快速成形技术在模具制造中的应用

快速成形技术是一种先进的、新型的制造技术,本文介绍了快速成形技术的主要类型和工作过程,并讨论了它在模具制造中的应用.     

7475合金复杂薄壁件的超塑成形技术

以椭球形零件为例，介绍了7475合金复杂薄壁件的超塑成形技术。采用有限元分析技术，对成形过程实施仿真，从而突破了零件壁厚均匀化、模具的设计、超塑成形工艺参数的优化等技术关键，采用CAD/CAM技术进行模具CAD/CAM设计和制造，实现(产品、工装)设计、工艺、制造三结合，所制造的某型号复杂薄壁件在形状尺寸精度、壁厚机械性能要求等方面均符合技术指标要求。     

快速成形制造质量研究

针对快速成形设备成形质量不高的问题，利用STL快速成型设备进行试验。进行了相应的实验设计，运用粗糙集理论对实验数据进行处理，得到了对快速成型制造质量有影响的各因素的显著性，并得到了改进加工质量的参数组合，详细阐述了该方法的原理及运用该方法进行分析的步骤。     

超塑成形技术研究及其在航空航天上的应用

从超塑成形技术的早期研究入手,综合分析了超塑成形技术的研究现状,包括合金材料、成形设备、陶瓷模具及模拟技术现状等,总结归纳了超塑成形技术在航空航天工业上的应用,重点介绍了EADS-CASA采用SPF或SPF/DB制造发动机零件及外壳零件,以及美国、欧空局、日本制造航天器贮箱的SPF技术,最后探讨了目前国际上超塑成形技术的几个主要研究方向,包括轻质镁合金的超塑成形、用于SPF的搅拌摩擦焊插件以及陶瓷、透明金属的超塑成形技术研究等。     

国外太空制造技术研究

介绍了美国宇航局(NASA)对太空制造技术的研究情况,包括连接技术和原位制造技术,找出了适用于太空连接的真空电子束钎焊技术和适合太空成形的自由成形制造(激光F3)技术,并介绍了太空制造设备的要求、集成制造单元和太空集成制造工厂的概念等,最后得出结论,太空制造技术的研究将成为长期载人航天项目中最重要的部分.     

先进钣金成形技术在航天制造领域应用分析

针对航天产品对先进钣金成形技术的需求,介绍了板材充液成形技术、管材内高压成形技术、超塑成形/扩散连接技术(SPF/DB)、旋压成形技术、橡皮囊成形技术等钣金成形技术的成形原理、技术特点及其在国内外航天制造领域的典型应用情况。在此基础之上简要分析了先进钣金成形技术在未来航天领域的应用前景。     

激光快速成形技术在液体动力领域的应用前景

随着液体火箭发动机性能的不断提高,发动机核心构件呈现复杂、薄壁、多功能、整体化和轻质化等新特征,为发动机的研制与生产带来挑战,急需开展新工艺、新技术的研究来满足发动机的制造需求。激光快速成形技术是近年来迅速发展起来的一种新工艺,该技术使用激光作为热源,将金属粉逐层熔化,可直接制备出形状复杂、尺寸精度高、组织结构致密、性能稳定的金属构件,在液体动力产品制造上具有独特应用优势。介绍了激光快速成形技术的原理及分类,综述了其国内外研究现状及发展趋势,分析了该技术在液体火箭发动机上的应用优势,并阐述了其在液体火箭发动机上的应用前景。     

特种制造工艺在航天产品研制中的应用分析

特种制造工艺－非传统制造技术在切除、连接装配、成形、热处理、表面处理等领域中发展迅速。选择及应用合适，会产生良好的技术、经济优势。结合运载火箭技术发展需求。有重点地对一些特种制造工艺特点，应用实例进行了技术分析。针对承担航天产品商品生产的企业，加强发展及应用特种制造工艺技术提出了若干看法和建议。     

快速成形制造质量研究

针对快速成形设备成形质量不高的问题,利用STL快速成型设备进行试验.进行了相应的实验设计,运用粗糙集理论对实验数据进行处理,得到了对快速成型制造质量有影响的各因素的显著性,并得到了改进加工质量的参数组合,详细阐述了该方法的原理及运用该方法进行分析的步骤.     

高强铝合金薄壁高筋大型壁板精确成形制造技术研究

针对现有铝合金薄板加筋条铆接或轧制厚板铣削的制造方式已经难以满足新型运载火箭舱段壁板在轻量化、高性能和低成本快速制造等方面的发展需求,从挤压成形所具有的高效率、高成形精度和良好的稳定性等特点出发,围绕高强韧高成形性可焊铝合金设计、高纯均质熔铸工艺、挤压流变整体成形以及复杂断面构件热处理调控的研究,提出采用带筋筒形件挤压开坯、精近成形后剖展的方法,制造宽幅薄壁高筋壁板,在降低宽幅薄壁高筋壁板对工装高要求的同时提高成形稳定性,并兼具高效、低成本、高性能等特点,能够支撑轻质高强薄壁大型舱段的高性能、低成本、高效制造。     

精确制导武器虚拟样机技术研究

精确制导武器虚拟样机技术是进行精确制导武器研究的一项关键技术。本文充分考虑到建立一体化、通用化的虚拟样机系统支撑平台的需要,选取景象匹配技术作为精确制导技术的研究对象。研究过程中重点讨论了虚拟样机系统的组成、方案及算法分析、算法仿真试验、试验结果分析、系统集成等问题。其中,精确制导算法仿真的试验结果揭示了典型匹配算法的抗干扰能力和各种主要因素对匹配结果的影响规律,与理论分析一致;系统集成过程中详细分析了控制流、数据流与系统集成的组织过程和方法;最后对整个精确制导武器虚拟样机系统的研制工作进行了总结。     

固体火箭发动机虚拟样机集成设计环境

为支持固体火箭发动机基于虚拟样机的设计技术,提出了固体火箭发动机虚拟样机集成设计环境软件架构。介绍了支持固体火箭发动机虚拟样机的集成设计环境(SRM IDE),该环境集成了发动机设计常用软件和商用软件,以项目管理为中心,采用分布式体系结构,支持分布在异地的设计人员协同构建发动机虚拟原型和协同仿真,以及发动机设计过程中文档、数据、流程、产品结构及资源等的管理。     

快速控制原型仿真技术应用

快速控制原型技术在汽车、航空航天等领域得到了广泛的应用.快速控制原型技术改变了传统设计方法,提高了系统开发效率,降低了系统开发费用.采用基于PC构造的快速原型系统,造价低、硬件开放性好.本文介绍了基于xPC的快速控制原型开发方法,构造了采用xPC的分布式仿真构架.最后,通过一个具体的实例,说明快速控制原型技术在产品研制过程中的应用.     

A novel autonomous low-cost on-board data handling architecture for a pin-point planetary lander

There has been increased interest in the exploration of the Moon in recent years. Pin-point precision landing is highly desirable for future lunar missions. This paper is concerned with the design of the on-board data handling (OBDH) subsystem for the pin-point lunar lander of the Magnolia-1 project, funded by NASA. Four proposed on-board data handling architectures are outlined and compared in terms of power consumption, performance and reliability. Implementation results are presented, which are obtained from prototyping of the flight computer for the optimal OBDH architecture option on a Xilinx Virtex-5 Field Programmable Gate Array.     

Plastic Cubesat: An innovative and low-cost way to perform applied space research and hands-on education

This paper describes the design and the manufacturing of a Cubesat platform based on a plastic structure.The Cubesat structure has been realized in plastic material (ABS) using a “rapid prototyping” technique. The “rapid prototyping” technique has several advantages including fast implementation, accuracy in manufacturing small parts and low cost. Moreover, concerning the construction of a small satellite, this technique is very useful thanks to the accuracy achievable in details, which are sometimes difficult and expensive to realize with the use of tools machine. The structure must be able to withstand the launch loads. For this reason, several simulations using an FEM simulation and an intensive vibration test campaign have been performed in the system development and test phase. To demonstrate that this structure is suitable for hosting a complete satellite system, offering innovative integrated solutions, other subsystems have been developed and assembled.Despite its small size, this single unit (1U) Cubesat has a system for active attitude control, a redundant telecommunication system, a payload camera and a photovoltaic system based on high efficiency solar cells.The developed communication subsystem has small dimensions, low power consumption and low cost. An example of the innovations introduced is the antenna system, which has been manufactured inside the ABS structure. The communication protocol which has been implemented, the AX.25 protocol, is mainly used by radio amateurs. The communication system has the capability to transmit both telemetry and data from the payload, in this case a microcamera.The attitude control subsystem is based on an active magnetic system with magnetorquers for detumbling and momentum dumping and three reaction wheels for fine control. It has a total dimension of about 50×50×50 mm. A microcontroller implements the detumbling control law autonomously taking data from integrated magnetometers and executes pointing maneuvers on the basis of commands received in real time from ground.The subsystems developed for this Cubesat have also been designed to be scaled up for larger satellites such as 2U or 3U Cubesats. The additional volume can be used for more complex payloads. Thus the satellite can be used as a low cost platform for companies, institutions or universities to test components in space.     

Planning, implementation and optimization of future space missions using an immersive visualization environment (IVE) machine

Beginning in 1995, a team of 3-D engineering visualization experts assembled at the Lockheed Martin Space Systems Company and began to develop innovative virtual prototyping simulation tools for performing ground processing and real-time visualization of design and planning of aerospace missions. At the University of Colorado, a team of 3-D visualization experts also began developing the science of 3-D visualization and immersive visualization at the newly founded British Petroleum (BP) Center for visualization, which began operations in October, 2001. BP acquired ARCO in the year 2000 and awarded the 3-D flexible IVE developed by ARCO (beginning in 1990) to the University of Colorado, CU, the winner in a competition among 6 Universities. CU then hired Dr. G. Dorn, the leader of the ARCO team as Center Director, and the other experts to apply 3-D immersive visualization to aerospace and to other University Research fields, while continuing research on surface interpretation of seismic data and 3-D volumes. This paper recounts further progress and outlines plans in Aerospace applications at Lockheed Martin and CU.     

Building components for an outpost on the Lunar soil by means of a novel 3D printing technology

3D-printing technologies are receiving an always increasing attention in architecture, due to their potential use for direct construction of buildings and other complex structures, also of considerable dimensions, with virtually any shape. Some of these technologies rely on an agglomeration process of inert materials, e.g. sand, through a special binding liquid and this capability is of interest for the space community for its potential application to space exploration. In fact, it opens the possibility for exploiting in-situ resources for the construction of buildings in harsh spatial environments. The paper presents the results of a study aimed at assessing the concept of 3D printing technology for building habitats on the Moon using lunar soil, also called regolith. A particular patented 3D-printing technology – D-shape – has been applied, which is, among the existing rapid prototyping systems, the closest to achieving full scale construction of buildings and the physical and chemical characteristics of lunar regolith and terrestrial regolith simulants have been assessed with respect to the working principles of such technology. A novel lunar regolith simulant has also been developed, which almost exactly reproduces the characteristics of the JSC-1A simulant produced in the US. Moreover, tests in air and in vacuum have been performed to demonstrate the occurrence of the reticulation reaction with the regolith simulant. The vacuum tests also showed that evaporation or freezing of the binding liquid can be prevented through a proper injection method. The general requirements of a Moon outpost have been specified, and a preliminary design of the habitat has been developed. Based on such design, a section of the outpost wall has been selected and manufactured at full scale using the D-shape printer and regolith simulant. Test pieces have also been manufactured and their mechanical properties have been assessed.     

航天器再入全过程轴对称烧蚀热防护数值仿真研究

对航天器再入全过程轴对称烧蚀热防护进行了全过程数值仿真研究.采用修正Lees驻点热流密度方法和参考焓方法计算再入热流密度.采用JANAF模型计算烧蚀率.利用有限元法计算钝锥体再入航天器烧蚀层在移动边界条件下的轴对称温度场.采用碳化层-热解面-原始材料的轴对称碳化烧蚀模型;推导了热解气体流量计算方法.针对再入飞行大热流密度条件下,用有限元方法求解瞬态温度场时会产生的时间和空间上解的振荡问题.通过分析温度振荡现象产生的原因,采用集中热容矩阵向后差分方法解决振荡问题.计算结果表明,在时间步长选择合适的情况下,求解集中热容矩阵能够很好地解决数值振荡问题,同时烧蚀率和温度场计算比较准确.     

非高斯杂波背景中的两个距离扩展目标检测器

针对采用球不变随机向量(SIRV)建模的非高斯杂波背景中检测具有稀疏散射点的距离扩展目标问题,先假设目标强散射点的位置信息已知,采用广义似然比检验(GLRT)理论,提出了基于散射点位置的GLRT (SL-GLRT) 检测器。然后,采用门限法估计散射点的位置信息,提出了双门限恒虚警率(DT-CFAR)检测器,推导了虚警概率与检测门限关系的解析表达式,并给出门限的确定方法。与现有方法相比,散射点位置信息已知时, SL-GLRT 具有最佳的检测性能,散射点位置信息未知时,DT-CFAR具有较好的鲁棒性。