大型爆炸焊接半球消波器研究
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摘要
爆炸容器广泛应用于工业、国防、科研等领域,随着爆炸技术的进步,爆炸容器已成为爆炸法制备纳米材料、爆炸焊接、爆炸压实和爆炸成型等生产所必须的设备。由于对复合板面积要求日益增大,相应要求爆炸容器的有效空间也越来越大,炸药的爆炸当量也相应增加,爆炸容器的设计和使用也面临越来越多的问题;另一方面,因爆破噪声扰民、房屋损坏而造成的矛盾日显突出。爆炸焊接经常会涉及到结构安全防护问题,如何有效地进行爆炸容器结构设计是该领域重要的研究课题之一。对于大型爆炸容器的设计和使用,采用有限元数值模拟对于结构安全评估和结构参数优化都具有重要的研究意义,但是由于数值模拟方法受到计算条件的限制,在结构加工、单元划分、边界条件确定、参数的选取等方面带有人为的因素,因此对大型爆炸容器的研究应该将数值模拟与模型实验相结合,才能得出一些可靠的结论。本文对大型爆炸焊接半球消波器进行研究,主要遵循以下原则:安全性、经济性、消波效果、生产效率(排烟效率)及耐久性。主要研究内容:结构静力分析、屈曲分析、动态响应分析及排烟效率分析。采用LS-DYNA程序和理论公式对原型爆炸冲击载荷进行计算并用LS-DYNA对模型进行流固耦合分析;用ANSYS程序分析消波器结构在土压条件下的静力强度、稳定性和爆炸冲击载荷下的瞬态应力分布;采用STAR-CD模拟了球壳中爆生气体的流动。主要研究成果有:
1静载作用下的结构强度
将上覆土作为结构的荷载,采用有限元方法分析了结构在静载作用下的强度和变形特性。研究表明,无论对于上部开口8m还是15m的结构,结构绝大部分的等效应力小于材料的强度设计值。而等效应力大于材料强度设计值的部位,发生在应力集中部位,例如板与门框和地粱的相会处,在设计中应予重视。
2静载作用下的稳定性
根据弹性屈曲理论和有限元模拟方法,对不同结构形式下的屈曲稳定性进行了模拟研究。研究表明,当结构采用24根肋时,结构屈曲稳定性安全系数为2.532:当结构采用48根肋、上部开口为8m时,结构屈曲稳定性安全系数为4.276;当结构采用48根肋、上部开口为15m时,结构屈曲稳定性安全系数为3.629。
用光学投影条纹法测试了球壳变形量,并进行了过载一倍试验,实验证实球壳稳定性安全系数超过2.52倍;用ANSYS程序分析了消波器在土压条件下的应力场、静压稳定性,计算结果其安全系数为4.276,因此结构安全。
3动态响应数值模拟分析结果
通过LS-DYNA数值模拟可以发现,消波器正上方附近为最大压应力区。对炸药质量分别为600kg,800kg,1000kg三种情况进行分析,随炸药质量的增加,反射超压极值逐渐增加,而且极值产生时间提前。计算结果表明,在爆炸冲击荷载作用下模型或原型结构的大部分等效应力小于材料强度的设计值,局部部位由于应力集中的影响,有限元计算的等效应力值会大于材料强度的设计值。由于在爆炸响应计算时,没有考虑结构上大量粱和肋的综合作用,实际的应力会比有限元模拟结果小很多。
动载应力测试为典型爆炸冲击下应力测试结果。球壳在爆炸冲击作用下第一次冲击应力峰值最大,之后基本以拉压应力状态来回振动,经过1～2个来回后立刻减小到100MPa以下,土的堆压对消除球壳振动起到了较好的作用。因为爆炸冲击波作用时间很短,故在球壳应力校核时只需考虑单次的正压冲击,可以不考虑冲击波在球壳中的复杂反射过程。刚性位移测试表明,5kg炸药爆炸时下底环最大位移仅为4mm(平均2mm)。300余次加强冲击疲劳试验表明,球壳整体结构无破坏,2处局部焊缝开裂,在将振松的土石回填后,裂纹不再扩展。
4排烟效率分析
对比理论分析与三维数值模拟得到1/6模型和原型的时间比例常数为2.5。故根据1/6模型测得的CO衰减至50PPM所用的时间,可推算出,当环境处于一级风,且风向符合下进上排时,原型消波器CO浓度衰减至50PPM的时间需要8分钟;当环境处于一级风,且风向符合上进下排时,原型CO浓度衰减至50PPM的时间需要25分钟。根据数值模拟结果可知,在上排气口总面积相同的条件下,单上排气口布置方案明显优于多上排气口布置方案。对于单上排气口布置方案,在相同排气口直径条件下,随排气口高度的增加,CO浓度衰减到标准状态所用的时间增加。
5在模型上进行了抗爆试验,分别采用炸药量为2kg、3kg、4kg、5kg,按模型率放大到原型,将对应432kg、648kg、864kg和1080kg铵油炸药,分别对应TNT当量为331kg、497kg、663kg、828kg。在该模型上进行了加强多次爆破冲击疲劳试验,进行了300余次爆破实验,采用药量为6kg铵油,折算至原型上为1296kg铵油,994kgTNT当量。
6消声试验表明,在正对进出口方向冲击波超压消减50%,90°方向消减到90%,消波效果较为明显。
Explosion vessel is widely applied in many fields such as industry,national defense, scientific research and etc.With the advancement of the explosion technique,explosion vessel has been the necessary device for explosion method to produce nanometer material,explosive welding,explosive compaction,explosive forming and so on.As the larger requirement of complex material the wider space is required for the explosion vessel.On the other hand,the contradiction between the blasting noise and residents nearby the plant area or constructions is outstanding day by day.The security protection of the structures was often involved in explosive welding.How to design the structure of the explosion vessel is one of the important research topics in this field.As far as the design and use of large explosion vessel is concerned,finite element method is adopted for structure simulation analysis.It is significant research whether for the structure security estimate prediction or structure parameter optimization.While the numerical simulation method is limited by calculation condition for the artificial factor in structure shop,unit division,boundary condition determination, parameters selection.As for research on large explosion vessel,reliable conclusion can be achieved by combing the numerical simulation and the experiment.Welding wave attenuator in large explosion vessel research is studied in this paper,and the following principle shall be obeyed:safety performance,economy,wave dissipation effect,production efficiency(smoke exhaust efficiency),and durability.The main research content is included as follows:static analysis,post-buckling analysis,dynamic response analysis,solid wall overpressure analysis and production efficiency analysis.Authors mainly adopt LS-DYNA program and theoretical formula to determine the prototype explosive impact load and use LS-DYNA program to the simulate fluid-solid coupling analysis;adopt ANSYS program to analyze the structural strength,structural stability under the shock-wave trap shell earth pressure static load condition,and the instant stress distribution under the shock wave load;and adopt STAR-CD to simulate denotation gas flow within the shell.The main research results are:
1.Structural strength under the action of static load
The covering earth serves as the load to the structure.This thesis adopts the finite element method to analyze the structural strength and deformation characteristics under the action of static load.The research indicates that most equivalent stresses of the structure of that the upper port is 8m or 15m diameter is smaller than the strength design value.The part that the equivalent stress is bigger than the material strength design value is in the position where the stresses concentrate,for example,the joint between plates,door frame and ground beam. Importance shall be attached to in the design.
2.Stability of hemispherical shell under the action of static load
This thesis has simulated and studied the buckling stability under different structure forms on the basis of elastic buckling theory and finite element simulation method.The research indicates that the structural buckling stability safety coefficient is 2.532 when the structure adopts 24 ribs;4.276 when adopts 48 ribs and the upper port is 8m;3.629 when adopts 48 ribs and the upper port is 15m.The test was made by adopting optical projection stripe method to measure the deformation amount of the spherical hell.Further,a test of double overload experiment was made.The results verified that the safety coefficient was more than 2.52 times,while the calculation results achieved by ANSYS program was 4.276 times of the safety coefficient,So the structural is safety.
3.Result of dynamic response simulation
It is observed from LS-DYNA numerical simulation that the area over the protection cover is the maximum pressure zone.This thesis has made an analysis on three situations when the explosive dosage is 600kg,800kg and 1000kg respectively.With the increase of explosive dosage,the reflection overpressure extreme value increases gradually,and appears earlier. This thesis adopts LS-DYNA/ANSYS numerical simulation method to calculate and analyze the dynamic response of model and Prototype structure.The result indicates that most structural equivalent stresses under the action of the explosive shock load are smaller than the material strength design value.However,the equivalent stress of some parts calculated by means of finite element method is bigger than the material strength design value due to the effect of stress concentration.Since the synthetic action on most beams and ribs of the structure is not taken into consideration when the explosion response is calculated,the actual stress will be much smaller than the result of finite element simulation.
The dynamic load stress test results are the typical stress test results under explosive impact.The first impact stress peak value is the maximum on the spherical shell under the explosive impact effect,the other was tension-compression stress.The vibration stress shall be immediately reduced to below 100 Mpa after 1 to 2 circulations.Obviously,the accumulation of soil can eliminate the vibration of spherical hell.We shall only consider of the positive pressure impact in single explosion when the spherical hell stress check is determined,without consideration of the complex reflection process of the explosive impact wave in the spherical hell because the positive pressure characteristic time is very short.The results of rigid displacement test show that the maximum bottom ring at explosive dosage of 5 kg is only 4 mm displacement(the average is 2mm).The strengthen impact fatigue tests for more than 300 times show that there are no destruction of the overall structure in the spherical hell and 2 part local welding crack.The crack didn't extend any more after the loosed soil was refilled.
4.Analysis of smoke exhaust efficiency
It is obtained by comparing theoretical analysis and three-dimensional numerical simulation that the time proportionality constant between the 1/6model and the prototype is 2.5.Therefore,it could be calculated based on the measured duration in which CO concentration of the 1/6 model will attenuate to 50PPM that it will take 10min for CO concentration of the prototype explosion cave to attenuate to 50PPM when there is light air and the wind direction conforms to the requirement of "lower entrance and upper discharge"; 25min for CO concentration to attenuate to 50PPM when there is light air and the wind direction conforms to the requirement of "upper entrance and lower discharge".It is know from the numerical simulation result that the single upper exhaust outlet is superior to multi-upper exhaust outlets if total exhaust outlet areas of both the former and the latter are the same.As for the single upper exhaust outlet arrangement scheme,if the diameter of the exhaust outlet is unchangeable,the duration in which CO concentration attenuates to the standard state will increase with the increase of exhaust outlet height.
5.An anti-blast experiment is made based on this model,explosive dosage is 2 kg,3 kg,4 kg,5 kg is adopted separately,accordingly enlarge the substance to 432 kg,648 kg,864 kg, 1080 kg ANFO explosive,equal to 331 kg,497 kg,663 kg and 828 kg TNT equivalent.We also made strengthen explosive impact fatigue experiment on this model for many times.Up to now,more than 300 times explosion tests with ANFO explosive dosage for 6 kg have made, which was converted to original mode as 1296 kg ANFO and 994 kg TNT equivalent.
6.Wave dissipation test results show that the impact wave overpressure on the upright direction of the outlet was subtracted to 50%,to 90%in the direction of 90~angle,the dissipation effect was more obvious.
1静载作用下的结构强度
将上覆土作为结构的荷载,采用有限元方法分析了结构在静载作用下的强度和变形特性。研究表明,无论对于上部开口8m还是15m的结构,结构绝大部分的等效应力小于材料的强度设计值。而等效应力大于材料强度设计值的部位,发生在应力集中部位,例如板与门框和地粱的相会处,在设计中应予重视。
2静载作用下的稳定性
根据弹性屈曲理论和有限元模拟方法,对不同结构形式下的屈曲稳定性进行了模拟研究。研究表明,当结构采用24根肋时,结构屈曲稳定性安全系数为2.532:当结构采用48根肋、上部开口为8m时,结构屈曲稳定性安全系数为4.276;当结构采用48根肋、上部开口为15m时,结构屈曲稳定性安全系数为3.629。
用光学投影条纹法测试了球壳变形量,并进行了过载一倍试验,实验证实球壳稳定性安全系数超过2.52倍;用ANSYS程序分析了消波器在土压条件下的应力场、静压稳定性,计算结果其安全系数为4.276,因此结构安全。
3动态响应数值模拟分析结果
通过LS-DYNA数值模拟可以发现,消波器正上方附近为最大压应力区。对炸药质量分别为600kg,800kg,1000kg三种情况进行分析,随炸药质量的增加,反射超压极值逐渐增加,而且极值产生时间提前。计算结果表明,在爆炸冲击荷载作用下模型或原型结构的大部分等效应力小于材料强度的设计值,局部部位由于应力集中的影响,有限元计算的等效应力值会大于材料强度的设计值。由于在爆炸响应计算时,没有考虑结构上大量粱和肋的综合作用,实际的应力会比有限元模拟结果小很多。
动载应力测试为典型爆炸冲击下应力测试结果。球壳在爆炸冲击作用下第一次冲击应力峰值最大,之后基本以拉压应力状态来回振动,经过1～2个来回后立刻减小到100MPa以下,土的堆压对消除球壳振动起到了较好的作用。因为爆炸冲击波作用时间很短,故在球壳应力校核时只需考虑单次的正压冲击,可以不考虑冲击波在球壳中的复杂反射过程。刚性位移测试表明,5kg炸药爆炸时下底环最大位移仅为4mm(平均2mm)。300余次加强冲击疲劳试验表明,球壳整体结构无破坏,2处局部焊缝开裂,在将振松的土石回填后,裂纹不再扩展。
4排烟效率分析
对比理论分析与三维数值模拟得到1/6模型和原型的时间比例常数为2.5。故根据1/6模型测得的CO衰减至50PPM所用的时间,可推算出,当环境处于一级风,且风向符合下进上排时,原型消波器CO浓度衰减至50PPM的时间需要8分钟;当环境处于一级风,且风向符合上进下排时,原型CO浓度衰减至50PPM的时间需要25分钟。根据数值模拟结果可知,在上排气口总面积相同的条件下,单上排气口布置方案明显优于多上排气口布置方案。对于单上排气口布置方案,在相同排气口直径条件下,随排气口高度的增加,CO浓度衰减到标准状态所用的时间增加。
5在模型上进行了抗爆试验,分别采用炸药量为2kg、3kg、4kg、5kg,按模型率放大到原型,将对应432kg、648kg、864kg和1080kg铵油炸药,分别对应TNT当量为331kg、497kg、663kg、828kg。在该模型上进行了加强多次爆破冲击疲劳试验,进行了300余次爆破实验,采用药量为6kg铵油,折算至原型上为1296kg铵油,994kgTNT当量。
6消声试验表明,在正对进出口方向冲击波超压消减50%,90°方向消减到90%,消波效果较为明显。
Explosion vessel is widely applied in many fields such as industry,national defense, scientific research and etc.With the advancement of the explosion technique,explosion vessel has been the necessary device for explosion method to produce nanometer material,explosive welding,explosive compaction,explosive forming and so on.As the larger requirement of complex material the wider space is required for the explosion vessel.On the other hand,the contradiction between the blasting noise and residents nearby the plant area or constructions is outstanding day by day.The security protection of the structures was often involved in explosive welding.How to design the structure of the explosion vessel is one of the important research topics in this field.As far as the design and use of large explosion vessel is concerned,finite element method is adopted for structure simulation analysis.It is significant research whether for the structure security estimate prediction or structure parameter optimization.While the numerical simulation method is limited by calculation condition for the artificial factor in structure shop,unit division,boundary condition determination, parameters selection.As for research on large explosion vessel,reliable conclusion can be achieved by combing the numerical simulation and the experiment.Welding wave attenuator in large explosion vessel research is studied in this paper,and the following principle shall be obeyed:safety performance,economy,wave dissipation effect,production efficiency(smoke exhaust efficiency),and durability.The main research content is included as follows:static analysis,post-buckling analysis,dynamic response analysis,solid wall overpressure analysis and production efficiency analysis.Authors mainly adopt LS-DYNA program and theoretical formula to determine the prototype explosive impact load and use LS-DYNA program to the simulate fluid-solid coupling analysis;adopt ANSYS program to analyze the structural strength,structural stability under the shock-wave trap shell earth pressure static load condition,and the instant stress distribution under the shock wave load;and adopt STAR-CD to simulate denotation gas flow within the shell.The main research results are:
1.Structural strength under the action of static load
The covering earth serves as the load to the structure.This thesis adopts the finite element method to analyze the structural strength and deformation characteristics under the action of static load.The research indicates that most equivalent stresses of the structure of that the upper port is 8m or 15m diameter is smaller than the strength design value.The part that the equivalent stress is bigger than the material strength design value is in the position where the stresses concentrate,for example,the joint between plates,door frame and ground beam. Importance shall be attached to in the design.
2.Stability of hemispherical shell under the action of static load
This thesis has simulated and studied the buckling stability under different structure forms on the basis of elastic buckling theory and finite element simulation method.The research indicates that the structural buckling stability safety coefficient is 2.532 when the structure adopts 24 ribs;4.276 when adopts 48 ribs and the upper port is 8m;3.629 when adopts 48 ribs and the upper port is 15m.The test was made by adopting optical projection stripe method to measure the deformation amount of the spherical hell.Further,a test of double overload experiment was made.The results verified that the safety coefficient was more than 2.52 times,while the calculation results achieved by ANSYS program was 4.276 times of the safety coefficient,So the structural is safety.
3.Result of dynamic response simulation
It is observed from LS-DYNA numerical simulation that the area over the protection cover is the maximum pressure zone.This thesis has made an analysis on three situations when the explosive dosage is 600kg,800kg and 1000kg respectively.With the increase of explosive dosage,the reflection overpressure extreme value increases gradually,and appears earlier. This thesis adopts LS-DYNA/ANSYS numerical simulation method to calculate and analyze the dynamic response of model and Prototype structure.The result indicates that most structural equivalent stresses under the action of the explosive shock load are smaller than the material strength design value.However,the equivalent stress of some parts calculated by means of finite element method is bigger than the material strength design value due to the effect of stress concentration.Since the synthetic action on most beams and ribs of the structure is not taken into consideration when the explosion response is calculated,the actual stress will be much smaller than the result of finite element simulation.
The dynamic load stress test results are the typical stress test results under explosive impact.The first impact stress peak value is the maximum on the spherical shell under the explosive impact effect,the other was tension-compression stress.The vibration stress shall be immediately reduced to below 100 Mpa after 1 to 2 circulations.Obviously,the accumulation of soil can eliminate the vibration of spherical hell.We shall only consider of the positive pressure impact in single explosion when the spherical hell stress check is determined,without consideration of the complex reflection process of the explosive impact wave in the spherical hell because the positive pressure characteristic time is very short.The results of rigid displacement test show that the maximum bottom ring at explosive dosage of 5 kg is only 4 mm displacement(the average is 2mm).The strengthen impact fatigue tests for more than 300 times show that there are no destruction of the overall structure in the spherical hell and 2 part local welding crack.The crack didn't extend any more after the loosed soil was refilled.
4.Analysis of smoke exhaust efficiency
It is obtained by comparing theoretical analysis and three-dimensional numerical simulation that the time proportionality constant between the 1/6model and the prototype is 2.5.Therefore,it could be calculated based on the measured duration in which CO concentration of the 1/6 model will attenuate to 50PPM that it will take 10min for CO concentration of the prototype explosion cave to attenuate to 50PPM when there is light air and the wind direction conforms to the requirement of "lower entrance and upper discharge"; 25min for CO concentration to attenuate to 50PPM when there is light air and the wind direction conforms to the requirement of "upper entrance and lower discharge".It is know from the numerical simulation result that the single upper exhaust outlet is superior to multi-upper exhaust outlets if total exhaust outlet areas of both the former and the latter are the same.As for the single upper exhaust outlet arrangement scheme,if the diameter of the exhaust outlet is unchangeable,the duration in which CO concentration attenuates to the standard state will increase with the increase of exhaust outlet height.
5.An anti-blast experiment is made based on this model,explosive dosage is 2 kg,3 kg,4 kg,5 kg is adopted separately,accordingly enlarge the substance to 432 kg,648 kg,864 kg, 1080 kg ANFO explosive,equal to 331 kg,497 kg,663 kg and 828 kg TNT equivalent.We also made strengthen explosive impact fatigue experiment on this model for many times.Up to now,more than 300 times explosion tests with ANFO explosive dosage for 6 kg have made, which was converted to original mode as 1296 kg ANFO and 994 kg TNT equivalent.
6.Wave dissipation test results show that the impact wave overpressure on the upright direction of the outlet was subtracted to 50%,to 90%in the direction of 90~angle,the dissipation effect was more obvious.
引文
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