An approach for machining distortion measurements and evaluation of thin-walled blades with small datum

Inspection techniques for aero-engine blades are a hot topic in industry. Since these blades have a sculptured surface and a small datum, measurement results may deviate from an actual position. There are few proper approaches compensating for non-uniform distribution errors that are within specified tolerance ranges. This study aimed to develop a meshing structure measur-ing approach for the distortion of blades via non-contact optical 3D scanning. A rough measure-ment and a registration procedure are initially adopted to rectify the coordinate system of a blade, which avoids the initial coordinate system errors caused by the small datum. A measurement path with meshing structure is then unfolded on the blade surface. For non-uniform distribution errors, the meshing structure measurement is more visual and clear than the traditional constant height curves method. All measuring points take only 7 min to complete, and the distribution of error is directly and accurately presented by the meshing structure. This study provides a basis for future research on distortion control and error compensation.     

宇航压力容器表面裂纹的断裂判据

用非线性线弹簧模型,对含有表面裂纹的球瓶破坏性实验结果进行了弹塑性断裂力学分析。讨论了对宇航薄壁压力容器表面裂纹建立安全评定标准的必要性。采用线弹性断裂力学分析方法可能给出危险的结果。将J_(m.d.p)=J_(IC)作为宇航压力容器表面裂纹弹塑性断裂的判据,具有准确,简便的优点。     

铝合金薄壁中空结构件重负荷铣削切削振动研究

使用直径为20mm的商用高速钢和硬质合金刀具,在中低切削速度和大切宽条件下对高速列车车体用T5热处理6N01铝合金双壳薄壁W型结构件进行重负荷铣削试验,重点对铣削振动及其影响因素进行研究.结果表明:当铣刀铣削至结构件的筋板交叉处时振幅有突变增加,其值为铣削铝合金薄壁时的3～6倍;在中低速铣削范围内,重负荷铣削该结构件时易发生自激振动和强迫振动.研究同时表明,机床转速和每齿进给量是影响切削振动的显著因素,波刃刀具切削振动幅值显著大于非波刃,螺旋角较大的刀具和齿数较少的刀具其切削振动较小;在剧烈的切削振动下,高速钢刀具易发生刀尖崩刃,波刃刀具则易发生严重粘结.     

锥形件结构的半自动化电磁铆接托架

分析了航天锥形件结构普通铆接方法存在的问题,提出采用电磁铆接技术具有一定的优势。针对手工电磁铆接和自动化电磁铆接的不足,提出了电磁铆接技术在航天锥形件结构装配应用中的工艺方法,设计了半自动化电磁铆接系统托架的结构和工作流程。该系统关键技术包括铆枪和顶铁自动对中、工件精确角度自动调整及铆枪减振系统设计。最后,对半自动化电磁铆接托架可以解决手工铆接出现的问题进行了总结。     

Chatter stability and precision during high-speed ultrasonic vibration cutting of a thin-walled titanium cylinder

Titanium alloys are widely used in the aviation and aerospace industries due to their unique mechanical and physical properties. Specifically, thin-walled titanium (Ti) cylinders have received increasing attention for their applications as rocket engine casings, aircraft landing gear, and aero-engine hollow shaft due to their observed improvement in the thrust-to-weight ratio. However, the conventional cutting (CC) process is not appropriate for thin-walled Ti cylinders due to its low thermal conductivity, high strength, and low stiffness. Instead, high-speed ultrasonic vibration cutting (HUVC) assisted processing has recently proved highly effective for Ti-alloy machining. In this study, HUVC technology is employed to perform external turning of a thin-walled Ti cylinder, which represents a new application of HUVC. First, the kinematics, tool path, and dynamic cutting thickness of HUVC are evaluated. Second, the phenomenon of mode-coupling chatter is analyzed to determine the effects and mechanism of HUVC by establishing a critical cutting thickness model. HUVC can increase the critical cutting thickness and effectively reduce the average cutting force, thus reducing the energy intake of the system. Finally, comparison experiments are conducted between HUVC and CC processes. The results indicate that the diameter error rate is 10% or less for HUVC and 51% for the CC method due to a 40% reduction in the cutting force. In addition, higher machining precision and better surface roughness are achieved during thin-walled Ti cylinder manufacturing using HUVC.     

A novel stability prediction approach for thin-walled component milling considering material removing process

The milling stability of thin-walled components is an important issue in the aviation manufacturing industry,which greatly limits the removal rate of a workpiece.However,for a thin-walled workpiece,the dynamic characteristics vary at different positions.In addition,the removed part also has influence on determining the modal parameters of the workpiece.Thus,the milling stability is also time-variant.In this work,in order to investigate the time variation of a workpiece's dynamic characteristics,a new computational model is firstly derived by dividing the workpiece into a removed part and a remaining part with the Ritz method.Then,an updated frequency response function is obtained by Lagrange's equation and the corresponding modal parameters are extracted.Finally,multi-mode stability lobes are plotted by the different quadrature method and its accuracy is verified by experiments.The proposed method improves the computational efficiency to predict the time-varying characteristics of a thin-walled workpiece.     

超高强度钢立铣工件温度分析及对加工表面质量的影响

以航空难加工材料300M钢为研究对象,基于立铣加工中的工件温度判断在铣削加工中是否出现了金相组织转变,进而分析不同工况下影响加工表面质量的因素。首先,将移动热源法应用于铣削加工中,计算考虑后刀面磨损的立铣加工工件温度,实验表明,计算值与实验值相比误差在10%以内。然后,分析了工件温度在时间上与空间上的分布,以及不同刀具磨损和加工参数条件下工件表面的温升规律,据此预测加工表面是否出现了组织转变,并结合金相组织观察进一步确认。最后,依据加工表面质量物理层面残余应力和显微硬度的检测数据,初步探讨了各因素对表面质量的影响。结果表明,在研究的加工参数范围内,并未达到金相组织转变温度,表面质量主要受铣削热力作用下的剪切面塑性凸出效应、后刀面挤光效应和热效应的影响。     

薄壁通壳体类零件加工技术

以铝合金薄壁通壳体零件为例,对工件的定位、装夹、刀具的选择、切削参数设置、程序的编制等方面进行了探索,从而有效地克服了薄壁通壳体类零件在加工过程中出现的颤振、变形、表面质量差、尺寸精度低等问题,并大幅缩短了加工时间。     

用光纤半圆阵列测量准二维工件表面粗糙度参数的仿真研究

提出了一种反散射计算的简单、快速方法,用于用光纤半圆阵列的光散射技术测量准二维工件表面的粗糙度参数。这些参数包括高度特性参数 R_a、间距特性参数λ_a 和混合参数△_a。我们的研究证明了上述测量方法的正确性。因而,这种测量方法可用于测量工件表面粗糙度参数仪器的设计。     

On the free-vibration of rotating composite beams using a higher-order shear formulation

The free vibration behavior of rotating blades modeled as laminated composite, hollow (single celled) boxed beams is investigated. To this end, geometrically nonlinear structural model incorporating a number of non- classical effects such as anisotropy, heterogeneity, transverse shear flexibility, and warping inhibition is developed. Centrifugal and Coriolis force field effects are also considered in the formulation. However, Coriolis effect is discarded during the solution process. It is assumed that in-plane cross-sectional distortion is negligible. In contrast to the existing structural blade models, the traction free boundary conditions on the external surfaces of the beam are identically satisfied. The linearized dynamical equations and numerical results addressing the problem of the free vibration are supplied. Results obtained for the present higher-order shearable model are compared with those of the existing first-order shearable and the non-shearable structural models. Tailoring studies using the present model reveal an enhancement of eigenfrequency characteristics.