Development Concepts and Technical Challenges of Digital Twin Gun Barrel Focused on Barrel Burst Warning

doi:10.12382/bgxb.2025.0437

Abstract

Abstract:

Erosion wear and fatigue cracks are the key factors causing the failure of gun barrel.Erosion wear leads to a decrease in shooting accuracy，while the propagation of fatigue cracks can weaken the barrel strength and potentially lead to catastrophic explosion，posing a potential threat to the safety of gun launches.For this purpose，a construction scheme for a digital twin model of gun barrel based on fatigue fracture simulation is proposed.This involves developing the high-fidelity geometric and finite element models of gun barrel and comprehensively considering the effects of the high-temperature，high-pressure impact loads and their coupled interactions，as well as the structural and manufacturing factors such as coatings and preload forces.A digital twin simulation model for gun barrel is constructed based on elucidating the propagation behavior of micro-cracks on the inner wall of gun barrel.Building upon the health monitoring and remaining service life evaluation method for gun barrels based on outer wall strain measurements，the real-time online detection of damage parameters for crack propagation in gun barrels is achieved.This scheme lays the foundation for constructing an interactive digital twin model of gun barrels and provides a new technical path for preventing the barrel burst and achieving the dynamic prediction of barrel life.Finally，the key technologies for constructing the digital twin model of gun barrels atr proposed，which can serve as a valuable reference for digital twin research on other barrel-type weapon systems.

Key words: gun barrel, fatigue fracture, crack propagation, digital twin, barrel burst

SI Dongya, WU Bin, LUO Tianfang, LI Kun, ZHOU Ziming. Development Concepts and Technical Challenges of Digital Twin Gun Barrel Focused on Barrel Burst Warning[J]. Acta Armamentarii, 2025, 46(S1): 250437-.

Figures/Tables 4

References 24

[1]	李磊, 杜度, 仝哲, 等. 国外舰艇装备数字孪生技术应用研究[J]. 舰船科学技术, 2024, 46(19):185-189.
	LI L, DU D, TONG Z, et al. Research on the application of digital twin technology in foreign naval equipment[J]. Ship Science and Technology, 2024, 46(19):185-189. (in Chinese)
[2]	盛碧琦, 孙盛智, 刘玉, 等. 数字孪生技术在模拟训练系统中的应用研究[J]. 战术导弹技术, 2024(4):152-160.
	SHENG B Q, SUN S Z, LIU Y, et al. Research on the application of digital twin technology in simulation training systems[J]. Tactical Missile Technology, 2024(4):152-160. (in Chinese)
[3]	熊宇涵, 李雄. 数字孪生战场:概念、架构与技术[J]. 系统工程与电子技术, 2025, 47(1):141-152. doi: 10.12305/j.issn.1001-506X.2025.01.15
	XIONG Y H, LI X. Digital twin battlefield:concept,architecture,and technology[J]. Systems Engineering and Electronics, 2025, 47(1):141-152. (in Chinese)
[4]	洪东跑, 方伟光, 李浩, 等. 面向智能运维的装备数字孪生体构建与应用研究[J]. 宇航学报, 2024, 45(6):854-865.
	HONG D P, FANG W G, LI H, et al. Research on the construction and application of equipment digital twin for intelligent maintenance[J]. Journal of Astronautics, 2024, 45(6):854-865. (in Chinese)
[5]	顾晓飞, 张亮, 彭小明, 等. 数字孪生技术在导弹战斗部领域的应用与展望[J]. 新技术新工艺, 2024(9):1-7.
	GU X F, ZHANG L, PENG X M, et al. Application and prospect of digital twin technology in missile warhead[J]. New Technology & New Process, 2024(9):1-7. (in Chinese)
[6]	曹渊, 邱志明, 郝坤鹏, 等. 小口径转管炮数字化技术发展综述[J]. 海军工程大学学报, 2023, 35(6):6-10.
	CAO Y, QIU Z M, HAO K P, et al. Review on the development of digital technology for small-caliber gatling guns[J]. Journal of Naval University of Engineering, 2023, 35(6):6-10. (in Chinese)
[7]	闫仲秋, 陈义平, 邵奇, 等. 基于数字工程的武器装备发展研究[J]. 兵工自动化, 2023, 42(5):92-96.
	YAN Z Q, CHEN Y P, SHAO Q, et al. Research on weapon equipment development based on digital engineering[J]. Ordnance Industry Automation, 2023, 42(5):92-96. (in Chinese)
[8]	朱金达, 陈佳辉, 秦志英, 等. 基于虚拟现实与数字孪生技术的自行火炮辅助维修系统[J]. 数字印刷, 2022(6):117-127.
	ZHU J D, CHEN J H, QIN Z Y, et al. Self-propelled artillery auxiliary maintenance system based on virtual reality and digital twin technology[J]. Digital Printing, 2022(6):117-127. (in Chinese)
[9]	王帅, 王亚彬, 岳帅, 等. 自行火炮维修保障系统数字孪生体仿真模型[J]. 火炮发射与控制学报, 2023, 172(2):8-13,45
	WANG S, WANG Y B, YUE S, et al. A digital twin simulation model of the self-propelled artillery maintenance support system[J]. Journal of Gun Launch & Control, 2023, 172(2):8-13,45 (in Chinese)
[10]	马佳瑞. 基于数字孪生的转管火炮发射状态监测系统研究[D]. 哈尔滨: 哈尔滨工程大学, 2022.
	MA J R. Research on gatling gun condition monitoring system based on digital twin[D]. Harbin: Harbin Engineering University, 2022. (in Chinese)
[11]	王宏伟, 刘文军, 邓伟倩, 等. 基于模型的复杂装备数字孪生体建模方法[J]. 新技术新工艺, 2024(5):51-59.
	WANG H W, LIU W J, DENG W Q, et al. Digital twin modeling method for complex equipment based on model[J]. New Technology & New Process, 2024(5):51-59. (in Chinese)
[12]	王韫泽, 王树山, 魏平亮, 等. 穿甲弹异物阻滞膛炸机理数值仿真分析[J]. 兵工学报, 2018, 39(5):859-866. doi: 10.3969/j.issn.1000-1093.2018.05.004
	WANG Y Z, WANG S S, WEI P L, et al. Numerical simulation analysis of bore explosion mechanism caused by foreign object obstruction in armor-piercing projectiles[J]. Acta Armamentarii, 2018, 39(5):859-866. (in Chinese)
[13]	毛保全, 赵其进, 白向华, 等. 火炮身管延寿技术研究现状与展望[J]. 兵工学报, 2023, 44(3) :638-655. doi: 10.12382/bgxb.2021.0787
	MAO B Q, ZHAO Q J, BAI X H, et al. Review and prospect of life extension technology for gun barrels[J]. Acta Armamentarii, 2023, 44(3):638-655. (in Chinese) doi: 10.12382/bgxb.2021.0787
[14]	许耀峰, 单春来, 刘朋科, 等. 火炮身管寿终机理及寿命预测方法研究综述[J]. 火炮发射与控制学报, 2020, 41(3):89-94,101.
	XU Y F, SHAN C L, LIU P K, et al. Review of the research on failure mechanism and life prediction method of gun barrel[J]. Journal of Gun Launch & Control, 2020, 41(3):89-94,101. (in Chinese)
[15]	聂林涛. 某型高射炮杀伤榴弹膛炸问题研究[J]. 舰船电子工程, 2020, 40(12):119-121.
	NIE L T. Research on bore premature of anti-aircraft gun killing howitzer[J]. Ship Electronic Engineering. 2020, 40(12):119-121. (in Chinese)
[16]	吴斌, 司东亚, 郑靖, 等. 基于应变的火炮身管健康监测和剩余寿命评估的可行性研究[J]. 兵器装备工程学报, 2024, 45(1):49-58.
	WU B, SI D Y, ZHENG J, et al. Feasibility study on strain-based health monitoring and life assessment of gun barrel[J]. Journal of Ordnance Equipment Engineering, 2024, 45(1):49-58. (in Chinese)
[17]	苏玉昆, 马涛, 赵晓鑫, 等. 基于有限元技术的疲劳裂纹扩展方法研究进展[J]. 力学进展, 2024, 54(2):308-343.
	SU Y K, MA T, ZHAO X X, et al. Research progress of fatigue crack propagation method based on finite element technology. Advances in Mechanics, 2024, 54(2):308-343. (in Chinese)
[18]	DAI Y F, HOU B, LEE S, et al. A thermal-hydraulic-mechanical-chemical coupling model for acid fracture propagation based on a phase-field method[J]. Rock Mechanics and Rock Engineering, 2024, 57(7): 4583-4605.
[19]	HU Z Y, SUO X F, WANG M J, et al. A phase-field-cohesive-zone framework to simulate multiple failure mechanisms of elastoplastic fiber-reinforced composites[J]. International Journal of Fracture, 2023, 244(1):43-59.
[20]	BUSAR Y O, MANURUNG Y H P, LEITNER M, et al. Numerical evaluation of fatigue crack growth of structural steels using energy release rate with VCCT[J]. Applied Sciences, 2022.12(5):2641.
[21]	GAIROLA S, RENGASWAMY J, VERMA R. A study on XFEM simulation of tensile,fracture toughness,and fatigue crack growth behavior of Al 2024 alloy through fatigue crack growth rate models using genetic algorithm[J]. Fatigue & Fracture of Engineering Materials & Structures, 2023.46(6):2121-2138.
[22]	WEN L F, TIAN R, WANG L X, et al. Improved XFEM for multiple crack analysis:Accurate and efficient implementations for stress intensity factors[J]. Computer Methods in Applied Mechanics and Engineering, 2023, 411:116045.
[23]	MARTULLI L M, BERNASCONI A. An efficient and versatile use of the VCCT for composites delamination growth under fatigue loadings in 3D numerical analysis:the Sequential static fatigue algorithm[J]. International Journal of Fatigue,2023.170:107493.
[24]	董雷霆, 周轩, 赵福斌, 等. 飞机结构数字孪生关键建模仿真技术[J]. 航空学报, 2021, 42(3):023981.
	DONG L T, ZHOU X, ZHAO F B, et al. Key technologies for modeling and simulation of airframe digital twin[J]. Acta Aeronautica et Astronautica Sinica, 2021, 42(3):023981. (in Chinese)

方法	优势	缺点
有扩展有限元法	1.无需重划网格 2.可以模拟任意方向路径 3.可以解决不连续几何问题 4.具有较好的精度和收敛性	1.富集函数收敛耗时较长 2.模拟复杂多个裂纹尚存在局限性 3.计算精度较低
粘聚力模型法	1.使用方便简单 2.计算时间较少 3.计算结果精度较高	1.网格敏感性 2.需要提前确定裂纹路径 3.需要预制裂纹
虚拟裂纹闭合技术	1.使用方便简单 2.准确计算应变能释放率	1.网格敏感性 2.需要提前确定裂纹路径 3.需要预制裂纹 4.计算时间较长、精度较低

方法	优势	缺点
有扩展有限元法	1.无需重划网格 2.可以模拟任意方向路径 3.可以解决不连续几何问题 4.具有较好的精度和收敛性	1.富集函数收敛耗时较长 2.模拟复杂多个裂纹尚存在局限性 3.计算精度较低
粘聚力模型法	1.使用方便简单 2.计算时间较少 3.计算结果精度较高	1.网格敏感性 2.需要提前确定裂纹路径 3.需要预制裂纹
虚拟裂纹闭合技术	1.使用方便简单 2.准确计算应变能释放率	1.网格敏感性 2.需要提前确定裂纹路径 3.需要预制裂纹 4.计算时间较长、精度较低