A review of friction stir joining of SiCp/Al composites

SiCp/Al composites have excellent comprehensive properties and have been widely used in aerospace, automotive industry and other fields. Due to the huge difference in performance between SiC particles and matrix alloys, traditional fusion welding methods are difficult to meet the join requirements of SiCp/Al composites. Friction stir joining (friction stir welding), as a solid phase joining process, has been proved to be a new technology with fine prospect in joining SiCp/Al composites compared with fusion welding process. Although some progress has been made in recent years, there are still full of challenges. In this paper, the research status of friction stir joining of SiCp/Al composites in recent years is expatiated, including the weldability of SiCp/Al composites, the macrostructure and the microstructure of joints, mechanical properties of joints, and tool wear and monitoring. Furthermore, the existing challenges of friction stir joining of SiCp/Al composites are summarized and the future development directions are prospected.     

微小整体叶轮五轴联动微细铣削加工试验研究

微小整体叶轮作为微型发动机的重要组成部分,其加工质量直接影响微型发动机的使用性能。针对微小整体式复杂叶轮流道狭窄、叶片扭曲大和长厚比大等特点,开展了微小复杂扭曲整体式叶轮五轴联动微细铣削加工方法研究。针对微小叶轮加工过程极易发生变形、过切和碰撞干涉等问题,对微小叶轮的加工过程进行工艺规划,建立了微小叶轮流道加工刀具选择的约束方程,计算出叶轮加工刀具的最大理论直径。通过CAM软件对叶轮进行切削仿真,验证了刀具选择和工艺规划的正确性。通过五轴联动微细铣削试验,得到了具有6个直径10mm的叶片、叶片最小厚度0.15mm、叶片最小相邻间距0.58mm的7075铝合金微小整体叶轮。     

基于UG的多轴加工策略研究

介绍了多轴加工技术以及多轴编程中的关键参数——驱动方法、投影矢量、刀轴矢量,包括其定义、功能、作用及分类等;同时介绍了UG软件“可变轮廓铣”和“MILL MULTI BLADE”两个多轴加工策略,包括其功用、参数、设置技巧等.     

基于特征识别的整体壁板快速编程推理算法

航天器整体壁板的编程效率已成为型号研制过程中的主要瓶颈之一.本文首先阐述特征识别技术在数控编程中的应用和发展现状.与传统编程过程先总体规划,再逐条编程的总-分方法不同,特征编程采取先生成单个特征的刀轨,再完成整个零件程序的分-总方法,易于覆盖从毛坯向模型最终状态全过程.在此基础上,提出了单特征和多特征数控推理算法,完成了整体壁板快速编程系统的开发.实践证明,使用该方法能够初步实现整体壁板数控加工程序的自动生成.     

刀具库房信息化管理实践及展望

本文针对科研生产混合型的数控车间刀具库房管理过程,以流程优化、完善制度和信息化管理为重点,总结归纳出刀具库房信息化管理的方法和手段,并以中航工业北京航空制造工程研究所数控某刀具库房信息化系统建设为实例,说明了刀具库房管理实施方法及过程。     

Laser-induced oxidation assisted micro milling of high aspect ratio microgroove on WC-Co cemented carbide

Severe tool wear and poor surface quality are the main problems during micro machining of cemented carbide. In this work, an innovative hybrid process of laser-induced oxidation assisted micro milling (LOMM) was proposed to solve the problems. A nanosecond laser was utilized to induce oxidation of the WC-20%Co material, producing loose oxide which was easy to remove. The micro machinability of the material was improved by laser-induced oxidation. The oxidation mechanisms of cemented carbide were studied. A microgroove with a depth of 2.5 mm and aspect ratio of 5 was fabricated successfully. The milling force, surface quality and tool wear mechanisms were investigated. For comparison, a microgroove was also fabricated with conventional micro milling (COMM) using identical milling parameters. Results revealed that in LOMM the milling force and tool wear rate were extremely low during removing the oxide. The machined surface quality and dimensional accuracy achieved by LOMM were superior to those obtained by COMM. The surface roughness S_a of the microgroove bottom reached 88 nm in LOMM, while the cross-sectional geometry of the microgroove was a trapezoid. Perpendicularity of the microgroove sidewall machined by LOMM was better than that by COMM. The tool wear forms in LOMM were coating spalling and slight tool nose breakage. Compared with COMM, the tool life in LOMM was prolonged significantly. It indicates that the proposed hybrid process is an effective and efficient way to fabricate high aspect ratio micro-features with high dimensional accuracy.     

一种新型火星定点着陆轨迹快速优化方法

针对火星定点着陆任务大气进入段的轨迹规划问题,给出了一种基于hp Radau伪谱法的快速优化算法。综合考虑大气进入段的动力学约束、边值约束、以及着陆器的机动能力约束和安全性约束,结合hp Radau伪谱法的配点特性,将轨迹优化问题转换成一个大规模多约束参数优化问题,给出了大气进入段轨迹优化问题的求解框架;为了提高算法的计算效率,给出了参数优化过程中雅克比矩阵的解析表达式;并通过数学仿真对本文算法进行了数值验证,结果表明：     

带扰流柱内冷通道对表面气膜冷却特性的影响

为了讨论内冷通道结构对表面气膜冷却特性的影响,通过数值模拟的方法,计算研究不同结构下,冷气流过带有扰流柱内冷通道对表面气膜冷却特性的影响,并研究冷气通道与燃气掺混后的冷却效果;采用六种不同结构的扰流柱与气膜孔排列方式,计算中吹风比的范围为0．1〈M〈2．0。结果表明：冷气通道内的扰流柱对进入气膜孔的冷气起到稳定作用,比冷气通道内不加扰流柱的气膜冷却效果好,而且扰流柱与气膜孔不同的排列方式对气膜冷却效果有显著影响,因此选择合适的排列方式有利于气膜冷却。     

发动机高压两级涡轮盘联合低循环疲劳寿命试验

以某型发动机高压两级涡轮盘为研究对象,通过有限元计算得到试验载荷系数,组装和调试了全尺寸联合试验件,完成了低循环疲劳试验,得到了以传动臂销钉孔为定寿部位的两级涡轮盘低循环疲劳寿命。两级涡轮盘联合低循环疲劳试验在国内尚属首次,相对于单盘低循环疲劳试验,更加符合发动机实际工作状态,将传动臂销钉孔作为两级涡轮盘的定寿部位更为合理。该联合试验为外场涡轮盘重新定寿提供了依据。     

微小刀具同轴全息对刀方法研究

针对现有对刀方法存在的各种不足,提出了一种微小刀具的同轴全息对刀方法。在对全息成像原理和全息图像关键问题进行研究与分析的基础上,搭建了一套微细铣刀的全息对刀检测装置,并利用标准刀具在五轴加工中心进行了微细铣刀的对刀测量试验。试验结果表明:该对刀装置能够高效地进行微细铣刀的对刀检测,系统相对检测精度达5.1μm。在相同检测条件下,与高精度机外预调仪的测量结果相比,接触式对刀仪的相对误差为0.033%,而全息对刀样机的相对误差为0.007%,后者更能有效地实现微小刀具的对刀检测。该结果验证了微小刀具的同轴全息对刀方法的可行性,即全息测量可用于微细铣刀的高精度对刀。