泡沫铝夹芯结构抗鸟体冲击吸能机理及在飞机 机头端框挡板中的应用

张柱国; 吴志斌; 王家栋; 王怡; 黄甲; 崔浩; 李玉龙

doi:10.11883/bzycj-2025-0046

泡沫铝夹芯结构抗鸟体冲击吸能机理及在飞机机头端框挡板中的应用

doi: 10.11883/bzycj-2025-0046

张柱国^{1, 2,},
吴志斌^{1, 3},
王家栋¹,
王怡¹,
黄甲^1, ,,
崔浩¹,
李玉龙¹

1.
西北工业大学，陕西西安 710072
2.
上海航空器适航审定中心，上海 200232
3.
上海飞机设计研究院，上海 201210

基金项目: 国家自然科学基金（12472082）；中国商飞国家商用飞机制造工程技术研究中心创新基金项目（COMAC-SFGS-2023-2356）

详细信息

作者简介:
张柱国（1982－　），男，博士研究生，zhangzhuguo_hd@caac.gov.cn

通讯作者:
黄　甲（1991－　），男，副教授，博士生导师，jia.huang@nwpu.edu.cn

中图分类号: O389; V215.2
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- 文章访问数: 321
- HTML全文浏览量: 70
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- 被引次数: 0
出版历程
- 收稿日期: 2025-02-18
- 修回日期: 2025-07-27
- 网络出版日期: 2025-08-10

Energy absorption mechanism of aluminum foam sandwich structure against bird impact and its application in impact protection bulkhead inside airplane nose

ZHANG Zhuguo^{1, 2
,},
WU Zhibin^{1, 3},
WANG Jiadong¹,
WANG Yi¹,
HUANG Jia^{1
, ,},
CUI Hao¹,
LI Yulong¹

1.
Northwestern Polytechnical University, Xi’an 710072 Shaanxi China
2.
Shanghai Aircraft Airworthiness Certification Center, Shanghai 200232, China
3.
Shanghai Aircraft Design and Research Institute, Shanghai 201210, China

摘要

摘要: 针对现役民用飞机铝合金加筋结构机头端框挡板存在的轻量化不足问题，在深入探究泡沫铝夹芯结构抗鸟体冲击吸能机理的基础上，提出了一种新型泡沫铝夹层挡板结构。该结构采用非对称面板设计，高塑性2024-T3铝合金作为上面板，高强度7075-T6铝合金作为下面板，中间填充泡沫铝芯层，用以替代传统铝合金加筋板，旨在保证优异抗鸟撞性能的同时显著减轻结构重量。首先通过铝合金平板的高速鸟体撞击试验，验证了鸟体本构模型及接触算法的有效性，结合参数反演与仿真算例，验证了泡沫铝材料本构模型的准确性与适用性；进一步，利用Pam-crash软件对加筋板结构与泡沫铝夹芯结构端框进行了鸟撞瞬态冲击动力学仿真，对比分析了二者的冲击响应特性与能量吸收机理差异。研究表明：加筋板主要依靠塑性变形来吸收鸟撞能量，而泡沫铝夹芯结构则通过芯层的压缩坍塌失效、上面板的塑性大变形机制协同吸收能量；优化后的泡沫铝夹芯结构在能量吸收效率方面显著优于传统加筋板结构；基于泡沫铝夹芯结构的吸能特性，完成了覆盖挡板全区域的优化设计方案；基于全覆盖鸟撞冲击仿真结果，所提出的泡沫铝夹芯挡板设计方案在保持与现役结构同等抗鸟撞性能的前提下，减轻了30%以上的结构重量。
- 泡沫铝 /
- 夹芯结构 /
- 吸能机理 /
- 鸟撞 /
- 机头端框
Abstract: In response to the insufficient lightweight issue of the baffle plate for the nose end frame with an aluminum alloy stiffened structure in active civil aircraft, a new type of aluminum foam sandwich baffle structure is proposed based on an in-depth exploration of the energy absorption mechanism of aluminum foam sandwich structures against bird impact. This innovative design employs an asymmetric panel configuration that includes a highly ductile 2024-T3 aluminum alloy upper face sheet, a high-strength 7075-T6 aluminum alloy lower face sheet, and an aluminum foam core layer in between. It replaces the traditional aluminum alloy stiffened panel, aiming to significantly reduce structural weight while ensuring excellent bird strike resistance. First, the effectiveness of the bird body constitutive model and its contact algorithm was verified by comparing the high-speed bird body impact test on aluminum alloy flat plates with the simulated strain data. Based on previous experimental data, combined with parameter inversion and simulation cases, the simulation data of homogeneous and gradient aluminum foams are in good agreement with the test results, which verifies the accuracy and applicability of the aluminum foam material constitutive model. Furthermore, using the professional Pam-crash software, transient impact dynamics simulations of bird strikes were conducted on both the stiffened panel structure and the aluminum foam sandwich structure end frame. Combined with the damage and deformation conditions of each component and energy absorption data, a comparative analysis was made on the differences in their impact response characteristics and energy absorption mechanisms. The study shows that the stiffened panel mainly absorbs the energy of bird body impact through its plastic deformation, while the aluminum foam sandwich structure absorbs energy synergistically through the compressive collapse failure of the core layer and the large plastic deformation mechanism of the upper face sheet. The optimized aluminum foam sandwich structure is significantly superior to the traditional stiffened panel structure in terms of energy absorption efficiency. Subsequently, a full-coverage optimization design scheme for the baffle was completed based on the energy absorption characteristics of the aluminum foam sandwich structure. According to the full-coverage bird impact simulation results, the proposed aluminum foam sandwich baffle design achieves a structural weight reduction of more than 30% while maintaining the same bird strike resistance performance as the in-service structure. This research provides reliable technical references and innovative ideas for the lightweight bird strike-resistant design of the civil aircraft nose bulkhead.
- aluminum foam /
- sandwich structure /
- absorption mechanism /
- bird strike /
- nose bulkhead

HTML全文

图 1 空气炮试验装置

Figure 1. Air gun test device

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图 2 靶板

Figure 2. Target

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图 3 铝合金平板鸟撞仿真有限元模型

Figure 3. Finite element model of bird impact on aluminum alloy plate

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图 4 鸟撞平板过程试验与仿真模拟过程对比图

Figure 4. Comparison diagram of the bird-striking plate process test and simulation process

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图 5 试验中应变片1和4处的应变数据对比

Figure 5. Comparison of strain data at positions of strain gauge 1 and 4

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图 6 均质泡沫压缩仿真有限元模型

Figure 6. Finite element model of homogeneous foam compression simulation

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图 7 均质泡沫试验与仿真结果对比

Figure 7. Comparison of homogeneous foam test and simulation results

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图 8 梯度泡沫压缩仿真有限元模型

Figure 8. Finite element model of gradient foam compression simulation

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图 9 梯度泡沫试验与仿真结果对比

Figure 9. Comparison of gradient foam test and simulation results

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图 10 机头端框模型

Figure 10. Nose bulkhead model

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图 11 加筋挡板

Figure 11. Reinforced Bulkhead

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图 12 泡沫铝夹芯结构

Figure 12. Foam aluminum sandwich structure

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图 13 鸟体有限元模型

Figure 13. Finite element model of bird body

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图 14 夹芯结构C的应力云图

Figure 14. Stress contour diagram of sandwich structure C

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图 15 加筋板、夹芯结构A和夹芯结构B的应力响应云图

Figure 15. Stress response contours of stiffened plates, sandwich structure A and sandwich structure B

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图 16 三种挡板结构及其组成部分在鸟撞冲击下的能量吸收曲线

Figure 16. The energy absorption curve of three types of baffle structures and their components

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图 17 泡沫铝失效区域的正视图与侧面剖视图

Figure 17. Front view and side section view of failure area of aluminum foam

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图 18 鸟撞全覆盖冲击点位

Figure 18. Bird strikes cover the full impact point

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图 19 横向工字梁的位置图

Figure 19. Position diagram of horizontal I-beam

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表 1 两种铝合金材料参数

Table 1. Material parameters for two aluminum alloys

材料号	E/GPa	泊松比	a/MPa	b/MPa	n	D/s⁻¹	p	ε_fail
2024-T3	72	0.31	280	400	0.2	1	66.67	0.18
7075-T6	71	0.35	480	400	0.28	1	−1000	0.12

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表 2 不同构型和厚度的挡板参数

Table 2. Baffle parameters for different configurations and thicknesses

材料号	上面板	下面板	芯体	总质量/kg
夹芯结构A	2024_5	7075_0.5	0.2_15	25.97
夹芯结构B	2024_2	7075_0.5	0.1_15	12.16
夹芯结构C	7075_2	7075_0.5	0.1_15	12.16
加筋板	整体结构为2024-T3铝合金			26.26

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表 3 夹芯泡沫铝的参数优化表

Table 3. Parameter optimization table of sandwich aluminum foam

序号	厚度/mm			夹芯重量/ kg	上、下面板的面密度/(kg·m⁻²)	是否破坏击穿
序号	上面板	夹芯	下面板	夹芯重量/ kg	上、下面板的面密度/(kg·m⁻²)	是否破坏击穿
1	1.0	25	3.0	19.82	12.60	否
2	1.5	25	0.5			是
3	0.5	20	0.5			是
4	1.0	20	1.5			是
5	1.0	20	2.0			是
6	1.0	20	2.5			是
7	1.5	20	0.5			是
8	1.5	20	1.0			是
9	1.5	20	1.5			是
10	1.5	20	2.0			是
11	1.5	20	2.5			是
12	1.0	15	3.0	18.49	14.16	否
13	1.5	15	1.0			是
14	1.5	15	1.5			是
15	2.0	15	0.5	12.16	7.83	否
16	1.5	10	1.0			是
17	1.5	10	1.5	12.31	9.43	否

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表 4 各组件质量分配

Table 4. Quality distribution of each component

结构	面板	泡沫铝芯体	局部加强组件	总质量	原加筋板	减重
质量/kg	7.82	4.66	5.39	17.87	26.26	8.39

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