Refining FE Structural Mechanics Simulations of a Railgun by Taking Into Account Electromagnetic Effects

Modeling of the structural behavior of the housing of an electromagnetic railgun is usually carried out without considering the electromagnetic origin of the forces; the magnetic pressure acting on the rails is assumed to act at the rail surfaces only. This approximation proves to be a great challenge, as moving pressure profiles at speeds of a railgun projectile are very rare in purely mechanical investigations. In the past, we have published several papers on the structural mechanics of railgun housings characterized by discrete supports. We could show that the displacement of rail surfaces at the position of the armature can reach amplitudes that are not negligible. In fact, in the case of metal brush armatures, the increase in distance between the rail surfaces of only tenths of a millimeter can make the difference between the solid contact and arcing to increase. We also matched our findings to experimental data that were, however, so far only gained in static tests. In this paper, we analyze the foundations of our mechanical modeling using electromagnetic calculations. We calculate a 3-D distribution of the J \times B volume force density in the rails and use them as input for our structural mechanics model. A second point to be addressed concerns the parts made from conducting materials, such as our discrete supports made from steel bolts, which are situated in rapidly changing magnetic fields during the experiments. Again, the influence on our structural mechanics modeling is discussed.