Figure 1.8 and 1.9

shows the picture of Abalone shell and Kevlar Body Armor.

Table 1.2: Kevlar and Abalone types of vest (Vattam et al., 2007)

CRITERIA KEVLAR ABALONE Thickness 0.6 cm 0.9 cm Weight 2.3 kg 20.5 kg Stress 2.6x GPa 2.5x GPa