飞机导管数字化生产线探讨

介绍了国内外飞机导管制造技术的现状。参考国外飞机导管数字化生产的先进经验,结合国内实际情况,提出了实现导管数字化生产线总体设想方案。在导管CATIA数据转换、智能工艺性审查、三维弯曲仿真、数控弯管、组合夹具设计与制造、导管数控测量、系统集成等方面提出了切实可行的实施途径。     

Cf/Al复合材料管件的真空液相成型工艺研究

以高模高强碳纤维M40J(6K)增强铝基复合管为研究对象，研究了真空反压液相浸渗工艺中，纤维束丝分散技术、预制件压缩强度提高技术及碳纤维涂层对管件成型及性能的影响。结果表明：SiCp可以起分散作用，有利于浸渍；加入10％的偏磷酸盐的预制件经680℃真空去胶后的压缩性能满足浸渗要求，纤维保持了较好的平直度且分布均匀。C-Al2O3涂层对复合材料的性能有较大影响，经涂层处理后的预制件所制备出的复合材料的强度比未经涂层处理的提高了13％左右。所制备的复合材料的比强度、比模量较高，密度小于2．5g／cm^3。     

Effect of tube-electrode inner diameter on electrochemical discharge machining of nickel-based superalloy

Nickel-based superalloys are widely employed in modern aircraft engines because of their excellent material characteristics, particularly in the fabrication of film cooling holes. How-ever, the high machining requirement of a large number of film cooling holes can be extremely chal-lenging. The hybrid machining technique of tube electrode high-speed electrochemical discharge drilling (TEHECDD) has been considered as a promising method for the production of film cooling holes. Compared with any single machining process, this hybrid technique requires the removal of more complex machining by-products, including debris produced in the electrical discharge machin-ing process and hydroxide and bubbles generated in the electrochemical machining process. These by-products significantly affect the machining efficiency and surface quality of the machined prod-ucts. In this study, tube electrodes in different inner diameters are designed and fabricated, and the effects of inner diameter on the machining efficiency and surface quality of TEHECDD are inves-tigated. The results show that larger inner diameters could effectively improve the flushing condi-tion and facilitate the removal of machining by-products. Therefore, higher material removal efficiency, surface quality, and electrode wear rate could be achieved by increasing the inner diam-eter of the tube electrode.     

Plastic deformation analysis and forming quality prediction of tube NC bending

Plane strain assumption and exponent hardening law are used to investigate the plastic deformation in tube bending. Some theoretical formulae including stress, curvature radius of neu-tral layer, angle of neutral layer deviation, bending moment, wall thickness variation and cross-section distortion, are developed to explain the phenomena in tube bending and their magnitudes are also determined. During unloading process, the springback angle is deduced using the virtual work principle, and springback radius is also given according to the length of the neutral layer which remains unchanged before and after springback. The theoretical formulae are validated by the experimental results or the validated simulation results in literature, which can be used to quickly predict the forming quality of tube numerical control (NC) bending.     

二维三轴编织复合材料压缩失效行为的细观有限元模拟

为研究典型二维三轴编织复合材料（2DTBC）的压缩破坏机理，建立了细观有限元模拟方法体系。提出了反映编织复合材料真实几何特性的单胞模型建模策略，根据Murakami-Ohno损伤理论建立了各向异性损伤模型来模拟纤维束中的损伤起始和扩展行为，通过引入波动系数描述了纤维束的起伏状态，并采用内聚力单元来模拟界面分层。在此基础上，分析得到了二维三轴编织复合材料在压缩载荷下的破坏过程，研究了压缩载荷下纤维束和界面层的损伤演化，探讨了纤维束波动对压缩性能的影响规律。通过与相关试验结果对比，该模型能够准确预测二维三轴编织复合材料在面内压缩载荷下的力学响应和主要失效行为，以及自由边效应。细观失效过程分析结果表明，二维三轴编织复合材料轴向压缩的破坏是由轴向纤维束的纤维压缩失效主导的；横向压缩破坏则是由偏轴纤维束的纤维压缩失效引起的。     

CATIA软件Tubing Design模块应用研究

本文系统研究了CATIA软件Tubing Design模块,建立了直升机基于特征的零部件库的建库方法及组织架构,确定了直升机管路系统设计、协同设计的一般原则.针对工程实际,提出了管路设计过程中零部件装配不必严格采用摆放规则的原则以及软管建模的新方法.     

横越两圆柱体的传热特性

用数值方法求解绕过两圆柱的对流传热问题。贝克列数在０－５０的范围内，了四种不同间距时的传热情况。从中发现两圆柱的传热特性相互有影响，这种影响随意距变化很敏感，两圆柱中任一个的平均谢尔特数总是小于单个圆柱的。并给出了简化计算的条件与公式。     

Zukauskas关系式用于微细管式预冷器适用性的评价与分析

为研究Zukauskas关联式在计算微细换热管束管外换热特性上的适用性,本文利用数值分析方法,在分析空气横掠微细管束换热特性基础上,发现空气横掠管束入口几排换热管的换热尤为强烈,温降过程沿着流动方向呈现由急变缓的特点,剧烈的温度变化造成Zukauskas关联式按照一般均物性方法计算时,计算结果偏高27%以上;对比分析可知,过于剧烈的温度变化使基于换热管束整体给出的对数平均温差作为平均换热温差的处理方法不再适用;根据空气温度变化的特点,按照流动方向将换热区域分成若干部分,再分别利用Zukauskas关联式计算,预测精度得到了极大改善,当换热区域划分成12部分时,平均计算偏差降为了5.8%,鉴于此,在计算骤冷条件下气体横掠管束换热特性时,建议采用适当的分区方法进行计算。     

CVI沉积炭纤维束的组织结构

采用CVI工艺在常压下对单束炭纤维进行热解沉积,天然气为前驱体,N2为载气,沉积温度为1 020～1 100℃,沿纤维束轴向分布。对不同位置炭纤维束外和束内热解炭组织结构分别进行PLM表征。研究发现,束外热解炭在距离热电偶(0位置)上方40～80 mm处沉积厚度达到最大,在0～80 mm内组织结构良好,主体为高织构;束内沉积热解炭的厚度较均匀,组织结构的变化与束外一致。对气体裂解过程中的反应气体组分进行模拟并与实验对比,发现生成高织构时,热解反应中间产物中的C2H2/C6H6范围为15～35。     

穿刺结构参数对C/C复合材料拉伸性能的影响

采用不同间距、不同根数的纤维束穿刺成型炭纤维预制体,经进一步化学气相沉积、沥青浸渍-高压炭化致密制备穿刺C/C复合材料。拉伸性能测试结果表明,穿刺间距2.1mm、穿刺束纤维根数为12K的C/C复合材料获得高的拉伸强度,Z向拉伸强度131.4MPa,XY向拉伸强度111.3MPa;随着穿刺间距减小、穿刺丝束纤维根数增加,Z向纤维含量增加,Z向拉伸强度明显提高。穿刺C/C复合材料1800℃真空条件下的拉伸强度与室温相当,拉伸模量低于室温,延伸率高于室温;常温拉伸断口较平整,且纤维/基体间的裂纹明显,而高温拉伸断口参差不齐,纤维及基体断面粗糙,呈现出假塑性断裂特征。