涡流C扫描在钛合金SPF/DB结构检测中的实验研究

为了探索SPF/DB结构检测中有效的检测方法,应用涡流C扫描对钛合金SPF/DB结构进行了检测实验,将涡流C扫描结果和SPF/DB结构检测中常用的超声C扫描结果进行了对比分析。结果表明,涡流C扫描能够检测出SPF/DB结构的界面宏观缺欠以及一定尺度以上的界面微观缺欠,在SPF/DB结构检测中是可行的。有必要对该检测方法的有效性和检测结果的可靠性进行深入研究。     

错位散斑技术在钛合金SPF/DB结构检测中的应用初探

分析了钛合金SPF/DB结构缺陷及形成原因,介绍了错位散斑技术的基本原理,通过采用错位散斑技术对钛合金SPF/DB结构进行检测试验,能够发现明显的缺陷特征,从检测敏感度、效率等方面与X射线、超声C进行对比,结果表明,错位散斑技术能够应用于钛合金SPF/DB的结构检测,但仍需在检测精度、可靠性等方面进行深入研究.     

几何参数对SPF/DB三层结构表面质量的影响研究

以3层SPF/DB钛合金空心桁架结构为研究对象,通过平面应变有限元模型,研究了空心结构几何参数对超塑成形过程应力应变分布的影响以及与表面褶皱产生的关系,并进行了试验验证,得到了满足超塑成形工艺要求的参数调控范围,为3层SPF/DB空心结构设计提供依据。     

TC_4钛合金超塑成形/扩散连接组合工艺应用研究

 TC4（Ti-6Al-4V）钛合金板材超塑成形/扩散连接（SPF/DB）组合工艺的可行性和对影响钛板SPF、SPF/DB的主要工艺因素。着重阐述某机框段和舱门的研制情况,提供了合理的工艺参数和流程。     

飞机承力构件的超塑成形／扩散连接工艺

本文介绍了国内采用超塑成形/扩散连接(SPF/DB)组合工艺技术,首次研制某型号飞机钦合金主承力框构件的工作进展和成果;给出了适用于承力构件的SPF/DB工艺方法、工艺流程和工艺参数;解决了大尺寸零件超塑成形、扩散焊质量的控制问题。     

双层板激光焊接/ 超塑成形数值模拟及工艺研究

选取TC4 钛合金四层板加强结构中双层板为研究对象,采用激光穿透焊接工艺代替传统超塑成

形/ 扩散连接(SPF/ DB)工艺中涂止焊剂连接。借助ABAQUS 有限元分析软件对超塑成形过程进行分析,得到

优化的压力-时间(p-t)曲线,作为双层板超塑成形过程的气压加载曲线,进行实验验证。结果表明:成形后零

件壁厚分布均匀,焊缝处无撕裂现象,与有限元模拟结果保持一致;用此新工艺代替传统SPF/ DB 工艺中的止

焊剂具有可行性。

     

钛合金板超塑性成形/扩散连接成形因素影响的数值模拟

通过对超塑性成形与扩散连接(SPF/DB)成形原理和过程的讨论,以最优成形温度下的Ti-6AL-4V合金材料特性和超塑性成形气压加载理论优化结果为依据,利用Ansys有限元软件的建模和数值模拟,提取夹层板作为研究对象,建立模型和定义材料性能参数,定义接触和加载方式。     

民用飞机机体用钛合金的新技术探讨

随着LRF、SPF/DB技术的出现,很好地解决了钛合金材料利用率低、加工困难等问题,同时也缩短了制造周期、降低了制造成本。目前,尽管两种新技术在国内还处于研究和初步应用阶段,相信只要从事钛合金材料、制造和飞机设计等行业科技人员共同努力,同时承担起促进LRF、SPF/DB技术工程化应用的责任,必将为未来民用飞机研制提供新的技术途径。     

钛合金SPF／DB薄板构件高频超声检测

本文介绍了利用高频超声波解决钛合金SPF/DB薄板结构中微米级间隙连接缺陷的无损检测。     

TA15四层板结构超塑成形/扩散连接技术研究

进行了TA15合金超塑拉伸试验,在温度920℃和应变速率5.25×104s-1时,TA15合金的最大延伸率约为1100％,其应变速率敏感性指数约为0.57.在较佳超塑变形条件930℃和应变速率5.25×10-4s-1附近,TA15合金的超塑本构方程为σ=949(ε) 0.55.对TA15四层板结构超塑成形过程进行了有限元分析,获得了压力p-时间t曲线.在T =930℃和应变速率5.25×10-4s-1下,成功进行了TA15四层板结构SPF/DB成形试验,试验件的整体质量良好,无沟槽等缺陷,金相组织观测表明,TA15四层SPF/DB试验件扩散连接质量优良.     

Experimental and numerical investigation on surface quality for two-point incremental sheet forming with interpolator

The unsatisfied surface quality seriously impedes the wide application of incremental sheet forming (ISF) in industrial field. As a novel approach, the interpolator method is a promising strategy to enhance the surface quality in ISF. However, the mechanism for the improvement of surface quality and the influence of interpolator properties on surface roughness are not well understood. In this paper, the influences of process variables (i.e. tool diameter, step size and thickness of interpolators) on the forming process (e.g. surface roughness, forming force and geometric error) are investigated through a systematic experimental approach of central composite design (CCD) in two-point incremental sheet forming (TPIF). It is obtained that the increase in thickness of interpolators decreases the surface roughness in direction vertical to the tool path while increases the surface roughness in direction horizontal to the tool path. Nevertheless, the combined influence between thickness of interpolators and process parameters (tool diameter and step size) is limited. Meanwhile, the placement of interpolator has little influence on the effective forming force of blank. In addition, the geometric error enlarges with the increase of step size and thickness of interpolator while decreases firstly and then increase with an increase in tool diameter. Finally, the influencing mechanism of the interpolator method on surface quality can be attributed to the decrease of the contact pressure due to the increase of contact area with the unchanged contact force. Meanwhile, the interpolator method eliminates the sliding friction on the surface of blank due to the stable relative position between the blank and the interpolator.     

An investigation on adaptively machining the leading and tailing edges of an SPF/DB titanium hollow blade using free-form deformation

Titanium hollow blades are characterized with lightweight and high structural strength, which are widely used in advanced aircraft engines nowadays. Superplastic forming/diffusion bonding (SPF/DB) combined with numerical control (NC) milling is a major solution for manufacturing titanium hollow blades. Due to the shape deviation caused by multiple heat and pressure cycles in the SPF/DB process, it is hard to manufacture the leading and tailing edges by the milling process. This paper presents a new adaptive machining approach using free-form deformation to solve this problem. The actual SPF/DB shape of a hollow blade was firstly inspected by an on-machine measurement method. The measured point data were matched to the nominal SPF/DB shape with an improved ICP algorithm afterwards, by which the point-pairs between the measurement points and their corresponding points on the nominal SPF/DB shape were established, and the maximum modification amount of the final nominal shape was constrained. Based on the displacements between the point-pairs, an accurate FFD volume was iteratively calculated. By embedding the final nominal shape in the deformation space, a new final shape of the hollow blade was built. Finally, a series of measurement and machining tests was performed, the results of which validated the feasibility of the proposed adaptive machining approach.     

帽形件超塑性胀形的最佳压力-时间曲线与最小厚度的计算方法

 根据超塑性力学的基本方程和帽形件的变形模式,导出了帽形件超塑性气胀成形的最佳压力-时间曲线方程和最小厚度的理论计算公式,并举出数字实例加以分析。     

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。     

某型星形活塞发动机主连杆强度分析

针对某型九缸航空星形活塞发动机主连杆疲劳失效问题,采用运动学和动力学相结合的分析方法,确定了主连杆在工作循环中承受的最大附加弯矩工况。针对主连杆上的面载荷均为通过运动副传递的特点,采用商用有限元分析软件ANSYS提供的接触单元来模拟主连杆与曲柄销和活塞销的接触状态,对主连杆进行了有限元应力分析。分析表明,该连杆杆身疲劳强度储备偏低,计算危险点与疲劳失效发生点一致,为分析该杆失效原因提供了依据。      

因康镍718合金的超塑成形和扩散连接

介绍了用于制造火箭发动机零件的因康镍７１８合金的超塑成形和扩散连接工艺。经特殊加工的细晶粒因康镍７１８合金具有促进的超塑性，历而能用于超塑成形相当复的零件。     

Simulation of <Emphasis Type="Italic">Z</Emphasis>-crimp shaping with the use of the ansys finite element software

A finite element model of the Z-crimp shaping from a hard sheet blank is developed and a number of calculations using the ANSYS finite element software is conducted. The calculations are carried out in the framework of elastoplastic behavior of the blank material using the classical model of bilinear kinematic (translational) hardening with corresponding parameters of elasticity and plasticity. The model takes into account kinematics of spatial transformation of the shaping equipment as well as the time-variable conditions of its contact interaction with the blank.     

面向制造的飞机钣金零件多态模型

 针对飞机钣金零件数字化制造过程中零件信息定义问题，对多态模型作进一步研究，建立了基于状态、特征、要素和数据4个层次的模型结构，分析了模型的内容和组元关系，结合实例给出了模型各个状态的定义顺序，说明了模型的实际应用。工艺设计、工艺装备设计等应用系统可以直接引用模型的状态信息，实现飞机钣金制造过程的数字量传递和智能化决策。