Tools for the Formation of Optimised X-80 Steel Blast Tolerant Transverse Bulkheads
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Tools for the formation of optimised X-80 steel blast tolerant transverse bulkheads by Ian K. Raymond Masters of Engineering (Research) 2001 The University of New South Wales Abstract Surname: Raymond First name: Ian Other name: Kenneth Abbreviation for degree as given in the University calendar: ME School: Mechanical and Manufacturing Engineering Faculty: Engineering Title: Tools for the formation of optimised X-80 steel blast tolerant transverse bulkheads The Australian Maritime Engineering Cooperative Research Centre, and its partner organisation initiated this research effort. In particular, BHP and the Defence Science and Technology Organisation held the principal interest, as this research effort was a part of the investigation into the utilisation of X-80 steel in naval platforms. After some initial considerations, this research effort focussed on the development of X-80 steel blast tolerant transverse bulkheads. Unfortunately, due to the Australian Maritime Engineering Cooperative Research Centre not being re-funded after June 2000 and other project factors, the planned blast tests were not conducted, hence this research effort focussed on the tools needed for the formation of optimised blast tolerant transverse bulkheads rather than on the development of a single structural arrangement. Design criteria were formed from the worst case operational requirements for a transverse bulkhead, which would experience a 150 kg equivalent blast load at 8 m from the source. Since the development of any optimised blast tolerant structure had to be carried out using finite element analysis, material constants for X-80 steel under high strain rates were obtained. These material constants were implemented in the finite element analysis and the appropriate solid element size was evolved. The behaviour and effects of stress waves and high strain rates were considered and the literature reviewed, in particular consideration was given to joint structures and weld areas effects on the entire structural response to a blast load. Furthermore, to support the design criteria, rupture prediction and determination methodologies have been investigated and recommendations developed about their relevance. Since the response of transverse bulkheads is significantly affected by their joint and stiffener arrangements, separate investigations of these structures were undertaken. The outcomes of these investigations led to improvements in the blast tolerance behaviour of joints and stiffeners, which also improved the overall response of the transverse bulkhead to air blast loads. Finally, an optimisation procedure was developed that met all the design criteria and its relevant requirements. This optimisation procedure was implemented with the available data, to show the potential to develop optimised X-80 steel blast tolerant transverse bulkheads. Due to the constraints mentioned above the optimisation procedure was restricted, but did show progression towards more effective blast tolerant transverse bulkhead designs. Factors, such as double skin bulkheads, maximising plate separation, and the use of higher yield steel all showed to be beneficial in the development of optimal X-80 steel blast tolerant transverse bulkheads, when compared to the ANZAC- class D-36 steel transverse bulkheads. 1 Dedication This thesis is dedication to my parents, brother, and my fiancée. ii Declaration iii Table of contents Tools for the formation of optimised X-80 steel blast tolerant transverse bulkheads i Dedication ii Declaration iii Table of contents iv Chapter 1: Introduction 1 1.1. Introduction 2 1.2. Warship survivability 2 1.3. Explosives and their blast loads 15 1.4. Structural response to blast loads 27 · Material elasticity 50 · Influence of finite displacement 50 · Material strain rate sensitivity 50 · Combined influence of finite displacement and strain rate sensitivity 51 · Transverse shear and rotatory inertia 51 · Material strain hardening 52 · Bound method 52 · Mode approximation methods 53 · Dynamic plastic buckling 53 iv · Dynamic progressive buckling 54 · Scaling 55 · Ductile-brittle fracture transition related to size 58 1.5. Stress waves and strain rate 61 1.6. The J-integral and material failure 62 1.7. What is X-80 steel 64 1.8. What is being attempted in this research 67 1.9. Conclusion 68 Chapter 2: Design criteria for X-80 steel blast tolerant transverse bulkheads 70 2.1. Introduction 71 2.1.1. Transverse bulkhead attributes to naval platform survivability 71 2.1.2. Current transverse bulkhead formation 72 2.2. Operational requirements 73 2.2.1. Pre air blast loads 75 2.2.2. Air blast load 75 2.2.3. Post air blast load 76 2.3. Design criteria 76 2.3.1. Pre air blast loads 76 2.3.2. Air blast load 78 2.3.3. Post air blast load 80 2.3.4. Other relevant factors 81 2.4. Conclusion 82 Chapter 3: High strain rate data and analysis 84 3.1. Introduction 85 3.2. Experimental set-up 85 3.3. Constitutive Models 86 3.3.1. Cowper-Symonds model 86 3.3.2. Johnson-Cook model 87 3.4. Results from the compression Hopkinson bar tests 88 3.5. Results from the microscope investigation 94 3.6. Conclusion 98 v Chapter 4: Development and evaluation of a finite element modelling technique 99 4.1. Introduction 100 4.2. Modelling parameters 100 4.3. Initial finite element models 101 4.3.1. MSC/NASTRAN models 101 4.3.2. Simple LS/DYNA finite element models 103 4.4. LS/DYNA modelling of the D-36 steel transverse bulkheads 109 4.4.1. Shot 1, 4, 9, and 10 initial observations 111 4.5. Comparison of the finite element data set to the photometric data set 118 4.6. Conclusion 120 Chapter 5: Factors related to the design constraints 122 5.1. Introduction 123 5.2. Stress waves and strain rate in steel due to a blast load 123 5.3. Prediction of rupture 128 · MSC/PATRAN, MSC/NASTRAN, and LS/DYNA 137 · Check_set.for 139 · Solve_num.for 139 · Nastran_position.pm 140 · Nastran_stress.pm 140 · Dyna_position.pm 140 · Dyna_stress.pm 140 · Solve_stress.for 141 · Stress_dyn.for 141 · Check_element.for 141 · Face_Numbering.for 142 · J-integral.for 142 5.4. Conclusion 144 Chapter 6: Bulkhead component investigation 145 6.1. Introduction 146 vi 6.2. Joint structures 146 6.3. Stiffener structures 164 6.4. Conclusion 201 Chapter 7: Development of an optimised X-80 steel blast tolerant transverse bulkhead 202 7.1. Introduction 203 7.2. Optimisation procedure 203 · Step 1 203 · Step 2 204 · Step 3 205 · Step 4 206 · Step 5 206 · Step 6 206 · Step 7 206 · Step 8 206 7.3. Optimisation cycles 208 · Cycle 1 209 · Cycle 2 211 · Cycle 3 213 · Cycle 4 216 7.4. Additional outcomes 219 7.5. Conclusion 222 Chapter 8: Conclusion 223 8.1. Summary 224 Acknowledgements 229 Bibliography 230 Appendix A: Sheppard Interpolation 259 A.1. Sheppard interpolation explanation 260 vii A.2. Fortran codes 261 Appendix B: Sea Australia 2000 paper 267 B.1. Raymond et al. (2000a) 268 Appendix C: Structures Under Shock and Impact paper 276 C.1. Raymond et al. (2000b) 277 Appendix D: Structural Failure and Plasticity paper 287 D.1. Raymond et al. (2000c) 288 viii Chapter 1 Introduction Abstract: In this ‘Introduction’ chapter a literature survey of the topics covered in this research project is given. Additionally, an explanation of the research project is given and its interconnection to the literature survey. 1 1.1. Introduction In this chapter a survey of literature relevant to the research task has been covered. Due to the extreme broadness of the topics covered, the literature survey is quite diverse. The diversity of the literature topics ranges from ‘Warship survivability’ to ‘What is X-80 steel’, specifically focusing on blast loads, structural responses to blast loads, stress waves, strain rate effects and the J-integral. To finalise this chapter a brief explanation of the research project is given as well as the interconnection between this project and the literature survey. 1.2. Warship survivability Survivability of warships, i.e. resilience of warships, up to and through World War 2 had continually improved. These improvements were aimed at reducing the vessels vulnerability to kinetic weapons above the waterline and explosive weapons below the waterline on the side of the vessel, as mentioned in Begg et al. (1990), “From September 1943 to October 1944 the German battleship Tirpitz sustained direct hits from 2 underwater mines and 22 aerial bombs, totalling 22 tons of explosive charge – and survived. In November 1944 she was hit by a further 6 high explosive bombs of 5 tons each before capsizing through flooding. The Tirpitz can be described as a resilient warship. This can be attributed towards her 22 watertight subdivisions and armour plating up to 12 inches thick around her sides and deck, giving a displacement of 50,000 tons.” Post World War 2 the perception was that nuclear weapons would be used frequently in any future conflict, therefore designing warships to be resilient was not considered as highly as throughout the war. Additionally, since World War 2, torpedos and mines have been designed to explode under the keel of a vessel, making it almost impossible to deal with the blast pressure wave/bubble. Hence from 1950’s to late 1980’s warships were made lighter, and had more of their displacement directed to offensive 2 capabilities. Thus there was an improvement in their attacking capabilities and also a significant increase in battle damage, as supported in Dawson and Orton (1990), 16 out of the 23 warships sent by the Royal Navy to the Falklands War were damaged. Additionally, taking into consideration the incidents that have occurred in the Persian Gulf, modern warships are now being developed with greater consideration of survivability requirements. Before discussing the factors and the undertakings to improve survivability, the following recent examples of warship battle damage are canvassed.