Cutting path-dependent machinability of SiCp/Al composite under multi-step ultra-precision diamond cutting

Particle-tool interactions, which govern the synergetic deformation of SiC particle reinforced Al matrix composites under mechanical machining, strongly depend on the geometry of particle position residing on cutting path. In the present work, we investigate the influence of cutting path on the machinability of a SiCp/Al composite in multi-step ultra-precision diamond cutting by combining finite element simulations with experimental observations and characterization. Be consistent with experimentally characterized microstructures, the simulated SiCp/Al composite is considered to be composed of randomly distributed polygonally-shaped SiC particles with a volume fraction of 25vol%. A multi-step cutting strategy with depths of cut ranging from 2 to 10 μm is adopted to achieve an ultimate depth of cut of 10 μm. Intrinsic material parameters and extrinsic cutting conditions utilized in finite element simulations of SiCp/Al cutting are consistent with those used in corresponding experiments. Simulation results reveal different particle-tool interactions and failure modes of SiC particles, as well as their correlations with machining force evolution, residual stress distribution and machined surface topography. A detailed comparison between numerical simulation results and experimental data of multi-step diamond cutting of SiCp/Al composite reveals a substantial impact of the number of cutting steps on particle-tool interactions and machined surface quality. These findings provide guidelines for achieving high surface finish of SiCp/Al composites by ultra-precision diamond cutting.     

基于AFI混合聚类算法的轴承故障诊断方法

针对滚动轴承振动信号标记数据量小、故障模式多样的现状，提出了一种基于AFI混合聚类算法的半监督式轴承振动信号故障诊断方法。利用小波包分解方法提取了信号的能量特征谱，并通过主成分分析方法增强了信号的特征；参考迭代自组织数据分析的“分裂”和“合并”的思想，为人工鱼群算法中的个体鱼增加了“分裂进化”和“合并进化”行为；采用模糊C均值方法定义了隶属度矩阵和目标函数，并利用改进的人工鱼群算法，迭代搜寻了目标函数的全局最优解，得到了各故障模式的聚类中心；通过计算测试数据的最近邻聚类中心，实现了故障模式识别。结果表明，该方法无需指定聚类簇数，能在标记数据量小的情况下完成训练，较同类方法表现出了更优的故障模式识别性能。     

基于有限单元热网络法的航空发动机主轴轴承热分析

航空发动机主轴轴承温度场的精准预测对保证发动机润滑系统及整机稳定运转至关重要。针对传统热网络法精度低的问题，提出一种基于有限单元思想的有限单元热网络法。将轴承结构通过网格划分为有限个单元体，每个单元体设置一个温度节点代表该单元体的集总参数，节点间构建热阻关系并形成热网络，通过求解以温度为未知量的大型稀疏矩阵线性方程组来获得滚子轴承横截面的温度分布。该方法可以与轴承局部产热理论相结合，实现轴承局部产热的精准加载，完成温度场的精细化分析。通过与试验结果对比，本文方法对轴承外环表面中心线温度的预测结果与试验结果误差不超过13%。     

基于有限元的超精密空气静压主轴最佳综合刚度设计

超精密空气主轴的刚度是超精密主轴的一个非常重要的指标,轴承的结构形式、气膜结构参数均对刚度指标有影响。本文通过工程计算得到气膜刚度等参数后,在特定空间尺寸和重量的限制条件下,基于有限元进行Nanosys-600F五轴超精密机床的气浮主轴(C轴)机械结构设计,通过多次分析,得到了气浮主轴(C轴)最佳综合刚度结构参数。     

Impact of bending dies with different friction forms on forming force and quality of tubes manufactured by free bending technology

In the 3D free bending forming system, the bending die can be designed either in a sliding type or rolling friction type. Bending die-based sliding friction type is often called normal bending dies; however, the bending dies-based rolling friction type includes bending die-based roller type and ball type in structure. In the current study, the impact of three bending dies on the forming force, and the bent tube quality was investigated. The obtained results showed that the tangential stresses and strains of the tubes formed by the bending die-based roller type were the smallest among the three bending dies. Besides, the spherical bearing force P_U was reduced drastically after using the roller type and ball type compared to the sliding friction type. Moreover, the uniformity of the wall thickness distribution of the tubes formed by the roller type and ball type was better than those obtained from the sliding friction type. In addition, the cross-section distortion rate was reduced by 2.8% using the roller type, and 1.8% using ball-type compared to the sliding friction type.     

潜入式喷管喉衬界面间隙优化设计

为了解决固体火箭发动机潜入式喷管喉衬在热载荷与内压联合作用下界面间隙优化问题，数值模拟方法求解了喷管热结构响应。采用流体仿真软件，计算了潜入式喷管流动过程的稳态流场，获取了高温燃气流动参数与固体壁面对流换热系数。并采用三维有限元结构计算平台，编写了非均布壁面压力载荷与非均布对流换热系数子程序，求解了喉衬前后搭接界面间隙在0mm，0.05mm，0.10mm，0.15mm，0.20mm下喷管热结构耦合问题，获取了材料内部温度场与应力场分布。结果表明，喉衬环向压应力与拉应力都随时间增加，先增大后减小。其次，随间隙增大，喉衬拉应力先减小后增大，喉衬压应力先增大后减小。再次，依据界面闭合与喉衬环向受力最小的准则，确定了喉衬前后间隙的相对最优值，前间隙相对最优值0.10mm，后间隙相对最优值0.05mm。本文数值方法可为喷管热防护材料界面搭接与喉衬界面间隙设计提供指导，也可应用于评估喷管热防护与结构强度安全余量。     

叶片前缘仿形涡流检测仿真与试验设计

仿形涡流检测技术因其耦合性好可有效抑制检测过程晃动而特别适合对大曲率叶片前缘快速检测。针对涡轮叶片前缘仿形涡流检测建立前缘及仿形线圈有限元模型，运用有限元方法分析叶片前缘凹坑、长裂纹、边沿凹坑3种典型缺陷在内外两种激励、不同内径线圈、不同频率等模式下的检测信号特征。仿真结果表明：大曲率前缘实施仿形涡流检测，检测区域可有效覆盖整个前缘区域，检测频率越高，检测灵敏度越高。双线圈检测模式下，外激励内接收比内激励外接收灵敏高，当内检测线圈尺寸大于缺陷的尺度时，内接收线圈内径越小，其相对灵敏度越高。结合仿真结论，制作前缘缺陷试块，采用锁相放大及图形化编程技术，设计前缘仿形涡流检测系统，试验结果表明，仿形线圈可有效检出前缘典型缺陷，检测幅值相位输出结果与仿真结论相似。研究成果可用于指导大曲率叶片前缘的工程实践检测。     

Topology optimization in lightweight design of a 3D-printed flapping-wing micro aerial vehicle

Topology optimization is an effective method to obtain a lightweight structure that meets the requirements of structural strength. Whether the optimization results meet the actual needs mainly depends on the accuracy of the material properties and the boundary conditions, especially for a tiny Flapping-wing Micro Aerial Vehicle (FMAV) transmission system manufactured by 3D printing. In this paper, experimental and numerical computation efforts were undertaken to gain a reliable topology optimization method for the bottom of the transmission system. First, the constitutive behavior of the ultraviolet (UV) curable resin used in fabrication was evaluated. Second, a numerical computation model describing further verified via experiments. Topology optimization modeling considering nonlinear factors, e.g. contact, friction and collision, was presented, and the optimization results were verified by both dynamic simulation and experiments. Finally, detailed discussions on different load cases and constraints were presented to clarify their effect on the optimization. Our methods and results presented in this paper may shed light on the lightweight design of a FMAV.     

模块化永磁直线游标电机等效磁网络及漏磁分析

在模块化永磁直线游标电机的初始设计及优化设计中,使用有限元方法(FEM)计算漏磁系数时需要耗费大量的建模和计算时间。针对这一问题,建立该种电机的等效磁网络模型,在建模期间,考虑气隙中的边缘效应,并计算永磁体组与定子齿在不同相对位置时的等效磁导,得到该种电机在一个周期内不同相对位置时的漏磁磁导和漏磁系数的数学解析表达式。采用FEM验证了该数学解析表达式的准确性。研究结果为模块化永磁直线游标电机的设计提供了理论依据。     

紧凑型横向变焦系统关键器件的设计方法与功能验证

变焦系统可实现连续的光学变焦，可对不同景深的目标实现连续成像。在焦深延拓和光学检测等领域具有广泛地应用和发展潜力。本文提出了一种紧凑型可实现连续变焦功能的扁平化位相衍射元件，并设计分析和验证了横向调制相位型变焦衍射元件的功能。通过标量衍射基本理论模型，借助菲涅尔波带和多台阶相位衍射元件的设计方法，实现了横向变焦关键器件的设计仿真和实验验证。并以多波长响应的空间光调制器为基础，搭建了器件相位调制验证实验系统，通过测试证明了所设计器件的变焦能力，仿真和实验测试均可实现5倍变焦目标的有效调制。