CN110160413B - Large length-diameter ratio fusion cast explosive charging hot core rod feeding process design method - Google Patents
Large length-diameter ratio fusion cast explosive charging hot core rod feeding process design method Download PDFInfo
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- CN110160413B CN110160413B CN201910506007.3A CN201910506007A CN110160413B CN 110160413 B CN110160413 B CN 110160413B CN 201910506007 A CN201910506007 A CN 201910506007A CN 110160413 B CN110160413 B CN 110160413B
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F42—AMMUNITION; BLASTING
- F42B—EXPLOSIVE CHARGES, e.g. FOR BLASTING, FIREWORKS, AMMUNITION
- F42B33/00—Manufacture of ammunition; Dismantling of ammunition; Apparatus therefor
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F42—AMMUNITION; BLASTING
- F42B—EXPLOSIVE CHARGES, e.g. FOR BLASTING, FIREWORKS, AMMUNITION
- F42B33/00—Manufacture of ammunition; Dismantling of ammunition; Apparatus therefor
- F42B33/02—Filling cartridges, missiles, or fuzes; Inserting propellant or explosive charges
Abstract
A large length-diameter ratio fusion cast explosive charging hot core rod feeding process design method comprises three components of a large length-diameter ratio projectile body, a fusion cast explosive charging structure and a hot core rod, the process design method comprises two steps of casting process design and hot core rod feeding process design, the casting process design is divided into three stages, and process parameters such as casting speed, casting temperature and casting time are designed and controlled; the hot core rod feeding process is divided into three stages, and the feeding position and the heat preservation time of the hot core rod are designed and controlled. The method can carry out process simulation design aiming at different casting and hot core rod feeding working conditions of the cast fusion-cast explosive with large length-diameter ratio, and has strong pertinence and convenient operation.
Description
Technical Field
The invention belongs to the field of casting process and solidification feeding process design of a fusion cast explosive charging structure, and particularly relates to a large length-diameter ratio fusion cast explosive charging hot core rod feeding process design method.
Background
The fused cast explosive is a kind of explosive product widely loaded in various weapons and warfare parts. The conventional cast explosive has the process advantages of good material flowability, low preparation cost, high production efficiency and the like, and is often used for loading various weapons such as shells, grenades, projectile missiles, aeronautical missiles and the like on a large scale. The external shapes of these weapons tend to have a large aspect ratio. The solid-phase charging density of the fused and cast explosive after charging and forming is higher than the liquid-phase density in a molten state, and shrinkage porosity defects are easily generated due to volume shrinkage during solidification. Further causing the quality of the product of the charging structure to be reduced and affecting the use safety of the weapon ammunition. Therefore, a reasonable and effective casting and feeding process method needs to be established for the explosive charging type of the fusion-cast explosive with the large length-diameter ratio.
An important factor causing solidification defects of the fused cast explosive charging structure is that the temperature is rapidly reduced to be below the solidification point to form an internal closed area, and finally shrinkage porosity is developed. In order to make the feeding channel clear, a heating device can be used to make the temperature of the charge product above the melting point, and good flow feeding characteristics are maintained. The hot core rod is a common heating device, which is beneficial to the control of feeding process and improves the quality of products.
Chinese patent CN 200810060436.4 discloses a feeding process for gravity casting center casting, which takes aluminum melt as an object, improves the demoulding performance of aluminum castings and improves the material utilization rate by reducing the height of a feed inlet and casting twice. However, the technical scheme adopted by the invention is only improved on the die, the design of casting process parameters is not perfect enough, the feeding process design is lacked, the control level of the operation process is low, and the method cannot be popularized to the field of casting feeding of the charge of the cast explosive in an extending way.
At present, for a fused cast explosive charging structure in an projectile body with a large length-diameter ratio, the process control level mostly depends on field experience, and an invention method for designing a hot core rod feeding process from the process design point of view is lacked. Therefore, a method for designing a hot core rod feeding process by taking a fusion-cast explosive charging structure with a large length-diameter ratio as an object needs to be invented so as to improve the design level of products.
Disclosure of Invention
Aiming at the defects in the prior art, the invention provides a large length-diameter ratio fusion cast explosive charging hot core rod feeding process design method, which is used for carrying out process simulation design on the casting process and the hot core rod feeding process of various fusion cast explosive charging structures with large length-diameter ratio size characteristics.
In order to achieve the above object, the present invention adopts the following technical solutions:
the invention relates to a large length-diameter ratio fusion cast explosive charging hot core rod feeding process design method, which is characterized in that a simulation method is adopted to design a hot core rod feeding process, the process design method comprises three parts, namely an elastomer with a large length-diameter ratio, a fusion cast explosive charging structure and a hot core rod, the three parts are trimmed and assembled in process design software to form a non-overlapping non-penetrating space geometric model, and a tetrahedral mesh division method is adopted to form a robust calculation model with a mesh Jacobian value not lower than 0.75; the process design method comprises two steps of casting process design and hot core rod feeding process design.
Further, the length-diameter ratio of the large length-diameter ratio projectile body ranges from 10:1 to 5: 1.
Further, the types of the fusion-cast explosive materials of the fusion-cast explosive charging structure are as follows: the mixed explosive is prepared by taking 2,4, 6-trinitrotoluene or 2, 4-dinitroanisole as a main carrier and adopting a fusion casting process.
Furthermore, the material of the hot core rod is pure copper or other metal materials with high thermal conductivity.
The casting process design comprises the following steps:
step A1, specifying a conventional gravity action casting type, specifying a casting area as the whole area of the fusion-cast explosive charging structural component, and specifying a casting inlet as a top center node group or a top side node group;
step A2, the specified casting process is divided into three casting stages, and the casting conditions range is as follows: the casting speed is 2.0-4.0 m/s, the casting temperature is 95-110 ℃, the casting duration is 5.0-60.0 s, and the casting interval time is 100-200 s;
and step A3, designating the casting process as a flow and heat transfer coupling analysis model, designating the maximum casting percentage as 99.8%, stopping the casting process when the maximum casting percentage is reached, and switching to a single heat transfer analysis model.
Further, in step a1, the number of nodes included in the top center node group or the top side node group may be increased or decreased according to the area of the casting inlet.
Further, in step a2, the ratio of the casting mass to the total mass in each of the three casting stages is: 15% -25%: 40% -60%: 25 to 30 percent.
The hot core rod feeding process design comprises the following steps:
step B1, designating the initial position of the hot core rod, and designating the heat preservation temperature of the hot core rod to be 85-100 ℃;
step B2, the specified hot core rod feeding process is divided into three feeding stages, and the range of the interface heat exchange coefficient between the hot core rod and the fused cast explosive charging structural component is 1020 W.m-2·K-1～1200W·m-2·K-1. And the solidification time after the maximum casting percentage is reached is specified to be 3600 s-5400 s, so that the fused cast explosive charging structure is completely cooled and formed.
Further, in step B1, the initial position of the hot mandrel is outside of the fused cast explosive charge structure component.
Further, in step B2, the three feeding stages specifically include: the distance between the bottom end position of the hot core rod and the top end of the fusion cast explosive charging structural part in the first feeding stage accounts for 80-70% of the total length of the whole fusion cast explosive charging structural part, and the heat preservation duration is 400-800 s; the distance between the bottom end position of the hot core rod and the top end of the fusion cast explosive charging structural part in the second feeding stage accounts for 60-50% of the total length of the whole fusion cast explosive charging structural part, and the heat preservation duration is 600-1200 s; the distance between the bottom end position of the hot core rod and the top end of the fused cast explosive charging structural part at the third feeding stage accounts for 40-20% of the total length of the whole fused cast explosive charging structural part, and the heat preservation duration is 300-600 s.
The invention utilizes process design software to realize the simulation design of the fusion-cast explosive charging structure hot core rod feeding process in the projectile body with large length-diameter ratio. Firstly, the three parts of the large length-diameter ratio projectile body, the cast explosive charging structure and the hot core rod are assembled in a combined mode, and then the tetrahedral mesh division is carried out to form a robust calculation model. Secondly, designing a casting process, namely dividing the whole casting process into three stages, and designing process parameters including casting speed, casting temperature, casting interval time and casting quality proportion in each stage. And then designing a hot core rod feeding process, determining a proper hot core rod material and a heat preservation temperature, dividing the feeding process into three stages, and designing the position of the hot core rod and the heat preservation time length of each stage. And then, calling process design software to carry out flow and heat transfer numerical calculation on the casting and solidification processes of the fusion-cast explosive charging structure component under the design working condition, analyzing the effects and influences of the hot core rod compensation process on a temperature field and shrinkage porosity and shrinkage cavity, and improving the product quality of the fusion-cast explosive charging structure in the projectile body with large length-diameter ratio.
The invention has the following advantages:
(1) the invention abstracts and simplifies the actual process problem into three parts of a projectile body with large length-diameter ratio, a fusion-cast explosive charging structure and a hot core rod, and the three related parts can be flexibly and repeatedly modified and corrected for many times according to a processing drawing, so that the invention is the extraction and generalization of the general rule of the components of the actual process and also meets the basic requirement of process simulation design.
(2) The invention points to the fused cast explosive charge in the projectile body with large length-diameter ratio vividly, has strong pertinence, deep cut point, accurate idea and obvious effect, and the formed design method has high level, is easy to contact with practice and is convenient to operate and use.
(3) The casting process and the hot core rod feeding process of the fused cast explosive charging structure are creatively divided into three successive stages, and the combined mode of the working conditions is simulated and reproduced by adopting process design software, so that the times of process tests can be greatly reduced, the influences of various factors on the temperature field change and the solidification defects can be comprehensively analyzed, and the process design level of fused cast explosive charging products is comprehensively improved.
Detailed Description
The present invention will be further illustrated with reference to the following examples, but the present invention is not limited to the following examples.
Example 1
This example is designed for a process for feeding molten-cast explosive-charged hot-core rods, which uses 2,4, 6-trinitrotoluene as the main carrier.
The formula comprises the following components in parts by mass: 30 parts of 2,4, 6-trinitrotoluene and 70 parts of octogen, which are abbreviated as TOL-1 explosive.
According to a processing drawing, three parts, namely an projectile body with a large length-diameter ratio, a cast explosive charging structure and a hot core rod are modeled and designed, the length-diameter ratio of the projectile body with the large length-diameter ratio is 5:1, the type of the cast explosive material is TOL-1 explosive, and the material of the hot core rod is pure copper. Opening models of the three parts in process design software, trimming and assembling the three parts to form a non-overlapping and non-penetrating space geometric model, meshing the space geometric model by using tetrahedral meshes to enable Jacobian values of all meshes to be not less than 0.75 to form a robust calculation model, and continuing to perform casting process design and hot core rod feeding process design on the basis.
The casting process design comprises the following steps:
step A1, specifying a conventional gravity action casting type, specifying a casting area as the whole area of a fused cast explosive charging structural component, and specifying a casting inlet as a top end central node group;
step A2, the specified casting process is divided into three casting stages, and the casting conditions in the first casting stage are as follows: the casting speed is 2.0m/s, the casting temperature is 95 ℃, the casting duration is 5.0s, and the casting mass accounts for 15 percent of the total mass; the casting conditions in the second casting stage are as follows: the casting speed is 2.5m/s, the casting temperature is 97 ℃, the casting duration is 30.0s, the proportion of the casting mass to the total mass is 60%, and the casting interval time between the second casting stage and the first casting stage is 200 s; the casting conditions in the third casting stage are as follows: the casting speed is 2.2m/s, the casting temperature is 96 ℃, the casting duration is 20.0s, the proportion of the casting mass to the total mass is 25%, and the casting interval time between the third casting stage and the second casting stage is 150 s.
Step A3, designating the casting process as a flow and heat transfer coupling analysis model, designating the maximum casting percentage as 99.8%, stopping the casting process when the maximum casting percentage is reached, and switching to a single heat transfer analysis model;
the hot core rod feeding process design comprises the following steps:
step B1, designating the initial position of the hot core rod, wherein the initial position of the hot core rod is positioned outside the fused cast explosive charging structural component and is coaxial and consistent with the center of the fused cast explosive charging structural component, and the heat preservation temperature of the designated hot core rod is 85 ℃;
step B2, the specified feeding process of the hot core rod is divided into three feeding stages, the distance between the bottom end position of the hot core rod and the top end of the fused cast explosive charging structural component in the first feeding stage accounts for 70% of the total length of the whole fused cast explosive charging structural component, the heat preservation duration is 400s, and the interface heat exchange coefficient between the hot core rod and the fused cast explosive charging structural component is 1020 W.m-2·K-1(ii) a The distance between the bottom end position of the hot core rod and the top end of the fused cast explosive charging structural component in the second feeding stage accounts for 50% of the total length of the whole fused cast explosive charging structural component, the heat preservation duration is 600s, and the interface heat exchange coefficient between the hot core rod and the fused cast explosive charging structural component is 1080 W.m-2·K-1(ii) a The bottom end position of the hot core rod in the third feeding stageThe distance between the hot core rod and the top end of the fused cast explosive charging structural component accounts for 20% of the total length of the whole fused cast explosive charging structural component, the heat preservation duration is 300s, and the interface heat exchange coefficient between the hot core rod and the fused cast explosive charging structural component is 1050 W.m-2·K-1(ii) a And the solidification time after the maximum casting percentage is reached is specified to be 3600s, so that the fused cast explosive charging structure is completely cooled and formed.
Example 2
This example is designed for a process for feeding molten-cast explosive-charged hot-core rods, which uses 2,4, 6-trinitrotoluene as the main carrier.
The formulation of the fused cast explosive charge was the same as in example 1.
Modeling and designing three parts of a large length-diameter ratio projectile body, a cast explosive charging structure and a hot core rod according to a processing drawing, wherein the length-diameter ratio of the large length-diameter ratio projectile body is 8:1, the type of a cast explosive material is TOL-1 explosive, and the material of the hot core rod is pure copper. Opening models of the three parts in process design software, trimming and assembling the three parts to form a non-overlapping and non-penetrating space geometric model, meshing the space geometric model by using tetrahedral meshes to enable Jacobian values of all meshes to be not less than 0.75 to form a robust calculation model, and continuing to perform casting process design and hot core rod feeding process design on the basis.
The casting process design comprises the following steps:
step A1, specifying a conventional gravity action casting type, specifying a casting area as the whole area of a fused cast explosive charging structural component, and specifying a casting inlet as a node group at one side of the top end;
step A2, the specified casting process is divided into three casting stages, and the casting conditions in the first casting stage are as follows: the casting speed is 3.0m/s, the casting temperature is 98 ℃, the casting duration is 10.0s, and the casting mass accounts for 20 percent of the total mass; the casting conditions in the second casting stage are as follows: the casting speed is 2.5m/s, the casting temperature is 102 ℃, the casting duration is 40.0s, the proportion of the casting mass to the total mass is 50%, and the casting interval time between the second casting stage and the first casting stage is 200 s; the casting conditions in the third casting stage are as follows: the casting speed is 2.0m/s, the casting temperature is 95 ℃, the casting duration is 25.0s, the proportion of the casting mass to the total mass is 30%, and the casting interval time between the third casting stage and the second casting stage is 100 s.
Step A3, designating the casting process as a flow and heat transfer coupling analysis model, designating the maximum casting percentage as 99.8%, stopping the casting process when the maximum casting percentage is reached, and switching to a single heat transfer analysis model;
the hot core rod feeding process design comprises the following steps:
step B1, designating the initial position of the hot core rod, wherein the initial position of the hot core rod is positioned outside the fused cast explosive charging structural component and is coaxial and consistent with the center of the fused cast explosive charging structural component, and the heat preservation temperature of the designated hot core rod is 90 ℃;
step B2, the specified hot core rod feeding process is divided into three feeding stages, the distance between the bottom end position of the hot core rod and the top end of the fused cast explosive charging structural component in the first feeding stage accounts for 80% of the total length of the whole fused cast explosive charging structural component, the heat preservation duration is 600s, and the interface heat exchange coefficient between the hot core rod and the fused cast explosive charging structural component is 1060 W.m-2·K-1(ii) a The distance between the bottom end position of the hot core rod and the top end of the fused cast explosive charging structural component in the second feeding stage accounts for 50% of the total length of the whole fused cast explosive charging structural component, the heat preservation duration is 900s, and the interface heat exchange coefficient between the hot core rod and the fused cast explosive charging structural component is 1120 W.m-2·K-1(ii) a The distance between the bottom end position of the hot core rod and the top end of the fused cast explosive charging structural component at the third feeding stage accounts for 30% of the total length of the whole fused cast explosive charging structural component, the heat preservation duration is 600s, and the interface heat exchange coefficient between the hot core rod and the fused cast explosive charging structural component is 1100 W.m-2·K-1(ii) a And (3) setting the solidification time after the maximum casting percentage is reached to be 4800s, so that the fused cast explosive charging structure is completely cooled and formed.
Example 3
This example is designed for a process for feeding molten-cast explosive-charged hot-core rods, which uses 2,4, 6-trinitrotoluene as the main carrier.
The formula comprises the following components in percentage by mass: 30 parts of 2,4, 6-trinitrotoluene, 50 parts of hexogen, 16 parts of fine aluminum powder and 4 parts of microcrystalline wax, which are called THL-2 explosive for short.
Modeling and designing three parts of an projectile body with a large length-diameter ratio, a fused cast explosive charging structure and a hot core rod according to a processing drawing, wherein the length-diameter ratio of the projectile body with the large length-diameter ratio is 8:1, the type of a fused cast explosive material is THL-2 explosive, and the material of the hot core rod is high-thermal-conductivity aluminum alloy. Opening models of the three parts in process design software, trimming and assembling the three parts to form a non-overlapping and non-penetrating space geometric model, meshing the space geometric model by using tetrahedral meshes to enable Jacobian values of all meshes to be not less than 0.75 to form a robust calculation model, and continuing to perform casting process design and hot core rod feeding process design on the basis.
The casting process design comprises the following steps:
step A1, specifying a conventional gravity action casting type, specifying a casting area as the whole area of a fused cast explosive charging structural component, and specifying a casting inlet as a node group at one side of the top end;
step A2, the specified casting process is divided into three casting stages, and the casting conditions in the first casting stage are as follows: the casting speed is 2.7m/s, the casting temperature is 95 ℃, the casting duration is 20.0s, and the casting mass accounts for 19 percent of the total mass; the casting conditions in the second casting stage are as follows: the casting speed is 2.2m/s, the casting temperature is 101 ℃, the casting duration is 60.0s, the proportion of the casting mass to the total mass is 54%, and the casting interval time between the second casting stage and the first casting stage is 100 s; the casting conditions in the third casting stage are as follows: the casting speed is 2.5m/s, the casting temperature is 99 ℃, the casting duration is 30.0s, the proportion of the casting mass to the total mass is 27%, and the casting interval time between the third casting stage and the second casting stage is 200 s.
Step A3, designating the casting process as a flow and heat transfer coupling analysis model, designating the maximum casting percentage as 99.8%, stopping the casting process when the maximum casting percentage is reached, and switching to a single heat transfer analysis model;
the hot core rod feeding process design comprises the following steps:
step B1, designating the initial position of the hot core rod, wherein the initial position of the hot core rod is positioned outside the fused cast explosive charging structural component and is coaxial and consistent with the center of the fused cast explosive charging structural component, and the heat preservation temperature of the designated hot core rod is 95 ℃;
step B2, the specified hot core rod feeding process is divided into three feeding stages, the distance between the bottom end position of the hot core rod and the top end of the fused cast explosive charging structural component in the first feeding stage accounts for 75% of the total length of the whole fused cast explosive charging structural component, the heat preservation duration is 600s, and the interface heat exchange coefficient between the hot core rod and the fused cast explosive charging structural component is 1100 W.m-2·K-1(ii) a The distance between the bottom end position of the hot core rod and the top end of the fused cast explosive charging structural component in the second feeding stage accounts for 55% of the total length of the whole fused cast explosive charging structural component, the heat preservation duration is 1000s, and the interface heat exchange coefficient between the hot core rod and the fused cast explosive charging structural component is 1130 W.m-2·K-1(ii) a The distance between the bottom end position of the hot core rod and the top end of the fused cast explosive charging structural component at the third feeding stage accounts for 20% of the total length of the whole fused cast explosive charging structural component, the heat preservation duration is 450s, and the interface heat exchange coefficient between the hot core rod and the fused cast explosive charging structural component is 1200 W.m-2·K-1(ii) a And (3) setting the solidification time after the maximum casting percentage is reached to be 4800s, so that the fused cast explosive charging structure is completely cooled and formed.
Example 4
This example is designed for a process for feeding molten-cast explosive-charged hot-core rods, which uses 2,4, 6-trinitrotoluene as the main carrier.
The formulation of the fused cast explosive charge was the same as in example 3.
Modeling and designing three parts of an projectile body with a large length-diameter ratio, a fused cast explosive charging structure and a hot core rod according to a processing drawing, wherein the length-diameter ratio of the projectile body with the large length-diameter ratio is 10:1, the type of a fused cast explosive material is THL-2 explosive, and the material of the hot core rod is high-thermal-conductivity aluminum alloy. Opening models of the three parts in process design software, trimming and assembling the three parts to form a non-overlapping and non-penetrating space geometric model, meshing the space geometric model by using tetrahedral meshes to enable Jacobian values of all meshes to be not less than 0.75 to form a robust calculation model, and continuing to perform casting process design and hot core rod feeding process design on the basis.
The casting process design comprises the following steps:
step A1, specifying a conventional gravity action casting type, specifying a casting area as the whole area of a fused cast explosive charging structural component, and specifying a casting inlet as a top end central node group;
step A2, the specified casting process is divided into three casting stages, and the casting conditions in the first casting stage are as follows: the casting speed is 3.3m/s, the casting temperature is 96 ℃, the casting duration is 25.0s, and the casting mass accounts for 21 percent of the total mass; the casting conditions in the second casting stage are as follows: the casting speed is 2.8m/s, the casting temperature is 99 ℃, the casting duration is 55.0s, the proportion of the casting mass to the total mass is 50%, and the casting interval time between the second casting stage and the first casting stage is 150 s; the casting conditions in the third casting stage are as follows: the casting speed is 3.0m/s, the casting temperature is 96 ℃, the casting duration is 28.0s, the proportion of the casting mass to the total mass is 29%, and the casting interval time between the third casting stage and the second casting stage is 150 s.
Step A3, designating the casting process as a flow and heat transfer coupling analysis model, designating the maximum casting percentage as 99.8%, stopping the casting process when the maximum casting percentage is reached, and switching to a single heat transfer analysis model;
the hot core rod feeding process design comprises the following steps:
step B1, designating the initial position of the hot core rod, wherein the initial position of the hot core rod is positioned outside the fused cast explosive charging structural component and is coaxial and consistent with the center of the fused cast explosive charging structural component, and the heat preservation temperature of the designated hot core rod is 97 ℃;
step B2, the specified feeding process of the hot core rod is divided into three feeding stages, the distance between the bottom end position of the hot core rod and the top end of the fused cast explosive charging structural component in the first feeding stage accounts for 78% of the total length of the fused cast explosive charging structural component, the heat preservation duration is 700s, and the hot core rod and the fused cast explosive are fed with the hot core rodThe heat exchange coefficient of the interface between the explosive charging structural components of the cast explosive is 1090 W.m-2·K-1(ii) a The distance between the bottom end position of the hot core rod and the top end of the fusion cast explosive charging structural component in the second feeding stage accounts for 56% of the total length of the whole fusion cast explosive charging structural component, the heat preservation duration is 1100s, and the interface heat exchange coefficient between the hot core rod and the fusion cast explosive charging structural component is 1150 W.m-2·K-1(ii) a The distance between the bottom end position of the hot core rod and the top end of the fused cast explosive charging structural component at the third feeding stage accounts for 40% of the total length of the whole fused cast explosive charging structural component, the heat preservation duration is 500s, and the interface heat exchange coefficient between the hot core rod and the fused cast explosive charging structural component is 1200 W.m-2·K-1(ii) a And (3) setting the solidification time after the maximum casting percentage is reached to be 4800s, so that the fused cast explosive charging structure is completely cooled and formed.
Example 5
The example designs a feeding process of a fused cast explosive charging hot core rod with 2, 4-dinitroanisole as a main carrier.
The formula comprises the following components in percentage by mass: 32 parts of 2, 4-dinitroanisole, 28 parts of hexogen, 16 parts of fine aluminum powder, 21 parts of ammonium perchlorate and 3 parts of microcrystalline wax, which are called DRL-3 explosive for short.
According to a processing drawing, three parts, namely an projectile body with a large length-diameter ratio, a fused cast explosive charging structure and a hot core rod are modeled and designed, the length-diameter ratio of the projectile body with the large length-diameter ratio is 5:1, the type of a fused cast explosive material is DRL-3 explosive, and the material of the hot core rod is pure copper. Opening models of the three parts in process design software, trimming and assembling the three parts to form a non-overlapping and non-penetrating space geometric model, meshing the space geometric model by using tetrahedral meshes to enable Jacobian values of all meshes to be not less than 0.75 to form a robust calculation model, and continuing to perform casting process design and hot core rod feeding process design on the basis.
The casting process design comprises the following steps:
step A1, specifying a conventional gravity action casting type, specifying a casting area as the whole area of a fused cast explosive charging structural component, and specifying a casting inlet as a top end central node group;
step A2, the specified casting process is divided into three casting stages, and the casting conditions in the first casting stage are as follows: the casting speed is 3.6m/s, the casting temperature is 105 ℃, the casting duration is 10.0s, and the casting mass accounts for 23 percent of the total mass; the casting conditions in the second casting stage are as follows: the casting speed is 3.0m/s, the casting temperature is 108 ℃, the casting duration is 45.0s, the proportion of the casting mass to the total mass is 49%, and the casting interval time between the second casting stage and the first casting stage is 100 s; the casting conditions in the third casting stage are as follows: the casting speed is 3.2m/s, the casting temperature is 102 ℃, the casting duration is 35.0s, the proportion of the casting mass to the total mass is 28%, and the casting interval time between the third casting stage and the second casting stage is 150 s.
Step A3, designating the casting process as a flow and heat transfer coupling analysis model, designating the maximum casting percentage as 99.8%, stopping the casting process when the maximum casting percentage is reached, and switching to a single heat transfer analysis model;
the hot core rod feeding process design comprises the following steps:
step B1, designating the initial position of the hot core rod, wherein the initial position of the hot core rod is positioned outside the fused cast explosive charging structural component and is coaxial and consistent with the center of the fused cast explosive charging structural component, and the heat preservation temperature of the designated hot core rod is 99 ℃;
step B2, the specified hot core rod feeding process is divided into three feeding stages, the distance between the bottom end position of the hot core rod and the top end of the fused cast explosive charging structural component in the first feeding stage accounts for 80% of the total length of the whole fused cast explosive charging structural component, the heat preservation duration is 700s, and the interface heat exchange coefficient between the hot core rod and the fused cast explosive charging structural component is 1060 W.m-2·K-1(ii) a The distance between the bottom end position of the hot core rod and the top end of the fused cast explosive charging structural component in the second feeding stage accounts for 55% of the total length of the whole fused cast explosive charging structural component, the heat preservation duration is 1000s, and the interface heat exchange coefficient between the hot core rod and the fused cast explosive charging structural component is 1090 W.m-2·K-1(ii) a The distance between the bottom end position of the hot core rod and the top end of the fused cast explosive charging structural part at the third feeding stage accounts for the whole35% of the total length of the fused cast explosive charging structural component, the heat preservation duration is 500s, and the interface heat exchange coefficient between the hot core rod and the fused cast explosive charging structural component is 1120 W.m-2·K-1(ii) a The solidification time after the maximum casting percentage is designated as 5400s, so that the fused cast explosive charging structure is completely cooled and formed.
Example 6
The example designs a feeding process of a fused cast explosive charging hot core rod with 2, 4-dinitroanisole as a main carrier.
The formulation of the fused cast explosive charge was the same as in example 5.
Modeling and designing three parts of the large length-diameter ratio projectile body, the casting explosive charging structure and the hot core rod according to a processing drawing, wherein the length-diameter ratio of the large length-diameter ratio projectile body is 8:1, the casting explosive material is DRL-3 explosive, and the hot core rod is made of high-thermal-conductivity aluminum alloy. Opening models of the three parts in process design software, trimming and assembling the three parts to form a non-overlapping and non-penetrating space geometric model, meshing the space geometric model by using tetrahedral meshes to enable Jacobian values of all meshes to be not less than 0.75 to form a robust calculation model, and continuing to perform casting process design and hot core rod feeding process design on the basis.
The casting process design comprises the following steps:
step A1, specifying a conventional gravity action casting type, specifying a casting area as the whole area of a fused cast explosive charging structural component, and specifying a casting inlet as a node group at one side of the top end;
step A2, the specified casting process is divided into three casting stages, and the casting conditions in the first casting stage are as follows: the casting speed is 4.0m/s, the casting temperature is 110 ℃, the casting duration is 12.0s, and the casting mass accounts for 22 percent of the total mass; the casting conditions in the second casting stage are as follows: the casting speed is 3.3m/s, the casting temperature is 106 ℃, the casting duration is 55.0s, the proportion of the casting mass to the total mass is 52%, and the casting interval time between the second casting stage and the first casting stage is 200 s; the casting conditions in the third casting stage are as follows: the casting speed is 3.7m/s, the casting temperature is 108 ℃, the casting duration is 30.0s, the proportion of the casting mass to the total mass is 26%, and the casting interval time between the third casting stage and the second casting stage is 100 s.
Step A3, designating the casting process as a flow and heat transfer coupling analysis model, designating the maximum casting percentage as 99.8%, stopping the casting process when the maximum casting percentage is reached, and switching to a single heat transfer analysis model;
the hot core rod feeding process design comprises the following steps:
step B1, designating the initial position of the hot core rod, wherein the initial position of the hot core rod is positioned outside the fused cast explosive charging structural component and is coaxial and consistent with the center of the fused cast explosive charging structural component, and the heat preservation temperature of the designated hot core rod is 100 ℃;
step B2, the specified hot core rod feeding process is divided into three feeding stages, the distance between the bottom end position of the hot core rod and the top end of the fused cast explosive charging structural component in the first feeding stage accounts for 80% of the total length of the whole fused cast explosive charging structural component, the heat preservation duration is 800s, and the interface heat exchange coefficient between the hot core rod and the fused cast explosive charging structural component is 1160 W.m-2·K-1(ii) a The distance between the bottom end position of the hot core rod and the top end of the fusion cast explosive charging structural component in the second feeding stage accounts for 55% of the total length of the whole fusion cast explosive charging structural component, the heat preservation duration is 1200s, and the interface heat exchange coefficient between the hot core rod and the fusion cast explosive charging structural component is 1200 W.m-2·K-1(ii) a The distance between the bottom end position of the hot core rod and the top end of the fused cast explosive charging structural component at the third feeding stage accounts for 40% of the total length of the whole fused cast explosive charging structural component, the heat preservation duration is 600s, and the interface heat exchange coefficient between the hot core rod and the fused cast explosive charging structural component is 1150 W.m-2·K-1(ii) a The solidification time after the maximum casting percentage is designated as 5400s, so that the fused cast explosive charging structure is completely cooled and formed.
Comparative example 1
In this example, a molten explosive charge with a large length to diameter ratio was prepared by a conventional single casting and no hot-plug feeding process, using the same molten explosive charge formulation as in examples 1 and 2.
The length-diameter ratio of the large length-diameter ratio projectile body is 8:1, and the type of the fusion cast explosive material is TOL-1. The casting type is gravity casting, the casting speed is 2.5m/s, the casting temperature is 95 ℃, the casting process is ended continuously until the fusion casting explosive charging structure is completely filled, and the fusion casting explosive charging structure is naturally cooled to be molded in the air environment.
Comparative example 2
In this example, a large length to diameter ratio molten explosive charge was made using a conventional single casting and no hot-plug feeding process, using the same molten explosive charge formulations as in examples 3 and 4.
The length-diameter ratio of the large length-diameter ratio projectile body is 10:1, and the type of the fusion-cast explosive material is THL-2. The casting type is gravity casting, the casting speed is 3.0m/s, the casting temperature is 98 ℃, the casting process is ended continuously until the fusion casting explosive charging structure is completely filled, and the fusion casting explosive charging structure is naturally cooled to be molded in the air environment.
Comparative example 3
In this example, a large length to diameter ratio molten explosive charge was made using a conventional single-shot casting and no hot-plug feeding process, using the same molten explosive charge formulations as in examples 5 and 6.
The length-diameter ratio of the large length-diameter ratio projectile body is 5:1, and the type of the fusion-cast explosive material is DRL-3. The casting type is gravity casting, the casting speed is 4.0m/s, the casting temperature is 108 ℃, the casting process is ended continuously until the fusion casting explosive charging structure is completely filled, and the fusion casting explosive charging structure is naturally cooled to be molded in the air environment.
Performing post-processing on the process simulation calculation results of the embodiments 1 to 6 by adopting process design software, and analyzing and extracting a solidification defect calculation result; nondestructive inspection was performed on the fused cast explosive charges of comparative examples 1 to 3 using a 2MeV industrial CT, and the solidification defect results were detected, with the comparison results shown in table 1.
TABLE 1 solidification Defect analysis comparison results
The results shown in table 1 show that the method can be used for carrying out targeted process simulation design on the casting process and the hot core rod feeding process of the cast explosive charging structure with the large length-diameter ratio, and is beneficial to reducing the process test times and improving the product quality. The influence of various process factors on a temperature field and solidification defects can be comprehensively analyzed, so that the process design level of the fusion-cast explosive charging product is improved.
Although the invention has been described herein with reference to a number of illustrative embodiments thereof, it should be understood that numerous other modifications and embodiments can be devised by those skilled in the art that will fall within the spirit and scope of the principles of this disclosure.
Claims (1)
1. A large length-diameter ratio fusion cast explosive charging hot core rod feeding process design method is characterized in that a process simulation method is adopted to design a hot core rod feeding process, the process design method comprises the design of three parts, namely an elastomer with a large length-diameter ratio, a fusion cast explosive charging structure and a hot core rod, the three parts are trimmed and assembled in process design software to form a space geometric model without overlapping and penetration, and a robust calculation model with a mesh Jacobian value not lower than 0.75 is formed by adopting a tetrahedral mesh division method; the process design method comprises two steps of casting process design and hot core rod feeding process design;
the length-diameter ratio of the large length-diameter ratio projectile body ranges from 10:1 to 5: 1;
the fusion-cast explosive material type of the fusion-cast explosive charging structure is as follows: 2,4, 6-trinitrotoluene or 2, 4-dinitroanisole is used as a main carrier and is prepared by a fusion casting process to obtain a mixed explosive;
the casting process design comprises the following steps:
step A1, specifying a conventional gravity action casting type, specifying a casting area as the whole area of the fused cast explosive charging structural component, and specifying a casting inlet as a top center node group or a top side node group;
step A2, the specified casting process is divided into three casting stages, and the casting conditions range is as follows: the casting speed is 2.0 m/s-4.0 m/s, the casting temperature is 95 ℃ to 110 ℃, the casting duration is 5.0 s-60.0 s, and the casting interval time is 100 s-200 s; the proportion range of the casting quality in each of the three casting stages to the total mass is as follows: 15% -25%: 40% -60%: 25% -30%;
step A3, designating the casting process as a flow and heat transfer coupling analysis model, designating the maximum casting percentage as 99.8%, stopping the casting process when the maximum casting percentage is reached, and switching to a single heat transfer analysis model;
the hot core rod feeding process design comprises the following steps:
step B1, designating the initial position of the hot core rod, and designating the heat preservation temperature of the hot core rod to be 85-100 ℃;
step B2, the specified hot core rod feeding process is divided into three feeding stages, and the range of the interface heat exchange coefficient between the hot core rod and the fusion cast explosive charging structural component is 1020W ∙ m-2∙K-1~1200W∙m-2∙K-1(ii) a The solidification time after the maximum casting percentage is appointed to be 3600 s-5400 s, and the fusion-cast explosive charging structure is cooled and formed completely;
in step B2, the three feeding stages specifically include: the distance between the bottom end position of the hot core rod and the top end of the fusion cast explosive charging structure part in the first feeding stage accounts for 80-70% of the total length of the whole fusion cast explosive charging structure part, and the heat preservation duration is 400-800 s; the distance between the bottom end position of the hot core rod and the top end of the fusion cast explosive charging structure part in the second feeding stage accounts for 60-50% of the total length of the whole fusion cast explosive charging structure part, and the heat preservation duration is 600-1200 s; the distance between the bottom end position of the hot core rod and the top end of the fusion cast explosive charging structural part at the third feeding stage accounts for 40% -20% of the total length of the whole fusion cast explosive charging structural part, and the heat preservation duration is 300-600 s.
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