Thermal Stresses and Cracks During the Growth of Large-sized Sapphire with SAPMAC Method

本文利用有限元法对冷心放肩微量提拉法(SAPMAC)生长大尺寸蓝宝石单晶过程中的热应力进行了模拟计算,应用临界缺陷理论解释了裂纹的萌生与扩展机理。研究表明,晶体内的热应力主要与晶体生长速率,环境温度和结晶取向有关;较大热应力多出现在结晶界面,放肩、收尾以及直径急剧变化等位置;最大热应力总是出现在籽晶与新生晶体的界面附近。裂纹将在临界缺陷位置产生,并在应力作用下沿a或m面扩展。计算结果与实验结果基本吻合,通过晶体生长系统和生长工艺的改进,对晶体的开裂问题得到了有效的抑制。     

Study on Inclusions in Large Sapphire Optical Crystal Grown by SAPMAC Method

The sapphire (Al2O3) single crystal is a kind of excellent infrared transmission window materials. A large-sized sapphire (Φ225 mm×205 mm, 27.5 kg) was grown by SAPMAC method (sapphire growth technique with micro-pulling and shoulder-expanding at cooled center). Several kinds of inclusion in the large sapphire crystal were investigated by means of an optical microscopy (OM), scan-ning electron microscopy (SEM) and electron probe microanalysis (EPMA). The experimental results show that most inclusions are consisted of solid metallic and non-metallic particles as well as gas pores caused by the impurity of alumina as the raw material, the thermal dissociation of aluminum oxide melt and the reaction of the melt to the crucible material (Mo) at high temperatures. It is also found that in different crystal regions the inclusions are of varied sizes, morphology and chemical compositions. Finally, the measures to reduce and eliminate the inclusions are proposed to improve the crystal quality.     

GOI法蓝宝石单晶生长温场优化设计与模拟分析

通过对温场的数值模拟计算,发现外加轴向、径向温度梯度能够提高界面稳定性,减小熔体热对流,有利提高晶体的生长质量.根据大尺寸蓝宝石晶体生长的温场要求,对常规的GOI法晶体生长炉进行了改造,并设计了独特的加热体形状和隔热屏结构,能够为晶体生长系统提供可控的轴向、径向温度梯度.通过试验比较也证明了改造温场后的单晶炉能够生长出性能较好的大尺寸蓝宝石晶体.     

基于 N-S 方程的飞机风挡雨刷气动力计算

风挡雨刷在飞行过程中易出现被气流吹离复位位置、飘起现象,阻碍飞行员视野,严重影响飞行安全。选取某型机风挡雨刷作为优化对象,采用了结构、非结构混合网格的办法,在机身壁面附近生成结构化网格,在雨刷机构表面生成非结构化网格,用 Interface 面将两部分结合生成雨刷最终计算模型。利用 Fluent 软件,基于 N-S 方程和 S-A 湍流模型,采用时间平均法对不可压缩流的参数进行时均化,计算了不同飞行状态下,风挡雨刷在复位位置以不同角度停放及增加扰流板时所受气动力,对风挡雨刷的外形及停放角度进行优化,比较分析了优化前后雨刷所受气动力。仿真计算结果表明,雨刷合理的停放角度、在刷臂上加装扰流板能有效引导风挡雨刷迎风面气流的方向,从而减小雨刷迎风面所受气动力。通过试飞验证了数值计算的可靠性及优化方案的可行性,为风挡雨刷预紧力的设置及复位位置的确定提供依据。     

蓝宝石辐射源制造技术

自红外导弹问世以来，红外制导技术有了重大发展，各种先进的红外对抗手段被研制出来，而专用红外辐射源是红外对抗装备的核心部件，由于其独特的技术性能，多年来，一直是困扰我国红外干扰技术发展的关键技术难点。由于提高光源辐射强度和提高光源调制深度是相互矛盾的两个方面，对于红外辐射源在技术上同时实现这两个基本要求是比较困难的，而蓝宝石光源采用提高光谱范围内脉冲峰值辐射强度和强制风冷改善调制特性的办法来解决这个矛盾，但在技术实现上仍十分困难。本文介绍了蓝宝石光源在设计和制造方面的成功经验及独特的工艺方法。     

计及边界层汇流效应的多段翼型失速特性计算

 本文给出计及边界层汇流效应的多段翼型失速特性的解法。用高阶奇点分布面元法（Panel Method）求位流解,然后进行各翼段粘性尾迹形状迭代,并解出正常边界层和汇流边界层特性。当翼段上有后缘分离时,还要确定分离尾迹的形状,用位移厚度当量源（汇）模拟粘性效应。进行粘/位流迭代直至收敛。上述方法在超过多段翼型失速迎角时仍然有效。计算结果与实验数据比较,符合良好。     

多段翼型失速分离特性的计算

本文用高阶奇点分布板块法(Panel Method》及边界层理论,对多段翼型的失速性能进行计算。采用分离尾迹的模型,按尾迹是流线用迭代法求出分离尾迹边界(此为内迭代)。在尾迹上配置奇点,然后把尾迹考虑在内进行粘/位流迭代(此为外迭代)。收敛后可得多段翼型空气动力特性,且可计算到失速以后的情况。算例有单段翼型GA(W)-1,NACA 4412,和F111飞机的三段翼剖面,所得结果与实验值能很好地符合。     

飞机机翼结冰过程的数值模拟

提出了一种适用于各种结冰气象条件下飞机机翼结冰过程的数值模拟方法。结合欧拉坐标系下空气-过冷水滴两相流动控制方程的计算,对不同气象条件下飞机机翼的结冰过程进行了数值模拟,得到了4°攻角NACA-0012翼型表面霜状冰、混合冰及瘤状冰3种冰形。所得冰形与文献中的试验数据和计算结果吻合良好,表明本文方法有效。另外还计算了不同的冰形对机翼升、阻力的影响,结果表明瘤状冰对机翼气动特性的影响最大。      

Identification of crystal orientation for turbine blades with anisotropy materials

A novel approach to identify the crystal orientation of turbine blades with anisotropy materials is proposed. Based on enhanced mode basis, with the main advantages of its efficiency, accuracy and general applicability, the blade vibration mode of each order is linearly constructed by several specified mode shapes, which are obtained from the considered turbine blade with specified crystal orientations correspondingly. Then, a surrogate model based on Kriging method is introduced for constructing the condensed perturbed matrix of stiffness in order to improve the efficiency even further. The constructed surrogate model allows to perform the modal analysis of turbine blades with arbitrary crystal orientations in higher efficiency, due to the fact that the elements of condensed perturbed matrix of stiffness are considered in construction of the surrogate model rather than concerning the perturbation of all the elements of the initial stiffness matrix for the blade. Genetic algorithm is finally employed to optimize the defined fitness functions in order to identify the crystal orientation angles of turbine blades. Several corresponding examples demonstrated the accuracy, efficiency and general applicability of the proposed method.     

轻型低速飞机舵面前缘曲线圆弧拟合法

在飞机舵面设计中，舵面翼型一般均选用可以在气动手册中查到的现成翼型，但舵面前缘外形一般需自行设计。本文采用双圆弧插值计算及计算机辅助设计等方法，先后建立对称翼型和不对称翼型舵面前缘的效学模型，给出光顺流畅，且便于数控加工制造的舵面前缘外形。这些方法已成功地应用在多种轻型低速飞机舵面设计中，取得了令人满意的效果。     

超声速/高超声速双拐点喷管设计

为实现直连式试验台、高温风洞等试验设备的多马赫数运行,提出了双拐点喷管设计方法.喷管分2段设计,第1段共用,采用3次B-Spline函数描述喷管轴线马赫数分布.首先采用特征线方法求解Euler方程,得到无黏的理想喷管型面.其次采用参考温度方法求解边界层位移厚度,对无黏壁面进行修正得到实际壁面.共用段喷管出口的平行均匀流作为第2段喷管设计的初值.为验证设计方法的可行性,设计了中间马赫数为3.0,出口马赫数分别为4.0,4.5和5.0的双拐点喷管,并采用雷诺平均的Navier-Stokes方程对设计的喷管流场进行数值模拟.计算结果表明:喷管出口流场均匀,试验菱形区的马赫数误差小于1.2%.该方法提高了喷管设计精度,保证消波干净,为直连式试验台、高温风洞等设备的多个喷管共用一套动力系统提供了基础.      

Stability,flying qualities and longitudinal parameter estimation of a twin-engine CS-23 certified light aircraft

This paper presents some results of the flight test campaign conducted on the Tecnam P2006T aircraft, on the occasion of its certification process. This twin-engine propeller airplane is certified under the normal category CS-23 and FAR 23. A prototype of this light aircraft has been tested in flight for a post-design performance optimization and for the assessment of flight qualities. These experiences have led to the application of two winglets to the original wing. The final configuration has been extensively tested for the achievement of CS-23 certification. The longitudinal and lateral-directional response modes have been assessed and quantified. At the same time the longitudinal airplane model, through a dedicated set of flight maneuvers, has been characterized by means of parameter estimation studies. The aircraft stability derivatives have been estimated from the acquired flight data using the identification technique known as Output Error Method (OEM). Some estimated stability derivatives have been also compared with the corresponding values extracted from leveled flight tests and from wind tunnel tests performed on a scaled model of the aircraft.     

超声波加工系统动力特性的研究

一、引言 近20年来,宇航工业广泛地采用耐高温材料,以保证宇航器的某些部件在高温环境下有较好的耐久寿命。耐高温的材料往往具有硬而脆的特性。这就要求人们发展一种新的（非传统的）加工技术。在这些技术之中,特别值得提出来的是超声波加工技术,见图1。     

复杂薄壁构件自适应加工工艺几何模型重构

随着制造理念和制造水平的不断提高,大量复合制造工艺背景下的近净成形叶片被应用到现役或在研的航空发动机中。该类叶片是典型的复杂薄壁结构零件,无精确定位基准,且成形一致性差。采用传统叶身定位,加工后的前/后缘、榫齿形状和位置精度均难以保证,从而导致产品一致性差,易超差与合格率低。针对以上问题,提出一种面向自适应加工的复杂薄壁结构零件工艺几何模型重构方法。首先,建立复杂曲面的采样点分布模型,快速获取叶片精确成型区域的位置和形状;其次,提出基于特征曲线相似变形的模型重构算法,精确重构前/后缘非精确成型区域的工艺几何模型;最后,通过精锻叶片自适应加工试验进行验证。试验结果表明：该方法可有效满足以精锻叶片为代表的复杂薄壁构件自适应加工要求。     

基于筏化的镍基单晶合金高温蠕变模型

采用应力法以及界面能法对不同取向的镍基单晶合金在950℃下的筏化类型进行了预测.上述两种方法的筏化预测结果一致,[001]取向为N型筏化,[011]取向为P型筏化,[111]取向不筏化.进一步,根据筏化预测结果以及晶体滑移理论,结合Kachanov-Robotnov（K-R）损伤演化公式,建立了一个镍基单晶合金蠕变模型,采用该模型并结合商用有限元软件Abaqus的用户材料子程序（UMAT）二次开发接口,对[001],[011]和[111]取向下的CMSX-4镍基单晶合金,在950℃,180~450MPa应力条件下的蠕变变形行为进行了模拟.该模型能够准确预测镍基单晶合金的筏化类型以及滑移系开动规律,更加符合材料的蠕变变形物理机制,因此模型可以对镍基单晶合金的高温蠕变曲线的第2,3阶段进行很好的模拟,并得到了试验的验证.      

蓝宝石衬底的超光滑表面加工进展

回顾了(0001)面蓝宝石衬底在LED的重要作用及其磨粒加工方法的发展进程.归纳了磨粒加工在蓝宝石衬底的超光滑制备过程中的应用现状,分别对磨削、机械抛光、干式机械化学抛光、湿式机械化学和化学机械抛光在蓝宝石衬底中的应用进行了总结和分析,对比了不同方法对蓝宝石衬底的加工损伤特性和优缺点.     

Anhydrous based shear-thickening polishing of KDP crystal

Based on the special physical–chemical characteristics of optical crystal in the field of aeronautics, a new anhydrous based shear-thickening polishing (ASTP) method has been proposed to restrain deliquescence and to improve physical properties for KDP machining. The ultra-precision polishing of KDP crystal is completed by ASTP. A kind of anhydrous based thickening polishing slurry (ATPS) was proposed in our work, and high-performance rheological properties were determined to achieve the ASTP of KDP crystal. A material removal model of ASTP in KDP machining is established, followed by the verification experiment of the prediction model. The maximum error of the predictive model is only 9.8%, which proves the validity of the material removal model for KDP polishing. The polishing experiments were carried out on the polishing platform developed by ourselves. The results show that the new polishing method can polish 20 mm × 20 mm × 5 mm KDP crystal and obtain a super-smooth surface with a surface roughness of 1.37 nm and high shape accuracy. The surface accuracy of polished KDP crystal reaches up to 0.68λ (RMS). The experimental results show that the ASTP is a potential ultra-precision machining method for KDP crystal.     

基于细观位错机理的单晶合金高温力学性能模拟

利用基于细观位错运动的蠕变筏化模型对镍基单晶合金CMSX-4在1223K下的拉伸、蠕变、循环、蠕变疲劳交互及各向异性进行模拟,结果表明:拉伸过程中应变率较高时应力略微下降的现象;蠕变条件下应力越大则蠕变第1阶段越明显,而蠕变稳定阶段越短的趋势;蠕变疲劳交互作用下的应力松弛和应变增大;以及单晶3个典型晶体取向的循环应变硬化特征。通过与试验结果对比,验证了此模型在较高温度下对单晶合金性能的综合模拟能力。     

大型复杂航空产品质量评估模型研究

在市场日益激烈的条件下,质量是产品是否具有竞争力的关键因素。针对大型复杂航空产品,综合现有的理论研究成果,建立了航空产品质量评估体系。在此基础上,提出了一种大型复杂航空产品的质量评估模型。研究指出:制造过程质量和试实验过程质量对最终交付质量起着决定作用,其中制造过程质量受工程设计更改、代料状况、生产保留状况和故障状况的影响。最后,通过应用实例说明了模型的有效性。     

Convex shaping process simulation during counter-rotating electrochemical machining by using the finite element method

In counter-rotating electrochemical machining(CRECM), a revolving cathode tool with hollow windows of various shapes is used to fabricate convex structures on a revolving part. During this process, the anode workpiece and the cathode tool rotate relative to each other at the same rotation speed. In contrast to the conventional schemes of ECM machining with linear motion of a block tool electrode, this scheme of ECM is unique, and has not been adequately studied yet. In this paper, the finite element method(FEM) is used to simulate the anode shaping process during CRECM, and the simulation process which involves a meshing model, a moving boundary,and a simulation algorithm is described. The simulated anode profiles of the convex structure at different processing times show that the CRECM process can be used to fabricate convex structures of various shapes with different heights. Besides, the variation of the inter-electrode gap indicates that this process can also reach a relative equilibrium state like that in conventional ECM. A rectangular convex and a circular convex are successfully fabricated on revolving parts. The experimental results indicate relatively good agreement with the simulation results. The proposed simulation process is valid for convex shaping prediction and feasibility studies as well.