Topology Optimization of Additively-Manufactured, Lattice-Reinforced Penetrative Warheads

Abstract

Two different scaled penetrative warheads were developed using additive manufacturing processes in 15-5 stainless steel. The first warhead design had a singular unitary case based solely on existing penetrating warhead designs. The second warhead design was a modification of the first, where the nature and location of new internal members and lattice structures was determined using topology optimization methods. The relative physical properties of the two warheads were calculated using HyperWorks, a commercial finite element analysis software. Once these analyses were finalized, production of the warheads was accomplished using direct metal laser sintering. The two warheads will be live-fire tested at Eglin AFB, FL. The analysis and physical testing will validate the ability of additively manufactured warheads to penetrate targets, the ability of lattice structures to perform well in impact loading environments, and the utility of topology optimization methods for warhead design.