Design of Firing Impulse Simulator and Analysis of Its Key Research
and Development Technologies
Chi He
1
, Guangling Dong
2,3
, Hongquan Wu
3
, Qiang Li
3
and Kun Lu
3
1
School of Mechatronic Engineering, CUST, 7089 Weixing Road, Changchun, China
2
School of Astronautics, Harbin Institute of Technology, 92 Xidazhijie Street, Harbin, China
3
Department of Test Technology, Baicheng Ordnance Test Center of China, Mailbox 108, Baicheng, China
Keywords: Weapon System, Approval Test, Firing Impulse Simulator, Impulse Waveform Simulation, Key
Technology.
Abstract: A key technology problem with respect to approval testing is that of simulating firing impulse in large
calibre weapon systems without firing live ammunition with many problems as high cost, strict
environmental conditions, large numbers of staffing, wide test field, etc. There are two main methods in use
at present: the first method is to carry out numerical simulation of gun firing dynamics with modelling and
simulation (M&S) technology; the second method is to conduct hardware-in-the-loop simulation test with
firing impulse simulator (FIS). The latter types of methods generate impulse effect to simulate gun live
firing from power sources of gunpowder, gas, or liquid. FIS with gunpowder or gas as power source take on
problems as low control precision, complicated operating process, and poor safety. In this paper, a FIS
which transfer test data via CAN (Control Area Net) bus was designed and developed. System composition
and working principle are introduced based on analyzing features of similar products, where key
technologies as counter-recoil analysis, mass and speed choice of pounding head, system safety design are
studied with emphasis. The research results indicate that FIS can be used as an effective supplementary to
live firing in approval test of weapon system.
1 INTRODUCTION
Operational requirements in future wars are making
newer and higher requests on gun weapon system.
Constitutes of modern gun is growing more complex
with higher technology integration level, which
make the utilization of new theory, technology and
materials become an inexorable trend. Improvement
in overall operational effectiveness of gun increases
the cost of development and tests rapidly, which also
causes a longer and longer deployment cycle. In
order to solve this problem, it has become an
inevitable tendency to change the traditional mode
of "manual design to trial-manufacture to test
validation" with new techniques of simulation,
computer and experimental testing, which also
improves development level, shortens development
cycle and saves life cycle expense.
Simulation technology has been used widely in
development and test fields of gun weapon system at
present. The U.S. Army is also applying advanced
simulation technologies, real-time data-sharing
processes and communication architectures to be
able to test multiple weapon systems from different
locations, simultaneously. To make that possible, the
Army’s Developmental Test Command is focusing
on “virtual proving ground” technologies, which rely
on modelling and simulation to create realistic
testing environments (Cast, 2001). The FIS can
simulate the recoil, trunnion loads and ballistic
shock effects for tank and howitzer cannons. Thus, it
can be used to check mechanical structure strength
of weapon system and electrical system reliability,
examine mechanism action, stress-strain in critical
parts of gun carriage, transient response for recoil
and counter-recoil of gun, and inspect the
operational reliability of recoil mechanism,
dependability of trunnion, electrical apparatus, and
other accessories (Sanders and Patenaude, 1996).
In the field of gun firing impulse simulation
technology, experts and scholars focus mainly on
four aspects. The first is utilization and effectiveness
study on gun firing impulse simulation, such as
research report from the U.S. army Aberdeen test
453
He C., Dong G., Wu H., Li Q. and Lu K..
Design of Firing Impulse Simulator and Analysis of Its Key Research and Development Technologies.
DOI: 10.5220/0005511604530460
In Proceedings of the 5th International Conference on Simulation and Modeling Methodologies, Technologies and Applications (SIMULTECH-2015),
pages 453-460
ISBN: 978-989-758-120-5
Copyright
c
2015 SCITEPRESS (Science and Technology Publications, Lda.)
center “Army Combat Systems Test Activity - Best
Manufacturing Practices” (Aberdeen Test Center,
1994) analyzed the economic efficiency of FIS.
James G. Faller (1997) from Army test and
evaluation command of APD analyzed the
convenience of using FIS. The second is design
research on FIS, such as Lang (2012) developed a
shooting simulation device for multi types of
launcher, which could adjust loading attitude and
strength according to launcher type. The third is
testing technology study on key parameters of recoil
mechanism , such as Zhao (2003) realized
measurements for parameters as working pressure
and recoil resistance of recoil mechanism. The
fourth is key technology study on simulator design
and numerical simulation. Professor Yao (2001) and
Dr. Di (2012a) introduced the basic principle of gun
recoil simulation test system, and built numerical
simulation model of recoil dynamics with combined
calculation of gun recoil and interior ballistic
according to system features, where two different
types of gun are simulated to realize dynamics
simulation of recoil and counter recoil. Dr. Di
(2012b) established mechanical model and nonlinear
model of bumper, and calculated its kinematic
equation with fourth-order Runge-Kutta method in
Matlab, which is used to analyze the influences of
impulse mass, impulse speed, bumper linear rigidity,
nonlinear rigidity, and damp on recoil acceleration
of gun barrels. This research provided theoretical
basis for development of gun simulation test
mechanism.
In this paper, we mainly carry out three studies;
the first is on implementation of FIS, where
composition and working principle of controllable
hydraulic technology based FIS are introduced. The
second is on analyzing key techniques in developing
of FIS. The third is about simulated effect validation
of FIS with live firing results. In this way, practical
application problems of simulation in test and
evaluation of gun are solved.
2 SYSTEM DESIGN OF FIS
2.1 Implementation of FIS
2.1.1 FIS with Gunpowder Power Source
Simulation test system is composed of impulse
generator (1), centering mechanism (2) and pedestal
(3). Its structural representation is shown in Figure
1.
As the kernel component of simulation test
Figure 1: Structural representation of simulation test
system.
and piston, which takes on the function of simulating
system, impulse generator is composed of noumenon
gunpowder gas pressure of interior barrel at live
firing, and provides motive force of recoil motion
for gun under test. Centering mechanism guarantees
exact alignment of impulse generator piston axis and
gun-bore axis for reliable, safe, and stable recoil
motion.
As the support platform of simulation test system,
pedestal bears the gravity of testing machine and
resistance to recoil. Impulse generator takes on
elastic fixing instead of rigid connection to pedestal
via a suit of counter recoil mechanism, which
provides elastic and brake force for recoil part of
impulse generator.
Working principle of impulse generator is shown
in Figure 2 (Gao et al, 2014). It is similar to general
gun weapon system except the loaded informal pills
of blank ammunition with minor-caliber and little
dosage, which fires the recoil part of gun instead of
standard ammunition.
Figure 2: Working principle of impulse generator.
In simulation firing test, firing device (1) ignites
gunpowder in combustor (2) first. Then, the
generated propellant gas pushes piston component (3)
to drive the motion of gun muzzle (6) connected on
the other end of piston rod, which realizes the recoil
motion of gun in test. When the front face of piston
moves to vent hole (5) on noumenon, powder gas is
exhausted to atmosphere, which decreases pressure
rapidly. The driving force on piston component
drops down and stops motion by resistance to realize
separation from gun muzzle. After that, recoil part of
gun in test proceeds with inertial recoil and counter
recoil motion. On the other hand, recoil part of
impulse generator is driven to the opposite direction
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by pressure of propellant gas, whose buffer and reset
are realized through combined action of its recoil
apparatus and recuperator.
2.1.2 FIS with Power Source from Strikes of
High Speed Mass Block
As hydraulic power transmission is an easy way to
realize automatic control of high precision
movement with heavy load, it is often adopted as
power source of FIS. Composition diagram of
simulation test device is shown in Figure 3 (Liu et
al, 2011).
The test device is mainly composed of hydraulic
power subsystem and impulse subsystem. Where,
Hydraulic cylinder
Mass
Supporting
frame
Gun muzzle
Impact wave
generator
Hydraulic power
subsystem
Impulse
subsystem
System under test
Figure 3: Diagrammatic sketch of simulating test facility.
hydraulic power subsystem takes on the effect of
generating major flow rate in a short time, hydraulic
cylinder drives mass block to move with high speed.
At certain speed, piston rod and load would separate.
Impulse subsystem is composed of mass block and
bumper, which transmits kinetic energy to recoil part
via strikes of mass block and muzzle bumper. In this
way, it provides energy for recoil motion of gun.
Then, mass block reset under the effect of return
device for next strike. The purpose of above
program is to realize strong transient impulse, which
is centered on by subsystem designing.
2.1.3 FIS in Aberdeen Test Center of U.S.
Army
In 1990s, dynamic simulation test device of gun has
been used in Aberdeen test center of U.S. army in
test and approval process of main battle tank type
M1A2, which took full advantage of simulation test
technology, just as shown in Figure 4 (Aberdeen
Test Center, 2010).
Compared with live firing test, simulated firing
with dynamic simulation test device saved over 20
million dollars in the same year. Therefore, U.S.
military standard MIL-M-45976 stipulates clearly
that “Simulator can be used to carry out test and
evaluation”.
Figure 4: FIS of Aberdeen Proving Ground U.S. army.
The system takes on the following features
(Aberdeen Test Center, 2010):
Facility for testing the mechanical and hydraulic
components (recoil systems, bearings, seals, etc.)
of large caliber weapon systems without firing
live ammunition;
Inputs a repeatable force (up to 3 million pounds-
force) to the system under test to replicate actual
and projected firing loads at elevation from 0° to
85°;
Can be used to conduct life cycle wear, fatigue,
and reliability, availability, maintainability and
durability (RAM-D) tests of weapon systems or
cannon and recoil on a test mount;
Rate-of-fire is dependent upon the impulse level
and test item mounting configuration;
The FIS is also applicable to shock/impulse tests
of mounted electrical components, isolation
mounts, and shock absorption systems;
Indoor facility reduces test costs and
environmental impulse, and eliminates weather
delays;
On-site 32-channel analog and digital Data
Acquisition System is expandable to meet any
test requirement.
2.2 System Composition and Working
Principle of FIS
2.2.1 System Composition
FIS is designed as a distributed control and
measuring system based on CAN bus, which is
mainly composed of the following four parts: (1)
dynamic simulation mechanism; (2) bearing system
of power mechanism; (3) performance parameter
testing end of gun; (4) hydraulic power source.
Dynamic simulation mechanism is shown in Figure
5. Where, dotted line box indicates power source;
solid double lines are hydraulic pipeline connection;
bold solid double line arrows represent nonrigid
connection.
DesignofFiringImpulseSimulatorandAnalysisofItsKeyResearchandDevelopmentTechnologies
455
Industrial control
computer
Display Printer
Power control
front-end computer
Twisted-pair cable > 70 m
Impulse mechanism
front-end computer
Measurement
front-end computer
Electro hydraulic
servo controller
Hydraulic drive
mechanism
Impulse mechanism
Power supply
Impulse head
Wave generator
Muzzle
Gun parameters
under test
Displacement sensor Firing rate sensor
Figure 5: FIS system function block diagram.
2.2.2 Principle of Impulse Effect
There are many impulse generation types as explosion,
gravity, acceleration, electrical driven, hydraulic pressure,
etc. In this design, hydraulic power source is adopted,
which uses momentum transfer principle to simulate firing
impulse of gun. The impulse blow process is shown in
Figure 6.
Figure 6: Principle of muzzle impulse procedure.
As velocity generator (1) accelerates (6) impulse
head (3) to certain speed, impulse head separates (7)
from speed generator. Then, waveform generator (2)
set between gun muzzle (4) and impulse blow head
forms strikes on gun muzzle. In collision process,
transmission of pounding head momenta to gun
forms strong impulse force and acceleration. Where,
control on impulse blow waveform, impulse width,
impulse force and impulse acceleration could be
realized through modulating the stiffness of
waveform generator. After impulse, recovery device
(5) of pounding head retrieves impulse head (9), and
prepares for next impulse test.
3 ANALYSIS ON KEY
TECHNIQUES
3.1 Analysis of Counter Recoil Force
Firing dynamics simulation with gun impulse
simulation test technology is a feasible way for
repeated examination on counter recoil mechanism.
As counter recoil mechanism constitutes the core
component of gun, its comprehensive evaluation
improves safety factor in operation. Forces on
counter recoil mechanism determine forces imposed
on gun carriage, performance parameters of counter
recoil mechanism, and firing stability, etc.
Therefore, working conditions of counter recoil
mechanism determine the forces conditions on gun.
Recoil motion equation is shown in Equation (1).
p
tR
d
d
h
W
M
FF
t
(1)
Variable substitution of t to x in Equation (1) is
made to research relationship between recoil
resistance F
R
and recoil length λ, we get
ddd d
ddd d
WWx W
W
txt x

(2)
According to equation (2), we have
p
tR
d
d
h
W
M
WFF
x
(3)
Integrating Equation (4) from the start of free recoil
to any route point x,
pt R
000
ddd
Wxx
h
M
WW F x F x

2
pt R
00
1
dd
2
xx
h
WFxFx

(4)
At the end of recoil motion, we have x = λW = 0,
so
pt R
00
dd0Fx Fx


(5)
Generally, route λ at the end of recoil motion is far
larger than route x
0k
at after effect time. Namely, at
the end of after effect time, recoil motion would
continue instead of stop. Yet recoil force F
pt
vanishes after x
0k
. So the upper limit λ of integration
in above equation for F
pt
could be substituted by x
0k
,
with result unchanged.
0
pt R
00
dd
k
x
F
xFx

(6)
This equation shows such a conception that the total
power of recoil forces on recoil part equals to that of
resistance to recoil. Let
RR
0
d/
F
Fx
(7)
R
F
is mean resistance, namely the integral mean
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value along the whole recoil length λ, which can also
be expressed as:
RR
0
d/
F
xF
(8)
If the total power
R
0
dFx
of resistance to recoil is a
constant, the relationship between resistance to
recoil and recoil length can easily be seen from
above equation. Namely, as
R
F
increase, λ decreases;
as
R
F
decrease, λ increase. Yet the total power
pt
0
d
k
x
Fx
of recoil force is variable, total power of
resistance to recoil
R
0
dFx
is not a constant. It can be
described as follows: suppose the resistance to recoil
F
R
= F
pt
, then recoil part would not recoil, namely x
K
= 0, total power
pt
0
d
k
x
Fx
equals to zero; if F
R
= 0, i.e.
recoil motion is realized under free recoil conditions,
the route at the end of ulterior period is
x
0k
, the total
power would be
0
pt
0
d
k
x
Fx
, without doubt we can get
a maximal total power at this moment. In this way,
total power of recoil force on recoil part changes
with resistance to recoil. Generally, the selected
resistance to recoil
F
R
is much less than recoil force
F
pt
. Therefore, total power is close to integral value
0
p
t0
0
d
k
x
Fx
, whereas
0k
2
p
t0 0k
0
1
d
2
x
h
Fx MW
.
According to the analysis above, counter recoil
mechanism works as a kinetic energy absorption
device for free recoil motion. While firing on gun
carriage, the total power of recoil force to gun is
equal to that of resistance to recoil, and is
approximately the same size as maximal free recoil
kinetic energy. As long as the shooting momenta (or
impulse) on recoil part of gun can be simulated with
firing impulse simulation test technology, the same
recoil motion characteristics as living firing for
recoil part of gun can be generated, which mainly
include parameters as recoil route length, recoil
velocity, acceleration (recoil kinetic energy), recoil
and counter recoil time, maximal resistance to recoil
and work of resistance, etc.
3.2 Confirmation on Mass and Speed
of Impulse Head
According to impact working principle, as impulse
head is accelerated to certain initial speed v
1
to
impact on gun in test along specified axis direction,
analysis on axis direction can be simplified as shown
in Figure 7.
System under test
Hydraulic
velocity
generator
Impact wave generator
Accelerate to v
Impact mass
Figure 7: The principle diagram of FIS.
Suppose shock pulse generator and recoiling part
take on mass of
m
1
and m
2
respectively, their impact
happens along axis direction. In the shocking
process, shock pulse generator transmits the
momenta to recoiling part, and generates
corresponding impact impulse load. As the internal
force in collision process is far larger than external
force, momentum conservation theorem can be used
for the system composed of these two parts along
axis direction. Thus, we get Equation (9). The
obtained impact momenta
P
2
of recoiling part is
gotten from required integration of impulse load.
11 11 2
mv mv P
 (9)
Where,
m
1
is mass of shock pulse generator; v
1
is
initial impact speed of shock pulse generator;
1
v
is
residual impact speed of shock pulse generator;
P
2
is
the obtained impact momenta of recoiling part.
Using conservation of energy theorem to system
composed of shock pulse generator and recoiling
part before and after impact. As leading end of
shock pulse generator is a stiffness tunable elastic
impact programmer, and back end of recoiling part
is impact cushioning device, their impact is a non-
perfect elastic collision existing kinetic energy
rejection
E
. According to conservation of energy
theorem, we get Equation (10). The obtained kinetic
energy
E
2
from impact is determined by impact
impulse loading curve.
22
11 11 2
11
22
mv mv E E


(10)
Where,
E
2
is the obtained energy after impact
loading on recoiling part;
E
is the lost kinetic
energy in collision process.
Suppose the ratio of specific energy loss to
obtained impact energy of recoiling part is
α.
Reorganizing Equation (9) and (10), we get
Equation (11) and (12).
111 2
mvv P

(11)

111 11 2
21mvv vv E


(12)
Suppose the ratio of residual speed and initial speed
of shock pulse generator is β, we can get Equation
(13) and (14) from Equation (11) and (12).
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

2
1
2
21
1
E
v
P
(13)

2
2
1
2
2
1
21 1
P
m
E






(14)
For definite impact mission, the required impulse
waveform can be obtained by modulating impact
programmer after making clear shock pulse
generator mass m
1
and initial speed v
1
. In addition,
relevant impact impulse P
2
and E
2
are confirmed for
certain corresponding energy ratio α.
Shock pulse generator mass m
1
should be
confirmed first. On occasions of guaranteeing
impact impulse, increase in m
1
would reduce the
requirement of initial speed v
1
. As such, m1 should
be as large as possible. On the other hand, over size
of m1 could result in large residual speed of shock
pulse generator, which influences the effective
transmission of energy. Besides, large residual speed
would increase requirements on buffer and braking
system. Therefore, system design should guarantee
the residual speed be within 10%, i.e. β is no bigger
than 0.1.
From the above two principles, taking β in
equation (14), we can get m
1
.

2
2
1
2
0.61
1
P
m
E


(15)
Secondly, initial speed v
1
of shock pulse generator is
determined. Based on the given mass of shock pulse
generator, we can see from equation (11) that initial
speed is determined by impact momenta P
2
of
recoiling part in test. While taking β = 0.1, we can
get v
1
.
3.3 Research on Security Protection
Problem
Security protection of FIS is an important problem,
where passive protective layers as non-interference
physical construction, adequate component strength,
rational hydraulic and mechanical buffer guarantee
the security of FIS from bottommost level.
Security design for driving system of speed
generator provides basic safeguard and means for
security protection of system, which is active
executor of protection actions.
Hardware and software protect of control system
are uppermost protective layer for ultimate
realization of active protection strategy.
3.3.1 Mechanical System
In working process of FIS, it is required to guarantee
that no mechanical impacts between mechanical part
and actuating mechanism happen. Rational design
requirements and criteria for each component of FIS
are given out based on analysis of stressed state,
which gives out detailed calculation of strength,
stiffness, longevity, etc. and retains high enough
safety system and proper design allowance. To
prevent component damage in impact process,
mechanical cushioning device of shock pulse
generator need to be designed for residual energy
absorption of shock pulse generator. In this way,
impact effect on other components is reduced
effectively, which further ensures the safety,
reliability and long-time running of FIS.
3.3.2 Safeguard of Driving System
Driving system is both operative part of FIS and
specific safeguards executor. In order to guarantee
the safe operation of FIS, security protection
function is designed for hydraulic driving system.
Protection mode shown in Figure 9 can be adopted
in design of driving system, i.e. locking valve is
used to lock driving system on certain location when
system failures occur.
3.3.3 Safeguard of Loading System
When system failures appear, automatic switch from
loading control to position control is realized to keep
the system in the current position, which avoids
further damage on equipment. While control system
problem makes positioning safeguard unachievable,
the system links up cavity A and cavity B of hydro-
cylinder, thus the forces exerted on system in test
approaches zero, which realizes safeguard function.
3.3.4 Safeguard of Control System
The following measures can be adopted for
hardware protection of control system:
Monitoring and alarm of lines: main lines
including control and power supply loops as
control element, driven element, sensors, etc. are
monitored at real time. Once open wire or plug
loosening state is detected, protective treatment
can be proceeded in time by control system;
Millisecond level monitoring plant of computer
failure: millisecond level computer failure
monitoring plant (also called watchdog) could
detect running status of real-time controller in
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real time. Once failure or system halted appears
on real-time controller, system control would be
taken over by watchdog. Then, security
protection process is triggered to realize security
protection of system.
4 EXPERIMENTAL VALIDATION
4.1 Technical Specification of FIS
Technical specifications mainly include: maximal
recoil driving force, force cell precision, angle
range, adapting initial height, forward and astern
speed, maximal route, hydraulic cylinder retraction
speed, forward positioning error, positioning holding
time, tacho-generator precision, impact frequency,
simulation precision, performance parameter
measuring accuracy, etc.
Maximal recoil force: no less than 4000kN;
Force cell precision: no less than 0.5%;
Angle range: 0°-45°;
Adapting firing line altitude: 500mm-2000mm;
Impulse velocity: 10m/s (adjustable with
program);
Hydraulic cylinder rapid retraction speed:
0.1m/s;
Forward positioning error: ±5mm;
Impact frequency: impulses up to 2-3 rounds per
minute;
Performance parameter measuring accuracy:
superior to 1% F.S.
In order to check if impact test data of FIS satisfies
requirements of system design, its key parameters
need to be validated by actual test. Key technical
indexes of firing impact test model include duration
of shock pulse, impact force, impulse, impact
acceleration peak value, continual impact number,
impact speed, angle regulating range, etc. In this
paper, we give out validation results of three major
parameters as impulse duration, impact force and
impulse.
4.2 Comparison Validation Test with
Live Firing
Take live firing test data of certain shrapnel as truth
value, live firing impact (resultant force in gun bore)
curve is built. Three simulation impact tests of this
gun are carried out with FIS, correlation curves of
three simulated impact to live shrapnel are shown in
Figure 8 and 9.
Time t (ms)
Simulation
Live firing
Aftereffect
Impact force F (kN)
Figure 8: Contrast curve of a howitzer live firing with 1
st
simulation firing.
Time t (ms)
Simulatio
n
Aftereffect
Live firing
Impact force F (kN)
Figure 9: Contrast curve of a howitzer live firing with 2
nd
simulation firing.
Comparative data of three simulated impulses to
howitzer live firing for three kind of major
parameters are shown in Table 1.
Table 1: Comparative data of simulated impact to howitzer
live firing on certain gun.
No.
Total
impulse
Ns
Impulse
duration
ms
Maximum
impulse
force
kN
Live firing 27002 33.50 4813.5
Simulation
First 27794 15.60 4704.6
Relative
error
%
2.94 -53.43 -2.26
Second 27018 12.68 5048.8
Relative
error
%
0.06 -62.15 4.89
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5 CONCLUSIONS
In validation process for simulated impact of FIS,
measured data of bore pressure resultant force of a
howitzer 1 living firing is taken as truth value.
Simulation effect of FIS can be established via
comparisons of 2 simulated impact force values.
The following conclusions can be obtained from
measured test data and calculated results in Table 1:
Comparison results of selected three key
parameters as impulse, duration of shock pulse
and maximal impact force can be used as
simulation credibility assessment basis of FIS;
Maximum error of total impulse is 2.94 %,
maximal value error of impact force is 4.89 %,
which meet design requirements of 15% on
simulation error;
Maximum error for impulse duration is -62.15 %,
which do not meet design requirement of 15% on
simulation error;
The shape of bore pressure resultant force curve
in live firing is basically in accord with impact
force curve of FIS.
Maximum error for two impulse durations all exceed
50 %, the main reason is that live firing data include
20ms after pill's getting out of gun bore, namely
after-effect period. If after-effect period is
subtracted, maximum error for impulse duration
satisfies required simulation precision of 15%.
There are several advantages of the FIS over live
fire testing. For example, FIS is easily operated
indoors, not weather dependent. It also enables test
engineers to examine any failure repeatedly during
weapon approval test. FIS can be operated
approximately two to three times per minute thereby
enabling test engineers to examine the recoil
systems' response to repeated rapid firing. However,
the most important benefit of FIS is reduction in the
cost associated with live fire testing of large caliber
tank and howitzer cannons, which averages $500 to
$2K per round.
REFERENCES
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Cast, M., 2001. Army test move to ‘virtual proving
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Di, C. C., Liu, L., Zheng, J., and Chen, Y. C., 2012a.
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Sanders, P., and Patenaude, A., 1996. Study on the
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