Effects of fiber orientation on tool wear evolution and wear mechanism when cutting carbon fiber reinforced plastics

The aim of the present paper is to reveal the influence of different fiber orientations on the tool wear evolution and wear mechanism. Side-milling experiments with large-diameter milling tools are conducted. A finite element (FE) cutting model of carbon fiber reinforced plastics (CFRP) is established to get insight into the cutting stress status at different wear stages. The results show that different fiber orientations bring about distinct differences in the extent, profile and mechanism of tool wear. Severer wear occurs when cutting 45° and 90° plies, followed by 0°, correspondingly, the least wear is obtained when θ = 135° (θ represents the orientation of fibers). Moreover, the worn profiles of cutting tools when θ = 0° and 45° are waterfall edge, while round edge occurs when θ = 135° and a combined shape of waterfall and round edge is obtained when θ = 90°. The wear mechanisms under different fiber orientations are strongly dependent on the cutting stress distributions. The evolution of tool wear profile is basically consistent with the stress distribution on the tool surface at different wear stages, and the extent of tool wear is determined by the magnitude of stress on the tool surface. Besides, the worn edges produce an actual negative clearance angle, which decreases the actual cutting thickness and leads to compressing and bending failure of fibers beneath the cutting region as well as low surface qualities.     

间隙连接对胶接接头应力分布和强度的影响

运用弹塑性有限元法结合实验研究了连续和间隙连接的单搭接接头应力分布规律，并考虑了胶瘤的影响。结果表明，在相当大间隙长度范围内和适当的间隙位置条件下，间隙连接接头并没有大幅度地减小其承载能力，相反其有效搭接区域剪切强度呈明显升高趋势；胶层应力峰值仍然发生在搭接末端；胶瘤承担了相当大的载荷作用；过大的间隙长度以及不当的间隙位置会导致胶层靠近间隙端应力集中明显加剧，成为新的高应力区，可能导致接头破坏模式的改变。实验结果与数值分析结果很好地吻合。     

飞机空气配平系统应力补偿及校核分析

以某型飞机空气配平系统为研究对象,在分析空气导管结构布置、工作条件、材料物性等基础上,基于梁单元应力计算软件CAEPIPE对导管系统应力和位移分布进行仿真,并据此进行补偿设计与优化.同时,对于支撑部件等应力集中区采用MD NASTRAN有限元分析软件进行三维应力校核,获得关键部位的三维应力分布云图.该研究工作对于我国飞机空气导管系统的设计优化具有参考价值.     

TC4的铣削加工中铣削力和刀具磨损研究

通过TC4铣削加工时的铣削力试验,研究了干切削时和有氮气介质铣削时影响铣削力大小的几个因素,为提高金属去除率优化了切削参数。同时通过刀具磨损试验,对上述两种铣削方式,比较了在不同的切削速度下铣削时铣刀后刀面的磨损,证实了以氮气为切削介质能够大大地改善刀具的磨损状况和提高刀具的寿命。     

基于分子运动模拟的微喷管流体流动

深入研究微喷管内流场性能有助于微推进系统的优化设计.在高克努森数条件下,运用直接模拟蒙特卡罗方法模拟微喷管流动过程,对不同入口温度下的拉伐尔喷管流场进行二维数值模拟,模拟结果表明随着入口流体温度的升高,由于黏性力的增强,微喷管的推力减小而比冲增大.对微喷管的三维数值模拟表明,推力效率随着喷管蚀刻深度的减少而降低,微喷管蚀刻深度的增加将使三维壁面边界的影响降低.      

基于变域变分有限元的翼型反设计

反问题作为一种自由(未知)边界问题近年来得到了广泛的研究。变域变分通过把自由边界结合在变分泛函中，使其与求解流场的控制方程结合起来，从而自由边界求解和流场分析可以完全耦合进行。本文采用变域变分和可变形有限元来设计可压缩和不可压缩翼型，计算显示即使在初始翼型的一侧为三角形时仍能得到满意的结果。文中还采用了两种计算网格(H型和O型)来设计翼型，比较了它们的精度，计算表明本方法完全能用于翼型的反设计。     

同步发电机动态特性仿真方法研究

介绍了同步发电机基于电路模型的动态仿真方法,指出了应用它在分析同步发电机动态特性时具有的优点。     

Impact of aperture on dynamic response of sandwich plates with aluminium face-sheets and PMI core based on an alternative finite element formulation and experiments

Apertures generally exist in the sandwich structures attributing to mechanical connection and lightweight, which might induce failure of such structures. Thus, it is required to realize the impact of aperture on mechanical behaviors of sandwich structures. If transverse shear deformations are unable to be described accurately, the reasonable prediction of dynamic behaviors of the form-core sandwich plates with apertures will meet severe challenges due to a large difference of transverse shear mo...     

基于域对抗门控网络的变工况刀具磨损精确预测方法

刀具磨损的精确预测对保证零件加工质量、提高生产效率和降低制造成本具有重要作用。在实际加工过程中,切削参数、刀具几何参数、刀具材料等工况复杂多变,工况信息和刀具磨损量对监测信号的耦合作用为刀具磨损的精确预测带来了很大挑战。针对以上问题,提出了一种基于域对抗门控网络（DAGNN）的变工况刀具磨损精确预测方法。引入工况分类网络并利用无磨损量标签样本,通过域对抗和门控过滤机制自适应地从不同工况的原始监测信号中提取表征刀具磨损且对工况变化不敏感的关键信号特征。对信号特征提取网络和刀具磨损预测网络进行迭代优化,从而实现变工况刀具磨损的精确预测。实验结果表明：相比已有的方法,本文方法能够利用少量带磨损量标签的目标工况样本实现刀具材料和刀具直径变化情况下的刀具磨损量精确预测,预测精度大幅提高。     

减压器动态仿真的有限体积模型

通过对一维理想气体流动的有限元状态变量模型推导过程的拓展，获得了适用于变体积容腔的气体容积模型，并结合气体管道、气体阀门的有限元状态变量模型，通过对三者的组合运用发展了一种可仿真气体减压器动态工作过程的有限体积模型。采用此模型分别对某逆向卸荷膜片式减压器和某贮箱增压系统所用减压器进行了动态工作过程的仿真，前者仿真结果的稳态值与早期文献的实验数据和仿真结果相一致。表明有限体积模型的稳态精度合乎工程需要；后者的仿真获得了减压器各个腔室状态参数和阀芯开度的响应曲线，表明贮箱增压过程可以分为启动段、稳定段两个阶段，同时表明在理想气体绝热流动的假设下节流前后温度基本不变。数学模型和建模方法显示出良好的有效性和通用性。     

Full-scale crash test and FEM simulation of a crashworthy helicopter seat

Crashworthy seat structure with considerable energy absorption capacity is a key component for aircraft to improve its crashworthiness and occupant survivability in emergencies.According to Federal Aviation Administration(FAA) regulations,seat performance must be certified by dynamic crash test which is quite expensive and time-consuming.For this reason,numerical simulation is a more efficient and economical approach to provide the possibility to assess seat performances and predict occupant responses.A numerical simulation of the crashworthy seat structure was presented and the results were also compared with the full-scale crash test data.In the numerical simulation,a full-scale three-dimensional finite element model of the seat/occupant structure was developed using a nonlinear and explicit dynamic finite element code LS-DYNA3D.Emphasis of the numerical simulation was on predicting the dynamic response of seat/occupant system,including the occupant motion which may lead to injuries,the occupant acceleration-time histories,and the energy absorbing behavior of the energy absorbers.The agreement between the simulation and the physical test suggestes that the developed numerical simulation can be a feasible substitute for the dynamic crash test.      

航空发动机TC4机匣加工变形控制研究

航空发动机机匣零件的设计采用整体化、轻量化设计思想,使得结构复杂、规格尺寸大、薄壁特征多,而设计精度要求却在逐渐提高,机匣件加工后产生的变形问题尤显突出。探讨了薄壁结构机匣零件加工变形产生机理,提出分区去除余量控制加工变形的方法。使用Prism电子斑纹干涉钻孔残余应力仪测量了钛合金TC4机匣毛坯表层深度残余应力,通过有限元仿真结果预测出机匣毛坯内部残余应力分布规律。建立了机匣切削加工的有限元仿真模型并进行数值仿真,对两种工艺路线下的变形进行对比分析。最后,通过机匣的切削加工试验验证了仿真结果的正确性。     

Optimization on cooperative feed strategy for radial–axial ring rolling process of Inco718 alloy by RSM and FEM

During radial–axial ring rolling process,cooperative strategy of the radial–axial feed is critical for dimensional accuracy and thermo mechanical parameters distribution of the formed ring.In order to improve the comprehensive quality of the ring parts,response surface method(RSM) is employed for the first time to optimize the cooperative feed strategy for radial–axial ring rolling process by combining it with an improved and verified 3D coupled thermo-mechanical finite element model.The feed trajectory is put forward to describe cooperative relationship of the radial–axial feed and three variables are designed based on the feed trajectory.In order to achieve multiobjective optimization,four responses including thermo mechanical parameters distribution and rolling force are proposed.Based on the FEM results,RSM is used to establish a response model to depict the function relationship between the objective response and design variables.Through this approximate model,effects of different variables on ring rolling process are analyzed connectedly and optimal feed strategy is obtained by resorting to the optimal chart specific to a constraint condition.     

超声速和高超声速横向喷流数值模拟

为了解横向喷流的干扰影响和喷口附近的流场结构,采用分块对接网格和“0”型网格技术,数值求解N—S方程来模拟超声速和高超声速流场中横向喷流的干扰流场。对两种尖拱弹身外形的超声速和高超声速喷流干扰流场进行了数值计算,计算结果与风洞实验数据吻合一致。在此基础上,开展了某型导弹多喷构型干扰流场的数值模拟,得出一些横向喷流数值模拟的结论。     

前缘对进气道性能影响的数值模拟

应用质量平均的N-S方程和B-L代数湍流模型，在不同压缩面前缘半径条件下，以高超声速进气道的流场进行了数值模拟，对比研究了进气道压前缘半径对流场结构及性能的影响，在计算过程中，对方程中的对流项采用了空间为二阶精度的TVD格式，扩散项则采用了二阶中心差分离散。     

基于VERICUT刀具切削参数关系的研究及优化

本文通过对刀具切削参数进行分析研究,同时对VERICUT的优化原理进行了探索,建立了基于VERICUT刀具切削参数的优化模型,分析多种不同的优化方法。最后通过实例分析了基于VERICUT优化设计的过程,最终优化并改进不合理的加工轨迹,避免了实际加工过程中可能出现的异常现象,提高了数控机床加工功能和设计效率,时间减少了17．52％,降低了新产品研发的成本。     

基于加工误差仿真的半球谐振子优化设计

针对半球谐振陀螺谐振子制造过程中存在的加工误差,采用有限元仿真,分析了半球谐振子结构参数、尺寸公差和形位公差变化对其工作模态频率和临近模态频率的影响,研究了半球谐振子形位公差变化对频率裂解和品质因数的影响。通过仿真分析可知,半球谐振子结构参数壁厚、半球中心半径及内倒角半径都会影响模态频率;半球谐振子形位公差中的内外球心距离误差对其工作模态影响较大,中心轴平行误差对频率裂解和品质因数影响较大;半球谐振子壁厚、内倒角半径、小柱半径及内外球心距离误差变化会使工作模态频率与相邻模态间存在干扰。在此基础上,提出了半球谐振子结构参数及形位公差优化设计建议,并通过半球谐振子品质因数Q值和频率裂解测量对该建议进行了验证。     

固体火箭发动机药柱伞盘结构应力应变分析

应用三维粘弹性有限元分析方法,分析了某固体火箭发动机药柱在低温载荷作用下的应力应变场,讨论了前伞盘曲面形式、宽度和深度对该部位最大Von Mises应变值的影响。在此基础上,通过调整前伞盘顶端双圆弧曲面结构的半径比,在基本不减少装药量的前提下,有效降低了该处最大Von Mises应变值,并初步确定了最佳半径比的范围,所得结论可为固体火箭发动机装药设计提供定量参考。     

Drop test and crash simulation of a civil airplane fuselage section

Crashworthiness of a civil airplane fuselage section was studied in this paper. Firstly, the failure criterion of a rivet was studied by test, showing that the ultimate tension and shear failure loads were obviously affected by the loading speed. The relations between the loading speed and the average ultimate shear, tension loads were expressed by two logarithmic functions. Then, a vertical drop test of a civil airplane fuselage section was conducted with an actual impact velocity of6.85 m/s, meanwhile the deformation of cabin frame and the accelerations at typical locations were measured. The finite element model of a main fuselage structure was developed and validated by modal test, and the error between the calculated frequencies and the test ones of the first four modes were less than 5%. Numerical simulation of the drop test was performed by using the LS-DYNA code and the simulation results show a good agreement with that of drop test. Deforming mode of the analysis was the same as the drop test; the maximum average rigid acceleration in test was 8.81 g while the calculated one was 9.17 g, with an error of 4.1%; average maximum test deformation at four points on the front cabin floor was 420 mm, while the calculated one was 406 mm, with an error of 3.2%; the peak value of the calculated acceleration at a typical location was 14.72 g, which is lower than the test result by 5.46%; the calculated rebound velocity result was greater than the test result 17.8% and energy absorption duration was longer than the test result by 5.73%.     

An allowance allocation method based on dynamic approximation via online inspection data for deformation control of structural parts

Deformation resulting from residual stress has been a significant issue in machining. As allowance allocation can directly impact the residual stress on part deformation, it is essential for deformation control. However, it is difficult to adjust allowance allocation by traditional simulation methods based on residual stress, as the residual stress cannot be accurately measured or predicted,and many unexpected factors during machining process cannot be simulated accurately. Different from tradit...