基于蜂窝结构炸药低能高效爆炸焊接的关键参数控制理论与爆轰机理研究

Explosive welding, which has the advantages of simple process, good performance, has been widely used in engineering fields. However, Explosive welding exists backward method of charge, high noise and low efficiency problems. In order to resolve the problems, honeycomb structure explosives and double sided Explosive welding were invented. Honeycomb structure explosives can ensure the quality of the charge. The high noise and low efficiency of Explosive welding also improved by double sided Explosive welding which can clad two composite plates simultaneously. Composite plates on both sides of explosive is facing the problem of flying away in spite of significant improving the energy efficiency of explosives. A self-restrained explosive welding setup was proposed to restrict the flight of the welded plates. Honeycomb structure explosives has a different detonation mechanism from traditional explosives used in Explosive welding and double sided Explosive welding in the self-restrained explosive welding setup has a different empirical formula from traditional Explosive welding method. This project plans to study the influence of honeycomb materials on the detonation wave propagation by experiments, theory analysis and numerical calculation, and expects to reveal the characteristics of the detonation mechanism of the honeycomb structure. Through orthogonal experimental design, the relationship between the quality and the parameters is investigated by experiments and numerical calculation, and expects to establish the empirical formula for calculating the parameters of double sided Explosive welding. The numerical simulation of the generation process of boundary effect is carried out by using the SPH method, and expects to reveal the mechanism of boundary effect resistance of double sided Explosive welding. The work in this project can establish related theory for the self-restrained explosive welding, in order to lay a foundation of further study and application on it.

爆炸焊接工艺简单、性能优良，已广泛应用于工程领域，但存在装药方式落后和高噪低效等问题。课题组已采用蜂窝结构炸药保证装药质量；并通过双面爆炸焊接一次起爆得两组复合板，尽管炸药能量利用率显著提高，但面临炸药两侧复合板飞散问题，为此提出了自约束爆炸焊接方法。由于蜂窝结构炸药具有与传统焊接炸药不同的爆轰机理、自约束爆炸焊接方法中双面爆炸焊接具有与传统爆炸焊接不同的计算关键参数的经验公式，本项目采用实验和数值模拟相结合的研究方法，研究稀释剂和蜂窝材料对爆速和猛度的影响，揭示蜂窝结构炸药爆轰机理；通过正交试验设计，采用实验和数值模拟相结合的研究方法，研究双面爆炸焊接关键参数与焊接质量之间的关系，建立适合自约束爆炸焊接关键参数的控制理论；采用SPH方法对爆炸焊接边界效应进行数值模拟研究，揭示双面爆炸焊接抗边界效应机理。研究结果可建立蜂窝结构炸药与自约束爆炸焊接的相关基础理论，为其后续研究和应用奠定基础。

爆炸焊接工艺简单、性能优良，已广泛应用于工程领域，但存在高噪低效的问题。在实现低能高效爆炸焊接的过程中，对爆炸焊接关键参数的控制尤为重要。本项目系统地探讨爆炸焊接关键参数对爆炸爆爆产品结合质量及结合界面波形的影响；针对不同的炸药以及不同的基复板材料组合对爆炸焊接过程中的边界效应进行数值模拟研究，揭示边界效应产生的机理。主要结果有：通过大量的数值模拟，建立了爆炸焊接关键参数与爆炸焊接产品结合质量的预测关系；爆炸焊接工艺和材料保持不变时，复合板在上限间隙处的结合质量最好，基复板间隙遵循上限法则；结合界面处比波长与碰撞角呈正相关，碰撞速度越大，界面波长和波幅也越大，碰撞速度水平方向的分量决定波长数值的大小，碰撞速度竖直方向的分量决定波幅数值的大小；由于稀疏波对边界处爆轰产物的影响，导致复板边界处与内部存在速度差，从而使边界处的碰撞角变大,在速度差产生的应力下复板发生撕裂，在复板、炸药变化的情况下，复板极限抗拉强度越低或炸药爆速越高，边界效应现象越严重。研究成果可为低能高效爆炸焊接的产业化发展提供理论依据和相应的建议，有助于爆炸焊接产业的进一步发展，因而具有重要的学术意义和应用价值。