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.     

一种快速有效的薄壁件加工表面误差预测算法

 在切削力作用下，刀具/工件的变形是影响薄壁弱刚度件加工精度与质量的关键因素，快速有效地进行表面误差的预测是实现工艺参数优化及在线刀具路径补偿的前提。针对立铣加工过程，提出了一种考虑刀具/工件变形位置的快速柔性迭代算法，基于此建立了薄壁件加工变形预测的有限元计算模型，并通过等效集中力作用位置的确定、模型分割及最小化网格重划方法进一步提高了模型的计算速度。通过刀具/工件的瞬时接触区域的限定算法、实际切深的修正算法、材料去除效应的模拟等关键技术更提高了模型的计算精度。以典型航空铝合金材料为对象，合理安排试验，并通过数值计算结果和试验数据的对比，表明该方法计算精度高，计算速度较文献方法提高了近2倍。     

飞机薄壁件铆接过程变形分析与数值模拟

铆接是飞机薄壁件装配中应用最广泛的连接方式,有效分析和预测铆接变形对提高飞机铆接结构的性能、疲劳和损伤至关重要。针对铆接变形进行理论分析和数值模拟,并研究了被连接件接合面的应力应变分布。首先建立有限元模型,根据铆接力与镦头尺寸之间的关系验证模型有效性;其次根据铆钉变形特点和材料塑性流动,将铆接过程变形划分为6个阶段;最后分析了不同铆接力作用下钉孔的扩张变形,以及对被连接件接合面应力应变场分布的影响。结果表明,随着铆接力的增大,钉孔变形量增大,且变形量沿被连接件厚度方向极不均匀;同时接合面处于压缩应力状态的范围扩大,铆接结构的抗疲劳性能提高,但铆接力的影响范围有限。     

超高温NiAl合金锥形薄壳件制备成形一体化新工艺

针对NiAl合金板坯制备及板坯成形锥形薄壳件存在的材料流动及组织性能控制困难的问题,提出了一种制备成形一体化新工艺。该工艺是将塑性成形和反应合成在同一工步中,即先将Ni/Al叠层箔置于模具中进行塑性成形,随后对成形的Ni/Al叠层箔原位加热加压反应合成NiAl合金薄壳件。采用三维扫描仪及Geomagic Studio/Qualify对锥形薄壳件的形状精度进行了分析,采用扫描电子显微镜( Scanning Electron Microscope, SEM )和电子背散射衍射( Electron Backscatter Diffraction, EBSD )技术对其微观组织进行了表征,并对构件的高温力学性能进行了测试。结果表明,采用该新工艺制备的锥形薄壳件成形效果良好,整体型面偏差尺寸在±0.1 mm以内;构件沿轴截面壁厚平均偏差为0.012 mm,沿横截面壁厚平均偏差为0.072 mm,构件轴截面壁厚分布均匀性及组织成分均匀性高于横截面。构件高温力学性能稳定,1000 °C时平均屈服强度为77.8 MPa,平均抗拉强度为82.6 MPa。NiAl合金构件的微观晶粒形貌与Ni箔的初始热处理状态及Ni/Al箔的初始厚度有关,未退火的Ni箔将延缓粗晶区晶粒的长大,减小初始箔材厚度可实现晶粒的进一步细化。     

薄壁件周铣切削力建模与表面误差预测方法研究

薄壁件加工变形是影响加工精度与质量的关键因素,而切削力建模则是预测表面加工误差的基础。针对两种典型的切削力模型,系统地研究了薄壁件周铣加工过程中切削力变化及表面变形误差分布的有限元计算方法,提出了基于三维非规则网格的刀具/工件变形的耦合迭代格式以及恒定网格下材料去除效应的变刚度处理方法等关键技术,仿真过程充分考虑了切屑厚度变化及不同切削参数对预测结果的影响。以典型钛合金航空材料构件为例,数值计算结果与实验参考数据比较表明,两种切削力模型对同一切削过程的预测均具有很好的一致性。     

飞机结构件数控加工变形控制研究与仿真

以飞机弧形结构件这一典型易变形的零件为例,研究数控加工变形情况及其影响因素,分析数控加工过程中切削力对变形、残余应力对加工变形、装夹布局对飞机结构件数控加工变形的影响,并针对所研究的3个方面建立相应的物理仿真模型,模拟加工变形情况,提出了相应的解决方案。     

Stiffeners layout design of thin-walled structures with constraints on multi-fastener joint loads

The purpose of this paper is to present an extended topology optimization method for the stiffeners layout design of aircraft assembled structures.Multi-fastener joint loads and manufacturing constraints are considered simultaneously.On one hand,the joint loads are calculated and constrained within a limited value to avoid the failure of fasteners.On the other hand,the manufacturing constraints of the material distribution in the machining directions of stiffeners are implemented by an improved piecewise interpolation based on a beveled cut-surface.It is proven that the objective function is strictly continuous and differentiable with respect to the piecewise interpolation.The effects of the extended method with two different constraints are highlighted by typical numerical examples.Compared with the standard topology optimization,the final designs have clearly shown the layout of stiffeners and the joint loads have been perfectly constrained to a satisfying level.     

Effects of geometrical parameters on wrinkling of thin-walled rectangular aluminum alloy wave-guide tubes in rotary-draw bending

Inner flange and side wrinkling often occur in rotary-draw bending process of rectangular aluminum alloy wave-guide tubes, and the distribution and magnitude of wrinkling is related to geometrical parameters of the tubes. In order to study the effects of geometrical parameters on wrinkling of rectangular wave-guide tubes, a 3D-FE model for rotary-draw bending processes of thin-walled rectangular aluminum alloy wave-guide tubes was built based on the platform of ABA-QUS/Explicit, and its reliability was validated by experiments. Simulation and analysis of the influence laws of geometrical parameters on the wave heights of inner flange and side wrinkling were then carried out. The results show that inner flange wrinkling is the main wrinkling way to rectan- gular wave-guide tubes in rotary-draw bending processes, but side wrinkling cannot be neglected because side wrinkling is 2/3 of inner flange wrinkling when b and h are smaller. Inner flange and side wrinkling increase with increasing b and h; the influence of b on side wrinkling is larger than that of h, while both b and h affect inner flange wrinkling greatly. Inner flange and side wrinkling decrease with increasing R/h; the influence of h on inner flange and side wrinkling is larger than that of R.     

大型空间结构热弹性非线性有限元分析

由薄壁管组成的大型空间结构在外层空间受到太阳等星体的辐射加热，其热变形是值得关注的。为了准确地预测这种变形，首先推导了一种梁的热弹性几何非线性增量有限元格式，用以分析该类结构的热-力学响应，然后考虑到空间结构热流输入与变形耦合的特性，提出了一种热-力学耦合分析的有限元方法。对哈勃太空望远镜太阳能帆板热变形的实例计算表明，数值解与理论解符合较好。数值算例表明，结构内部热变形的不一致程度越大，考虑几何非线性对于热变形计算结果的影响越大；热流入射方向角和热变形大小是影响耦合效应的主要因素。     

六自由度数控铣床工件定位及后置处理系统

对传统3轴立式铣床进行了改造，安装了六自由度并联机构形成了一种新型数控铣床。本文介绍了其结构，推导了该铣床的工件定位和刀位文件后置处理两个子系统。该铣床具有造价低，结构简单，刚性好，精度高及易改造等优点，适合加工复杂曲面工件。