Abnormal changes of dynamic derivatives at low reduced frequencies

A number of studies have found that abnormal changes of dynamic derivatives occurred at very low reduced frequencies, but its inducement mechanism is not very clear. This paper has researched the abnormal changes and analyzed the influence on some parameters by solving the unsteady flow around forced oscillation airfoils based on Navier-Stokes equations. Results indicate that when the reduced frequency approaches to zero, the dynamic derivatives obtained by the numerical method will diverge. We have also proven it in theory that this phenomenon is not physical but completely caused by numerical singularity. Furthermore, the abnormal phenomenon can be effectively mitigated by using the time spectral method to solve the aerodynamic forces and the integral method to obtain the dynamic derivatives. When the reduced frequency is in the range of 0.001–0.01, the dynamic derivative maintains nearly unchanged for the whole speed region. This study can provide a reference for the reasonable choice of the reduced frequency in calculations and experiments of dynamic derivatives.     

Ultrasound assisted solidification process of ternary Cu–Sn–Sb alloy

It is well-known that the application of ultrasound during liquid to solid transitions for alloys can refine the solidification microstructure and thus improves the mechanical properties. How-ever, most published work focuses on single phase dendritic growth, whereas little has been con-ducted on the multiphase alloys with complicated phase transformations during solidification. In this work, the solidification process of ternary Cu40Sn45Sb15 alloy was realized within intensive ultra-sonic field with a resonant frequency of 20 kHz and ultrasound power from 0 W to 1000 W. The ultrasound refines the size of the primary e(Cu3Sn) intermetallic compound by two orders of mag-nitudes. If the ultrasound power increases to 1000 W, g(Cu6Sn5) phase nucleates and grows directly from parent liquid phase without the occurrence of peri-eutectic reaction on the top of the alloy sam-ple where the ultrasound intensity is sufficiently high. These microstructural variations lead to the enhancement of compressive strength and elasticity modulus of ternary Cu40Sn45Sb15 alloy.     

航空弧齿锥齿轮副风阻功率损失分析与优化

基于CFD理论，利用Fluent求解软件，借助超级计算机强大的并行运算能力对航空弧齿锥齿轮副风阻功率损失进行仿真计算。采用局部综合法建立弧齿锥齿轮副三维模型，选用RNG k-ε湍流模型，考虑平均流动中的旋流流动情况，与标准k-ε模型相比，RNG通过修正湍流黏度并很好地处理了高应变率以及流线弯曲程度较大的流动。齿轮边界运动通过UDF(user-defined functions)函数驱动，同时采用动网格模拟流场形状由于边界运动而随时间改变问题。最后得出无挡风罩和不同挡风罩配置下的齿轮副风阻功率损失，证实了合理安装挡风罩能够有效降低齿轮风阻损失，并分析多组仿真实验间的减速器内流场压力、速度、湍流动能云图变化，得出了最优化的挡风罩配置，以求最小化风阻功率损失，文中减阻效果最好的挡风罩能降低55.3%的齿轮风阻损失，此时挡风罩间隙为1 mm，为工程实际应用挡风罩的设计提供了参考。     

Plastic wrinkling prediction in thin-walled part forming process:A review

The precision forming of thin-walled components has been urgently needed in aviation and aerospace field. However, the wrinkling induced by the compressive instability is one of the major defects in thin-walled part forming. The initiation and growth of the wrinkles are interac-tively affected by many factors such as stress states, mechanical properties of the material, geometry of the workpiece and boundary conditions. Especially when the forming process involves compli-cated boundary conditions such as multi-dies constrains, the perturbation of clearances between workpiece and dies and the contact conditions changing in time and space, etc., the predication of the wrinkling is further complicated. In this paper, the current prediction methods were summa-rized including the static equilibrium method, the energy method, the initial imperfection method, the eigenvalue buckling analysis method, the static-implicit finite element method and the dynamic-explicit finite element method. Then, a systematical comparison and summary of these methods in terms of their advantages and limitations are presented. By using a combination of explicit FE method, initial imperfection and energy conservation, a hybrid method is recommended to predict plastic wrinkling in thin-walled part forming. Finally, considering the urgent requirements of com-plex thin-walled structures’ part in aviation and aerospace field, the trends and challenges in wrin-kling prediction under complicated boundary conditions are presented.     

A constitutive model coupling damage and material anisotropy for wide stress triaxiality

A constitutive model that can describe the damage evolution of anisotropic metal sheets during the complex forming processes which experience wide stress triaxiality history is essential to accurately predict the deformation and rupture behaviors of the processes. In this study, a modified Lemaitre damage criterion which couples with the anisotropic Barlat 89 yield function is established. The effects of stress triaxiality, Lode parameter and shear stress on damage accumulation are considered in the constitutive model. The model is numerically implemented and applied to fracture prediction in tensile tests with different stress triaxialities and a complex deformation process with wide stress triaxiality history. The good consistency of predictions and experiments indicates that the modified Lemaitre damage model has excellent fracture prediction ability. Finally, the accuracy of the model is analyzed and discussed.     

Prediction of cutting forces in ball-end milling of 2.5D C/C composites

Machining of carbon/carbon (C/C) composite materials is difficult to carry out due to its high specific stiffness, brittleness, anisotropic, non-homogeneous and low thermal conductivity, which can result in tear, burr, poor surface quality and rapid wear of cutters. Accurate and fast pre-diction of cutting forces is important for milling C/C composite materials with high quality. This paper presents an alternative cutting force model involving the influences of the directions of fiber. Based on the calculated and experimental results, the cutting forces’ coefficients of 2.5D C/C com-posites are evaluated using multiple linear regression method. Verification experiment has been car-ried out through a group of orthogonal tests. Results indicate that the proposed model is reliable and can be used to predict the cutting forces in ball-end milling of 2.5D C/C composites.     

Aerodynamic optimization of rotor airfoil based on multi-layer hierarchical constraint method

Rotor airfoil design is investigated in this paper. There are many difficulties for this high-dimensional multi-objective problem when traditional multi-objective optimization methods are used. Therefore, a multi-layer hierarchical constraint method is proposed by coupling principal component analysis (PCA) dimensionality reduction and e-constraint method to translate the orig-inal high-dimensional problem into a bi-objective problem. This paper selects the main design objectives by conducting PCA to the preliminary solution of original problem with consideration of the priority of design objectives. According to the e-constraint method, the design model is estab-lished by treating the two top-ranking design goals as objective and others as variable constraints. A series of bi-objective Pareto curves will be obtained by changing the variable constraints, and the favorable solution can be obtained by analyzing Pareto curve spectrum. This method is applied to the rotor airfoil design and makes great improvement in aerodynamic performance. It is shown that the method is convenient and efficient, beyond which, it facilitates decision-making of the high-dimensional multi-objective engineering problem.     

面向飞机装配精准定位的状态感知技术

状态感知、实时分析、自主决策、精准执行是航空智能制造的特征。总结影响飞机部件装配单元定位精度的多种因素,并结合感知技术发展,深入分析部件装配单元的可感知因素及其获取方式,确定了部件装配单元可感知的关键要素:装配现场温度、定位器所受载荷、定位器位移、产品位姿。结合飞机机翼装配单元,设计感知信息获取方式。通过模糊优选方法,构建传感器型号优选模型,完成部件装配单元传感器选型。通过传感器测量偏差平均化的方法,构建多种类、多数量的传感器布局模型,确定部件装配单元传感器的数目与位置,完成了传感器布局设计。基于多传感器信息融合方法,设计多传感器信息融合模型,对感知的多源异构信息进行融合处理,并通过构建状态感知模型,实现对部件装配单元定位状态的直观表达。     

Cross-sectional deformation behavior of double-ridged rectangular tube with fillers in different stages of H-typed bending

The bent double-ridged rectangular tube (DRRT) with high forming quality is helpful to improve the microwave transmission accuracy. For reducing the cross-sectional deformation in the H-typed bending process, in addition to using rigid mandrel to support the inside of tube, ridge groove fillers are also added to restrict the deformation of ridge grooves. Because of the change of stress and strain state of bent tube in bending, rigid mandrel retracting and specially twice-springback stages, and the springback of fillers, the cross-sectional deformation of tube in each stage may be different. Therefore, based on the ABAQUS platform, the finite element models (FEM) for H-typed bending, mandrel retracting and twice-springback stages of H96 DRRT with fillers were established and validated. It is found that, for the height and width deformation of tube and spacing deformation of ridge grooves, retraction of mandrel can make the distribution of these deformations more uniform along the bending direction. The first springback can reduce these deformations significantly, which should be emphasized. But the second springback only increases them by less amount, which can be ignored. The smaller height deformation of ridge groove and filler can be neglected.     

Vision-based pose estimation for cooperative space objects

Imaging sensors are widely used in aerospace recently. In this paper, a vision-based approach for estimating the pose of cooperative space objects is proposed. We learn generative model for each space object based on homeomorphic manifold analysis. Conceptual manifold is used to represent pose variation of captured images of the object in visual space, and nonlinear functions mapping between conceptual manifold representation and visual inputs are learned. Given such learned model, we estimate the pose of a new image by minimizing a reconstruction error via a traversal procedure along the conceptual manifold. Experimental results on the simulated image dataset show that our approach is effective for 1D and 2D pose estimation.