Analytic estimation and numerical modeling of actively cooled thermal protection systems with nickel alloys

Actively cooled thermal protection system has great influence on the engine of a hypersonic vehicle, and it is significant to obtain the thermal and stress distribution in the system. So an analytic estimation and numerical modeling are performed in this paper to investigate the behavior of an actively cooled thermal protection system. The analytic estimation is based on the electric analogy method and finite element analysis（FEA） is applied to the numerical simulation. Temperature and stress distributions are obtained for the actively cooled channel walls with three kinds of nickel alloys with or with no thermal barrier coating（TBC）. The temperature of the channel wall with coating has no obvious difference from the one with no coating, but the stress with coating on the channel wall is much smaller than that with no coating. Inconel X-750 has the best characteristics among the three Ni-based materials due to its higher thermal conductivity, lower elasticity module and greater allowable stress. Analytic estimation and numerical modeling results are compared with each other and a reasonable agreement is obtained.     

Stress analysis and damage evolution in individual plies of notched composite laminates subjected to in-plane loads

This work aims to investigate local stress distribution, damage evolution and failure of notched composite laminates under in-plane loads. An analytic method containing uniformed boundary equations using a complex variable approach is developed to present layer-by-layer stresses around the notch. The uniformed boundary equations established in series together with conformal mapping functions are capable of dealing with irregular boundary issues around the notch and at infinity. Stress results are employed to evaluate the damage initiation and propagation of notched composites by progressive damage analysis(PDA). A user-defined subroutine is developed in the finite element(FE) model based on coupling theories for mixed failure criteria and damage mechanics to efficiently investigate damage evolution as well as failure modes. Carbon/epoxy laminates with a stacking sequence of [45°/0°/ 60°/90°]sare used to investigate surface strains, in-plane load capacity and microstructure of failure zones to provide analytic and FE methods with strong validation. Good agreement is observed between the analytic method, the FE model and experiments in terms of the stress(strain) distributions, damage evaluation and ultimate strength, and the layerby-layer stress components vary according to a combination effect of fiber orientation and loading type, causing diverse failure modes in individuals.     

Convergence Analysis of the Numerical Solution for Cathode Design of Aero-engine Blades in Electrochemical Machining

As a main difficult problem encountered in electrochemical machining （ECM）, the cathode design is tackled, at present, with various numerical analysis methods such as finite difference, finite element and boundary element methods. Among them, the finite element method presents more flexibility to deal with the irregularly shaped workpieces. However, it is very difficult to ensure the convergence of finite element numerical approach. This paper proposes an accurate model and a finite element numerical approach of cathode design based on the potential distribution in inter-electrode gap. In order to ensure the convergence of finite element numerical approach and increase the accuracy in cathode design, the cathode shape should be iterated to eliminate the design errors in computational process. Several experiments are conducted to verify the machining accuracy of the designed cathode. The experimental results have proven perfect convergence and good computing accuracy of the proposed finite element numerical approach by the high surface quality and dimensional accuracy of the machined blades.     

基于自适应分层元的复合材料层合板低速冲击损伤分析(英文)

On the basis ofa 2D 4-node Mindlin shell element method, a novel self-adapting delamination finite element method is presented, which is developed to model the delamination damage of composite laminates. In the method, the sublaminate elements are generated automatically when the delamination damage occurs or extends. Thus, the complex process and state of delamination damage can be simulated practically with high efficiency for both analysis and modeling. Based on the self-adapting delamination method, linear dynamic finite element damage analysis is performed to simulate the low-velocity impact damage process of three types of mixed woven composite laminates. Taking the frictional force among sublaminations during delaminating and the transverse normal stress into account, the analytical results are consistent with those of the experimental data.     

Thermal–structure coupling analysis and multi-objective optimization of motor rotor in MSPMSM

With the high speed, the rotor of magnetically suspended permanent magnet synchronous motor(MSPMSM) suffers great thermal stress and mechanical stress resulting from the temperature rise problem caused by rotor losses, which leads to instability and inefficiency.In this paper, the mechanical–temperature field coupling analysis is conducted to analyze the relationship between the temperature field and structure, and multi-objective optimization of a rotor is performed to improve the design reliability and efficiency. Firstly, the temperature field is calculated by the 2 D finite element model of MSPMSM and the method of applying the 2 D temperature result to the 3 D finite element model of the motor rotor equivalently is proposed. Then the thermal–structure coupling analysis is processed through mathematic method and finite element method(FEM),in which the 3 D finite element model is established precisely in a way and approaches the practical operation state further. Moreover, the impact produced by the temperature and structure on the mechanical strength is analyzed in detail. Finally, the optimization mathematical model of the motor rotor is established with Sequential Quadratic Programming-NLPQL selected in the optimization scheme. Through optimization, the strength of the components in the motor rotor increases obviously and satisfies the design requirement, which to a great extend enhances the service life of the MSPMSM rotor.     

Determination of thermal expansion coefficients for unidirectional fiber-reinforced composites

In the present work, the coefficients of thermal expansion（CTEs） of unidirectional（UD）fiber-reinforced composites are studied. First, an attempt is made to propose a model to predict both longitudinal and transverse CTEs of UD composites by means of thermo-elastic mechanics analysis. The proposed model is supposed to be a concentric cylinder with a transversely isotropic fiber embedded in an isotropic matrix, and it is subjected to a uniform temperature change. Then a concise and explicit formula is offered for each CTE. Finally, some finite element（FE） models are created by a finite element program MSC. Patran according to different material systems and fiber volume fractions. In addition, the available experimental data and results of other analytical solutions of CTEs are presented. Comparisons are made among the results of the cylinder model,the finite element method（FEM）, experiments, and other solutions, which show that the predicted CTEs by the new model are in good agreement with the experimental data. In particular, transverse CTEs generally offer better agreements than those predicted by most of other solutions.     

Non-Fourier heat conduction analysis of a 2-D plate with inner cracks at arbitrary direction angles

This paper investigates the problem of a 2-D plate containing internal cracks at arbitrary angles to the heating surface under thermal shock. The finite difference method is applied to solve the temperature distribution and a difference scheme of the oblique crack is developed. For the first time, a non-Fourier heat transfer analysis method of a 2-D plate with inner cracks at arbitrary direction angles is established. Specifically, for a strip with an inner crack paralleling to the surface,numer...     

Numerical investigation of windage heating within shrouded rotor-stator cavity system with central inflow

The rotating disk surface temperature rise due to windage heating effect by numerically modeling the turbulent flow within a rotor-stator cavity which is available with a peripheral shroud and imposed through airflow was dealt with. The windage heating may be defined as viscous friction heating caused by relative velocity differences across the boundary layers between the fluid and the rotating disk surface. The kinetic energy dissipation process could transform the rotating shaft power into thermal heating. Commercial finite volume based solver, ANSYS/CFX was employed to numerically simulate this physical process by using the shear stress transport (SST) turbulence model. CFD results include the rotating disk surface temperature axial distribution and tangential velocity distribution of the fluid domain. The velocity difference between the result obtained by particle image velocimetry (PIV) experiments and CFD simulation are within 5%. The adiabatic disk temperature rise can be calculated by the tangential velocity of disk and fluid in large gap ratio and turbulent parameter. CFD temperature distribution results and those estimated via velocity differences are within 10%.     

Infrared radiation characteristics of a hypersonic vehicle under time-varying angles of attack

Hypersonic vehicles emit strong infrared(IR) radiation signatures that can be treated as a detecting source for object identification and routine diagnosis. This paper is aimed at examining the intrinsic radiation characteristics of a Boost-Glide Vehicle(BGV) under the condition of various Angles of Attack(AOAs). A two-temperature model considering the thermal and chemical nonequilibrium effects is coupled with Navier-Stokes equations solved by the finite volume technique.A gas–solid conjunction heat transfer model is also added into the fluid solver to simulate the surface temperature of the vehicle. The radiative transfer equation is solved with Line of Sight(LOS)algorithm. The computational results for a Hypersonic Technology Vehicle-2(HTV-2) type vehicle show that radiances of the vehicle are strongly dependent on the surface temperature. The presence of AOA results in the significant difference of the surface temperature. Infrared radiation characteristics are also changed in intensity and spectral band due to the AOA. Simulations are performed with two time-varying AOAs. Transient results indicate that the variation of AOA does have a great effect on the infrared radiance and is closely related to observation angle, spectral band, angle size,angular velocity and time history.     

A new surface catalytic model for silica-based thermal protection material for hypersonic vehicles

Silica-based materials are widely employed in the thermal protection system for hypersonic vehicles, and the investigation of their catalytic characteristics is crucially important for accurate aerothermal heating prediction. By analyzing the disadvantages of Norman's high and low temperature models, this paper combines the two models and proposes an eight-reaction combined surface catalytic model to describe the catalysis between oxygen and silica surface. Given proper evaluation of the parameters according to many references, the recombination coefficient obtained shows good agreement with experimental data. The catalytic mechanisms between oxygen and silica surface are then analyzed. Results show that with the increase of the wall temperature, the dominant reaction contributing to catalytic coefficient varies from Langmuir–Hinshelwood(LH)recombination(TW 620 K) to Eley–Rideal(ER) replacement(620 K TW 1350 K), and then to O2desorption(TW 1350 K). The surface coverage of chemisorption areas varies evidently with the dominant reactions in the high temperature(HT) range, while the surface coverage of physisorption areas varies within quite low temperature(LT) range(TW 250 K). Recommended evaluation of partial parameters is also given.     

Cutting tool temperature prediction method using analytical model for end milling

Dramatic tool temperature variation in end milling can cause excessive tool wear and shorten its life, especially in machining of difficult-to-machine materials. In this study, a new analyt-ical model-based method for the prediction of cutting tool temperature in end milling is presented. The cutting cycle is divided into temperature increase and decrease phases. For the temperature increase phase, a temperature prediction model considering real friction state between the chip and tool is proposed, and the heat flux and tool-chip contact length are then obtained through finite element simulation. In the temperature decrease phase, a temperature decrease model based on the one-dimension plate heat convection is proposed. A single wire thermocouple is employed to mea-sure the tool temperature in the conducted milling experiments. Both of the theoretical and experi-mental results are obtained with cutting conditions of the cutting speed ranging from 60 m/min to 100 m/min, feed per tooth from 0.12 mm/z to 0.20 mm/z, and the radial and axial depth of cut respec-tively being 4 mm and 0.5 mm. The comparison results show high agreement between the physical cutting experiments and the proposed cutting tool temperature prediction method.     

Experimental study on effect of inclination angles to ammonia pulsating heat pipe

In this paper, a novel study on performance of closed loop pulsating heat pipe（CLPHP）using ammonia as working fluid is experimented. The tested CLPHP, consisting of six turns, is fully made of quartz glass tubes with 6 mm outer diameter and 2 mm inner diameter. The filling ratio is50%. The visualization investigation is conducted to observe the oscillation and circulation flow in the CLPHP. In order to investigate the effects of inclination angles to thermal performance in the ammonia CLPHP, four case tests are studied. The trends of temperature fluctuation and thermal resistance as the input power increases at different inclination angles are highlighted. The results show that it is very easy to start up and circulate for the ammonia CLPHP at an inclining angle.The thermal resistance is low to 0.02 K/W, presenting that heat fluxes can be transferred from heating section to cooling section very quickly. It is found that the thermal resistance decreases as the inclination angle increases. At the horizontal operation, the ammonia CLPHP can be easy to start up at low input power, but hard to circulate. In this case, once the input power is high,the capillary tube in heating section will be burnt out, leading to worse thermal performance with high thermal resistance.     

Numerical simulations of turbulent flows in aeroramp injector/gas-pilot flame scramjet

To uncover the internal flow characteristics in an ethylene-fueled aeroramp injector/gaspilot(ARI/G-P)flame scramjet,a Reynolds-averaged Navier-Stokes(RANS)solver is constructed under a hybrid polyhedral cell finite volume frame.The shear stress transport(SST)k-x model is used to predict the turbulence,while the Overmann’s compressibility corrected laminar flamelet model is adopted to simulate the turbulent combustion.Nonreactive computations for Case 1(G-P jet on),Case 2(ARI jets on),and Case 3(both ARI and G-P jets on)were conducted to analyze the mixing mechanism,while reactive Cases 4–7 at equivalent ratios of 0.380,0.278,0.199 and0.167 respectively were calculated to investigate the flame structure and combustion modes.The numerical results are compared well to those of the experiments.It is shown that the G-P jet plays significant role in both the fuel/air mixing and flame holding processes;the combustion for the four reactive cases takes place intensively in the regions downstream of the ARI/G-P unit;Cases 4 and 5are under subsonic combustion mode,whereas Cases 6 and 7 are mode transition critical and supersonic combustion cases,respectively;the mode transition equivalent ratio is approximately 0.20.     

Crashworthiness uncertainty analysis of typical civil aircraft based on Box–Behnken method

The crashworthiness is an important design factor of civil aircraft related with the safety of occupant during impact accident. It is a highly nonlinear transient dynamic problem and may be greatly influenced by the uncertainty factors. Crashworthiness uncertainty analysis is conducted to investigate the effects of initial conditions, structural dimensions and material properties. Simplified finite element model is built based on the geometrical model and basic physics phenomenon. Box–Behnken sampling and response surface methods are adopted to obtain gradient information.Results show that the proposed methods are effective for crashworthiness uncertainty analysis.Yield stress, frame thickness, impact velocity and angle have great influence on the failure behavior,and yield stress and frame thickness dominate the uncertainty of internal energy. Failure strain and tangent modulus have the smallest influence on the initial peak acceleration, and gradients of mean acceleration increase because the appearance of material plastic deformation and element failure.     

A quasi-one-dimensional model for hypersonic reactive flow along the stagnation streamline

This study proposes a quasi-one-dimensional model to predict the chemical non-equilibrium flow along the stagnation streamline of hypersonic flow past a blunt body. The model solves reduced equations along the stagnation streamline and predicts nearly identical results as the numerical solution of the full-field Navier-Stokes equations. The high efficiency of this model makes it useful to investigate the overall quantitative behavior of related physical-chemical phenomena. In this paper two important properties of hypersonic flow, shock stand-off distance and oxygen disso-ciation, are studied using the quasi-one-dimensional model with the ideal dissociating gas model. It is found that the shock stand-off distance is affected by both chemical and thermal non-equilibrium. The shock stand-off distance will increase when the flow conditions are changed from equilibrium to non-equilibrium, because the average density of the shock-compressed gas will decrease as a result of the increase in translational energy. For oxygen dissociation, the maximum value of its dis-sociation degree along the stagnation line varies with the flight altitude. It is increased at first and decreased thereafter with the altitude, which is due to the combination effect of the equilibrium shift and chemical non-equilibrium relaxation. The overall variation of the maximum dissociation is then plotted in the speed and altitude coordinates as a reference for engineering application.     

Generation of Accelerated Stability Experiment Profile of Inertial Platform Based on Finite Element

The residual stress generated in the manufacturing process of inertial platform causes the drift of inertial platform parameters in long-term storage condition.However,the existing temperature cycling experiment could not meet the increased repeatability technical requirements of inertial platform parameters.In order to solve this problem,in this paper,firstly the Unigraphics(UG) software and the interface compatibility of ANSYS software are used to establish the inertial platform finite element model.Secondly,the residual stress is loaded into finite element model by ANSYS function editor in the form of surface loads to analyze the efficiency.And then,the generation based on ANSYS simulation inertial platform to accelerate the stability of experiment profile is achieved by the application of the analysis method of orthogonal experimental design and ANSYS thermal-structural coupling.The optimum accelerated stability experiment profile is determined finally,which realizes the rapid,effective release of inertial platform residual stress.The research methodology and conclusion of this paper have great theoretical and practical significance to the production technology of inertial platform.     

In-phase thermal-mechanical fatigue investigation on hollow single crystal turbine blades

Thermal-mechanical fatigue（TMF）is the primary cause of failure of nickel-based single crystal turbine blades.TMF experiments have been performed on the critical section which is subjected to the most serious damage and determined by numerical calculation combined with service failure experience.An experimental system including the loading,heating,air cooling,water cooling,and control subsystems,is constructed to satisfy the TMF experimental requirements.This experimental system can simulate the stress feld,temperature feld,air cooling process,and TMF spectrum on the critical section under service conditions in a laboratory environment.A metal loading device and a new induction coil are developed to achieve the required stress and temperature distributions on the critical section,respectively.TMF experimental results have indicated that cracks initiated at the trailing edge of the suction surface on the critical section.Based on these experiments,life prediction and failure analysis of hollow single crystal turbine blades can be investigated.     

Tear Resistance of Orthogonal Kevlar-PWF-reinforced TPU Film

This work seeks to investigate the notch sensitivity and fracture behaviour of orthogonal Kevlar-plain woven fabric (PWF)-reinforced thermoplastic polyurethanes (TPU) film applied to high altitude balloon. Four types of specimens are implemented to measure notched strength and fracture toughness by conducting static tension and tear tests on an MTS system respectively. The damage and failure mechanisms are discussed and the results for notched strength and tear resistance are evaluated and compared with each other. From the experiments, it is found that the notch sensitivity of the film increases with the increase in the size of the hole, but the notch sensitivity and the stress concentration of the notch are insignificant and there is a decrease of only about 4%-10% in tensile strength for the notched specimens with different hole sizes in diameter compared with the unnotched specimen. In contrast, the tear resistance containing a central slit with only 1 mm length is about half of tensile strength of the unnotched film, which implies that the tear resistance exists an significant notch sensitivity. The results of this study provide an insight into notch sensitivity and fracture behaviour of the Kevlar-PWF-reinforced TPU film and constitute a fundamental basis for the design of high altitude balloon.     

Formability enhancement in hot spinning of titanium alloy thin-walled tube via prediction and control of ductile fracture

The damage and fracture in hot spinning of titanium alloy is a very complex process under the combined effects of microstructure evolution and stress state. In this study, their dependences on processing parameters were investigated by an integrated FE model considering microstructure and damage evolution, and revealing the effects of microstructure and stress states on damage evolution. The results show that the inner surface of workpiece with the largest voids volume fraction is the place with...     

Improvement and application of Y2O3 directional solidification crucible

In order to satisfy the drastic temperature change and high chemical activity in directional solidification of Nb–Si based alloys, Y_2O_3 crucible is demanded to possess high thermal shock resistance and erosion resistance. This paper improved the sintering degree and density of Y_2O_3 crucible by optimizing the sintering temperature and time, and its practical application performance was investigated. Y_2O_3 grains gathered with the increase of sintering temperature and time, and the contact area enlarged, resulting in the open pores being changed into closed pores.The higher density caused the improvement of erosion resistance of Y_2O_3 crucibles. However, excessive density weakened the thermal shock resistance. Considering high-temperature strength, erosion resistance, thermal shock resistance and costs, optimum sintering temperature and time of Y_2O_3 directional solidification crucible were 1800 °C and 120 min, respectively, and the porosity was20%. Improved Y_2O_3 crucible has been successfully applied to directional solidification of Nb–Si based alloys, and significantly reduced the oxygen contamination. Slight interaction occurred between Hf and Y_2O_3, but no obvious dissolution, penetration or erosion was found, showing good erosion resistance and thermal shock resistance.