Coupling behavior between adhesive and abrasive wear mechanism of aero-hydraulic spool valves

Leakage due to wear is one of the main failure modes of aero-hydraulic spool valves. This paper established a practical coupling wear model for aero-hydraulic spool valves based on dynamic system modelling theory. Firstly, the experiment for wear mechanism verification proved that adhesive wear and abrasive wear did coexist during the working process of spool valves. Sec-ondly coupling behavior of each wear mechanism was characterized by analyzing actual time-variation of model parameters during wear evolution process. Meanwhile, Archard model and three-body abrasive wear model were utilized for adhesive wear and abrasive wear, respectively. Furthermore, their coupling wear model was established by calculating the actual wear volume. Finally, from the result of formal test, all the required parameters for our model were obtained. The relative error between model prediction and data of pre-test was also presented to verify the accuracy of model, which demonstrated that our model was useful for providing accurate prediction of spool valve’s wear life.     

Dynamic performance of a C/C composite finger seal in a tilting mode

The complex operating state of aeroengines has an impact on the performance of finger seals.However,little work has been focused on the issue and the dynamic performance of finger seals is also rarely studied.Therefore,a distributed mass equivalent model considering working conditions is proposed in this paper for solving the existing problems.The effects of the fiber bundle density and the preparation direction of the fiber bundle of a C/C composite on the dynamic performance of a finger seal are investigated in rotor tilt based on the proposed model.The difference between the C/C composite finger seal performances under the rotor precession and nutation tilt cases is also investigated.The results show that the fiber bundle density and the preparation direction of the fiber bundle have an influence on the dynamic performance of the finger seal as rotor tilt is considered,and the dynamic performance of the finger seal is different in the two kinds of tilting modes.In addition,a novel method for design of finger seals is presented based on the contact pressure between finger boots and the rotor.Finger seals with good leakage rates and low wear can be acquired in this method.     

Remaining useful life prediction based on the Wiener process for an aviation axial piston pump

An aviation hydraulic axial piston pump’s degradation from comprehensive wear is a typical gradual failure model. Accurate wear prediction is difficult as random and uncertain char-acteristics must be factored into the estimation. The internal wear status of the axial piston pump is characterized by the return oil flow based on fault mechanism analysis of the main frictional pairs in the pump. The performance degradation model is described by the Wiener process to predict the remaining useful life (RUL) of the pump. Maximum likelihood estimation (MLE) is performed by utilizing the expectation maximization (EM) algorithm to estimate the initial parameters of the Wiener process while recursive estimation is conducted utilizing the Kalman filter method to estimate the drift coefficient of the Wiener process. The RUL of the pump is then calculated accord-ing to the performance degradation model based on the Wiener process. Experimental results indi-cate that the return oil flow is a suitable characteristic for reflecting the internal wear status of the axial piston pump, and thus the Wiener process-based method may effectively predicate the RUL of the pump.     

Gaussian process regression model incorporated with tool wear mechanism

Cutting tool condition directly affects machining quality and efficiency. In order to avoid severely worn tools used during machining process and fully release the remaining useful life in the meanwhile, a reliable evaluation method of remaining useful life of cutting tools is quite necessary.Due to the variation of cutting conditions, it is a challenge to predict remaining useful life of cutting tools by a unified model. In order to address this issue, this paper proposes a method for predictin...     

Coupled evolution of piston asperity and cylinder bore contour of piston/cylinder pair in axial piston pump

The wear condition of the piston/cylinder pair is crucial to the performance and reliability of the axial piston pump. The hard piston surface, the soft cylinder bore surface, and the interface oil film affects each other during the wear process. Specifically, in the mixed lubrication region, the geometry of the hard piston surface asperity directly affects the wear of soft cylinder bore surface, while the asperities may deform or even degrade when penetrating and sliding against the cylinder bore. So far, there is no suitable method to simulate their coupled evolution. This paper proposed a wear process simulation model considering the real-time interaction between the elasto-plastic deformation of the piston surface asperity, the wear contour of the cylinder bore, and the lubrication condition of the interface. An offline library of the elasto-plastic constitutive behavior of the asperity based on the finite element method (FEM) is established as a part of the simulation model to precisely analyze the deformation and degradation of the asperity and quickly invoke them in the numerical wear process simulation. The simulation and experimental results show that the piston asperity and the cylinder bore contour converge to a steady state after running-in for about 0.5 h. The distribution of the simulated asperity degradation and wear depth is also verified by the experiment.     

Ion thruster accelerator grid erosion mechanism under extreme conditions of cylindrical erosion and chamfer erosion

In this paper, the abnormal experimental phenomenon on barrel erosion under extreme working conditions in the ultra-long life experiment(>10000 h) of ion thruster ion optics is studied by the Immersed-Finite-Element Particle-In-Cell Monte-Carlo-Collision(IFE-PIC-MCC) method and the grid erosion evaluation model. The transport process of beam ions and Charge Exchange(CEX) ions in the grid system, and the characteristics and mechanisms of the aperture barrel erosion under extreme erosion condit...     

高过载条件下绝热层烧蚀实验方法研究 (Ⅱ)收缩管聚集法

发展了一种能开展高过载条件下绝热层烧蚀研究的模拟实验方法——收缩管聚集法，研制了收缩管聚集高过载模拟烧蚀实验装置。对实验装置及固体火箭发动机过载条件下的三维两相内流场开展了对比数值模拟，结果表明这种实验装置产生的高浓度粒子流与40g纵横向过载条件下发动机内形成的高浓度粒子流状态很接近，说明这种实验方法是可以模拟高过载条件下绝热层烧蚀环境的。利用这套实验装置开展了高浓度粒子流冲刷条件下绝热层烧蚀实验，对6种绝热材料开展的烧蚀实验表明：所有试件表面均被冲蚀出一个凹坑，说明粒子冲刷对绝热层烧蚀影响很大。凹坑最大烧蚀部位与数值模拟得到的粒子浓度最大部位基本吻合。     

基于磨粒磨损机理的机械磨损状态监测

针对机械设备磨损状态监测准确率较低的问题,基于不同磨损机理下磨粒具有不同的形状和纹理特征,提出了一种基于磨粒特征识别的机械磨损状态监测的数学模型。通过形状特征识别球状磨粒和切削磨粒,结合形状、纹理特征识别疲劳磨粒和严重滑动磨粒,基于提取的特征参数建立机械磨损状态监测的特征向量,通过量子粒子群优化(QPSO)的径向基函数神经网络模型,实现对机械磨损状态的监测和判别。实验结果表明:QPSO-RBF神经网络数学模型结构简单,比传统PSO-RBF神经网络模型的识别准确率高5%,可用于常见机械磨损状态的检测。      

基于敏感性分析的反应动力学自适应建模方法

为了降低采用基元燃烧模型模拟反应流的计算时间,提出一种基于敏感性分析的自适应化学反应机理简化方法。该方法结合敏感性分析方法与自适应机理简化的思想对详细化学反应机理在不同工况点进行简化,并形成即时简化机理集。在燃烧模拟过程中,对于不同反应工况点使用不同的即时简化机理对反应流进行数值模拟,以替代传统的全局使用单一简化机理的反应流数值模拟方法。基于GRI-3.0机理,采用均相大空间甲烷自燃着火过程对该方法进行了测试;简化机理与详细机理计算结果的比较,证明了该方法的正确性与高效性。     

航空花键振动磨损预测与实验

基于Archard经典磨损理论,推导振动条件下航空花键的键齿之间的相对运动位移,考虑实验花键模拟工况循环和振动位移,对实验花键的磨损进行了预测,并搭建了航空花键磨损实验台,开展磨损实验测试。理论预测表明:磨损量随着磨损系数、传递扭矩的增加而线性增加,随着齿数、硬度增加而线性减小,而随着振动量的增大而非线性增大。实验与仿真结果定性一致,在磨损初期存在一定波动,磨损后期存在一定的偏差,这是由于花键制造和安装偏差、理论模型简化以及难以考虑的花键复杂工况等所致。振动对花键磨损具有决定性影响,因此应合理控制内、外花键所在转子的振幅、提高花键转子设计动平衡等级可以有效延缓花键磨损。      

Remaining useful life estimation for deteriorating systems with time-varying operational conditions and condition-specific failure zones

Dynamic time-varying operational conditions pose great challenge to the estimation of system remaining useful life (RUL) for the deteriorating systems. This paper presents a method based on probabilistic and stochastic approaches to estimate system RUL for periodically moni-tored degradation processes with dynamic time-varying operational conditions and condition-specific failure zones. The method assumes that the degradation rate is influenced by specific oper-ational condition and moreover, the transition between different operational conditions plays the most important role in affecting the degradation process. These operational conditions are assumed to evolve as a discrete-time Markov chain (DTMC). The failure thresholds are also determined by specific operational conditions and described as different failure zones. The 2008 PHM Conference Challenge Data is utilized to illustrate our method, which contains mass sensory signals related to the degradation process of a commercial turbofan engine. The RUL estimation method using the sensor measurements of a single sensor was first developed, and then multiple vital sensors were selected through a particular optimization procedure in order to increase the prediction accuracy. The effectiveness and advantages of the proposed method are presented in a comparison with exist-ing methods for the same dataset.     

Performance evaluation of complex systems using evidential reasoning approach with uncertain parameters

The composition of the modern aerospace system becomes more and more complex. The performance degradation of any device in the system may cause it difficult for the whole system to keep normal working states. Therefore, it is essential to evaluate the performance of complex aerospace systems. In this paper, the performance evaluation of complex aerospace systems is regarded as a Multi-Attribute Decision Analysis (MADA) problem. Based on the structure and working principle of the system, a new Evidential Reasoning (ER) based approach with uncertain parameters is proposed to construct a nonlinear optimization model to evaluate the system performance. In the model, the interval form is used to express the uncertainty, such as error in testing data and inaccuracy in expert knowledge. In order to analyze the subsystems that have a great impact on the performance of the system, the sensitivity analysis of the evaluation result is carried out, and the corresponding maintenance strategy is proposed. For a type of Inertial Measurement Unit (IMU) used in a rocket, the proposed method is employed to evaluate its performance. Then, the parameter sensitivity of the evaluation result is analyzed, and the main factors affecting the performance of IMU are obtained. Finally, the comparative study shows the effectiveness of the proposed method.     

竞争风险模型下变环境的发动机叶片可靠性分析

针对航空发动机转子叶片的恶劣工况导致其存在多种故障模式,各种故障的失效与使用环境紧密关联,给航空发动机转子叶片的可靠性分析或风险控制带来了难度这一问题,从转子叶片的磨损和裂纹两种主要故障模式特点出发,研究了变环境下的转子叶片磨损故障模型和疲劳裂纹故障模型,提出了一种基于竞争风险模型的转子叶片可靠性分析方法,并给出了求解算法;以某高压涡轮转子叶片为例进行了分析研究.结果表明:在可靠性分析中采用单个故障模型比竞争风险模型风险更大;且在竞争风险模型下,如果不考虑推力环境的影响,以不可靠度要求0.1为例,相应风险增加了33%,验证了所提方法的实用性.      

Evaluation of thermal effects on temperature-sensitive operating force of flow servo valve for fuel metering unit

The temperature-induced variation in operating force of flow control valves may result in performance degradation or even jam faults of fuel metering unit (FMU), which significantly affects the safety of aircrafts. In this work, an analytical modeling approach of temperature-sensitive operating-force of servo valve is proposed to investigate the temperature characteristics in varying temperature conditions. Considering the temperature effects, a new extended model of flow force is built and an analytical model of valve friction is also derived theoretically based on the dynamic clearance induced by thermal effects. The extremum condition of friction is obtained to analyze the characteristic-temperature points where jam faults occur easily. The numerical results show that flow force increases firstly and then decreases as temperature increases under a constant valve opening. The maximum friction of flow servo valve can be uniquely determined when the structural parameters and ambient temperature are given. The worst situation just happens at the characteristic-temperature points, which are linearly related to the axial temperature gradients of valve spool. Such evaluations may give an explanation for the temperature-induced jam faults of vulnerable valves and provide a reference for designers to determine a suitable working-temperature range of valves in practice.     

基于触发角定时控制的异步电机软起动控制器设计

针对起重设备专用三相异步电机的直接起动问题,分析了异步电机的T型等效电路,阐述了晶闸管调压电路的工作原理,提出了一种基于触发角定时控制的异步电机软起动方法。基于MATLAB/Simulink搭建了相应的系统仿真模型,进行了提出方法的仿真分析,验证了所提方法的正确性。最后,基于单片机设计了相应的软起动器的软硬件,进行了试验测试。结果表明提出的方法可以有效地实现三相异步电机的平滑起动,起动电流较小,有效地减少了起动过程对电机和电网的影响。     

基于灰色聚类的磨粒自动识别

 将灰色系统理论中的聚类分析技术用于磨损颗粒的自动识别, 编制了相应的计算机模拟程序。在对磨粒图象的形态特征参数进行敏感性分析的基础上, 确定了各参数的灰类白化权函数, 并结合磨粒识别的试验研究, 给出了磨粒各特征参数的聚类权值。应用此方法对一组标准磨粒进行了模拟识别, 识别正确率在90% 以上, 并且识别速度很快, 大大优于传统的磨粒识别方法。     

基于遗传算法的航空发动机状态变量模型建立方法

提出了一种采用遗传算法建立用于航空发动机控制系统设计的小偏差状态变量模型的方法,即根据发动机稳态工作点处的线性化数学模型的动态响应应该与该稳态工作点处的非线性数学模型动态响应一致的原则来构造遗传算法的适应度函数,通过优化算法,得出系统的状态变量模型。该方法不受系统模态及模型阶次的限制。应用该方法建立某型涡扇发动机的小偏差状态变量模型,具有较高的建模精度,根据该状态变量模型设计鲁棒控制器取得了良好的控制效果,从而验证了该方法的有效性。      

基于域对抗门控网络的变工况刀具磨损精确预测方法

刀具磨损的精确预测对保证零件加工质量、提高生产效率和降低制造成本具有重要作用。在实际加工过程中,切削参数、刀具几何参数、刀具材料等工况复杂多变,工况信息和刀具磨损量对监测信号的耦合作用为刀具磨损的精确预测带来了很大挑战。针对以上问题,提出了一种基于域对抗门控网络（DAGNN）的变工况刀具磨损精确预测方法。引入工况分类网络并利用无磨损量标签样本,通过域对抗和门控过滤机制自适应地从不同工况的原始监测信号中提取表征刀具磨损且对工况变化不敏感的关键信号特征。对信号特征提取网络和刀具磨损预测网络进行迭代优化,从而实现变工况刀具磨损的精确预测。实验结果表明：相比已有的方法,本文方法能够利用少量带磨损量标签的目标工况样本实现刀具材料和刀具直径变化情况下的刀具磨损量精确预测,预测精度大幅提高。     

基于改进粒子群算法的航空发动机状态变量建模

为了克服现有航空发动机状态变量建模过程中的不足,采用了一种改进粒子群算法建立航空发动机状态变量模型。首先改进了粒子群算法,提出一种每个粒子根据自身适应值动态调整其惯性系数方法来平衡搜索性能;对群体最优位置进行实时的代内更新以提高搜索速度;为避免陷入局部最优,在最优个体附近进行随机搜索。其次利用该算法建立航空发动机状态变量模型,根据航空发动机在稳态点处的线性化模型应与在该同一稳态工作点处的非线性模型响应一致的原则构造适应值函数,仿真结果表明所建立的状态变量模型不论是稳态过程还是动态过程都与非线性模型响应基本一致,建模精度较高,建立过程简便。     

飞机冲压空气涡轮系统的动态特性分析

冲压空气涡轮是飞机能源失效时使用的关键应急系统。首先依据冲击空气涡轮（RAT）工作原理确定其物理架构；然后对涡轮部件、能源转换装置、展开装置和展开随动机构等4个主要部件进行力学分析，建立各部件的力学方程组。依据该力学方程组，建立涉及力学、液压、刚体动力学的多学科冲压空气涡轮系统模型。使用该模型仿真了某真实系统在不同工况和设计参数下的动态特性，研究了关键设计参数对系统性能的影响，为冲压空气涡轮系统正向设计提供依据。最终，某型冲压空气涡轮系统风洞试验数据验证了所提系统模型的准确性。