Numerical Simulation of Double-Sided Explosive Welding
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摘要: 双面爆炸焊接一次起爆可同时焊接两组复合板，而且使炸药临界厚度显著降低，提高了炸药的能量利用率，解决了爆炸焊接现存的高噪低效问题。借助ANSYS/LS-DYNA动力学分析软件，运用光滑粒子流体动力学方法（SPH）与有限元（FEM）耦合算法，对双面爆炸焊接进行了三维数值模拟，并将模拟结果与实验结果和理论计算结果进行了对比。结果表明，数值模拟结果与实验结果较吻合，且与Deribas的理论计算结果一致性较好，说明Deribas公式和SPH-FEM耦合方法对双面爆炸焊接具有较好的指导意义。Abstract: The high noise and low efficiency of explosive welding can be improved by the double-sided explosive welding which can clad two composite plates simultaneously and significantly reduce the critical thickness of stable detonation of explosives.In this study, we simulated the double-sided explosive welding using the explicit finite element program LS-DYNA combined with the SPH (Smoothed Particle Hydrodynamics) and FEM (Finite Element Method) coupling, and compared the simulation results with the experiment and the calculation results.The results showed that the simulation results were in good agreement with the experiment results as well as the theoretical calculation results of Deribas's.It shows that the Deribas's formula and SPH-FEM coupling method can provide theoretical guidance for the engineering application of double-sided explosive welding.
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图 3 10 mm药厚下爆炸焊接结束时复板的z向位移云图
Figure 3. z-direction displacement contour of flyer plate with explosive thickness of 10 mm at the end of explosive welding
图 4 10 mm药厚下复板上3个特征单元的z向位移-时间历程
Figure 4. z-direction displacement histories of 3 characteristic elements with explosive thickness of 10 mm
图 5 10 mm药厚下的一对特征单元
Figure 5. A pair of characteristic elements with explosive thickness of 10 mm
图 7 10 mm药厚下复板结合界面处的3个特征单元
Figure 7. 3 characteristic elements at the bonding interface of flyer plate with explosive thickness of 10 mm
图 8 10 mm药厚下3个特征单元的速度-时间曲线
Figure 8. Velocity-time curves of 3 characteristic elements with explosive thickness of 10 mm
图 9 10 mm药厚下复板结合界面处的3个特征单元
Figure 9. 3 characteristic elements at the bonding interface of flyer plate with explosive thickness of 10 mm
图 10 10 mm药厚下3个特征单元的压力-时间曲线
Figure 10. Pressure-time curves of 3 characteristic elements with explosive thickness of 10 mm
图 11 5 mm药厚下爆炸复合结束时复板的z向位移云图
Figure 11. z-displacement contour of flyer plate with explosive thickness of 5 mm at the end of explosive welding
图 12 5 mm药厚下复板上特征单元的z向位移-时间历程
Figure 12. z-displacement histories of 3 characteristic elements with explosive thickness of 5 mm
图 13 5 mm药厚下的一对特征单元
Figure 13. A pair of characteristic elements with explosive thickness of 5 mm
图 15 5 mm药厚下复板结合界面处的3个特征单元
Figure 15. 3 characteristic elements at the bonding interface of flyer plate with explosive thickness of 5 mm
图 16 5 mm药厚下3个特征单元的速度-时间曲线
Figure 16. Velocity-time curves of 3 characteristic elements with explosive thickness of 5 mm
图 17 5 mm药厚下复板结合界面处的3个特征单元
Figure 17. 3 characteristic elements at the bonding interface of flyer plate with explosive thickness of 5 mm
图 18 5 mm药厚下3个特征单元的压力历程
Figure 18. Pressure histories of 3 characteristic elements with explosive thickness of 5 mm
表 1 计算模型中材料的相关参数
Table 1. Related parameters of materials in calculation models
Calculationmodel Flyer plate Base plate Gap
δ/mmSize of explosive/(mm×mm×mm) Material Size/(mm×mm×mm) Material Size/(mm×mm×mm) Ⅰ 45 steel 300×150×2 Q235 300×150×16 6 300×150×10 Ⅱ 45 steel 300×150×2 Q235 300×150×16 6 300×150×5 
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ρ/(g·cm-3) D/(m·s-1) AJWL/GPa BJWL/GPa R1 R2 ω E0/(kJ·cm-3) 1.12 4 510 326.42 5.808 9 5.80 1.56 0.57 3.323
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ρ/(g·cm-3) G/GPa A/GPa B/GPa C n m Tm/K Tr/K 7.83 77 0.792 0.51 0.014 0.26 1.03 1 793 294
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表 4 10 mm药厚下碰撞速度理论计算结果与数值模拟结果的比较
Table 4. Comparison of collision velocity between theoretical calculation and numerical simulation with explosive thickness of 10 mm
Theoreticalformula Massfraction Collision velocity/(m·s-1) Error/% Theoretical calculation[18] Simulation Gurney 0.75 1 089 897 -21.0 Aziz 0.75 711 897 20.0 Deribas 0.75 853 897 4.9
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表 5 5 mm药厚下碰撞速度理论计算结果与数值模拟结果的比较
Table 5. Comparison of collision velocity between theoretical calculation and numerical simulation with explosive thickness of 5 mm
Theoreticalformula Massfraction Collision velocity/(m·s-1) Error/% Theoretical calculation[18] Simulation Gurney 0.45 863 565 -52.7 Aziz 0.45 480 565 15.0 Deribas 0.45 576 565 -1.9
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表 6 10 mm药厚下碰撞压力理论计算结果与数值模拟结果的比较
Table 6. Comparison of collision pressure betweentheoretical calculation and numerical simulationwith explosive thickness of 10 mm
Theoreticalformula Collision pressure/GPa Error/% Calculation Simulation Gurney 22.08 17.08 -29.3 Aziz 14.42 17.08 15.6 Deribas 17.30 17.08 -1.3
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表 7 5 mm药厚下碰撞压力理论计算结果与数值模拟结果的比较
Table 7. Comparison of collision pressure betweentheoretical calculation and numerical simulationwith explosive thickness of 5 mm
Theoreticalformula Collision pressure/GPa Error/% Calculation Simulation Gurney 17.50 11.25 -55.6 Aziz 9.73 11.25 13.5 Deribas 11.68 11.25 -3.8
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