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.     

点阵结构空气舵及内部流体热流固耦合研究

开展了钛合金TC4材料激光粉末床熔融(LPBF)工艺研究,在此基础上设计了多孔轻质空气舵模型,并基于有限差分法(FDM),采用三维流固耦合共轭传热数值计算方法,利用流体体积法(VOF)追踪流体自由液面,研究了典型的点阵夹层结构的空气舵内部冷却液动态换热过程的相互影响过程,考虑了冷却液与钛合金材料蒙皮间的耦合传热及湍流换热。结果表明,空气舵的内部流体压强随速度的增加而增加,从而导致流体出口的速度增加。当压强增加到一定程度时,流体的出口以水柱形式喷出。虽然较大的流体速度可以带走较多的热量,但是影响远小于对压强的影响。综合考虑空气舵的服役要求,获得了合适的冷却水入口速度。     

基于激光扫描技术的大型船舶舱容量计量技术研究

介绍了一种应用三维激光扫描技术，采集获取船舱三维点云数据，对点云数据进行配准、修补，完成船舱内部构件精细建模，快速高精度的重建大型船舱三维模型，实现大型船舱容量快速计算的方法。运用三维激光扫描技术完成158000吨大型油轮液货舱容量计量，通过与传统容量计量方法进行比对分析，解决了单点数据采集模式弊端，达到了大型船舶舱容量快速、精准计量效果。     

小半径弯管弯胀复合成形研究

为解决小半径弯管内侧起皱、外侧减薄的成形缺陷,提出了一种弯胀复合成形的方法。通过几何关系解析了初始弯曲半径和初始管坯直径与最终管径和最终弯曲半径之间的关系,确定了初始弯曲半径的取值范围。采用有限元与实验相结合的方式研究了不同初始弯曲半径对零件壁厚分布的影响,分析了胀形过程中零件弯曲处及直壁处的变形规律。最终发现:初始弯曲半径越大,零件的最终减薄越小,胀形过程中弯曲处内外侧发生均匀减薄,直壁处内侧减薄明显大于外侧减薄。     

航天铝合金深腔零件整体成形预制坯优化设计

提出航天铝合金深腔零件整体成形方法,开展预制坯优化设计。对比分析直筒和变径筒两种预制筒坯结构变形规律,数值模拟研究了底部圆角对开口球形件液压成形的影响规律。以直径D=450 mm的球形整体零件为验证对象,进行底部圆角r=60 mm的变径筒形件的液压成形试验验证。结果表明:直筒坯液压成形时,赤道位置发生破裂;变径筒坯液压成形时,当胀形压力为16 MPa即发生贴模;液压成形时,筒端口自适应补料,所以上半球的壁厚分布均匀;随着底部圆角越大,筒底部减薄越小,筒壁厚越均匀;当底部圆角为r=60 mm时,开口球壳赤道位置壁厚减薄最严重,减薄率为11.1%,球底部减薄率为9.8%,开口球壳上半球壁厚差为0.17 mm,下半球壁厚差为0.43 mm。     

Thermal-optical design of a geodetic satellite for one millimeter accuracy

The LAGEOS (LAser GEOdynamic Satellite) satellites use a 1.5 in. uncoated retroreflector (cube corner). Design studies done for LAGEOS-1 showed that using smaller cubes would result in greater accuracy and lower thermal gradients. However, this would require using a larger number of cubes. Simulations showed that the accuracy goal of 5 mm could be met using 1.5 in. cubes by adding a dihedral angle offset. The LARES (LAser RElativity Satellite) satellite launched in 2012 is a smaller version of LAGEOS using the same size cube corner and floating mount as LAGEOS.The recent development of COTS (Commercial Off-The-Shelf) cube corners has eliminated cost as an obstacle to using a larger number of smaller cubes. COTS cubes have no dihedral angle offset. However, no offset is needed if the size is chosen properly. The diffraction pattern of a 1.0 in. uncoated cube with no dihedral angle offset has 6 lobes around the central peak due to total internal reflection, The velocity aberration for LAGEOS is about 32–40 microradians. The OCS (Optical Cross Section) of a one inch uncoated COTS retroreflector is about 0.5 million sq m for the LAGEOS orbit.Testing of 10 inexpensive COTS cubes by Ludwig Grunwaldt and Reinhart Neubert shows good cross section (unpublished work done at GFZ Potsdam, Germany). Measurement of 50 COTS cubes at INFN (Mondaini et al., 2018), shows a loss of cross section of only 33% (Slide 10). Simulations show that systematic range errors on the order of a half millimeter are possible for a spherical geodetic satellite such as LARES. Adjustments for the holding and ejection system result in some loss of accuracy.     

InfraRed Astronomy Satellite Swarm Interferometry (IRASSI): Overview and study results

The far-infrared (FIR) regime is one of the few wavelength ranges where no astronomical data with sub-arcsecond spatial resolution exist yet. Neither of the medium-term satellite projects like SPICA, Millimetron or OST will resolve this malady. For many research areas, however, information at high spatial and spectral resolution in the FIR, taken from atomic fine-structure lines, from highly excited carbon monoxide (CO) and especially from water lines would open the door for transformative science. These demands call for interferometric concepts. We present here first results of our feasibility study IRASSI (Infrared Astronomy Satellite Swarm Interferometry) for an FIR space interferometer. Extending on the principal concept of the previous study ESPRIT, it features heterodyne interferometry within a swarm of five satellite elements. The satellites can drift in and out within a range of several hundred meters, thereby achieving spatial resolutions of <0.1 arcsec over the whole wavelength range of 1–6 THz. Precise knowledge on the baselines will be ensured by metrology methods employing laser-based optical frequency combs, for which preliminary ground-based tests have been designed by members of our study team. We first give a motivation on how the science requirements translate into operational and design parameters for IRASSI. Our consortium has put much emphasis on the navigational aspects of such a free-flying swarm of satellites operating in relatively close vicinity. We hence present work on the formation geometry, the relative dynamics of the swarm, and aspects of our investigation towards attitude estimation. Furthermore, we discuss issues regarding the real-time capability of the autonomous relative positioning system, which is an important aspect for IRASSI where, due to the large raw data rates expected, the interferometric correlation has to be done onboard, in quasi-real-time. We also address questions regarding the spacecraft architecture and how a first thermomechanical model is used to study the effect of thermal perturbations on the spacecraft. This will have implications for the necessary internal calibration of the local tie between the laser metrology and the phase centres of the science signals and will ultimately affect the accuracy of the baseline estimations.     

基于激光反射层析法的换能器声场测量技术及仿真研究

换能器的辐射声场分布能够直接反映出换能器声学性能的好坏，若不能精确测量出换能器的辐射声场，则会对换能器的诊断和评估造成严重影响。从理论仿真的角度出发，推导了运用激光反射层析法重建换能器辐射声场的理论公式，着重利用推导出的理论公式对激光反射层析法进行了仿真计算。结果表明激光反射层析法能够精确地重建出换能器的辐射声场分布及声场中的声压量值，这为换能器的声场重建及声压测量提供了一种可行的方法。     

激光动态液位测量技术研究

如今,运载火箭大量使用液氧、煤油等液体推进剂,其液位测量技术主要有浮子式、激光式、电容式、雷达式等。介绍并实现了一种激光液位测量系统,该系统体积小、功耗低,可适应多种测量环境,能满足航天燃料液位测量高精度、高动态、连续稳定测量的要求。系统利用相位式激光测距技术,通过测量激光回波信号的相位延迟,计算激光光程从而得到距离数据并通过客户端进行直观展示和数据存储。系统最大测量距离可达100 m,精度为±1 mm。该系统为非接触测量,耐腐蚀,通过加入反射板可实现透明、非透明液体测量。     

基于正交试验的超声波喷丸成形工艺参数分析及弧高值预测

针对带筋板的超声波喷丸成形,采用正交试验法研究了撞针速度、撞针直径、成形轨迹间距、喷丸区域宽度对带筋板超声波喷丸成形弧高值的影响,得出最佳参数组合方案,并以此作为样本数据,建立多元回归分析数学模型。通过实验验证模型的准确性,试验数据和回归分析数据相符较好,可以用回归分析的数学模型来预测喷丸弧高值,提高工艺设计效率。