Multiscale modeling of mechanical behavior and failure mechanism of 3D angle-interlock woven aluminum composites subjected to warp/weft directional tension loading

The mechanical behavior and progressive damage mechanism of novel aluminum matrix composites reinforced with 3D angle-interlock woven carbon fibers were investigated using a multiscale modeling approach. The mechanical properties and failure of yarns were evaluated using a microscale model under different loading scenarios. On this basis, a mesoscale model was developed to analyze the tensile behavior and failure mechanism of the composites. The interfacial decohesion, matrix damage, and failure of fibers and yarns were incorporated into the microscopic and mesoscopic models. The stress–strain curves and fracture modes from simulation show good agreement with the experimental curves and fracture morphology. Local interface and matrix damage initiate first under warp directional tension. Thereafter, interfacial failure, weft yarn cracking, and matrix failure occur successively. Axial fracture of warp yarn, which displays a quasi-ductile fracture characteristic, dominates the ultimate composites failure. Under weft directional tension, interfacial failure and warp yarn rupture occur at the early and middle stages. Matrix failure and weft yarn fracture emerge simultaneously at the final stage, leading to the cata-strophic failure of composites. The weft directional strength and fracture strain are lower than the warp directional ones because of the lower weft density and the more serious brittle fracture of weft yarns.     

A review of friction stir joining of SiCp/Al composites

SiCp/Al composites have excellent comprehensive properties and have been widely used in aerospace, automotive industry and other fields.Due to the huge difference in performance between SiC particles and matrix alloys, traditional fusion welding methods are difficult to meet the join requirements of SiCp/Al composites.Friction stir joining(friction stir welding), as a solid phase joining process, has been proved to be a new technology with fine prospect in joining SiCp/Al composites compared wit...     

A partition of unity level set method with moving knot CS-RBFs for optimizing variable stiffness composites

A partition of unity level set method with moving knot Compactly Supported Radial Basis Functions (CS-RBFs) is proposed for optimizing variable stiffness composite structures. The iso-contours of a level set function are utilized to represent the curved fiber paths, and the tangent vector of the iso-contour defines the orientation of fiber. The level set function of the full design domain is constructed according to the Partition of Unity (POU) method by a set of local level set functions defined on an array of overlapping subdomains, and they are constructed by using the CS-RBFs. The positions of knots are iteratively changed during the optimization to improve the performance of composite structures. Several examples of compliance minimization are presented.     

Recent progress in flexible supporting technology for aerospace thin-walled parts: A review

Thin-walled parts are widely used in the aerospace industry owing to their light weight and high specific strength. However, due to the low rigidity of thin-walled parts, elastic deformation and chatter easily occur, which seriously affect the machining accuracy and workpiece surface quality. To solve this problem, several supporting technologies have been reported in recent years. This paper reviews the recent research progress of flexible supporting technologies in the aerospace field by class...     

A review of numerical analyses and experimental characterization methods for forming of textile reinforcements

The forming of textile reinforcements is an important stage in the manufacturing of textile composite parts with Liquid Composite Molding process. Fiber orientations and part geometry obtained from this stage have significant impact on the subsequent resin injection and final mechanical properties of composite part. Numerical simulation of textile reinforcement forming is in strong demand as it can greatly reduce the time and cost in the determination of the optimized processing parameters, which is the foundation of the low-cost application of composite materials. This review presents the state of the art of forming modeling methods for textile reinforcement and the corresponding experimental characterization methods developed in this field. The microscopic, mesoscopic and macroscopic models are discussed. Studies concerning the simulation of wrinkling are also presented since it is the most common defect occurred in the textile reinforcement forming. Finally, challenges and recommendations on the future research directions for textile reinforcement modeling and experimental characterization are provided.     

一种装配体模型的离散量化与相似性分析方法

装配体模型相似性分析作为产品信息重用领域的重点问题而得到广泛关注,目前一些方法利用图论的相关知识,能够实现结构信息的发掘但通常较为复杂,也有一些方法从向量集合的角度入手以获得更好的计算效率,但忽略了零件间的连接关系。针对这些方法的优势与不足,提出了一种基于结构离散的装配体模型信息量化方法,将装配体结构信息融入向量化描述符中,并建立相应的索引结构与相似性度量方法。该方法首先提取装配体中结构特征形成连接图,并将装配体分解为若干个相互连接的零件构成的结构单元;然后,利用结构-形状距离函数对各个结构单元进行量化表征,以此为基础构建基于高维向量的装配体描述符;最后,基于词袋（BOW）模型和超球体软分配策略建立倒排索引与过滤机制,通过求解查询装配体模型与库模型间的最优匹配,最终实现装配体模型的相似性分析。     

一种平纹编织复合材料的三维通用单胞模型

为了解决采用通用单胞(GMC)方法开展编织复合材料多尺度模拟的技术难题,发展了一种三维通用单胞模型,可用于二维平纹编织复合材料的多尺度模拟。概述了三维通用单胞方法的基本理论和求解流程;基于对二维平纹编织复合材料细观结构特征分析,建立了其三维通用单胞模型,并通过与传统有限元单胞模型的宏细观力学响应分析计算结果对比,验证了所建模型的正确性。采用基于通用单胞模型的有限元多尺度模拟方法,开展了二维平纹编织复合材料平板试件的模态分析。与试验结果对比表明,采用所建立的通用单胞模型预测得到的前五阶固有频率绝大部分的精度较传统有限元方法有了明显提升。该方法的优势在于可以基于通用单胞模型开展多尺度模拟,进而研究宏细观力学响应的相互关联。      

Modified micro-mechanics based multiscale model for progressive failure prediction of 2D twill woven composites

To consider fiber random distribution at the microscale for the multiscale model based on the micro-mechanics failure(MMF) theory, clustering method is used for the extraction of amplification factors. As the clustering method is a kind of unsupervised machine learning method, the elements with similar mechanical behavior under external loading can be included in a cluster automatically at the microscale. With this modification, the fiber random distribution model can be used for multiscale dama...     

Machining of SiC ceramic matrix composites: A review

Continuous fiber reinforced SiC ceramic matrix composites (FRCMCs-SiC) are currently the preferred material for hot section components, safety–critical components and braking components (in the aerospace, energy, transportation) with high value, and have triggered the demand for machining. However, the high brittleness, anisotropy, and heterogeneity of materials bring great challenges to machining, due to high mechanical and thermal loads, severe tool wear, and poor machining quality. With the increasing demand of FRCMCs-SiC parts, high-quality and high-efficient machining has become a hot issue. This review paper provides a detailed literature survey on the machining of FRCMCs-SiC. The material removal mechanism, defect form, and interfacial mechanical properties of FRCMCs-SiC were summarized. The machining processes of FRCMCs-SiC were introduced, and their respective advantages and disadvantages were compared. Given the low machinability (high hardness, high brittleness, anisotropy, and heterogeneity) of FRCMCs-SiC, preliminary experiments have proved that ultrasonic-assisted machining and laser-assisted machining have shown unique advantages in reducing force and tool wear, improving machining quality and machining efficiency. The machined surface integrity was discussed, the influence of process parameters on the machined surface quality was analyzed, and the machining defects of FRCMCs-SiC were summarized. But for FRCMCs-SiC, the existing quantitative evaluation of the machined surface integrity was weak and unsystematic.     

A novel virtual material layer model for predicting natural frequencies of composite bolted joints

A novel virtual material layer model based on the fractal theory was proposed to predict the natural frequencies of carbon fiber reinforced plastic composite bolted joints. Rough contact surfaces of composite bolted joints are modeled with this new proposed approach. Numerical and experimental modal analyses were conducted to validate the effectiveness of the proposed model. A good consistence is noted between the numerical and experimental results. To demonstrate the necessity of accurately modeling the rough contact surfaces in the prediction of natural frequencies, virtual material layer model was compared with the widely used traditional model based on the Master-Slave contact algorithm and experiments, respectively. Results show that the proposed model has a better agreement with experiments than the widely used traditional model (the prediction accuracy is raised by 8.77% when the pre-tightening torque is 0.5 N∙m). Real contact area ratio A* of three different virtual material layers were calculated. Value of A* were discussed with dimensionless load P*, fractal dimension D and fractal roughness G. This work provides a new efficient way for accurately modeling the rough contact surfaces and predicting the natural frequencies of composite bolted joints, which can be used to help engineers in the dynamic design of composite materials.     

An efficient analytical homogenization technique for mechanical-hygrothermal responses of unidirectional composites with applications to optimization and multiscale analyses

The elasticity-based Locally Exact Homogenization Theory (LEHT) is extended to study the mechanical-hygrothermal behaviors of unidirectionally-reinforced composites. Based on the framework developed previously, thermal and moisture effects are incorporated into the LEHT to study the homogenized and localized responses of heterogeneous materials, which are validated using available analytical and numerical techniques. The LEHT programs are then encapsulated as subroutines with Input/Output (I/O) interfaces, to be readily applied in different computational scenarios. In order to illustrate the efficiency of the LEHT, the theory is firstly coupled to the Particle Swarm Optimization (PSO) algorithm in order to minimize the axial thermal expansion mismatch in hexagonal and square fiber arrays by tailoring the fiber volume fraction. The LEHT is then implemented into the lamination theory to study fabrication-induced residual stresses arising during the cool-down process which introduces local laminate stresses owing to thermo-mechanical property mismatch between plies. Both of these applications illustrate the efficiency and accuracy of the LEHT in generating effective properties and local stress distributions, making the theory a golden standard in validating other analytical or numerical techniques as well as a reliable tool in composite design and practice for professionals and non-professionals alike.     

基于细观力学的复合固体推进剂模量预估方法

应用分子动力学方法得到了复合固体推进剂颗粒在基体内随机分布的填充模型。针对推进剂所含颗粒大小不同,采用细观力学有限元法和Mori-Tanaka分析法相结合的方法计算了推进剂的模量,计算所得模量与不同颗粒体积分数推进剂的单向拉伸试验结果比较吻合。此外,该方法可以获得推进剂细观结构应力,从而为推进剂的细观损伤分析奠定基础。     

Mechanical wear debris feature,detection, and diagnosis: A review

Mechanical debris is an important product of friction wear, which is also a crucial approach to know the running status of a machine. Many studies have been conducted on mechanical debris in related fields such as tribology, instrument, and diagnosis. This paper presents a comprehensive review of these studies, which summarizes wear mechanisms (e.g., abrasive wear, fatigue wear, and adhesive wear) and debris features (e.g., concentration (number), size, morphology, and composition), analyzes detection methods principles (e.g., offline: spectrograph and ferrograph, and online: optical method, inductive method, resistive-capacitive method, and acoustic method), reviews developments of online inductive methods, and investigates the progress of debris-based diagnosis. Finally, several notable problems are discussed for further studies.     

任意最大应力梯度路径轮盘模拟件设计方法

建立基于应力寿命轮盘二维模拟试件设计准则,提出了具有任意最大应力梯度路径的轮盘模拟试件优化设计方法,包括自动搜索第一主应力最大梯度路径和应力分布,以及模拟试件的二步优化设计策略,提出了模拟试件弹性和弹塑性设计等价原则.通过某轮盘模拟试件设计例说明了方法的应用.      

A new error-controllable method for smoothing the G01 commands

In real machining, the tool paths are composed of a series of short line segments, which constitute groups of sharp corners correspondingly leading to geometry discontinuity in tangent. As a result, high acceleration with high fluctuation usually occurs. If these kinds of tool paths are directly used for machining, the feedrate and quality will be greatly reduced. Thus, generating continuous tool paths is strongly desired. This paper presents a new error-controllable method for generating continuous tool path. Different from the traditional method focusing on fitting the cutter locations, the proposed method realizes globally smoothing the tool path in an error-controllable way. Concretely, it does the smoothing by approaching the newly produced curve to the linear tool path by taking the tolerance requirement as a constraint. That is, the error between the desired tool path and the G01 commands are taken as a boundary condition to ensure the finally smoothed curve being within the given tolerance. Besides, to improve the smoothing ability in case of small corner angle, an improved local smoothing method is also proposed by symmetrically assigning the control points to the two adjacent linear segments with the constrains of tolerance and G3 continuity. Experiments on an open five-axis machine are developed to verify the advantages of the proposed methods.     

一种超声速状态下机载推进系统模型的建模方法

为了满足机载航空推进系统模型对精度、实时性及数据存储量的苛刻要求,提出了一种机载模型建模方法.对传统的机载稳态模型建立过程中使用的相似准则进行了充分讨论,得出了一种具备更高建模精度的相似准则.在新的相似准则基础上,建立了包含泰勒展开式中非线性2阶项的高精度稳态变量模型,有效解决了分段线性稳态变量模型在大包线、变状态条件下精度难以保证的问题;为了解决超声速状态下安装推力与发动机净推力差别较大的问题,建立了考虑外流特性的简化进气道模型,给出了一种计算安装推力的方法,即由简化发动机模型计算安装推力中符合相似准则的部分,由进气道模型计算溢流阻力、放气阻力及发动机推力中不符合相似准则的部分.仿真结果表明:基于新的相似准则所建立的机载模型具有大包线、变状态适应性,输出参数误差均在0.5%以内.      

Integration of nanoindentation and finite element method for interpretable tensile properties: A cross-scale calculation method of uneven joints

Nanoindentation testing and its Reverse Analysis Method(RAM) show great potential in understanding the tensile properties of metallic alloys with various microstructures. Nevertheless,the tensile properties of heterogeneous materials such as nickel-based superalloy welded joints have not been well interpreted by combining the microstructures and nanoindentation results, due to their diverse and complex microscopic zones, which throws shade on the properties of separated zones in the material. He...     

直升机火控系统精度敏感性分析的BNSobol法

针对现有研究大都只分析了单误差源对直升机火控系统精度影响的现状,提出进行直升机火控系统精度的敏感性分析。根据传统敏感性分析法在数据量不充分或无法提供精确模型时存在的局限性,对基于贝叶斯网络和Sobol指数相结合的敏感性分析新方法（BNSobol法）进行了研究,并与传统Sobol法对比分析。结果表明BNSobol法在满足精度要求的同时还减小了对数据量的需求,它的分析不依赖于模型且可以确定出满足约束条件的具体误差源取值区间。该方法可为直升机火控系统设计研究时如何分配各模块误差大小从而提高总体效能提供参考和理论支持。     

A two-step weighted least-squares method for joint estimation of source and sensor locations: A general framework

It is well known that the Two-step Weighted Least-Squares(TWLS) is a widely used method for source localization and sensor position refinement. For this reason, we propose a unified framework of the TWLS method for joint estimation of multiple disjoint sources and sensor locations in this paper. Unlike some existing works, the presented method is based on more general measurement model, and therefore it can be applied to many different localization scenarios.Besides, it does not have the initialization and local convergence problem. The closed-form expression for the covariance matrix of the proposed TWLS estimator is also derived by exploiting the first-order perturbation analysis. Moreover, the estimation accuracy of the TWLS method is shown analytically to achieve the Cramér-Rao Bound(CRB) before the threshold effect takes place. The theoretical analysis is also performed in a common mathematical framework, rather than aiming at some specific signal metrics. Finally, two numerical experiments are performed to support the theoretical development in this paper.     

超大直径网格加筋筒壳快速屈曲分析方法

针对新一代重型运载火箭及大型飞机中存在的超大直径网格加筋壳结构,提出了一种快速屈曲分析方法。首先,基于渐进均匀化法的快速数值实现方法和瑞利-里兹法建立了快速屈曲分析框架,并通过与算例中等效刚度法屈曲载荷结果进行比较,验证了本文方法具有较高的预测精度。然后,对比了3种结构尺寸下网格加筋壳屈曲分析效率,结果表明本文方法不受结构尺寸影响,平均计算时间仅为6s,凸显了其用于超大直径结构分析的高效性。进而,基于本文方法对4种传统加筋构型及2种新型多级加筋构型进行屈曲载荷评估,其预测误差均在3.0%以内,表现出广泛的构型适用性。在此基础上,通过优化设计的方法对比了上述6种加筋构型的承载效率,优化结果表明本文提出的多级三角型加筋构型最具承载优势,相较于初始方案取得了82.2%的承载增幅,可作为一种新型超大直径网格加筋壳结构储备。