Impact Mitigation Simulation of Explosive Bolts Based on a Spherical-Shell Array Buffer Structure
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摘要:为抑制航天器分离过程中爆炸螺栓解锁所诱发的火工冲击，本研究提出一种球壳阵列缓冲垫块，并运用任意拉格朗日-欧拉（ALE）流固耦合方法，系统探究其孔隙率、高度以及材料对冲击响应谱（SRS）的影响。研究结果显示：缓冲垫块借助逐层胞元的屈曲、弯曲以及局部破碎，实现“级联式”能量吸收，能够显著降低高频冲击。当孔隙率为70%、高度为3层（约 14.4 mm）时，SRS峰值达到最低，测点 1 和测点 2 的 SRS 峰值分别降低48.1% 和 52.7%，且该结构可通过3D打印技术制造。对4340钢、Ti-6Al-4V、2024铝以及紫铜等材料进行对比分析发现，低屈服强度的铜合金与铝合金在中高频段展现出明显的降冲击优势，其中铜材料使4 500 Hz处的SRS峰值相较于钛合金降低 4 324g。综合考量缓冲性能、工艺可行性以及航天无多余物要求，推荐选用孔隙率为70%、高度为3层的2024铝合金阵列垫块。本研究为爆炸螺栓的降冲击设计提供了可直接用于工程实践的参数依据。
Abstract:To mitigate the pyro-shock generated by explosive-bolt unlocking during spacecraft separation, a spherical-shell array cushion is proposed. Arbitrary-Lagrangian-Eulerian (ALE) fluid-solid coupling simulations were performed to quantify the influence of porosity, height and material on the shock response spectrum (SRS). The pad absorbs energy in a “cascading” mode through sequential cell buckling, bending and local fracture, markedly attenuating high-frequency shock. At 70% porosity and three-unit-cell height (≈14.4 mm), SRS peaks at measurement points 1 and 2 are reduced by 48.1% and 52.7%, respectively, and the geometry is readily additively manufactured. Among 4340 steel, Ti-6Al-4V, 2024 Al and pure copper, the low-yield-strength copper and aluminium alloys outperform the others in the mid- and high-frequency bands; copper lowers the 4 500 Hz SRS peak by 4 324g compared with titanium. Balancing attenuation performance, manufacturability and the zero-debris requirement of space missions, a 70 % porosity, three-layer 2024 aluminium alloy pad is recommended. The findings provide directly applicable design parameters for low-shock explosive-bolt systems.
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