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This study details the design, analysis, and optimization of a two-stage gas gun system, emphasizing structural integrity and dynamic gas performance. The pressure vessel and first-stage chamber, engineered to withstand pressures up to 10,000,000 Pa, were evaluated through integrated analytical methods and ANSYS APDL numerical simulations. Analytical stress calculations for the reservoir yielded circumferential, axial, and radial stresses of 32.8 MPa, 11.4 MPa, and −10 MPa, respectively, aligning closely with numerical results showing deviations of 2.16, 8.16, and 9.83%. Numerical assessment of the rupture disc confirmed failure at 4,000,000 Pa, with induced stresses reaching 526 MPa, surpassing the material’s ultimate tensile strength of 515 MPa. Dynamic analysis of gas combinations identified Helium-compressed air as the optimal configuration, achieving the highest velocity ratio of 0.1545 alongside a temperature reduction from 1309.05 to 686.33 K. The dual-method validation underscores structural reliability under extreme pressures, while gas dynamics analysis establishes Helium-compressed air as superior for rapid pressure attainment. These findings offer actionable insights for enhancing gas gun systems, prioritizing robustness, efficiency, and performance in high-pressure applications.

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First-Stage Optimization and Structural Integrity Analysis in a Two-Stage Gas Gun System: Enhancing Initial Propulsion Dynamics

  • 会议论文

  • 发表日期：

    2026年

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  • Arjun Suresh,
  • Surya Sajeev,
  • Ramu Murugan,
  • S. Chidambara Raja,
  • B. Venkataraman

摘要

This study details the design, analysis, and optimization of a two-stage gas gun system, emphasizing structural integrity and dynamic gas performance. The pressure vessel and first-stage chamber, engineered to withstand pressures up to 10,000,000 Pa, were evaluated through integrated analytical methods and ANSYS APDL numerical simulations. Analytical stress calculations for the reservoir yielded circumferential, axial, and radial stresses of 32.8 MPa, 11.4 MPa, and −10 MPa, respectively, aligning closely with numerical results showing deviations of 2.16, 8.16, and 9.83%. Numerical assessment of the rupture disc confirmed failure at 4,000,000 Pa, with induced stresses reaching 526 MPa, surpassing the material’s ultimate tensile strength of 515 MPa. Dynamic analysis of gas combinations identified Helium-compressed air as the optimal configuration, achieving the highest velocity ratio of 0.1545 alongside a temperature reduction from 1309.05 to 686.33 K. The dual-method validation underscores structural reliability under extreme pressures, while gas dynamics analysis establishes Helium-compressed air as superior for rapid pressure attainment. These findings offer actionable insights for enhancing gas gun systems, prioritizing robustness, efficiency, and performance in high-pressure applications.