Journal of Mechanical Science and Technology 37 (8) 2023
1007/s12206-023-0718-9
Journal of Mechanical Science and Technology 37 (8) 2023
Original Article
DOI 10.1007/s12206-023-0718-9
Keywords:
· Fan blade out
· Damage mechanism
· Explosion release
· Titanium alloy
· Shaped jet explosion
· SPH
Correspondence to:
Zekan He
laokan@zju.edu.cn
Citation:
Zhang, Y., He, Z., Liu, C., Wang, M.,
Xuan, H., Qu, M., Fang, Z. (2023). Re-
search on the explosion release method
and damage mechanism of titanium alloy
fan blade. Journal of Mechanical Science
and Technology 37 (8) (2023) ?~?.
http://doi.org/10.1007/s12206-023-0718-9
Received November 24th, 2022
Revised March 5th, 2023
Accepted April 10th, 2023
† Recommended by Editor
Chongdu Cho
© The Korean Society of Mechanical
Engineers and Springer-Verlag GmbH
Germany, part of Springer Nature 2023
DOI 10.
Research on the explosion release
method and damage mechanism of
titanium alloy fan blade
Yanan Zhang1, Zekan He1, Chuang Liu2, Meng Wang3, Haijun Xuan1, Mingmin Qu4 and Zehui
Fang4
1 2
College of Energy Engineering, Zhejiang University, Hangzhou 310027, China, Key Laboratory of
Aeroengine on Impact Dynamics in Liaoning Province, AECC Shenyang Engine Research Institute,
3
Shengyang 110015, China, School of Material and Engineering, Anhui University of Science and
4
Technology, Huainan, Anhui 232000, China, Zhejiang HIRO Aeronautics Technology Co., LTD., Deqing
313219, China
Abstract The current advanced aero-engine fan rotors are usually integrally-bladed rotor
discs, and the root of the fan blade has irregular curved surface, which brings technical difficul-
ties and challenges to achieve the blade releasing. In this paper, the dynamic response and
energy dissipation process of the titanium alloy blade under shaped charge jet explosion were
analyzed by numerical model, and the explosion damage mechanism of titanium alloy fan
blades was clarified. Finally, a FBO test was conducted to verify the blade explosion release
method in rotating state. Through the energy dissipation analysis of the whole explosion proc-
ess, it can be seen that the overall residual kinetic energy of the blade is about 15.7 J, which is
only 0.02 % of the initial kinetic energy of the releasing blade in rotating. It is indicated that the
explosion separation method will not generate additional kinetic energy to the released blade.
1. Introduction
Aero-engine includes many high-speed rotor components, such as fan, compressor, turbine,
etc. When these rotor parts are impacted by external objects (such as bird strike) or damaged
by material fatigue, it is easy to cause blade released-off. The rotor blade fragments will impact
the casing, causing serious damage. If the casing is not strong enough to contain broken rotor
fragments, the fragments may penetrate the casing, causing the engine to lose power, and
even further impact the oil circuit, control circuit or other structural components of the aircraft.
Such "uncontainment accident" of the engine is easy to cause catastrophic consequences [1].
Considering the serious consequences of aero-engine un-containment accidents, the world's
aviation powers have strict rules on the casing containment, such as the federal aviation regu-
lations (FAR-33) in the United States [2], European Union Aero Engine Certification Specifica-
tion (CS-E 810) [3], China Aviation Engine Airworthiness Regulations (CCAR-33) [4]. Article
33.94 of FAR-33 stipulates: it must be demonstrated by engine tests that the engine is capable
of containing damage without catching fire and without failure of its mounting attachments when
operated for at least 15 seconds, unless the resulting engine damage induces a self shutdown
after the event of “Failure of the most critical compressor or fan blade while operating at maxi-
mum permissible r.p.m”. The blade failure must occur at the outermost retention groove or, for
integrally-bladed rotor discs, at least 80 percent of the blade must fail.
The blade release speed needs to be precisely controlled in the containment test. If the
speed is too high or too low, it will directly affect the damage of the casing, which will greatly
interfere with the reasonable design of the casing [5]. Therefore, the precise and controllable
blade released-off technology at constant speed is one of the key technologies in the casing
containment test. At present, there are three mainstream blade released-off methods, namely
1
 Journal of Mechanical Science and Technology 37 (8) 2023
(a) Notched blade
Fig. 1. Traditional method of fans blade out.
prefabricated crack method, electric heating method and ex-
plosion released-off method [6-8], as see in Fig. 1.
In the notched blade method, the electrical discharge ma-
chining is used to make notches at the released-off position of
the blade, so that t the nothced section would not be able to
withstand the centrifugal load and would damage at the target
speed, as shown in Fig. 1(a). The method is simple to operate
and has no influence on the additional kinetic energy of the
blade. However, this method requires repeated dismantling of
the test components during the actual operation, thus affecting
the test efficiency. This problem will become harder to deal with
in the whole engine FBO test. In addition, the properties of
blade materials always have a certain dispersion, so it is diffi-
cult to ensure the calculation accuracy of this method. For
complex curved blades, the stress distribution in the fracture
cross-section is far from uniform, which makes failure judgment
difficult.
In the local heating method, a hole was drilled along the
dovetail to introduce a weak cross-section and provide the
mounting space for the heater. Utilizing the inverse relationship
between the tensile strength of material titanium alloy and tem-
perature, the blade can be released under centrifugal load
when the dovetail of blade is locally warm up, as shown in Fig.
1(b). When the rotor reaches the predetermined speed, the
heating rod is activated to locally heat the root of the blade. As
the temperature increases, the local material strength of the
blade weakens, and then the blade breaks and flies out at the
weakened strength under the tensile action of centrifugal force.
The method also successfully solved the problem of the blade
released-off at a constant speed in the test, and did not add
additional kinetic energy to the blade, nor did it affect the shoot-
ing effect of high-speed photography. However, this method
takes a certain amount of time from the start of heating to the
breaking of the blade, and it can only be applied to materials
with high temperature sensitivity. In addition, for fan blades with
complex curved structures in the blisk, it is very difficult to in-
stall the heating device.
As explosion released method, National Aeronautics and
Space Administration (NASA) mainly used the embedded ex-
plosive method to achieve the released-off of aero-engine fan
blades, and carried out relevant experiments and numerical
simulation analysis [9]. As shown in Fig. 1(c), in the explosion
released method, two symmetric non-penetrating cracks were
prefabricated along the root of the fan blade, and the charge
2
DOI 10.1007/s12206-023-0718-9
(b) Local heating (c) Explosion release
Fig. 2. Schematic diagram of the shaped jet explosion.
and explosion control device were inserted along the dovetail
of the blade, or linear shaped charge (LSC) jet was used to
penetrate the blade. The blade was released in a controlled
explosion. Because the root of the blade has enough space to
fill the explosion, the method is mainly set at the root of the
blade. Although this method also has certain applications in the
curved surface structure, the normal filling of explosives is
mainly used on the curved surface of the blade. Obviously,
multiple cavities are opened on the curved surface of the blade
and filled with explosives, and multiple detonators need to be
detonated at the same time. This has very high requirements
on the simultaneity, reliability and rationality of the detonator
detonation. Crucially, the presence of multiple cavities in this
method is not suitable for materials with high notch stress sen-
sitivity, which is likely to lead to premature released-off of the
blade.
As shown in Fig. 2, the shaped jet explosion method is a
charge structure in which the explosive is made into a specific
shape so that the explosive impact energy is concentrated in a
preset direction [10]. There is a metal cover on the outside of
the explosive. Its function is to gather the explosive energy to
form a high-speed moving metal jet knife at the moments of the
explosion, and its head speed is as high as 3000~5000 m/s.
Fomin et al. [11] proposed in the research on the tensile and
fracture characteristics of shaped jets on metals, because this
method can concentrate the explosion energy and release it in
one direction, it will not produce multiple angles of force on the
blade. Therefore, in the case of the same charge, this method
has a large separable thickness, and has obvious advantages
in the separation of high-strength metal materials and compos-
ite materials, but at the same time, there is a large impact after
work and the leakage of explosive products is obvious. Short-
comings. Elshenawy et al. [12] used Autodyn to numerically
simulate the detonation of shaped charge, analyzed the proc-
 Journal of Mechanical Science and Technology 37 (8) 2023
ess of blasting and separating the target plate with shaped
cutting cables, and obtained the calculation method of the
maximum penetration depth according to the failure process of
the virtual source point. Jang et al. [13] carried out numerical
simulation and experimental research on the double-layer
shaped jet method, and compared the intrusion ability of the
separated objects under the shaped jet and ordinary explosion
methods, respectively, and obtained the relationship between
the amount of explosive and the depth of penetration.
With the continuous improvement of design and manufactur-
ing technology of fan blade and disc, many engines nowadays
adopt integrally-bladed rotor disc structure. Most of the ad-
vanced aero-engine fan blades have complex curved surface
structure, which leads to the uneven thickness of the released-
off section of the blade. The traditional blade released-off
method has poor applicability. If the blade is separated by ex-
plosion, the explosion fracture of the blade must be uniform,
the released -off attitude of the blade should not be changed,
and the additional kinetic energy generated at the moment of
explosion should be avoided. Therefore, the previous explosion
studies have some limitations: (I) Most of the existing studies
[14-16] mainly focus on blade root or flat stucture, and do not
consider the effectiveness of the separation method for the
complex curved surface structure of real blades. (II) Although
some studies have been carried out on the explosion failure
modes of titanium alloy materials [17-19], there is no clear ex-
planation for the explosion damage mechanism of blades with
complex curved surfaces.
In order to solve the technical problems of explosive separa-
tion of complex curved blades, this paper focuses on the dam-
age mechanism of curved fan blades under explosive load of
shaped charge jet. Because the complex three-dimensional
surface of aero-engine fan blade, an appropriate explosion
separation method is determined by simulation and verified by
static explosion test. The effect of explosion separation mode
on blade additional kinetic energy is considered. The dynamic
response and energy dissipation process of the blade during
the explosion were analyzed by selecting the acceleration and
energy change of the Gaussian point on the blade simulation
piece. The explosion damage mechanism of titanium alloy
blade is clarified，the penetration depth of shaped charge jet
to titanium alloy blade and the residual kinetic energy of explo-
sion are evaluated. Finally, the blade explosion separation is
tested on the high-speed spin tester, which fully proves the
effectiveness and feasibility of the shaped jet explosion method
for the separation of complex curved blades. This work can
provide a useful technical reference for the experimental de-
sign of aero-engine FBO test.
2. Explosion released method and damage
mechanism of blades
2.1 Finite element model
Aero-engine fan blades and disc are shown in Fig. 3. In this
DOI 10.1007/s12206-023-0718-9
Fig. 3. Schematic diagram of the fan blade released off.
(a) SG1 (b) SG2 (c) SG3
Fig. 4. Slotting method of specimens.
model, the whole fan rotor is an integral structure. In the FBO
test, one of the blades is selected to be released, and the ex-
plosive is installed at the released-off section of the blade.
Since the fan blades are complex curved structures, the instal-
lation method of explosives needs to consider the destruction
ability of TNT to the blades. In addition, the residual cross sec-
tion area on both sides of TNT should be considered as consis-
tent as possible to ensure the stable released-off attitude of the
blade.
There is no centrifugal load of the blade in the process of
static explosion simulation, only the local damage of the explo-
sive to the blade needs to be considered. Therefore, in the
static explosion simulation, the simulated blade is designed
according to the 1:1 structure of the real blade, and the length
of the simulated blade is 1/3 of the length of the real blade,
which is convenient to improve the calculation efficiency. Three
different opening modes are selected as static explosion simu-
lation models to facilitate the investigation of the damage de-
gree of blades caused by different opening modes. The model
size is shown in Fig. 4. The position of the released-off section
of the three schemes is consistent.
In scheme 1, a through groove with a depth of 4 mm is
opened at the blade back. A 4 mm diameter semi-through hole
is punched at the leaf basin for placing the detonator. The
length of the hole is 111 mm, with a remaining thickness of
5mm in the middle, marked as SG1. In scheme 2, a through
slot with a depth of 4 mm is opened at the back of the leaf, a
through hole with a diameter of 4 mm is punched at the leaf
basin, and the remaining thickness in the middle is 5 mm,
which is marked as SG2. In scheme 3, a hole with a diameter
of 4 mm was punched in the center at a position 20.5 mm from
the bottom surface of the blade root, and the remaining thick-
nesses on both sides were 5.4 mm and 3.6 mm, marked as
SG3.
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 Journal of Mechanical Science and Technology 37 (8) 2023 DOI 10.1007/s12206-023-0718-9

2.2 SPH method

Numerical simulation calculation of explosion separation in-
volves complex problems such as high pressure, high strain
rate and material damage. At the same time, it is necessary to
simulate the explosion boundary conditions and record the
crack propagation process [20]. When dealing with such com-
plex problems, traditional grid numerical calculation methods
will lead to grid distortion and fragmentation. The SPH method
is a meshless Lagrangian numerical calculation method. When Fig. 5. Finite element simulation model.
using the SPH method to discretize the physical model, it does
not need to construct a grid but uses a series of particles. This
tenon simulation piece. It is proposed that, in order to improve
method constructs approximate functions by assigning mass,
the computational efficiency, the finite element modeling of the
displacement, velocity, internal energy, etc. to particles to solve
fixture is ignored without changing the boundary conditions. The
practical problems [21].
entire finite element model is mainly composed of 3 parts, the
Due to the meshless nature of the SPH method, initial mesh-
first is the TNT explosive part, which is blasted by a shaped
ing and reconstruction are no longer required. In addition, the
energy jet, because in the actual modeling process, the charge
particles interact with each other through force, so there is no
cover and TNT need to be modeled together and set to part 1
mesh distortion phenomenon during the calculation, which is of
and part 2. According to the actual size of the shaped jet flexible
great significance for solving large deformation problems. The
detonating cord, the grid size on the section is required to be ≤
SPH method discretizes matter into a series of particles with
0.5 mm, and the grid size in the length direction is ≤ 1 mm. The
physical properties, but in the SPH algorithm, instead of solving
finite element mesh size is shown in Fig. 5. The second is the
a particle individually, a kernel function is used to approximate
simulated blade part, which has the same structural shape as
the field variables near all particles within the calculation range
the real blade. Considering the complex curved structure of the
[22]. The particle density expression is:
blade, the thickness on the section is not uniform. Therefore, the
mesh size needs to be comprehensively considered when divid-
ρ = ∑m Wij ( x − x j , h )
N
i j i (1) ing the mesh. If the mesh size is too small, the calculation
j =1
amount will increase, and if the mesh size is too large, the mesh
failure will occur in the parts with small thickness. After repeated
where, ρ is the density, i and j are the particle numbers at dif-
modeling tests, it was finally determined that the number of grid
ferent positions, N is the total number of particles, mj is the
layers at the minimum grid thickness was set to 2.
mass of particle j, Wij is the kernel function, xij is the particle
In order to constrain the explosion flare during the explosion
center position, h is the smooth length. The definition of W is:
test, the related research work is carried out by covering it with
copper sheets, but considering that the surface of the blade
1
W ( x, h ) = θ ( x) . (2) simulation part is smooth and has a curved structure, the cop-
h( x ) d
per sheets are not suitable for installation and fixation. There-
fore, in the test, it is considered to cover the surface of the TNT
Where, d is the space dimension, x is the distance between explosive with a layer of glass fiber cloth instead of the copper
the particles in space. The mass, momentum and energy con- sheet, and fix it with epoxy resin glue. The thickness size of the
servation equations in the SPH algorithm can be expressed as: fiber cloth is set with reference to the actual curing ratio, and
the glass fiber cloth only plays a role in constraining the energy
dρi N m ∂W ⎫
= ρ j ∑ j ( viβ − v βj ) βij ⎪ during the actual explosion process. Therefore, the number of
dt j =1 ρ j ∂xi ⎪ grid layers is set to 1 in the thickness direction, and the grid
dviα N ⎛σ αβ
σ ⎞ ∂W ⎪⎪
αβ size is ≤ 0.5 mm.
= ∑ m j ⎜ j2 + j2 ⎟ βij ⎬ (3) It is worth noting that TNT is an energetic material, and the
⎜ ρi ⎠⎟ ∂xi ⎪
dt j =1 ⎝ ρj non-reflective air boundary allows energy leakage. Although
dEi σ iαβ N ∂W ⎪
= 2 ∑ m j ( viβ − vαj ) βij ⎪ peeling off the fiber cloth cannot completely avoid energy leak-
dt ρi j =1 ∂xi ⎭⎪ age, it can reduce the energy leakage rate to a certain extent,
and this method can reduce the explosion flare to a certain
where, V, E, t and σ represent velocity, energy, time and stress, extent, so that high-speed photography has a certain clear
respectively. α and β represent the summation repetition index vision. Since this test and simulation model is mainly aimed at
in the coordinate direction. the structural damage and dynamic response of the blade
In the test, the simulated blade is fixed by the fixture, but the simulated parts, the propagation form of the explosion energy
fixture is usually not damaged in the actual explosion process, in the air is not considered, so the influence of the air is ignored
and the function of the fixture is only to provide support for the in the modeling process.

4
 Journal of Mechanical Science and Technology 37 (8) 2023 DOI 10.1007/s12206-023-0718-9

where, P is the pressure, E0 is the initial internal energy per unit

volume, V is the initial relative volume, A, B, R1, R2, ω are con-
stants determined by experiments. The three terms of this for-
mula play a major role in the pressure at high pressure, me-
dium pressure and low pressure, respectively. The calculation
assumes that the detonation shock wave propagates forward
at a constant speed. TNT is used as the explosive, and the
material parameters are shown in Table 1.
2) TC4 model
Fig. 6. Gaussian point distribution selected in the simulation calculation. In this paper, both the simulated blade and the real blade are
made of TC4 material. In order to describe the large deforma-
tion, nonlinearity and viscoplasticity of the TC4 material during
Considering the explosion mode and particularity of the
the explosion, the Johnson-Cook model is selected as the
shaped jet, the failure mode under the action of high frequency
constitutive model of TC4 [27]. This model can better reflect the
impact needs to comprehensively consider the coupling effect of
hardening, temperature softening and strain rate softening
material compression and tension. Therefore, a Gaussian point
effects of materials. Its constitutive equation is:
is set every 1 mm along the direction of the shaped jet to deter-
mine whether the Gaussian point is broken, and then to deter-
σ e = ⎢⎡ A + B ( ε ep ) ⎥⎤ ⎡⎣1 + C ln ε ∗ ⎤⎦ ⎡⎣1 − T ∗m ⎤⎦
n
mine whether the entire structure is cut off by the shaped jet. In (5)
⎣ ⎦
the calculation and analysis of Autodyn, when the selected node
at the corresponding Gaussian point fails, the node will not be
where σ e is the flow stress, ε ep is the equivalent plastic strain,
able to obtain the subsequent acceleration trend, which is simi-
ε* = εep / ε0 is the dimensionless equivalent plastic strain rate.
lar to the idea of deleting failed nodes in Ls_Dyna [23, 24].
Where εep is the plastic strain rate, ε0 is the reference plastic
Therefore, the acceleration variation law for the Gaussian
strain rate. T* = (T-T0)/(Tm-T0) is the dimensionless temperature,
point can also be used as a judgment method for structural
where T is the actual temperature of the material, T0 is the
failure. In the Autodyn calculation and analysis, in order to fa-
room temperature, Tm is the melting point of the material. The
cilitate the analysis of the impact response and energy change
Johnson-Cook cumulative damage criterion of continuous
trend of the Gauss point in the blade span direction under the
damage mechanics was used in the material failure criterion of
jet impact load, set Gaussian points to obtain relevant informa-
TC4, and defines the damage parameter D as [28]:
tion, and the distribution positions are shown in Fig. 6.

⎛1⎞
2.3 Material model and parameters D = ∫ ⎜ ⎟ dε ep (6)
⎝ εf ⎠
In the explosion numerical simulation, the material model is
used to describe the dynamic response of the material under where the failure strain is defined as:
the action of external force, such as deformation, flow and
fracture. The material model can be divided into three parts:
equation of state, constitutive model and failure model. The
(
ε f = D1 + D2e D σ 3
∗

) (1 + D ln ε )(1 + D T )
4
∗
5
∗
(7)

equation of state is used to describe the relationship between

the volume strain, pressure, and internal energy of a material, where σ*= P/σeff = -Rσ, P is the hydrostatic pressure, σeff is the
the constitutive model is used to describe the relationship be- von Mises equivalent stress, and Rσ is the stress triaxiality.
tween the deviatoric stress and the deviatoric strain of the ma- Initially, D = 0. The material fails when D = 1. The material
terial, the failure model is used for the reduction of the stress model parameters are shown in Table 1.
bearing capacity of the material due to the accumulation of 3) Pb model
damage [25]. The metal back skin material of the shaped energy jet cutting
1) TNT model device used in this paper is plumbum. In order to describe the
The state equation of the explosion reaction used in the nu- thermodynamic behavior and large strain rate state of plum-
merical simulation program is the JWL equation, which can bum under impact load, the Shock equation of state [29] and
accurately describe the pressure, volume and energy changes the Steinberg-Guinan constitutive model [30] are used for lead.
of the detonation products during the explosion process, and is The shock state equation is:
suitable for describing the volume expansion behavior of the
detonation products. This equation is [26]: ⎧ p + Γ ρ ( e − eH ) , μ.0
p=⎨ H (8)
⎩ ρ0C0 μ , μ <0
⎛ ω ⎞ -R 2V ⎛ ω ⎞ ωE 0 ρ0C02 μ (1 + μ )
P=A ⎜1- ⎟ e +B ⎜ 1- ⎟+ (4) pH = (9)
⎝ R 1V ⎠ ⎝ R 2V ⎠ V [1 − ( S − 1) μ ]2

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 Journal of Mechanical Science and Technology 37 (8) 2023 DOI 10.1007/s12206-023-0718-9

Table 1. Material model [16, 31, 32].

TNT_*MAT
-3 -3 -1
ρ/(g/cm ) A/GPa B/GPa R1 R2 ω E/(J·m ) D/(m·s ) Pcj/GPa
9
1.0 371 3.2 4.5 1.5 0.3 3.6×10 6097 7.63
TC4_*MAT_JOHNSON_COOK
-3
ρ(g/cm ) G/ GPa E/ GPa PR A/GPa B/GPa N C
-2 -2
4.44 0.410 1.13 0.33 1.098×10 1.092×10 0.93 0.014
D1 D2 D3 D4 D5
-0.09 0.27 0.48 0.014 3.87
TC4_*EOS_GRUNEISEN
C S1 S2 S3 γ α E0 V0
0.513 1.03 0 0 1.23 0 0 1
Pb_*MAT_Steinberg-Guinan
G0/GPa σ0/MPa σmax/MPa β n GP′ GT′ (MPa/K) σ P′
-4
8.6 8 100 110 0.52 1 -9.98 9.30×10
Pb_*EOS_SHOCK
3
ρ0/(kg/m ) Γ C0/(m/s) S
11340 2.74 2006 1.43

1 pH ⎛ μ ⎞ tively close, and both of these two explosion methods can

eH = ⎜ ⎟
2 ρ0 ⎝ 1 + μ ⎠
where p is the pressure; Γ is the Gruneisen coefficient, ρ is the
density, e is the internal energy; ρ0 is the initial density, μ is the
compression ratio, μ = ρ/ρ0-1. There is a linear empirical rela-
tionship between the shock wave velocity U and the particle
velocity up of metal materials U = C0+Sup, C0 is the speed of
sound at normal temperature and pressure without distur-
bance. In the Steinberg-Guinan constitutive model of lead, the
constitutive relation between shear modulus G and yield
stress σ is:
⎡ ⎛ G′ ⎞ p ⎛ G′ ⎞ ⎤
G = G0 ⎢1 + ⎜ P ⎟ 1/3 + ⎜ T ⎟ (T − 300) ⎥
⎢⎣ ⎝ G0 ⎠ η ⎝ G0 ⎠ ⎥⎦
⎡ ⎛ σ' ⎞ p ⎛ G ' ⎞ ⎤ 2.5 Explosion damage mechanism
σ=σ 0 ⎢1+ ⎜ P ⎟ 1/3 + ⎜ T ⎟ (T-300)(1+βε) n ⎥
⎢⎣ ⎝ σ 0 ⎠ η ⎝ G0 ⎠ ⎥⎦
σ 0 (1 + βε ) -σ max
n
where p is the pressure; T is the melting temperature; η is the
compression coefficient η = V0/V; ε is the effective plastic
strain; β is the hardening constant; n is the hardening expo-
nent; σ P' and GT' are the reference states (T = 293 K, p = 0,
ε = 0) with respect to pressure and temperature. The constitu-
tive model parameters of lead are shown in Table 1.
2.4 Simulation results
Three kinds of open-hole explosion methods designed in Fig.
4 are selected for simulation analysis, and the results are
shown in Fig. 7. The damage degree of SG1 and SG2 is rela-
(10) achieve local explosion separation of fan blades. However, the
explosion damage of SG3 model is not obvious. This is be-
cause the residual area of section of SG3 model is too large,
and the damage ability of explosives is limited, which leads to
the lack of local damage ability of blades. If the SG3 model
achieves the same destruction level as SG1 and SG2, the
explosive density needs to be increased by at least three times,
which is very unfavorable for controlling the additional kinetic
energy in the explosion process. Therefore, SG1 and SG2
models were selected as the preliminary explosion modes by
comparing the degree of explosion damage of the three simu-
lation models. In order to better compare the effectiveness of
SG1 and SG2 models, it can be determined by static explosion
(11) test.
(12)
In order to further analyze the explosion damage mechanism
(13) and structural dynamic response of the blade simulation part
during the explosion separation process of the shaped jet,
according to the Gauss point distribution selected on the blade
simulation part in Fig. 6, the acceleration of different Gauss
points is obtained for dynamic response analysis.
The impact penetration of the shaped jet has obvious high-
frequency transient characteristics, and the titanium alloy blade
receives a severe impact load in a very short time. After a short-
time high-frequency impact, the impact effect in the blade de-
cays rapidly and enters the low-frequency oscillation decay
stage. In the high-frequency shock stage in the explosion sepa-
ration, the shock acceleration on the blade presents a transient
high-amplitude oscillation, and the energy on the blade reaches
the maximum state at this time.

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 Journal of Mechanical Science and Technology 37 (8) 2023 DOI 10.1007/s12206-023-0718-9

(a) SG1

(b) SG2

(c) SG3

Fig. 7. Explosion simulation results of different schemes.

(1#) (2#)
4 X Direction 4 X Direction
Y Direction Y Direction
Acceleration(×105 m/s2)

Acceleration(×105 m/s2)

2 2

0 0
0.1
0.02

-2 -2
0.0
0.00

-4 -4 -0.1
-0.02 40 50 60 70 80
40 50 60 70 80

0 20 40 60 80 100 120 140 160 0 20 40 60 80 100 120 140 160

Time/μs Time/μs

(3#) (4#)
4 X Direction 2 X Direction
Y Direction Y Direction
Acceleration(×105 m/s2)
Acceleration(×105 m/s2)

2 1

0 0

-2 -1

-4 -2

0 20 40 60 80 100 120 140 160 0 20 40 60 80 100 120 140 160

Time/μs Time/μs

Fig. 8. 1#--4# Gauss point vibration response.

As shown in Fig. 8, in the direction of blade thickness, the pulse width of 3# and 4# is basically maintained at about
high-frequency pulse width of Gauss points 1# and 2# are 0.06 ms. Although the 1#-4# Gauss points of the blade are in
basically maintained at about 0.02 ms, and the high-frequency the same position of the jet, there is a significant difference in

7
 Journal of Mechanical Science and Technology 37 (8) 2023 DOI 10.1007/s12206-023-0718-9

4 4
(5#) X Direction (6#) X Direction
Y Direction Y Direction
2 2

Acceleration(×105 m/s2)

Acceleration(×105 m/s2)
0 0

0.6

-2 0.3 -2
0.5
0.0

-0.3
0.0
-0.6
-4 70 80 90 100 -4
100 105 110 115 120

0 20 40 60 80 100 120 140 160 0 20 40 60 80 100 120 140 160

Time/μs Time/μs

Fig. 9. 5# and 6# Gauss point vibration response.

the thickness because the separation section is a curved struc-

ture. Therefore, the stress wave action time and tensile effect
in the penetration direction of the shaped jet are not the same,
and the response to the impact is not linear. It can be seen that
there are obvious differences in the acceleration curves of the
1-4# Gaussian points of the blade.
With the movement of the stress wave generated by the
shaped jet along the thickness direction, peaks appear at each
point in turn. The 1# and 2# Gaussian point shock responses
basically attenuate to 0 in the later stage, it can be seen that
the damage depth of the detonation gas generated by the
shaped jet to the material is about 1 mm.
It is worth noting that compared with the vibration responses Fig. 10. Energy dissipation curve of the tenon simulation.
of 1# and 2# Gaussian points, 3# and 4# Gaussian points have
different degrees of oscillation, this is caused by compression stress wave. The curve of the total energy of the test piece
and tension waves formed by shock waves reflected back and over time, which can summarize several stages under the ac-
forth through the thickness of the material. While the detonating tion of shaped energy cutting, as seen in Fig. 10.
gas hits the material, the shock wave continues to propagate 1) Linear energy absorption stage (O-A): This stage is mainly
forward, converges and collides with the shock wave on the the process in which the shaped energy jet transfers energy to
other side in the center of the thickness direction, and then the the test piece, and the change of energy absorption with time is
reflected stretch waves formed propagate in opposite direc- basically linear.
tions to cause a stretching effect on the material [17]. 2) Energy loss stage (A-B): Since TNT is a high-energy ma-
From the vibration responses of 3# and 4#, it can be seen terial, the impact energy at the moment of explosion has en-
that the stress wave propagates along the thickness direction ergy leakage at the non-reflecting air boundary, resulting in a
and exhibits obvious alternating oscillation characteristics, re- small amount of energy loss.
sulting in a large number of delamination damage and micro- 3) Steady-state energy absorption stage (B-C): In this stage,
cracks inside the material. The Gauss point vibration re- the jet penetrates the test piece stably forward, accounting for
sponses of 5# and 6# are shown in Fig. 9. There is no obvious about 60 % of the entire energy dissipation process. In this
vibration response after the high-frequency shock oscillation far stage, the energy-time curve reaches a peak when the jet
away from the explosion position of the blade, but there is a reaches its maximum penetration depth.
small-amplitude vibration fluctuation in the later stage. Because 4) Stress wave acting alone stage (C-D): In this stage, the
the stress wave generated at the moment of explosion propa- explosion area of the blade continues to separate under the
gates inside the curved structure, and when the stress waves action of stress waves. The stress wave energy inside the ma-
are superimposed on each other, there will be small-scale vi- terial dissipates rapidly, and the energy decreases rapidly also.
bration fluctuations. This also indicates that there is a stress After the fracture process, the overall kinetic energy of the
wave interaction throughout the blade during the explosion, material tends to be stable, and the residual kinetic energy is
and this stress wave interaction decreases when moving away so small about 15.7 J, which is only 0.02 % of the initial kinetic
from the explosion location. energy of the releasing blade in rotating. It means that the ex-
From the perspective of energy, the explosion separation plosion separation method in this paper will not add additional
process is essentially a high transient energy dissipation proc- kinetic energy to the released blade in the engine case con-
ess of the test piece on the impact effect of the jet and the tainment test.

8
 Journal of Mechanical Science and Technology 37 (8) 2023
3. Static explosion test
3.1 Test method design
Compared with the traditional equal-thickness flat specimen,
the complex surface structure of the fan blade has obvious
variable thickness characteristics, which leads to uneven stress
distribution in the section during the blast cutting process.
Therefore, in order to effectively obtain a reasonable surface
explosive cutting method, it is necessary to carry out experi-
mental verification. Because there is no centrifugal load of the
blade in the static test, only the local damage caused by the
explosion needs to be considered. Therefore, 1/3 of the overall
blade is selected as the static explosion test sample to facilitate
sample processing and reduce manufacturing costs. The three
blade slotting schemes in Fig. 4 were selected to process the
static explosion.
In the test, the shell of the shaped jet cutter should have a
good constraining effect on the energy of the explosion. Plum-
bum is selected as the shell material for its large density and
ductility. TNT explosives with high power and high explosive
pressure are selected, and the detonating device adopts elec-
tronically controlled detonators.
During the test installation process, the electronically con-
trolled detonator and the TNT explosive were put into the load-
ing position together. One end of the electronically controlled
detonator was connected to the TNT explosive, and the other
end was connected to the detonation signal line. In order to
ensure that the TNT explosives on both sides can be deto-
nated at the same time, a high-speed detonating cord is se-
lected to connect and fix the TNT explosives on both sides.
Fig. 11. Static explosion test device.
(a) SG1
Fig. 13. Tensile test results.
DOI 10.1007/s12206-023-0718-9
The static explosion test device is shown in Fig. 11.
3.2 Static explosion test results
The static explosion test results are shown in Fig. 12. The
damage and deformation on both sides of the explosive are
relatively small, but the damage along the thickness direction is
relatively large. The reason is that the main intrusion manner of
the shaped jet explosion is the high-pressure impact damage
along the thickness direction. By comparing SG1 and SG2, it
can be seen that the explosive cutting effect of the shaped jet
is stable, which is basically the same as the simlulation.
For the SG3 specimen, the middle opening is used for ex-
plosive cutting in this specimen. Since the specimen is a
curved structure, the thickness in the middle is much larger
than that in the two sides. Therefore, most of the energy is lost
from the weak points on both sides during the explosion, result-
ing in an insignificant effect of explosion damage on the SG3
specimen. In order to accurately evaluate the residual strength
of the specimen after the explosion, the static tensile strength
tests of the specimens were carried out on a tensile testing
machine.
Through the quasi-static tensile test, the residual strength of
the TC4 simulated blade after the blasting test is obtained. The
experimental objects are TC4 blade simulation specimens with
different slotting methods (after the blasting test), as shown in
Fig. 12. The test was conducted on the MTS test system, the
protective load was set to 120 KN. As the target breaking load
should be lower than 30 % of the released blade centrifugal
load. So δmax is marked as the target limit load.
The tensile specimens are shown in Fig. 13, where both the
(a) SG1 (b) SG2 (c) SG3
Fig. 12. The explosion results of the blades simulation.
(b) SG2 (c) SG3
9
 Journal of Mechanical Science and Technology 37 (8) 2023
120
SG1
SG2
100
δmax
SG3
80
Force/kN
60
Area—α
40
20
0
0 1 2 3 4
Displacement/mm
Fig. 14. Force-displacement curve of the specimens.
SG1 and SG2 specimens were pulled off within the limit load.
After the blasting test, there were obvious cracks at both ends
inside the slot. During the tensile test, the stress is concen-
trated at the crack tip, and some internal damage has accumu-
lated, so it is more likely to be pulled off. However, the SG3
was not broken under the target load δmax, because the remain-
ing area of the blade basin was too large, so it could not be
easily broken.
The force-displacement curve of the specimen during the
tensile process as shown in Fig. 14. The peak loads of the SG1
and SG2 specimens are 56 KN and 52 KN, respectively, less
than 30 % of the centrifugal load δmax. It is worth noting that in
the force-displacement curve of the SG1 test piece, it can be
seen that its tensile process has experienced two stages, indi-
cating that the two ends of the test piece SG1 are not simulta-
neously fractured. Due to the different residual areas on both
sides of the SC1 specimen, the residual area on one side is
small. During the stretching process, the small position of the
remaining area is first broken when the peak load is reached,
and then the main force-bearing part becomes the other side
until all the ends are broken, as shown in the area α in Fig. 14.
Considering that both ends of the SG1 test piece are not
broken at the same time, the released attitude of the blade will
change in the rotating state, so the test piece SG1 is not a
preferred solution. The SG3 specimen was not broken at
120 KN, which was higher than the requirement of 30 % cen-
trifugal load δmax. In summary, the slotting method of the
specimen SG2 is selected as the optimal solution.
4. Blade explosion release test under rotat-
ing conditions
According to the previous simulation and static explosion test
research, the appropriate explosion separation method was
determined. In order to further evaluate the effectiveness of the
explosion separation method of complex curved blades, the
explosion separation method was tested and verified on a high-
speed spin tester. The schematic diagram of the overall struc-
ture and test system of the fan blade rotating explostion re-
leased-off test is shown in Fig. 15. Two fan blades are symmet-
rically mounted on the disc. The disc is connected to the power
10
DOI 10.1007/s12206-023-0718-9
Fig. 15. Schematic diagram of rotating explosion test system.
drive shaft of the spin test bench. A safety protection ring is
installed inside the tester to withstand the impact of the releas-
ing blade.
In the test detonation system, the lead wire of the electric
detonator is connected to the wireless detonation signal receiver,
and a signal antenna is installed inside the test cavity. The deto-
nation signal is transmitted through the external detonation con-
trol circuit to realize the explosion released-off process.
The blades used in the test are installed 180 degrees sym-
metrically. The blade tip size is about 1020 mm. During the test,
the rotor was speed up to 13600 r/min and keep steady for
30 s. Then the detonation signal was given. When the blade is
released by explosion, the blade impact the containment guard
ring, cuts off the trigger wire wound inside the guard ring. A
trigger signal is formed and triggers the speed control system
to control the test bench to slow down and stop in time. At the
same time, the high-speed camera installed at the bottom of
the test bench was also trigged to photograph the process of
blade released off.
According to the static blasting test results of the previous
blade simulation parts, the same method was used in the rotat-
ing blasting test. The installation method of the explosion de-
vice and the blade slotting method in rotation test are the same
as those of the specimen SG2 in static test. The lead wire of
the electric detonator is connected to the detonation system
and controlled by wireless detonation. During the test, when
the rotor reached to the predetermined speed and maintains
the load, the detonation button was pressed to output the deto-
nation signal, so that the blades break and released-off at the
predetermined speed. The installation process of the explosive
device is shown in Fig. 16.
The high-speed photography results of blade rotational ex-
plosions are shown in Fig. 17. The test results show that the
explosion released-off mode has high reliability, and the explo-
sion firelight control is good in high-speed photography. The
explosion regulation does not affect the actual shooting results,
and the released posture of the explosion blade is stable, and
the two blades almost break at the same time. Fan blade rota-
 Journal of Mechanical Science and Technology 37 (8) 2023
Fig. 16. Explosive device installation process for fan blades.
t = 0 ms t = 0.3 ms
t = 0.8 ms t = 1.2 ms
Fig. 17. Blades explosion and breaking process.
Fig. 18. Damage model of fan blades explosion section.
tion explosion fracture damage is shown in Fig. 18. It can be
seen that the damage forms of explosion section and tensile
fracture are obviously different in blade fracture. The fracture of
the explosive released-off section is relatively neat, while the
tensile sections on both sides show obvious tensile morphology.
The comparison of fan blade explosion damage between the
simulation and test results in are shown in Fig. 19. The explo-
sion damage forms of fan blades are mainly concentrated in
the place where TNT is placed (A) and its two ends (M and N).
From the damage form at A, it can be seen that TNT has a
good destructive effect on the blade. Since the blade is a
curved structure, which also causes the damage at M and N is
very obvious. However, it can be seen from the simulation re-
sults that there is no obvious damage to the structure where
TNT is not placed. This also indicates that O and P are tensile
fractures under centrifugal load in the rotating explosion test.
Fig. 20 shows the microstructure of the fracture at the explo-
sion location of the fan blade. Faults, stratified craters, cracks
DOI 10.1007/s12206-023-0718-9
Fig. 19. Comparison of test and simulation results.
Fig. 20. SEM of the explosion fracture of the released fan blade section.
and crushed debris can be obviously observed at the fracture
of blasting. The fault damage is mainly concentrated at the
explosion fracture, and shows multi-layer fault damage. This
indicates that the high-energy shock wave generated by the
fan blade in the shaped charge jet explosion is rapidly released
along the jet direction, which causes great damage to the
curved surface structure and leads to multiple faults, which is
consistent with the change trend of Gaussian point energy
along the jet direction in the simulation results. In addition, a
large number of cracks, ranging from 4 μm to 16 μm, were
found in the micro-morphology around the explosion fracture.
Considering that titanium alloy material itself has high strength,
but it is very sensitive to cracks and defects, which will directly
affect its strength.
The fracture morphology of tensile fracture is obviously dif-
ferent from that of explosive fracture. In the case of tensile
11
 Journal of Mechanical Science and Technology 37 (8) 2023 DOI 10.1007/s12206-023-0718-9

failure, the fracture of O and P is relatively smooth, and there nancial interests or personal relationships that could have ap-
is no crack and delamination damage. By observing the energy peared to influence the work reported in this paper.
spectrum of the explosion fracture, it can be seen that the ma-
terial composition of the fracture surface has changed obvi-
ously. A large amount of plumbum and oxygen elements can
Nomenclature------------------------------------------------------------------
be captured, which indicates that a strong chemical reaction ρ : Density
happened at the moment of explosion. mj : Mass of particle
Wij : Kernel function
5. Conclusion xij : Particle center position
x : Distance between the particles in space
The complex curved surface structure of the advanced aero- h : Smooth length
engine fan blade was considered in the research of blade re- d : Space dimension
lease method. In this paper, the effectiveness of the explosion V : Velocity
method is verified by simulation, static test and rotating test. It E : Energy
is concluded that: t : Time
1) The numerical simulation results show that the fan blades σ : Stress
are subjected to large impact and oscillation loads in a very P : Pressure
short time. Subsequently, the impact effect in the blade decays E0 : Initial internal energy per unit volume
rapidly and the blade enters the phase of low frequency vibra- V : Initial relative volume
tion stage. In addition, the stress wave pulse oscillates con- σe : Flow stress
tinuously inside the material structure. When the jet stops εep : Equivalent plastic strain
penetrating, the stress wave in the blade continues to propa- ε * : Dimensionless equivalent plastic strain rate
gate along the blade thickness direction. After colliding with the εep : Plastic strain rate
stress wave on the other side at the center of the blade, the ε0 : Reference plastic strain rate
reflected tensile wave formed propagates in opposite directions T* : Dimensionless temperature
and causes the certain tensile effect on the blade. T : Actual temperature of the material
2) From the perspective of energy, the shaped charge cutting T0 : Room temperature,
is essentially a highly transient energy distribution process. Un- σeff : Von mises equivalent stress
der the action of shaped charge jet, the material firstly absorbs Rσ : Stress triaxiality
energy linearly. At this time, the elastic deformation of the blade Γ : Gruneisen coefficient
structure occurs and the energy absorption changes with time ρ0 : Initial density
basically linearly. When the steady-state energy absorption μ : Compression ratio
reaches saturation stage, the time-energy curve shows the ε : Effective plastic strain
maximum point. This is when the jet reaches its maximum β : Hardening constant
penetration depth and then the energy starts to decrease. Fi- n : Hardening exponent
nally, the blade explosion zone continues to separate under the σ P' : Reference states of pressure
action of stress waves. The stress wave energy inside the mate- GT' : Reference states of temperature
rial is rapidly dissipated and the energy is rapidly reduced.
3) The static explosion test results are in good agreement with
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Zhang Yanan is Postdoctoral Fellow of
College of Energy Engineering, Zhejiang
University, Hangzhou, China. He re-
ceived his Ph.D. from Shenyang Univer-
sity of Technology in June 2020. His
major research areas are structural
strength failure analysis and health con-
dition monitoring of aeroengines.
He Zekan is the lecturer of the High-
speed Rotating Machinery Laboratory of
the Institute of Chemical Machinery,
Zhejiang University, Hangzhou, China.
He got his doctor degree June 2018 from
Zhejiang University in the field of high-
speed rotating machinery. His major
research areas are application solid me-
chanics and structural strength failure analysis of aeroengine.
13