The role of test in total quality management

The quality of a delivered product or system is ultimately limited by the quality of its design and manufacturing process. Defects that escape the design, manufacturing, and test processes are delivered to customers. Process Potential Index (Cp) and Process Capability Index (Cpk) are now widely used to express design and manufacturing quality. Design quality may be estimated from product models, if they exist, or measured using parameter test data. The difficulty in using test data is not so much in the calculations, but in the recording, storing, and selection of the data to be used in the calculations. This paper defines the metrics of quality estimation and describes an implementation of a system for estimating defect levels and process capabilities. The implementation includes the definition of a standardized parametric data exchange language for test data and an analytical system to standardize product quality measurement     

Collaborative manufacturing technologies of structure shape and surface integrity for complex thin-walled components of aero-engine: Status,challenge and tendency

Presently, the service performance of new-generation high-tech equipment is directly affected by the manufacturing quality of complex thin-walled components. A high-efficiency and quality manufacturing of these complex thin-walled components creates a bottleneck that needs to be solved urgently in machinery manufacturing. To address this problem, the collaborative manufacturing of structure shape and surface integrity has emerged as a new process that can shorten processing cycles, improve machining qualities, and reduce costs. This paper summarises the research status on the material removal mechanism, precision control of structure shape, machined surface integrity control and intelligent process control technology of complex thin-walled components. Numerous solutions and technical approaches are then put forward to solve the critical problems in the high-performance manufacturing of complex thin-wall components. The development status, challenge and tendency of collaborative manufacturing technologies in the high-efficiency and quality manufacturing of complex thin-wall components is also discussed.     

小孔节流静压轴承多目标模糊优化设计

在静压轴承的设计中，有许多设计参数属于模糊变量，而且有许多模糊因素（如设计水平、制造水平、材质优劣等）也影响设计结果。为解决这些问题，寻求静压轴承的最佳设计方案，本文推导出小孔节流静压轴承模糊约束多目标优化数学模型，阐述了应用最优水平截集法和扩增系数法，通过二级模糊综合评判，将模糊约束多目标优化问题逐步转化为普通约束单目标优化问题，最后用复合型法求出静压轴承最优解的全部过程，为静压轴承的设计提供了一套更符合客观实际的切实可行的多目标优化方法。     

一种面向飞机制造和维护的质量风险识别与评估方法

各飞机制造厂一直在努力减少飞机制造与使用维护过程中的质量安全事件。单纯使用生产制造阶段的过程故障模式影响分析（PFMEA）方法进行质量风险识别与评估时,存在分析不包含飞机使用维护过程、失效模式识别率和准确性不高、建议措施不完善等问题。提出质量风险识别与评估方法,将制造过程PFMEA 范围拓展到使用、维护过程,并以设计故障模式影响分析（DFMEA）作为PFMEA 的输入,以扩大分析范围,改善失效模式的识别率和准确性;使用树形分析图方法对风险控制措施进行覆盖性和重复性分析,获得完整、最简措施集。使用该方法对某液压系统一根液压泵循环散热导管进行分析,结果表明：本文提出的方法可以更全面、更准确地分析飞机制造与使用维护过程中的质量风险,获得更为优化的质量风险控制措施集合。     

拓扑优化与增材制造结合:一种设计与制造一体化方法

被誉为"第三次工业革命"的增材制造技术通过材料层层累加的方式实现结构的制备,这种独特的制造方式实现了高度复杂结构的自由"生长"成形,极大地拓宽了设计"空间",为新型结构及材料的制备提供了强大的工具。制造工艺的飞速发展往往需要设计技术的快速跟进,拓扑优化方法因其不依赖初始构型及工程师经验,可获得完全意想不到的创新构型,已成为结构创新设计的重要工具。因此,将拓扑优化(先进设计技术)与增材制造(先进制造技术)融合,发展面向增材制造的创新设计技术具有广阔的前景。从面向增材制造的优质结构构型设计以及考虑增材制造工艺约束的拓扑优化设计方法两个方面,介绍了现阶段基于拓扑优化方法所建立的结构创新设计理论,并指出未来研究的趋势。     

浅议精密惯性产品制造中的增材制造

惯性技术已经成为国防及国民经济建设各行业中运动信息感知测量的核心技术.但是制造环节却成为制约其精度提高、性能改善、效率提高、成本降低的“黑障”,困扰着惯性技术再进步的步伐.刚刚兴起却迅猛发展的三维数字化增材制造(3D打印)技术彻底颠覆了传统制造,从装备到工艺、从材料到设计的理念,对制造业形成了革命性的冲击.以惯性技术产品三维数字化增材制造为目标,详细叙述了三维数字化增材制造的概念,国内外发展现状和其在精密惯性技术产品制造中的可能性、可行性和推动惯性技术产品制造变革的价值;并根据近几年对三维数字化增材制造的一些学习认知、实践感悟,提出了一些三维数字化增材制造在精密惯性技术产品制造中应用的粗浅看法和思路,以求共进.     

以损失函数为基础的驾驶姿势不便度评价

为了将人体模型运用于汽车开发,引入了损失函数的概念并开发了姿势函数。有关姿势的‘损失’是测定各种姿势下所感到的不适度而给出的定义。按膝盖、臀部(身躯)、肩膀、肘部4个关节各导出了损失函数,而且为了预测驾驶员可能综合地感到的姿势不适度以各个损失函数值为独立变量导出了姿势函数。在对姿势不适度的推定正确度方面评价导出函数的适应性结果,已确认了能得出与实际值非常相似的值,有望应用于车辆的设计。     

Data-driven reliability analysis of Boeing 787 Dreamliner

The Boeing 787 Dreamliner, launched in 2011, was presented as a game changer in air travel. With the aim of producing an efficient, mid-size, wide-body plane, Boeing initiated innovations in product and process design, supply chain operation, and risk management. Nevertheless, there were reliability issues from the start, and the plane was grounded by the U.S. Federal Aviation Administration (FAA) in 2013, due to safety problems associated with Li-ion battery fires. This paper chronicles events associated with the aircraft’s initial reliability challenges. The manufacturing, supply chain, and organizational factors that contributed to these problems are assessed based on FAA data. Recommendations and lessons learned are provided for the benefit of engineers and managers who will be engaged in future complex systems development.     

基于普通车床的微V型槽飞切装置分析与设计

通过对飞刀轴的强度、刚度和振动模态的分析,设计制作了基于普通车床的飞切装置.并采用PCD成形车刀在铝材料上进行了飞切加工V型槽的实验.测试结果证明了该飞切装置的可用性,为生产实践提供了必要的技术参考与装备,并为进一步分析飞切理论打下了基础.     

Review on residual stress and its effects on manufacturing of aluminium alloy structural panels with typical multi-processes

In the aerospace industry, integrated aluminium alloy plates and stiffened panels with high accuracy and performance attract significant interest. To manufacture these panels as integrity with high accuracy, multiple processes need to be utilised, such as machining, welding and forming. During the whole manufacturing chain, residual stresses can be generated and redistributed in the components among different processes. The residual stress would significantly affect the shapes and properties of the final products. Currently, these great effects are not well considered in the design and manufacturing processes. This paper aims to draw a general understanding of the residual stress generated in the pre-manufacturing processes and its effects on subsequent manufacturing processes. The mechanisms and distributions of residual stresses generated in typical pre-manufacturing processes of structural panels, including machining, welding and additive manufacturing (AM), are firstly summarised. The detailed effects of generated residual stresses on distortion and application properties in subsequent manufacturing processes are then concluded. In addition, current methods developed for the investigation of residual stress effect in multi-processes manufacturing are critically reviewed, including experimental, analytical, finite element (FE) and machine learning methods. Furthermore, the future development trend of methods for residual stress consideration and control in the design of manufacturing processes is summarised, providing comprehensive guidance to achieve the high accurate manufacturing of aluminium alloy structural components.     

虚拟制造技术在飞机设计与制造中的应用

虚拟制造技术可以在产品设计阶段对产品的整个生命周期进行建模、仿真和优化,从而更加高效、经济、灵活地组织生产,达到了缩短产品研发周期、降低研发成本、优化产品质量和提高生产效率的目的。介绍了虚拟制造技术的含义、特点及国内外应用概况;综述了虚拟制造技术在航空制造业的应用,包括飞机虚拟设计、零件虚拟制造、部件虚拟装配和生产线规划等方面应用的成功案例,从而展示应用虚拟制造技术的意义;最后,总结了虚拟现实技术在飞机设计与制造过程中被广泛应用的发展现状,并且展望了虚拟制造技术的发展及应用前景。     

Data mining technology for failure prognostic of avionics

Adverse environmental conditions have combined cumulative effects leading to performance degradation and failures of avionics. Classical reliability addresses statistically-generic devices and is less suitable for the situations when failures are not traced to manufacturing but rather to unique operational conditions of particular hardware units. An approach aimed at the accurate assessment of the probability of failure of any avionics unit utilizing the known history-of-abuse from environmental and operational factors is presented herein. The suggested prognostic model utilizes information downloaded from dedicated monitoring systems of flight-critical hardware and stored in a database. Such a database can be established from the laboratory testing of hardware and supplemented with real operational data. This approach results in a novel knowledge discovery from data technology that can be efficiently used in a wide area of applications and provide a quantitative basis for the modern maintenance concept known as service-when-needed. An illustrative numerical example is provided     

电子束熔丝增材制造过程随动测温阵列系统

实时监测电子束熔丝增材制造过程的温度场分布对于抑制变形、提高电子束熔丝增材制造质量具有重要意义.研制了一套电子束熔丝增材制造过程的随行动态测温阵列系统,对整个装置进行了系统设计、硬件集成、软件编写和试验验证.结果表明,该随动测温阵列系统在电子束熔丝增材制造过程的高真空、高温、高辐射、高金属蒸气等恶劣环境中能稳定工作,不...     

Improving the productivity of complex electronic systems design byutilizing applied design methodologies

The design process of complex electronic systems consists of four traditional main stages, which are system design, electronic design, mechanical design, and design for manufacturing. Even today when many integrated computer aided design environments are in use for electronic systems design, we still seem to accept that the design process really has to follow this path of four individual design stages. It is common that we are dealing with data transfer problems between different types of CAE-applications. However, there is a possibility to avoid the disadvantages due to integration problems between the design stages if we decide to develop the design methodology itself instead of developing those independent software applications. One effective way to improve the productivity of complex electronic systems design is to tune the so-called systematic design approach by adding special aspects of electronic systems design into the questionnaires used for collecting the requirement lists for further mechanical design and DFM. Another important tool is the carefully made manufacturability analysis. The deep interaction of mechanical and electronic design, extended by manufacturability analysis can also lead to innovative solutions as presented previously by the author. In the article entitled “Manufacturability Analysis-A Useful Subset of Systems Engineering” we were able to show that the number of iteration cycles during the different design and manufacturing stages could be reduced by 50% compared to the conventional design methodology. In this paper, we illustrate additional tools to continue this promising development work     

直升机结构设计的三维虚拟装配技术应用分析

虚拟现实技术通常被认为是三维计算机图形学在先进的输入和输出设备支持下的一种自然延生和增强。这项技术最近已发展成熟足以可保证应用于实际工程中。这项新技术和工程、设计及制造的软件系统的集成将对计算机辅助工程领域起着新的推动作用。深受虚拟现实技术影响的设计和制造领域中的一个重要方面就是装配设计。本文着重介绍此项技术概念以及如何运用到直升机结构装配设计中,及如何产生一个虚拟装配设计环境。     

复合材料制造过程仿真技术综述

复合材料制造过程仿真技术的有效应用可以在复合材料构件设计之初对其制造过程中可能出现的缺陷,如分层、孔隙、温度不均、变形等问题进行预测,从而为优化构件结构、调整工艺参数或模具型面提供依据。对目前复合材料设计制造领域常用的一些软件进行简要介绍,并针对目前复合材料制造过程温度场分布和固化变形仿真技术中存在的问题进行了阐述与讨论。     

一种智能防错的辅助人工作业系统开发与应用

针对航空制造业人工装配出现的操作易出错、效率低、培训成本高、质量不稳定等问题,开发了一种辅助人工作业系统,通过投影指示、体感摄像、触摸显示等方式来辅助人员装配。同时对于作业引导、零件选取、螺钉拧紧等易出现问题进行了智能防错设计。通过一种航空机载机电产品的手工装配工程应用,实现了装配过程的辅助引导监控,提高人工装配的质量和效率。     

TWT Reliability in Space

The question of Traveling Wave Tube (TWT) reliability in space poses some unique problems. First, since tube reliability has a tremendous impact on system design and overall cost, if problems do occur, they are highly visible. Second, attaining high reliability is made difficult by small production runs and short delivery schedules. Finally, the now-common 10 year life specification is combined with state-of-the-art performance requirements, forcing design changes and adding risk. To meet these requirements, we emphasize certain design and manufacturing ground rules. When orbital TWT problems do occur, our experience is that they are usually caused by infant mortality, not wearout. Data based on operation in space show that with close attention to the details of design and manufacturing, reliability exceeding the 500,000 hours MTBF normally specified is achieved. Traveling Wave Tube reliability and overall performance have a tremendous impact on system design and the overall cost of a satellite. TWT reliability determines the amount of redundancy needed to meet a given satellite mission objective. Increased redundancy means increased complexity and weight of the spacecraft. The TWTs, with their Electronic Power Conditioners, also dissipate over 80% of all spacecraft power. Increased tube efficiency will therefore simplify matters all around. Because of the critical impact of tubes, if technical problems do occur, they are highly visible at the system level, where rumors of failure spread like wildfire in the fairly small space community. Attaining high reliability is difficult because of the many conflicting requirements.     

面向增材制造的拓扑优化技术发展现状与未来

增材制造技术通过材料逐层打印制备结构,为复杂构件制造提供了新的成形方式。拓扑优化因不依赖于初始构型的选择,可设计出传统理念难以获得的创新构型,已成为航空航天和高端装备领域高性能、轻量化结构设计的重要手段。拓扑优化与增材制造有机融合,充分发挥各自优势和潜力,在现代制造业中展现出广阔应用前景。回顾了近年来关于增材制造与拓扑优化技术融合研究的主要内容和应用成果,包括以材料结构一体化为核心的多尺度/多层级结构优化设计、以设计制造一体化为核心的考虑增材制造工艺约束的优化方法等。同时,也分析了未来研究工作中存在的问题与挑战,如点阵结构性能表征及其尺度关联效应、增材制造材料成形各向异性、功能梯度材料与结构、增材制造材料与结构疲劳特性等对设计方法和成形工艺带来的挑战,为未来相关研究工作和航空航天应用提供参考。     

UG NX 平台模型质量检查应用与扩展技术研究

CAD模型质量检查是通过有效的机制检查数据模型发现不符合标准、规范的问题,并及时地处理解决以提高产品的设计制造质量。详细研究了主流CAD平台的模型检查模块,针对NX平台具体分析其模型质量检查Check-Mate机制,发掘应用Check-Mate基于知识工程进行知识获取、封装和扩展的功能。结果表明:基于Teamcenter PDM平台实现的应用和扩展技术方案可有效提高模型质量,保证模型知识数据的有效性。