火箭发动机泵后供应系统水力激振试验

为了研究某型发动机泵后供应系统的动力学特性,对全尺寸的氧泵后供应系统在中、高频范围内开展了水力激振试验。试验数据表明:供应系统的谐振特性被激发起来。在试验条件下,可以清晰地辨识出泵后供应系统的前4阶谐振频率和振型。第1阶谐振频率响应幅值最高,第2阶和第3阶相当,响应幅值次之,第4阶响应幅值再次之。在外界扰动下,该发动机泵后供应系统能够较容易地达到流体谐振状态,当外界扰动频率接近其谐振频率时,供应系统沿程脉动压力出现了明显的共振波形。在不同的谐振频率下,喷前腔位置均为压力振荡的波节位置,也即为流量振荡的波腹位置。      

ELID成形磨削实验研究与表面粗糙度预测

为了探究ELID成型磨削中磨削参数和电解参数对表面粗糙度的影响规律,基于未变形切屑厚度模型,考虑砂轮上磨粒出刃高度的随机性以及ELID磨削中氧化膜的影响,建立了针对ELID磨削的表面粗糙度预测模型。单因素实验研究了ELID成形磨削电源参数对表面粗糙度的影响规律,并探讨了电解电流与氧化膜厚度之间的关系。全因子实验以工件转速、砂轮转速和进给切深为影响因素,研究了磨削参数对表面粗糙度的影响规律,并对预测模型进行了验证。结果表明:磨削参数中,其他条件一定时,表面粗糙度随砂轮转速的增大而减小,随工件转速和切深的增大而增大;同时对于粗糙度的预测误差达到了8.75%,预测模型有效可靠。     

方波形单脉冲射流调节对进气道 再起动特性的影响

对方波形单脉冲射流作用下的混压式超声速进气道再起动过程进行了非定常数值仿真研究.结果表明,在外压缩楔面注入单个周期的方波形脉冲射流,在射流阻挡作用下,进入进气道的流量减小,脱体激波被吸入唇口,当射流流量大于某阈值后,进气道即能实现再起动.该阈值约为进气道流量的5%,再起动所需的射流作用时间小于15ms,所需的射流总质量小于0.0014kg.研究还发现,当射流流量略小于阈值时,射流作用下的进气道流场为135Hz的高频振荡流场.当射流流量大于阈值时,射流流量越大,流场响应越快,再起动所需的脉冲射流作用时间也越短,射流总质量越小.      

航空发动机叶片叶缘随形磨抛刀路规划

航空发动机叶片是整机核心零件,其制造量占到30%以上。叶片叶缘具有大弯扭复杂曲面、薄壁圆角半径微小渐变、精度要求苛刻等特征,末端工序磨抛的精度和品质直接决定整机的性能与寿命。人工仍然是叶片叶缘磨抛的主要手段,然而粉尘危害健康、经验依赖性强、零件一致性差等不足决定了自动化磨抛是必然趋势。叶片叶缘自动化磨抛多采用砂轮横磨或纵磨的刀路规划方式,存在刀路不连续且分行密集、力控制困难等不足,易造成叶缘局部过切,难以保证圆角轮廓创成。为此,建立了砂带包络叶缘的螺旋进给力控磨抛工艺,提出了面族与复杂曲面高阶切触的随形磨抛路径规划方法,实现了叶片叶缘的宽行高效磨抛。首先对叶缘区域进行横磨刀路规划,然后依照圆弧拟合曲线原理进行高阶切触式包络段再规划,最后进行横纵混合磨抛路径规划实现螺旋式连续进给。针对航空发动机叶片开展仿真和实验验证,结果表明所提出的方法相比于传统的横磨或纵磨方法,可将刀触点减少78.8%,轮廓精度由-0.06~+0.07 mm提高到-0.015~+0.05 mm,表面粗糙度由R_a>3.2 μm提高到0.175 μm,并且有效保证了叶缘轮廓形状,避免了过切现象。     

Profile error compensation in precision grinding of ellipsoid optical surface

Optical glass elements with the ellipsoidal surface are used in many critical aerospace instruments, such as satellites, telescope and cameras. Their optical performance is mainly affected by profile accuracy and surface quality. In this paper, a rectangular ellipsoid surface is precisely ground on a BK7 optical glass blank by grating scanning grinding path with a three-axis CNC precision surface grinder. A profile error compensation procedure for ellipsoidal grinding is proposed based on the error analysis about the primary error sources in the XY and YZ projection planes during the grinding process. The mathematical prediction models of the wheel arc profile error, the measurement and wear error of the grinding wheel radiuses are established. By applying the proposed error compensation procedure, the profile accuracy of the ellipsoidal surface was improved from 4 μm to 2 μm in the XY plane, and improved from 15 μm to 5 μm in the YZ plane.     

Performance evaluation of creep feed grinding of γ-TiAl intermetallics with electroplated diamond wheels

This paper evaluates the performance of creep feed grinding γ-TiAl intermetallic (Ti-45Al-2Mn-2Nb) using electroplated diamond wheels. Firstly, a comparative analysis with the grinding results by using electroplated CBN wheels was conducted, mainly involving abrasive wheel wear behavior and maximum material removal rate below surface burn limit. It was found that the diamond wheel would produce much better grinding results including lower wheel wear rate and higher maximum material removal rate. Then the surface integrity obtained at different level of material removal rate was characterized with the utilization of the diamond wheel. The poor ductility of this γ-TiAl intermetallic material was found to have a marginal effect on the surface integrity, as no severe surface defects such as material pullout were generated during the stable wheel wear stage. For the involved operating parameters, a deformation layer was produced with ∼10 μm or more in thickness depending on the material removal rate used. Meanwhile, a work-hardened layer extending to more than 100 μm was produced with a maximum microhardness of above 520 HV_0.05 (bulk value 360 HV_0.05). The residual stress remained compressive, with a value of above −100 MPa and even up to −500 MPa for an elevated material removal rate. Shearing chip was the main chip type, indicating good wheel sharpness in the grinding process.     

非定常条件下喷嘴结构对燃油流量脉动的影响

假设油路处于小脉动条件下,燃油流量连续,以流量数为中间变量,推导了燃油流量脉动关于喷嘴结构的关系模型.得出结论:当外部激励一定时,燃油流量脉动与流量数成正比,与平均燃油压降的0.5次方成反比.通过喷嘴标定得出了减小流量数进而减小燃油流量脉动的方法:增加节流级数、减小节流面积,并用脉动试验证明了此方法的正确性,为喷嘴设计者在面对不稳定性问题时提供了一般的设计步骤.      

基于燃烧室压力振荡的火焰筒结构优化

实验对比了双层与单层火焰筒的燃烧室压力振荡特性.实验结果表明:在相同的实验工况下,前者的压力振荡幅值要小.检验了基于叠加原理的多孔共振腔模型在分析上述压力振荡特性中的适用性.通过敏感性分析,探讨了在保证火焰筒冷却气分配不变的情况下,用于减小燃烧室压力振荡幅值的火焰筒结构改良方向.分析结果表明:火焰筒壁面的孔数量(孔直径)是用于减小燃烧室压力振荡工程优化的主要参数.      

Effects of pressure oscillation on aerodynamic characteristics in an aero-engine combustor

The effects of pressure oscillation on aerodynamic characteristics in an aero-engine combustor are investigated. A combustor test rig is designed to simulate the pressure drop characteristics of a practical annular combustor. The pressure drop characteristics are firstly measured under atmosphere condition with non-reacting flow (or cold flow), and the air mass flow proportion of each component (dome/liner) are obtained; these properties are base lines for comparison with combustion state. The combustion tests are then carried out under conditions of inlet temperature 340–450 K, fuel air ratio 0.010–0.028. The stability map and the oscillation frequencies are obtained in the tests, the results show that pressure oscillation amplitude increases with the increase of fuel air ratio. Phase trajectory reconstruction is applied to classify the pressure oscillation motion; there are three motions captured in the tests including: “disk”, “ring” and “cluster”. The pressure drops across the dome under strong pressure oscillation are distinctly divergent from the cold flow, and the changes of pressure drops are mainly affected by pressure oscillation amplitude, but is less influenced by pressure oscillation motion nor oscillation frequencies. Based on the mass flow conservation, the reduction of effective flow area of combustor under strong pressure oscillation is demonstrated. Liner wall temperatures are analyzed through Multiple Linear Regression (MLR) method to estimate the reduction of the air mass flow proportion of the liner cooling under strong pressure oscillation. Finally, the air mass flow proportions of each component under strong pressure oscillation are estimated, the results show that the pressure oscillation motion also has influence on air mass flow proportion.     

Effect of laser-discrete-quenching on bonding properties of electroplated grinding wheel with AISI 1045 steel substrate and nickel bond

To improve the bonding strength between the nickel bond and the hub of the electroplated diamond grinding wheel, a hybrid technique was proposed to combine laser pre-quenching steel substrate and post-electroplating nickel. To validate the effectiveness of the proposed technique, AISI 1045 substrate was nickel-coated. The bonding properties between the electroplated nickel coating and substrate with or without laser-discrete-quenching were discussed comparatively by scratch, indentation, and thermal shock tests. The results show that the pre-quenching treatment leads to phase transformation of AISI 1045 microstructure from the mixed pearlite and ferrite phases into the martensitic phase. Since the martensitic phase is characterized as a high corrosion resistance, the interface of substrate/coating is smooth and flat in the pre-quenched zone, and the coating is bonded well with the steel substrate. In contrast to the steel substrate without pre-quenching treatment, the proposed technique significantly enhanced the bonding strengths of the electroplated nickel-coating. On one hand, the average hardness of electroplated nickel-coating on the laser pre-quenched zone is increased by 18.7%, and the scratch depth with the same load become narrower and shallower. On the other hand, the coefficient of friction (CoF) and the vibration amplitude are reduced, and the coating is bonded effectively with the substrate to inhibit the crack initialization at the interface. This prevents effectively the coating from peeling off and improves significantly the thermal shock resistance property.