Research on directional rock blasting based on different slotted pipe materials of the combined charge structure.

For shaped charge blasting projects in mining, civil engineering, and similar fields, it is proposed to modify the charge structure by combining slotted tubes and shaped charge liners to obtain a new type of charge structure. This aims to achieve directional rock breaking through the focused action of the shaped charge. The influence of different slotted pipe materials on the directional rock-breaking effect of concentrated energy using a new charge structure is explored through theoretical analysis combined with model test study, high-speed camera, stress-strain gauge, and other equipment. A comparison is made between slotted pipes made of aluminum, kraft paper, and PVC, with the cutting width of 2 mm. Based on the characteristics of the cracks formed after blasting, the new charge structure made of aluminum slotted pipe produces a penetrating crack that is almost consistent with the pre-cracking direction. Based on the corresponding characteristics of successively released blasting energy, the guiding and convergence effect of the new charge structure made of aluminum slotted pipe on the explosion energy is greater than that of the new charge structure made of the other two types of slotted pipe material. According to the strain data measured after blasting, the peak arrival time of the strain peak in the direction of the slotted pipe on one side of the shaped hood is shorter than that in the other two directions, and the peak strain is greater than that in the other two directions while having a better energy gathering effect. Based on the findings, the new charge structure with directional energy concentration has a damage reduction effect. Furthermore, the material of aluminum slotted pipe is found to be better than PVC slotted pipe, whereas the material of PVC slotted pipe is better than kraft paper slotted pipe in achieving directional rock breaking.

Study on Perforation Behavior of PTFE/Al Reactive Material Composite Jet Impacting Steel Target.

To study the penetration and cratering effect of reactive material composite jets, a series of experiments are carried out for the shaped charge (SC) with different composite liners damaging steel targets. The inner layer of composite liners is metal and the outer one is a polytetrafluoroethylene/aluminum (PTFE/Al) reactive material. Copper (Cu), titanium (Ti) and Al inner liners are used in this paper. The reactive material liner is composed of 73.5 wt.% PTFE and 26.5 wt.% Al powder through mass-matched ratios. Reactive material composite liners are prepared through machining, cold pressing and a sintering process. The SC mainly consists of a case, a composite liner, high-energy explosive and an initiator. The steel target is steel 45#, with a thickness of 66 mm. A standoff of 1.0 CD (charge diameter) is selected to conduct the penetration experiments. The experimental results show that when the inner layer of the composite liner is composed of Ti and Al, the hole diameters on the steel target formed by the reactive material composite jet are significantly larger than that of the inner Cu liner. By introducing the initiation delay time (τ) and detonation-like reaction model of PTFE/Al reactive materials, an integrated numerical simulation algorithm of the penetration and detonation-like effects of reactive material composite jets is realized. Numerical simulations demonstrate that the initial penetration holes on the steel targets are enlarged under the detonation-like effects of PTFE/Al reactive materials, and the simulated perforation sizes are in good agreement with the experimental results.

The Influence of Closed-Cell W-Shaped Liner Parameters on the Penetration Performance of Integral Annular Shaped Charge.

To further enhance the hole-opening ability of the metal jet formed by the annular shaped charge on the armored steel target, a new annular shaped charge structure of a closed-cell W-shaped charge liner is designed based on a certain penetration depth. The impact of the length-diameter ratio of the charge, the inverted cone angle, and the cone angle of the liner on the opening diameter of the annular metal jet are studied through the orthogonal optimization of the annular shaped charge structures carried out by numerical simulation, which shows that the inverted cone angle and the cone angle of the liner are among the main factors that affect penetration depth and the opening diameter of the annular jet, respectively. According to this, an optimum annular charge structure considering both penetration depth and opening diameter is designed and tested by experiments. According to the results, the optimized annular jet records an opening diameter of 0.83 CD (Charge Diameter) when it penetrates the armored steel target with a thickness of 0.53 CD. The experimental results are consistent with the numerical simulation. The research results have certain practical engineering significance for guiding the design of the front-stage annular shaped charge structure of the multi-effect destructive warhead.

Study on Forming Law and Penetration of a Spherical Cone Composite Structure Liner Based on the Explosion Pressure-Coupling Constraint Principle.

The liner is an important part of shaped charge. In this paper, the spherical cone composite structure liner composed of a spherical missing body and truncated cone (hereinafter referred to as the SCS liner) is studied. The SCS liner is made of copper. Based on this, a shaped charge structure based on the explosion pressure-coupling constraint principle is designed, filling an 8701 explosive (RDX-based explosive). Through pulse X-ray tests, numerical simulation, and static explosion tests, the significance of the detonation pressure-coupling constraint principle, as well as the forming law and penetration efficiency of the SCS liner are studied. The results show that in the pulsed X-ray test, a split jet with high velocity is formed in the SCS liner. The explosion pressure-coupling constraint principle delays the attenuation of the internal explosion pressure and improves the shape of jet. After the SCS liner is selected, the penetration depth is increased by 70.38%. The average head velocity of the explosive charge jet is 7594.81 m/s. The diameter of the hole formed by the jet of the explosive charge is 20.33 mm. The hole expands inside, and the perforation depth is 178.87 mm. The numerical simulation is in good agreement with the test.

Experimental and Numerical Study on the Penetration Performance of a Shaped Charge.

In guided ammunition, because a shaped energy jet warhead is located behind the control cabin (including the guidance cabin, the steering gear cabin, and the flight control cabin), the penetration order of a shaped energy jet is the control cabin and the target plate. In order to obtain maximum penetration depth by a shaped energy jet into a Q235 steel plate, the penetration performance of shaped energy jets was studied by numerical simulation and experimental verification. Firstly, the penetration performance of a warhead under different conditions at a certain explosion height is studied, which is the penetration performance of a Q235 steel plate with and without the control cabin. Secondly, the numerical simulation results are verified by experimental method. The numerical simulation and experimental results showed that, after penetration of the shaped energy jet warhead into the control cabin, it continued to penetrate the 20 mm-thick Q235 steel plate. At a certain explosion height, the maximum penetration depth of the shaped energy jet warhead into the Q235 steel plate was about 80 mm. Alongside the numerical simulation and experiment, the armor-breaking process of the shaped charge jet was analyzed theoretically. The results show that when the shaped energy jet warhead is located behind the control cabin, although the control cabin will have a certain impact on the penetration ability of shaped energy jet, the penetration performance of the residual jet still has the ability to penetrate light armor.

Experimental Study on Damage Characteristics of Copper-Reinforced Polytetrafluoroethylene Shaped-Charge Warhead Liner.

Polymer materials have important applications in the4 terminal effect and damage by shaped-charge warheads. However, the low strength of pure PTFE materials reduces the penetrability of the expansive jet from these warheads, hindering its application. This study improves the strength of pure PTFE material by adding Cu powder to the shaped-charge liner. Three types of PTFE/Cu composites with different densities are prepared. The effect of increasing the density on the performance of an expansive jet is studied by a dynamic mechanical property experiment, microscopic analysis, numerical simulation, and a penetration experiment. The results show that the toughness and impact strength of the PTFE/Cu composites improve when 18-50.5% Cu is added. The strength of the composite increases linearly with the increase in Cu content. Numerical simulations and X-ray pulse experiments reveal that the addition of Cu powder enhances the cohesiveness of the head of the expansive jet. The jet head becomes more cohesive as the Cu content is increased. However, the length and diameter of the jet become smaller. The jet can create a deeper hole in the steel target and increase damage as more Cu is added to the liner.

Penetration and Cratering of Steel Target by Jets from Titanium Alloy Shaped Charge Liners.

In order to enlarge the crater diameter of shaped charge jet penetration into steel targets, this paper investigates the penetration and cratering characteristics of steel targets by shaped charge jets from titanium alloy liners. Titanium alloy shaped charge liners are prepared separately with mechanical processing and selective laser melting (SLM), and pulsed X-ray radiography is used to identify jet formation characteristics. Jet formation is numerically simulated by AUTODYN-3D, and steel target penetration tests are carried out at a short jet stand-off distance. The results show that AUTODYN-3D can realistically simulate jet formation from titanium alloy liners and that the SLM-processed liner exhibits better penetration performance than the mechanically processed liner. The existing cratering formula of jet penetration is modified to make it consistent with the aperture variations of jet penetration from titanium alloy-lined shaped charges at a short stand-off distance. The findings of this study are expected to provide technical and theoretical support for research on the penetration characteristics of the jets from titanium alloy-lined shaped charges.

Research on the Formation Characteristics of the Shaped Charge Jet from the Shaped Charge with a Trapezoid Cross-Section.

The formation characteristics of the shaped charge jet (SCJ) from the shaped charge with a trapezoid cross-section is analyzed in this work. A theoretical model was developed to analyze the collapsing mechanism of the liner driven by the charge with a trapezoid cross-section. Based on the theoretical model, the axial and radial velocities of the SCJ from different trapezoid cross-section charges. The pressure model was employed to calculate the velocity for the subcaliber shaped charge, which was verified through numerical simulation. The results show that the influence of the angle of the trapezoidal charge (acute angle) on the axial velocity of the SCJ is not distinct, whereas the variation of the radial velocity of the shaped charge jet is obvious as the change in the angle of the trapezoidal charge. In addition, the related X-ray experiments were conducted to verify the theory. The theoretical results correlate with the experimental results reasonably well.

Research on structural parameter optimization of elliptical bipolar linear shaped charge based on machine learning.

Numerical simulation based on SPH method, compared with laboratory experiments, using the grey correlation theory to analyze the correlation between the parameters of the elliptical bipolar linear shaped charge and the performance of the shaped charge jet. The structure of shaped charge is optimized by machine learning to obtain the optimal structural parameters, and it is compared with the rock crack development of shaped charge blasting in practical application. The results show that the structural parameters of the shaped charge have the same influence on the jet head velocity, and there are certain differences in the impact on the jet length. The fitted curve of the support vector machine (SVM) regression model based on the genetic algorithm (GA) is high prediction accurate. By comparing the optimization results with the actual engineering application of the shaped charge structure, the rock breaking effect has been significantly improved, which has important guiding significance for the actual engineering application.

Formation Behaviors of Coated Reactive Explosively Formed Projectile.

The formation behavior of coated reactive explosively formed projectiles (EFP) is studied by the combination of experiments and simulations. The results show that the coated EFP can be obtained by explosively crushing the double-layer liners, and the simulation agrees with the experiment well. Then, the interaction process between the two liners is discussed in detail, and the formation and coating mechanism are revealed. It can be found that there are three phases in the formation process, including the impact, closing and stretching phases. During the impact phase, the velocities of two liners rise in turns with the kinetic energy exchange. In the closing phase, the copper liner is collapsed forward to the axis and completely coats the reactive liner. It is mentioned that the edge of the copper liner begins to form a metal precursor penetrator in this stage. During the stretching phase, the coated reactive EFP is further stretched and fractured, resulting in the separation of the metal precursor penetrator and the following coated reactive projectile. Further studies show both the edge thickness and the curvature radius of the copper liner have significant influences on formation behaviors. By decreasing the edge thickness or the curvature radius, the difficulty of closing decreases, but the tip velocity and the length of precursor penetrator increases. As the thickness and diameter of the reactive liner decrease, the coating velocity increases slightly, but the total length of coated reactive EFP tends to decrease.

The Effect of Cylindrical Liner Material on the Jet Formation and Penetration Capability of Cylinder-Cone-Shaped Charge.

The jet formation and penetration capacity of cylinder-cone-shaped charges against steel targets were studied using the method of numerical simulation. Cylinder-cone-shaped charge models with five cylindrical liner materials, including nickel, tungsten, tantalum, steel 4340 and copper, were established to investigate the penetration capability and were compared with the classical conical-shaped charge. Moreover, the influence of the connection method of the cylindrical liner and the truncated liner on the jet performance was examined. The results show that the head velocity of the projectile formed by the cylinder-cone-shaped charge with a cylindrical nickel liner was larger than that with other cylindrical liner materials; in addition, it was larger by 50.2% compared with that formed by the classical conical-shaped charge. The penetration depth of the steel target by the cylinder-cone-shaped charge with a cylindrical copper liner was the largest, which could be 51.7% higher than that of a classical conical-shaped charge at a standoff of 2.5 D. For 2.0 D and 2.5 D standoff distances, the penetration depths were increased by 18.4% and 29.5%, respectively, by using the connection method of putting the cylindrical nickel liner on the neck of the truncated liner compared with that of the previous cylinder-cone-shaped charge with a cylindrical nickel liner.

Formation of Shaped Charge Projectile in Air and Water.

With the improvement of the antiknock performance of warships, shaped charge warheads have been focused on and widely used to design underwater weapons. In order to cause efficient damage to warships, it is of great significance to study the formation of shaped charge projectiles in air and water. This paper uses Euler governing equations to establish numerical models of shaped charges subjected to air and underwater explosions. The formation and the movement of Explosively Formed Projectiles (EFPs) in different media for three cases: air explosion and underwater explosions with and without air cavities are discussed. First, the velocity distributions of EFPs in the formation process are discussed. Then, the empirical coefficient of the maximum head velocity of EFPs in air is obtained by simulations of air explosions of shaped charges with different types of explosives. The obtained results agree well with the practical solution, which validates the numerical model. Further, this empirical coefficient in water is deduced. After that, the evolutions of the head velocity of EFPs in different media for the above three cases are further compared and analyzed. The fitting formulas of velocity attenuation of EFPs, which form and move in different media, are gained. The obtained results can provide a theoretical basis and numerical support for the design of underwater weapons.

The Penetration-Explosion Effects of Differently Distributed Inactive/Active Composite Shaped Charge Jets.

An analysis of the penetration-explosion (PE) effects of four distributions of inactive/active composite jets shows that a well-designed inactive/active double-layer liner can promote composite jet damage. Penetration experiments were then carried out for shaped charge jets having a single inactive (Cu) liner or an inactive/active (Cu/Al) double-layer liner with variable liner height. The behaviors and firelight patterns of the different jets were captured by high-speed photography. The perforation, deformation area, and deflection were measured for each plate, showing that the Cu/Al jets have stronger PE effects. Numerical simulation shows that the tip of the composite jet generated from the full-height liner is only Cu, whereas for the other jet, from the double-layer liner, Cu is almost wrapped entirely by Al.

Formation Behavior and Reaction Characteristic of a PTFE/Al Reactive Jet.

To reveal the expansion phenomenon and reaction characteristics of an aluminum particle filled polytetrafluoroethylene (PTFE/Al) reactive jet during the forming process, and to control the penetration and explosion coupling damage ability of the reactive jet, the temperature and density distribution of the reactive jet were investigated by combining numerical simulation and experimental study. Based on the platform of AUTODYN-3D code, the Smoothed Particle Hydrodynamics (SPH) algorithm was used to study the evolution behaviors and distribution regularity of the morphology, density, temperature, and velocity field during the formation process of the reactive composite jet. The reaction characteristic in the forming process was revealed by combining the distribution of the high-temperature zone in numerical simulation and the Differential Scanning Calorimeter/Thermo-Gravimetry (DSC/TG) experiment results. The results show that the distribution of the high-temperature zone of the reactive composite jet is mainly concentrated in the jet tip and the axial direction, and the reactive composite jet tip reacts first. Combining the density distribution in the numerical simulation and the pulsed X-ray experimental results, the forming behavior of the reactive composite jet was analyzed. The results show that the reactive composite jet has an obvious expansion effect, accompanied by a significant decrease in the overall density.

Formation and Penetration Properties of a Shaped Charge with Zr41.2Ti13.8Cu12.5Ni10Be22.5 Liner.

In the military field, determining how to increase the hole-expanding ability of shaped charge warheads is a key and difficult issue with respect to warhead development. Amorphous alloys have grains or grain boundaries, with unique mechanical properties. Zr41.2Ti13.8Cu12.5Ni10Be22.5 can be used as the liner material of shaped charges, resulting in high-speed particle flows that differ from those of traditionally shaped charges. In this paper, based on the analysis of the mechanical response characteristics of Zr41.2Ti13.8Cu12.5Ni10Be22.5 and its fracture morphology under impact, combined with the formation theory of shaped charge jets, a semi-empirical formula is derived to calculate the velocity of non-cohesive high-speed particle flow considering the elastic strain energy loss. Additionally, the reliability of the proposed theoretical model is verified through experiments. The penetration process of Zr-based amorphous alloy high-speed particle flow into a concrete target is theoretically analyzed, and the penetration stages of the high-speed particle flow into the target are clearly distinguished. Combined with the penetration theory of shaped charge particle jets, a high-speed particle flow penetration model is proposed, and a pore expansion model is established through an energy method. The experimentally obtained data on depth of penetration are in agreement with the theoretical calculation results.

Numerical Simulation of Conical and Linear-Shaped Charges Using an Eulerian Elasto-Plastic Multi-Material Multi-Phase Flow Model with Detonation.

This study developed a hydrocode to numerically simulate both conical and linear-shaped charges using an Eulerian multi-material and multi-phase flow model. Elasto-plastic solids and the detonation of a high explosive charge were modeled using a Johnson-Cook material model and the programmed burn model, respectively. Further, the plasticity of the solids was calculated using a radial return mapping algorithm. The model was solved using a high-resolution computational fluid dynamics (CFD) technique on Cartesian grids. Material interfaces were tracked using the level-set method, and the boundary conditions were imposed using the ghost fluid method. The developed hydrocode was validated using high-speed impact problems. Consequently, the developed hydrocode was used to successfully simulate the evolution and penetration of metal jets in shaped charges after a detonation.

Experimental and Numerical Study on the PG-7VM Warhead Performance against High-Hardness Armor Steel.

Analyses presented in the article were carried out in order to characterize the main parameters of the shaped charge jet formed due to detonation of the PG-7VM warhead. As opposed to the previously published studies in which rolled homogeneous armored steel was mainly used as a target, in the current work the warhead penetration capability was determined against more contemporary high-hardness (500 HB) ARMSTAL 30PM steel armor with precisely determined mechanical properties. The research included experimental depth of penetration tests and their numerical reproduction in the LS-Dyna software. Special attention was paid to factors that could perturbate the shaped charge jet formation process and under- or overestimate its penetration capability. For this reason, warheads were X-ray inspected for structural discrepancies (voids or air inclusions in explosive, misalignment between the body, explosive, and liner, or lack of contact between the explosive and the liner) and properties of materials (explosive, targets, and most important warhead components) were analyzed before the experiments. The numerical model of the warhead was defined more accurately than in previously published studies, since it was based on the real grenade dimensions and its technical documentation. Thanks to this, the depth of penetration of the target made of ARMSTAL 30PM armored steel plates by the shaped charge jet formed from the PG-7VM warhead obtained by numerical simulation was consistent with the experimental results and equaled 278 mm and 280 mm, respectively. The difference between the experimental and numerical value was smaller than 1%, which confirms that the developed methodology of modeling allows users to properly reproduce the PG-7VM shaped charge jet formation and target penetration processes. A verified numerical model of the shaped charge jet penetration into a steel target was used to determine depth of penetration in function of stand-off distance for the PG-7VM warhead. A maximum depth of penetration of about 317 mm was obtained for the stand-off distance of 360 mm, which may indicate the potential direction of modernization of warheads.

Damage Mechanism of PTFE/Al Reactive Charge Liner Structural Parameters on a Steel Target.

The incorporation of reactive material damage element technology in ammunition warheads is a research hotspot in the development of conventional ammunition. The research results are of great significance and military application value to promote the development of high-efficiency damage ammunition technology. In this paper, we aimed to understand the behavior of the reactive jet and its damage effect on a steel target by undertaking theoretical analysis, numerical simulation, and experimental research. We studied the influence of structural and material parameters on the shape of the reactive jet based on autodyn-2d finite element simulation software, and the formation behavior of the reactive jet was verified using a pulsed X-ray experiment. By studying the combined damage caused by the steel target penetrating and exploding the reactive jet, the influence of the structural and performance parameters, and the explosion height of the reactive jet liner on the damage effect to the steel target was studied. A static explosion experiment was carried out, and the optimal structural and performance parameters for the reactive material and explosion height of the reactive jet liner were obtained.

Study on Penetration Performance of Rear Shaped Charge Warhead.

In guided munitions, the shaped charge jet (SCJ) warhead is located behind the simulation compartment (including the control cabin, the steering gear cabin, and the guidance cabin). Therefore, the order of penetration of the SCJ is the simulation cabin and the target. To study the penetration performance of the SCJ to the target plate, the numerical simulation method is used to study the penetration performance of the designed warhead for the steel target at different standoffs, and the depth of penetration (DOP) at the best standoff is obtained, that is, the DOP of the steel target is about 128 mm. Additionally, the penetration performance of the SCJ warhead to target is studied by numerical simulation and experimental verification. Numerical simulation and experimental results show that the DOP of the SCJ warhead to the steel target is 50 mm without the simulation cabin, and about 30 mm with the simulation cabin. The results show that the penetration performance of SCJ is greatly weakened under the condition of non-optimal standoff, but the rear shaped charge warhead still has a strong penetration performance after completing the penetration of the simulated cabin.

Comparison of Shaped Charge Jet Performance Generated by Machined and Additively Manufactured CuSn10 Liners.

The Selective Laser Melting (SLM) technique has attracted attention in a wide range of manufacturing research areas, including the defense industry because of its high efficiency and good consistency of manufactured material properties. Shaped charge liner is the crucial unit in the shaped charge warhead. However, jet performance formed by SLM-produced liner remains to be studied systematically. In the present research work, the SLM technique was applied to manufacture CuSn10 shaped charge liners. Casted CuSn10 liners were also fabricated using the classical turning method for comparison. The grain size of the SLM-produced liner was found to be much smaller than the machined liner due to the rapid heating and cooling rate during the SLM manufacturing process. This contributed to improved jet performance. A flash X-ray photography system was applied to capture jet stretching appearances. Necking appears at the jet tip formed by the machined liner, while the jet formed by the SLM-produced liner remains continuous. Penetration test results show that the penetration depth of the jet formed by the SLM-produced liner is around 27% larger than that formed by the machined liner. Segments along the sidewall of the penetration tunnels were selected for in-depth micro analysis. Energy dispersed spectrum (EDS) surface scanning results indicate the composition at the side wall of the penetrated tunnel. Metallurgical microscope was applied to distinguish four different phase zones of the target. The width of these different zones indicates the severity of the lateral interaction between the jet and target, which can be adopted to evaluate jet penetration capability. The present study analyzes the factors that influence jet performances and proves that SLM technology is well-adapted in the manufacturing of shaped charge liners.