Improving the process forming limit considering forming defects in the transitional region in local loading forming of Ti-alloy rib-web components

The isothermal local loading forming technology provides a feasible way to form Ti-alloy large-scale rib-web components in aerospace and aviation fields.However,the local load ing process forming limit is restricted by forming defects in the transitional region.In this work,the feasibility of controlling forming defects and improving the process forming limit by adjusting die parameters is explored through finite element (FE) simulation.It is found that the common cavum and folding defects in the transitional region are significantly influenced by the fillet radii of left rib and middle rib,respectively.The cavum and folding defects can be effectively controlled by increas ing the fillet radii of left rib and middle rib,respectively.The process forming limits considering forming defects in the transitional region are determined by the stepwise searching method under various die parameters.Moreover,the relationship between the process forming limit and die parameters is developed through the response surface methodology (RSM).The developed RSM models suggest that increasing the fillet radii of left and middle ribs is effective to improve the pro cess forming limit during local loading forming of rib-web components.The results will provide technical basis for the design of die parameters and the reduction amount,which is of great impor tance to control forming defects and improve the process forming limit in local loading forming of Ti-alloy large-scale rib-web components.     

Optimization of Preform Shapes by RSM and FEM to Improve Deformation Homogeneity in Aerospace Forgings

This article, in order to improve the deformation homogeneity in aerospace forgings, proposes an approach that combines the finite element method (FEM) and the response surface method (RSM) to optimize the preform shapes. New expressions that take into account the influences of equivalent effective strain distribution are developed to evaluate the homogeneity of deformation distribution in aerospace forgings. In order to reduce the number of design variables, the domain-division method is put forward to determine the optimal design variables. On the basis of FEM results, the RSM is used to establish an approximate model to depict the relationship between the responses (deformation homogeneity and die underfilling) and the design variables represented by geometric parameters of the preform shape. With a typical aeroengine disk as an example, the proposed method is verified by achieving an optimal combination of design variables. By comparing the preform shape obtained with the proposed method to that with the existing one, it is evidenced that the former could achieve more homogeneous deformation in forging.     

基于高拟真度模型的高超声速飞行器静气动弹性优化

为解决基于计算流体动力学(CFD)和计算结构动力学(CSD)高拟真度模型的静气动弹性优化过程中模型更新自动化困难、求解速度慢的难点,提出了基于几何主模型技术的CFD/CSD一体化参数化建模方法和基于网格单元修正的常体积四面体(CVT)数据交换技术,并引入响应面模型来降低气动弹性优化求解难度.通过AGARD 445.6机翼静气动弹性分析对上述方法的可行性和有效性进行了验证;并以某高超声速飞行器为例,采用基于二次响应面的多目标优化算法进行了CFD/CSD气动弹性分析与优化,优化后飞行器升阻比增加16%,结构质量减少9%,且响应面模型精度拟合误差不超过1.5%.计算结果表明:所发展的CFD/CSD一体化参数化建模与优化方法能够有效地解决高拟真度模型的静气动弹性优化问题.      

应用基于FEM的预成形最优化方法提高锻件变形均匀性

锻件变形分布不均匀将导致锻件各部位的组织和性能产生很大差异。应用基于正向有限元数值模拟和最优化方法进行坯料预成形设计的新方法,可显著提高锻件各部位的变形均匀性。首先介绍了以提高锻件变形分布均匀性为目的的坯料预成形最优化方法的基本原理,并针对典型的IN718合金涡轮盘锻件进行了坯料预成形设计。给出了预成形坯料与普通圆柱坯料的对比结果,并进行了相应的试验验证。结果表明,应用这种方法对IN718合金涡轮盘锻件进行坯料预成形设计,可使盘锻件各部位变形均匀性明显改善。     

折叠球形气囊展开过程仿真

球形气囊展开和折叠过程复杂,采用实验手段研究其展开过程存在诸多不便。建立以单侧内折方式折叠的球形气囊数值分析模型,研究球形气囊折叠后充气展开的动态应用特性,比较相同充气条件不同折叠层数和相同折叠层数不同充气条件下气囊展开动态特性的差异;对影响气囊展开过程中体积和内压曲线变化的因素进行分析,分别讨论折叠层数、充气速率和充气量对球形气囊动态特性的影响。结果表明:单侧内折折叠次数增多会导致气囊内压最大值增大,应用时设定气囊折叠次数应考虑气囊材料最大内压承受能力;充气速率和充气量均会影响气囊展开的稳定性,充气速率的影响主要在充气及气囊展开初期阶段,而充气量的影响主要在充气完成后的自由展开阶段。     

水平集法在多相材料细观结构优化中的应用

利用高精度通用单胞模型将多相材料的细观拓扑结构和宏观力学性能联系起来,将一个单胞离散成有限个单元,通过单元中材料的有无来描述细观结构,利用水平集法将这个离散变量的拓扑优化问题转化为连续变量的形状优化问题,从而实现了多相材料的细观结构优化.以一种多相材料结构为例进行了细观结构的优化,并获得了具有负泊松比的特性,从而验证了所提出方法的合理性.      

Optimization of structural parameters for elliptical cross-section spiral equal-channel extrusion dies based on grey theory

The elliptical cross-section spiral equal-channel extrusion (ECSEE) process is simulated by using Deform-3D finite element software. The ratio m of major-axis to minor-axis length for ellipse-cross-section, the torsion angle u, the round-ellipse cross-section transitional channel L1, the elliptical rotation cross-section transitional channel L2 and the ellipse-round cross-section transitional channel L3 are destined for the extrusion process parameters. The average effective strain eave on cross-section of blank, the deformation uniformity coefficient a and the value of maximum damage dmax are chosen to be the optimize indexes, and the virtual orthogonal experiment of L16 (45) is designed. The correlation degree of the process factors affecting eave, a and dmax is analyzed by the numerical simulation results using the weights and grey association model. The process parameters are optimized by introducing the grey situation decision theory and the ECSEE optimal combination of process parameters is obtained: u of 120 , m of 1.55, L1 of 7 mm, L2 of 10 mm, and L3 of 10 mm. Simulation and experimental results show that the material can be refined with the optimized structural parameters of die. Therefore, the optimization results are satisfactory.     

拓扑优化在机载计算机结构设计中的应用

为了解决机载计算机零件结构设计过程中出现的材料分布不合理及重量要求苛刻等问题，在设计过程中引入拓扑优化。介绍了基于变密度法的拓扑优化理论，以Hyperworks／Optistruct为拓扑优化分析平台，对某机载计算机零件进行了拓扑优化，确定了零件的最佳材料分布。结果表明：通过优化设计可以在保持零件基本结构性能的基础上减轻其重量。     

CFD在概念-初步设计阶段三维气动外形优化中的应用

在飞行器概念-初步设计阶段,建立基于CFD的气动优化链对于提高优化计算的效率具有较好的工程应用价值。使用德国宇航院开发的CPACS数据格式给出飞行器平面形状,结合NURBS翼型参数化方法对飞行器几何外形进行参数化;自动生成计算网格并求解Euler方程数值模拟流场以评估参数化气动外形的气动特性,进而构建响应面模型;使用SQP梯度算法搜索响应面模型以获取满足约束的最优解。以Onera M6机翼为例,对该优化链进行验证。结果表明:在满足约束的条件下,基于CFD的气动优化链能够成功地进行气动外形优化。     

离心压气机通流/造型/CFD参数化优化设计集成反问题方法

在自主开发的离心压气机通流/造型反问题设计程序的基础上, 发展了一套离心压气机的通流/造型/CFD于优化设计程序系统下集成的反问题方法, 建立了离心压气机的参数化优化设计平台.采用“试验设计+响应曲面模型+近似优化”的快速优化算法, 对一个10 daN推力级微型涡喷发动机的离心压气机进行了多准则气动优化.结果表明, 这种过程集成的快速优化方法是很有效的.      

航空电液伺服系统阀套珩磨材料去除体积预测研究

针对珩磨加工阀套孔生产率低、加工精度难控制等问题,开展了内孔珩磨技术研究,通过分析9Cr18不锈钢珩磨过程中材料去除率的变化规律,提出一套适用于珩磨加工的材料去除体积理论公式.同时为使珩后孔不同轴向位置处的孔径趋近一致,需要在上下越程处增设停留时间,以此改进初始模型.基于初始模型与优化模型分别开展单因素珩磨试验,结果表...     

Adaptive-surrogate-based robust optimization of transonic natural laminar flow nacelle

Natural Laminar Flow (NLF) technology is very effective for reducing the skin friction drag of aircraft engine nacelle, but the aerodynamic performance of NLF nacelle is highly sensitive to uncertain working conditions. Therefore, it’s imperative to incorporate uncertainties into the design of NLF nacelle. In this study, for a robust optimization of NLF nacelle and for improving its efficiency, an adaptive-surrogate-based robust optimization strategy is established, which is an iterative optimization process where the surrogate model is updated to obtain the real Pareto front of multi-objective optimization problem. A case study is carried out to validate its feasibility and effectiveness. The results show that the optimization increases the favorable pressure gradient region and the volume ratio of the nacelle by increasing its lip radius and reducing its maximum diameter. And the aerodynamic robustness of the NLF nacelle is mainly determined by the lip radius, maximum diameter of nacelle and location of the maximum diameter. Compared to the initial nacelle, the optimized nacelle maintains a wide range of low drag and high laminar flow ratio in the disturbance space, which extends the average laminar flow region to 21.6% and facilitates a decrease of 1.98 counts in the average drag coefficient.     

基于变分法的冷却结构优化设计与分析方法

为了改善冷却结构的综合换热性能,需要对冷却结构的优化设计进行研究。以冷却结构的平均温度、温度不均匀度和冷却剂流动压力损失为目标函数,基于变分法生成优化分布的冷却通道,该通道可以根据当地的边界条件而自适应地调整。随后对冷却结构进行流固耦合传热的数值计算,得到冷却结构的温度分布、冷却剂的压力损失、冷却剂出口温度等参数,多次迭代进而得到满足目标要求的冷却结构优化设计。计算结果表明,基于变分法的冷却结构优化设计方法可以根据当地边界条件生成优化的冷却通道;对于不同的优化方案,存在各自对应的最佳通道个数和冷却通道分布使目标函数最优;对于优化方案三,优化设计的冷却通道和常规设计的冷却通道相比:冷却结构平均温度从816K下降到807K,温度不均匀度从211K降低到172K,代价是压力损失从8kPa上升到17kPa。     

A new localization theory of adaptive machining of near-net-shape blades

In the fabrication of aero-engine blades, a great deal is gained when massive material removal is avoided at the end of the process, and as little as possible material is left on the blade billet. Due to the uncertainty of pre-process, the billet shapes are inconsistent. Sometimes, the near-net-shape billet doesn’t cover the blade design surface to be cut. Therefore, blade localization is necessary for these billets before the machining. In conventional localization methods, the design surface’s location focused on guaranteeing enough material to be cut. However, because the to-be-cut surface is in near-net and free-form shape, it is difficult to find a valid localized surface model to generate the tool path. Different from the localized surface is taken as rigid in previous investigation, it is allowed to deviate from the design surface no more than the tolerance band. In term of this principle, the tolerance band is utilized to promote localization ability. A series of optimization models with different priorities is established to avoid the abandonment expensive blade billet. Finally, with the experiments performed on the near-net-shape blades, the blade localization theory and the promotion of localization ability are verified.     

基于可行域调整的多相材料结构拓扑优化设计

针对多相材料结构柔顺度拓扑优化问题及其存在多个局部优化解的情况,提出一种新的多相材料结构柔顺度拓扑优化问题的求解方法, 并研究其获得多个局部优化解及寻找较好的优化解的能力。基于材料属性有理近似 （RAMP）模型,引入可行域调整技术,构建多相材料结构拓扑优化模型及近似优化模型。提出一种改进的交替主动相算法,该算法将多相材料结构拓扑近似优化模型分解为多个含2个主动相材料体积约束的系列二元相拓扑优化子模型,并利用光滑化对偶算法进行优化求解。与现有方法相比,采用多个不同的优化初始拓扑,提出的方法可找到更优的多相材料结构拓扑, 且为多相材料结构拓扑优化的多样性设计提供了一种有价值的思路与方法。     

吸附式压气机叶型和抽吸方案优化设计

将智能优化算法与准三维叶栅计算程序相结合,对某吸附式压气机叶型进行了优化设计,对优化设计前后的流场进行了详细分析.优化设计之后叶型总压损失下降40%,静压升提高0.6%.优化得到最佳抽吸位置位于分离区起始点上游,优化叶型具有更均匀的负荷分布,并且优化后叶型的性能在全攻角范围内均得到了提升.结果表明:更均匀的负荷分布会提高叶型的性能,减小叶型分离,降低抽吸所需要的能量.对于在尾缘处存在轻微分离的叶型其最优抽吸位置位于分离区上游.     

基于遗传算法与响应面模型的压气机叶片气动优化设计

1引言由于叶轮机械内部复杂的三维流动,各种波涡结构的广泛存在,吸引了众多学者对其进行了积极的探索与研究。CFD作为可靠省时的设计手段之一,在叶轮机械气动设计的过程中显示了其卓越的性能[1~3]。June Chung和Lee K i D[4]采用基于梯度法的优化程序,以绝热效率为目标函数对NA     

TC4合金叶片热模锻过程的数值模拟

文摘为了生产出质量合格的叶片,针对TC4合金叶片的成形特点,为其制订了相应的热模锻成形工艺。同时采用基于有限体积的材料成形模拟技术,对TC4合金叶片热模锻过程进行了模拟,分析了坯料成形过程中的充填情况、应变场、应力场及终锻温度场的分布规律。模拟结果表明:锻件轮廓清晰,模具型腔充填完整,未出现充不满或折叠等锻造缺陷。实际生产出来的叶片经理化检测和外观检查,质量符合要求,制定的工艺方案合理,可以满足TC4合金航空风扇转子叶片的成形质量要求。     

气体二次喷射推力矢量控制的响应面优化设计

采用基于部分正交多项式的响应面法结合数值模拟试验对某实验发动机气体二次喷射推力矢量控制系统进行优化设计, 结果表明:这种优化方法可以减少为得到近似函数式而对主/次流干扰流场进行计算的次数, 节省计算时间, 能方便地对气体二次喷射系统各个参数进行优化与分析.      

优化设计技术在民机结构设计中的应用

基于HyperWorks结构优化设计软件,对某型民用飞机平尾后缘舱铰链支架进行优化设计,在给定的边界条件下通过拓扑优化技术寻找出在优化空间内的最体材料布局,介绍了优化设计技术在飞机结构设计技术中的应用,探讨拓扑优化、尺寸优化、形状优化在飞机结构件设计技术中的应用。