Process-scheme-driven N C machining cell for automatic construction of aircraft structural parts

In order to enhance the NC programming efficiency and quality of aircraft structural parts （ASPs）, an intelligent NC programming pattern driven by process schemes is presented. In this pattern, the NC machining cell is the minimal organizational structure in the technological process, consisting of an operation machining volume cell, and the type and parameters of the machining operation. After the machining cell construction, the final NC program can be easily obtained in a CAD/CAM system by instantiating the machining operation for each machining cell. Accordingly, how to automatically establish the machining cells is a key issue in intelligent NC program- ming. On the basis of the NC machining craft of ASP, the paper aims to make an in-depth research on this issue. Firstly, some new terms about the residual volume and the machinable volume are defined, and then, the technological process is modeled with a process scheme. Secondly, the approach to building the machining cells is introduced, in which real-time complement machining is mainly considered to avoid interference and overcutting. Thirdly, the implementing algorithm is designed and applied to the Intelligent NC Programming System of ASP. Finally, the developed algorithm is validated through two case studies.     

Dependence on forming parameters of an integral panel during the electromagnetic incremental forming process

Nowadays, more and more attentions are paid to electromagnetic incremental forming(EMIF), especially for a part with a large-scale size, e.g., an integral panel with stiffened ribs. In this work, the bending of a panel into a double-curvature profile via EMIF is carried out experimentally and evaluated by comparing the formed profile with the desired profile. During the process,discharges at four positions along different discharge paths are designed. The effects of forming parameters on the die-fittingness of the workpiece are discussed, for which two evaluation indices are used to judge forming results. The results show that a discharge voltage in an incremental mode is helpful to improve the fittingness and avoid the collision rebound against the die at the same time.Discharging at the diagonal positions with the ‘‘X" discharge path exhibits the minimal shape deviation and the best forming uniformity. On the contrary, discharging at the parallel positions with the ‘‘Z" discharge path obtains the worst forming quality. Overlap of the coil at different positions should be given during EMIF; however, a lower overlap rate of the coil helps improve the forming quality. The results obtained in this work are useful for forming integral panels with stiffened ribs via the EMIF process.     

Weighted marginal fisher analysis with spatially smooth for aircraft recognition

Due to limitations to extract invariant features for recognition when the aircraft presents various poses and lacks enough samples for training, a novel algorithm called Weighted Marginal Fisher Analysis with Spatially Smooth （WMFA-SS） for extracting invariant features in aircraft rec- ognition is proposed. According to the Graph Embedding （GE） framework, Heat Kernel function is firstly introduced to characterize the interclass separability when choosing the weights of penalty graph. Furthermore, Laplacian penalty is applied to constraining the coefficients to be spatially smooth in this algorithm. Laplacian penalty is able to incorporate the prior information that neigh- boring pixels are correlated. Besides, using a Laplacian penalty can also avoid the singularity of Laplacian matrix of intrinsic graph. Once compact representations of the images are obtained, it can be considered as invariant features and then be performed in classification to recognize different patterns of aircraft. Real aircraft recognition experiments show the superiority of our proposed WMFA-SS in comparison to other GE algorithms and the current aircraft recognition algorithm; the accuracy rate of our proposed method is 90.00% for dataset BH-AIR1.0 and 99.25% for dataset BH-AIR2.0.     

Dynamic Characteristic Analysis and Experiment for Integral Impeller Based on Cyclic Symmetry Analysis Method

A cyclic symmetry analysis method is proposed for analyzing the dynamic characteristic problems of thin walled integral impeller. Reliability and feasibility of the present method are investigated by means of simulation and experiment. The fundamental cyclic symmetry equations and the solutions of these equations are derived for the cyclic symmetry structure. The computational efficiency analysis between whole and part is performed. Comparison of results obtained by the finite element analysis (FEA) and experiment shows that the local dynamic characteristic of integral impeller has consistency with the single cyclic symmetry blade. When the integral impeller is constrained and the thin walled blade becomes a concerned object in analysis, the dynamic characteristic of integral impeller can be replaced by the cyclic symmetry blade approximately. Hence, a cyclic symmetry analysis method is effectively used to improve efficiency and obtain more information of parameters for dynamic characteristic of integral impellers.     

Robust Control for Static Loading of Electro-hydraulic Load Simulator with Friction Compensation

Load simulator is a key test equipment for aircraft actuation systems in hardware-in-the-loop-simulation. Static loading is an essential function of the load simulator and widely used in the static/dynamic stiffness test of aircraft actuation systems. The tracking performance of the static loading is studied in this paper. Firstly, the nonlinear mathematical models of the hydraulic load simulator are derived, and the feedback linearization method is employed to construct a feed-forward controller to improve the force tracking performance. Considering the effect of the friction, a LuGre model based friction compensation is synthesized, in which the unmeasurable state is estimated by a dual state observer via a controlled learning mechanism to guarantee that the estimation is bounded. The modeling errors are attenuated by a well-designed robust controller with a control accuracy measured by a design parameter. Employing the dual state observer is to capture the different effects of the unmeasured state and hence can improve the friction compensation accuracy. The tracking performance is summarized by a derived theorem. Experimental results are also obtained to verify the high performance nature of the proposed control strategy.     

基于多Agent的舰载机弹射起飞仿真层次模型(英文)

With the aid of multi-agent based modeling approach to complex systems, the hierarchy simulation models of carrier-based aircraft catapult launch are developed. Ocean, carrier, aircraft, and atmosphere are treated as aggregation agents, the detailed components like catapult, landing gears, and disturbances are considered as meta-agents, which belong to their aggregation agent. Thus, the model with two layers is formed i.e. the aggregation agent layer and the meta-agent layer. The information communication among all agents is described. The meta-agents within one aggregation agent communicate with each other directly by information sharing, but the meta-agents, which belong to different aggregation agents exchange their information through the aggregation layer first, and then perceive it from the sharing environment, that is the aggregation agent. Thus, not only the hierarchy model is built, but also the environment perceived by each agent is specified. Meanwhile, the problem of balancing the independency of agent and the resource consumption brought by real-time communication within multi-agent system （MAS） is resolved. Each agent involved in carrier-based aircraft catapult launch is depicted, with considering the interaction within disturbed atmospheric environment and multiple motion bodies including carrier, aircraft, and landing gears. The models of reactive agents among them are derived based on tensors, and the perceived messages and inner frameworks of each agent are characterized. Finally, some results of a simulation instance are given. The simulation and modeling of dynamic system based on multi-agent system is of benefit to express physical concepts and logical hierarchy clearly and precisely. The system model can easily draw in kinds of other agents to achieve a precise simulation of more complex system. This modeling technique makes the complex integral dynamic equations of multibodies decompose into parallel operations of single agent, and it is convenient to expand, maintain, and reuse the pro     

Research on uncertainty in measurement assisted alignment in aircraft assembly

Operations in assembling and joining large size aircraft components are changed to novel digital and flexible ways by digital measurement assisted alignment.Positions and orientations（P＆O）of aligned components are critical characters which assure geometrical positions and relationships of those components.Therefore,evaluating the P＆O of a component is considered necessary and critical for ensuring accuracy in aircraft assembly.Uncertainty of position and orientation（U-P＆O）,as a part of the evaluating result of P＆O,needs to be given for ensuring the integrity and credibility of the result;furthermore,U-P＆O is necessary for error tracing and quality evaluating of measurement assisted aircraft assembly.However,current research mainly focuses on the process integration of measurement with assembly,and usually ignores the uncertainty of measured result and its influence on quality evaluation.This paper focuses on the expression,analysis,and application of U-P＆O in measurement assisted alignment.The geometrical and algebraical connotations of U-P＆O are presented.Then,an analytical algorithm for evaluating the multi-dimensional U-P＆O is given,and the effect factors and characteristics of U-P＆O are discussed.Finally,U-P＆O is used to evaluate alignment in aircraft assembly for quality evaluating and improving.Cases are introduced with the methodology.     

An innovative study on low surface energy micronano coatings with multilevel structures for laminar flow design

Laminar flow design is one of the most effective ways to reduce the drag of a commercial aircraft by expanding the laminar flow region on the surface of the aircraft. As material science develops, the emergence of new materials such as low surface energy materials has offered new choices for laminar flow design of commercial aircraft. Different types of low surface energy micro-nano coatings are prepared to verify the effects on the boundary layer transition position and the drag of the airfoil through wind tunnel tests. The infrared thermal imaging technology is adopted for measuring the boundary layer transition, while the momentum integral approach is employed to measure the drag coefficient through a wake rake. Infrared thermal imaging results indicate that the coatings are capable of moving backward the boundary layer transition position at both a low velocity of Mach number 0.15 and a high velocity of Mach number 0.785. Results of the momentum integral approach demonstrate that the drag coefficients are reduced obviously within the cruising angle of attack range from 1° and 5° by introducing the low surface energy micro-nano coating technology.     

A multi-aircraft conflict detection and resolution method for 4-dimensional trajectory-based operation

Conflict Detection and Resolution(CDR) is the key to ensure aviation safety based on Trajectory Prediction(TP). Uncertainties that affect aircraft motions cause difficulty in an accurate prediction of the trajectory, especially in the context of four-dimensional(4D) Trajectory-Based Operation(4DTBO), which brings the uncertainty of pilot intent. This study draws on the idea of time geography, and turns the research focus of CDR from TP to an analysis of the aircraft reachable space constrained by 4D waypoint constraints. The concepts of space–time reachability of aircraft and space–time potential conflict space are proposed. A novel pre-CDR scheme for multiple aircraft is established. A key advantage of the scheme is that the uncertainty of pilot intent is accounted for via a Space-Time Prism(STP) for aircraft. Conflict detection is performed by verifying whether the STPs of aircraft intersect or not, and conflict resolution is performed by planning a conflict-free space–time trajectory avoiding intersection. Numerical examples are presented to validate the efficiency of the proposed scheme.     

飞机整体壁板智能数控编程系统

结合飞机整体壁板结构特点、典型加工工艺路线.针对目前数控编程中存在的问题,对智能数控编程相关技术作了一定的探索.主要内容包括飞机整体壁板智能数控编程系统结构建立、数控加工知识综合表示、广义槽加工单元分层识别、基于几何特性加工刀具自动选取、基于知识推理的加工自动排序等.最后应用上述技术开发了飞机整体壁板快速数控编程系统.     

飞机结构件轮廓特征加工自动分区算法

作为飞机结构件重要组成部分，轮廓特征包含大量复杂曲面，且与工艺凸台等干涉物相连接，使得轮廓特征编程需综合考虑复杂曲面及干涉物信息，在自动编程模式下，轮廓特征编程仍严重依赖人工经验，其编程周期占结构件编程周期的40%以上，严重影响了结构件编程效率。针对该问题，提出了一种综合考虑复杂曲面及干涉物信息的轮廓特征加工自动分区方法，基于相邻轮廓面连接边属性及凸边约束原则对轮廓面进行初分区，依据干涉物信息构建虚拟边界，并基于虚拟边界对轮廓面初分区结果进行横向和纵向加工区域划分，通过对划分区域进行合并得到轮廓特征加工分区结果。根据提出的方法开发了飞机结构件轮廓特征加工自动分区系统，经过多项典型飞机结构件测试，该方法稳定可靠，可为轮廓特征加工程序编制提供支撑。     

复杂结构件数控编程加工特征用户自定义方法

加工特征是实现复杂结构件高效、高质量数控编程的有效手段,但是同一类加工特征只是几何形状和加工工艺相似,并不完全相同。如何适应不同的企业资源与工艺水平、不同类型的复杂结构件进行加工特征定义是基于加工特征进行自动数控编程的一个难题。针对以上难题,本文提出了一种复杂结构件数控编程加工特征用户自定义方法,基于全息属性面边图表达加工特征几何信息,给出了具有一定柔性的加工特征几何信息定义方法,基于语义与规则建立加工特征工艺信息及其与几何信息之间的关联关系,实现了由用户根据企业的制造资源、零件结构和工艺人员的编程习惯等因素自定义加工特征。根据本文提出的方法开发了飞机复杂结构件加工特征用户自定义及自动编程系统,已成功应用于国内某大型航空制造企业的飞机结构件数控编程,经过多项飞机结构件测试,本文提出的方法特征识别正确率平均达到97%。     

基于测量数据的雕塑曲面数控粗加工

提出一种新的雕塑曲面数控粗加工刀位规划方法。被加工曲面用多面体模型来描述 ,采用分层切削方法加工。在各切削层分别用一个参考平面与毛坯和曲面模型求交 ,根据各相交环之间的拓扑关系 ,求出有效加工区域 ,利用数控编程自动生成粗加工刀具轨迹 ,并进行干涉检查和修正。该方法成功地解决了层切法加工雕塑曲面时不能处理岛中岛的难题。     

Blank Panel Design of Integral Wing Skin Panels Based on Feature Mapping Methods

A blank panel design algorithm based on feature mapping methods for integral wing skin panels with supercritical airfoil surface is presented.The model of a wing panel is decomposed into features,and features of the panel are decomposed into information of location,direction,dimension and Boolean types.Features are mapped into the plane through optimal surface development algorithm.The plane panel is modeled by rebuilding the mapped features.Blanks of shot-peen forming panels are designed to identify the effectiveness of the methods.     

水轰五飞机大型整体壁板的设计与制造

 本文介绍水轰五飞机大型整体壁板的结构设计和经济效果及其数控加工,喷丸成形和毛坯扁挤压制造工艺特点。     

飞机橡皮囊成形零件毛坯精确预示方法研究

 橡皮囊成形是飞机钣金零件成形的主要方法之一,其初始毛坯形状的预示是橡皮囊成形中的一个难点问题。针对橡皮囊成形的工艺特点,提出了一种基于一步逆成形有限元法的飞机橡皮囊成形钣金零件毛坯快速精确预示方法。首先将设计好的飞机钣金零件作为最终构形,然后采用一步逆成形有限元法进行初始毛坯的快速反向模拟,最后将通过该方法获得的毛坯外形应用到实际飞机钣金橡皮囊成形中,实验结果表明该方法可以快速精确地预示出飞机橡皮囊成形钣金零件的初始毛坯形状。     

整体壁板三维裂纹应力强度因子计算与分析

近年来,整体壁板成为飞机结构设计上一个新的研究方向。针对典型的飞机整体壁板,应用有限元软件ABAQUS建立了含裂纹整体壁板的参数化模型,对裂纹在凸台和筋条中的扩展轨迹进行三维裂纹扩展模拟。分析了裂纹在扩展过程中,凸台、筋条、蒙皮中裂纹应力强度因子的变化情况以及凸台、筋条的止裂性能。研究结果对整体壁板的损伤容限设计和评定具有一定的指导意义。     

飞机自动制孔离线编程数据准确提取技术

针对目前飞机组部件自动制孔离线编程人工参与程度高、效率低,质量问题无法预防的现状,提出了基于数据库及标签定义的准确离线编程技术。根据飞机自动制孔的工艺特点,制定了离线编程流程。根据离线编程数据需求,建立了编程数据库。结合数据库以及MBD模型,制定了自动制孔标准件、叠层、厚度、工艺参数等信息提取规则,利用DELMIA中标签具备属性特征、方向特征、点位特征的特点,实现了基于标签的工艺信息表达及设备姿态控制。最后对标签在产品坐标系和设备坐标系的转换进行了分析,实现了加工程序坐标值的正确输出。     

TC1钛合金端盖零件热拉深成形工艺研究

针对TC1钛合金端盖零件的结构特点,分析了零件的成形难点,对热拉深工艺的模具材料、温度、压边间隙、拉深速度等对零件成形性能的影响进行了研究,提出了合理的工艺参数。结果表明,该工艺方法可实现薄壁、大拉深比的TC1钛合金零件的精确成形,采用空气脱模的方式可获得平面度满足设计要求的零件,为类似零件的取件提供了工艺参考。