Improving the process forming limit considering forming defects in the transitional region in local loading forming of Ti-alloy rib-web components

The isothermal local loading forming technology provides a feasible way to form Ti-alloy large-scale rib-web components in aerospace and aviation fields.However,the local load ing process forming limit is restricted by forming defects in the transitional region.In this work,the feasibility of controlling forming defects and improving the process forming limit by adjusting die parameters is explored through finite element (FE) simulation.It is found that the common cavum and folding defects in the transitional region are significantly influenced by the fillet radii of left rib and middle rib,respectively.The cavum and folding defects can be effectively controlled by increas ing the fillet radii of left rib and middle rib,respectively.The process forming limits considering forming defects in the transitional region are determined by the stepwise searching method under various die parameters.Moreover,the relationship between the process forming limit and die parameters is developed through the response surface methodology (RSM).The developed RSM models suggest that increasing the fillet radii of left and middle ribs is effective to improve the pro cess forming limit during local loading forming of rib-web components.The results will provide technical basis for the design of die parameters and the reduction amount,which is of great impor tance to control forming defects and improve the process forming limit in local loading forming of Ti-alloy large-scale rib-web components.     

航空发动机主轴滚子轴承非典型失效机理

针对某航空发动机圆柱滚子轴承的非典型失效问题，基于滚动轴承动力学理论，考虑滚子动不平衡量及滚子与套圈挡边间的碰摩，建立高速圆柱滚子轴承的动力学微分方程组，采用预估-校正GSTIFF（Gear stiff）变步长积分算法进行求解，分析了轴承工况参数和结构参数对动不平衡滚子的最大歪斜角和滚子与挡边最大碰撞力的影响。结果表明：滚子最大歪斜角和滚子与挡边最大碰撞力大小随滚子动不平衡量、轴承内圈转速增加而增大，与径向载荷间未表现出明显的相关性；较小的轴向游隙能够有效抑制滚子歪斜，但会增大滚子与挡边碰撞力，存在合理的轴向游隙范围使得在滚子歪斜角不会过大的情况下滚子与挡边碰撞力较小；较小的保持架兜孔周向游隙与挡边负背角和较大的滚子球端面半径能够减小滚子最大歪斜角和滚子与挡边最大碰撞力。     

带斜孔肋大宽高比矩形通道的强化传热特性

为了获得带斜孔肋大宽高比矩形通道的强化传热特性,并寻求最佳的孔排倾斜角度,调节孔排倾斜角度和通道雷诺数,使其分别在0°~30°和3×104~9×104范围内变化,通过数值计算系统分析了通道摩擦因数和带肋壁努塞尔数等参数的变化规律.研究发现:相比于常规肋片,新型斜孔肋有效改善了肋片后方紧邻肋片的局部区域的壁面换热,并降低通道的摩擦因数,但传热增强因子有所减小;随着孔排倾斜角度的增大,通道的相对摩擦因子单调升高,传热增强因子则呈现出先升高后降低的变化过程,因此存在着最优孔排倾斜角度为15°,此时斜孔肋的强化传热综合指标达到最大值;随着通道雷诺数的增大,斜孔肋通道的摩擦因数小幅减小,换热则逐渐增强.      

Plastic wrinkling model and characteristics of shear enforced Ti-alloy thin-walled tubes under combination die constraints and differential temperature fields

Plastic wrinkling predictions and shear enforced wrinkling characteristics of Ti-alloy thin-walled tubes under combination die constraints have become key problems urgently in need of solutions in order to improve forming quality in their shear bending processes under differential temperature fields. To address this, a wrinkling wave function was developed by considering their shear bend deformation characteristics. Based on this wave function and the thin shell theory, an energy prediction model for this type of wrinkling was established. This model enables considera-tion of the effects of shear deformation zone ranges, material parameters, loading modes, and fric-tion coefficients between tube and dies on the minimum wrinkling energy. Tube wrinkling sensitive zones (WSZs) can be revealed by combining this wrinkling prediction model with a thermal-mechanical coupled finite element model for simulating these bending processes. The reliability of this wrinkling prediction model was verified, and an investigation into the tube wrinkling char-acteristics was carried out based on the experimental conditions. This found that the WSZs are located on either a single side or both sides of the maximum shear stress zone. When the friction coefficients between the tube and the various dies coincide, the WSZs are located on both sides. The larger the value of the tube inner corner radius and/or the smaller the value of the outer corner radius, the smaller the wrinkling probability. With an increase in the value of the moving die dis-placement, the wrinkling probability increases at first, and then decreases.     

楔形扰流柱通道流动与传热特性

针对处在高速旋转(哥氏力、离心力以及诱导产生的浮升力)状态下的涡轮转子叶片尾缘独特的几何结构(带扰流柱的楔形通道)和特殊的流动方式(径向进气侧向出流),采用实验的方法在实际工况参数范围内对其传热和流阻特性进行了详细研究:雷诺数和旋转数的变化范围为20 000~45 000、0~0155。实验结果表明:扰流柱的存在使得径向区域底部的滞止区域变大,但这也让中部传热有明显的提升;流阻和综合传热系数的比光滑参数随着雷诺数的增加而下降;旋转对顶部传热有增强作用,底部传热减弱;总地来说旋转使得通道的平均传热减弱,流阻增加,综合传热系数下降。      

底部封闭倾斜细管内沸腾临界热流密度的实验

用实验方法对浸没在饱和液体中的底部封闭倾斜细管内的沸腾临界热流密度进行了实验研究,考察了管内径,管长,倾斜角和工质对临界热流密度的影响。实验条件是:加热管内径2.1 mm,3.2 mm和4.0 mm 3种;管长100 mm和300 mm两种;倾斜角从90°到0°。实验工质为水和R-113两种液体。本文考虑倾斜角对重力的影响,对前人提出的用于预示底部封闭垂直管内沸腾临界热流密度的半理论半经验式进行了修正。修正后的公式能较好的预示倾斜角对沸腾临界热流密度的影响。      

捕获型线对内转式进气道外压段几何与气动特性的影响

以直内收缩锥流场为基准流场,构建了一套内转式进气道外压段的设计与性能快速分析程序.进而以矩形捕获型线为例,研究了决定捕获型线形状、位置的3个参数(中心距、旋转角和宽高比)对进气道外压段几何与气动特性的影响,将捕获型线为矩形、带圆角矩形及圆形时的外压段进行了对比.结果表明:捕获面平均半径是可作为评价外压缩段设计的一个重要几何参数,平均半径越大,总压恢复系数越高;对于矩形捕获型线而言,当中心距增加时,前缘长度、弧长、湿润面积单调增加,外收缩比单调减小,而旋转角和宽高比对外压段几何参数的影响比较复杂;在矩形捕获型线的3个参数中,中心距对总压恢复系数的影响最显著.此外,当捕获型线的中心距与面积保持不变时,圆角半径对外压段几何与性能参数影响不大.      

流路参数对收扩喷管内流特性影响的数值研究

用经冷态缩比模型内流特性试验验证的三维有黏定常程序,对某轴对称收扩喷管进行了收敛调节片长度、喉道圆弧半径、扩张调节片长度和喷管扩张面积比对内流特性影响规律的计算研究.研究结果表明:收敛调节片长度和喉道圆弧半径主要是对收敛半角较大工况的流量系数有一定的影响,可以在确保收敛半角小于45°前提下适当减小收敛调节片长度;扩张调节片长度和喷管扩张面积比主要是对推力系数影响较大,扩张调节片长度和喷管扩张面积比的选择应在确保扩张半角小于16°前提下力争气流完全膨胀.      

弧线齿面齿轮齿面几何设计及径向齿宽特性

为适应航空领域对面齿轮传动的设计要求,综合弧线齿圆柱齿轮、面齿轮传动的各项优点,提出了弧线齿面齿轮齿面设计并研究了其径向齿宽特性。以端面渐开线齿廓弧线齿圆柱齿轮作为产形齿轮通过包络成形建立面齿轮齿面数学模型;结合齿面方程在MATLAB中进行齿面可视化分析,并通过MATLAB软件的数值计算和CATIA软件的复杂曲面造型实现面齿轮的参数化建模;确立内端根切、外端顶尖对径向有效齿宽的限制条件,计算面齿轮的径向有效齿宽,分析刀具齿轮的齿线圆弧半径和坐标系位置参数对径向有效齿宽的影响。研究表明:当增大齿线的圆弧半径,面齿轮的内径减小,外径、径向有效齿宽均增大;当增大坐标系位置参数,面齿轮的内径、外径均增大,径向有效齿宽减小。      

Interference and grinding characteristics in ultra-precision grinding of thin-walled complex structural component using a ball-end grinding wheel

As for ultra-precision grinding of difficult-to-process thin-walled complex components with ball-end grinding wheels, interference is easy to occur. According to screw theory and grinding kinematics, a mathematical model is established to investigate the interference and grinding characteristics of the ball-end wheel. The relationship between grinding wheel inclination angle, C axis rotation angle, grinding position angle and grinding wheel wear are analyzed. As the grinding wheel inclination angle increases, the C axis rotatable range decreases and the grinding position angle increases. The grinding position angle and wheel radius wear show a negative correlation with the C axis rotation angle. Therefore, a trajectory planning criteria for increasing grinding speed as much as possible under the premise of avoiding interference is proposed to design the grinding trajectory. Then grinding point distribution on the ball-end wheel is calculated, and the grinding characteristics, grinding speed and maximum undeformed chip thickness, are investigated. Finally, a complex structural component can be ground without interference, and surface roughness and profile accuracy are improved to 40.2 nm and 0.399 μm, compared with 556 nm and 3.427 μm before ultra-precision grinding. The mathematical model can provide theoretical guidance for the analysis of interference and grinding characteristics in complex components grinding to improve its grinding quality.     

Modelling and analysis of metal flowing behaviors in constraining ring rolling of tapered ring with thin wall and three high ribs

Tapered ring with thin wall and three high ribs(TRTWTHR), showing complicated geometry(wall thickness is less than 4 mm and rib height exceeds 20 mm), is extensively utilized to fabricate the critical structural parts of aerospace equipment such as spacecraft cabin, rocket body and fuel tank because of light weight and high carrying capacity. How to fabricate TRTWTHR with high performance is a critical problem that aerospace area needs to solve. In this work, constraining ring rolling(CRR) techn...     

涡产生器倾角对换热器内流动与换热特性的影响

为优化涡产生器强化传热的性能,通过改变三角翼式涡产生器的倾角,数值分析了倾角变化对板式换热器通道内流动与换热特性的影响,倾角变化范围为-30°～30°。获得了不同倾角下通道内的纵向涡、涡量分布,换热及阻力特性。结果表明涡产生器倾斜方向对流动与换热的影响不同,存在最佳的涡产生器倾角-10°,使得换热通道内涡产生器强化换热的性能最优;改变倾角可进一步提高涡产生器的强化传热性能,不同倾角对应努塞尔数和热性能评价因子间的最大差值分别达到8.9%和5.7%。     

旋转光滑及带肋U形通道的局部换热特性

用实验方法研究了旋转状态下光滑及带肋U形方截面通道的换热特性。带肋通道中,90°直肋对称布置在前后缘,肋片高径比为0.143,节距比为7。在实验雷诺数及旋转数范围分别为6100~25100和0~0.26下,对比分析了光滑及带肋通道的旋转换热特性。结果表明,带肋通道的换热明显好于光滑通道;旋转强化了第1通道后缘及第2通道前缘的换热,但削弱了第1通道前缘及第2通道后缘的换热;旋转效应对带肋结构的第1通道前后缘换热的影响最为明显;光滑通道中,弯道效应对其下游换热的影响较为显著。     

平行四边形截面的旁路式双喉道气动矢量喷管数值研究

将异型出口设计与气动推力矢量喷管结合,提出了平行四边形截面的旁路式双喉道气动矢量喷管(bypass dual throat nozzle,BDTN),并与基准矩形截面的BDTN进行流场结构及气动性能的对比研究。三维数值计算表明:平行四边形构型与矩形构型具有相同的气动性能变化规律;相较于基准矩形BDTN构型,由于壁面倾斜导致流场结构变化,平行四边形构型在矢量状态下的俯仰矢量角及推力系数有所降低,但对非矢量状态下的推力系数和流量系数影响不大;壁面倾角是性能变化的重要因素,相同落压比时壁面倾角越小,矢量角越小,壁面倾角不小于60°时喷管的稳定矢量角均可达10°以上,最大矢量角均可达15°以上;平行四边形出口增强了尾喷流与环境气流的掺混,出口射流中心线速度衰减大大加快,有利于提高红外隐身特性。     

收-扩喷管与飞行器后体的一体化气动优化设计

以轴对称收-扩喷管与飞行器后体的气动特性为研究对象,基于部分正交多项式的响应面法结合自编程序进行了三维流场的数值模拟.选取流量系数和推力系数为优化指标,选取收敛半角、喉道半径、扩张半角、底部面积和尾部收缩角为研究对象,在两种工况下进行了分析.通过响应面函数的构造及求解,结果表明:扩张半角和收敛半角对气动性能的影响程度约为90%;只考虑流量系数时,收敛半角、喉道半径和底部面积的影响程度约为85%;只考虑推力系数时,扩张半角的影响程度约为85%;只考虑H=0km,Ma=0工况时,扩张半角、收敛半角和喉道半径的影响程度达到90%以上;只考虑H=20km,Ma=2工况时,扩张半角和收敛半角的影响程度达到85%以上.     

LY12合金翼片等温模锻的缺陷分析

 简要叙述了大型薄腹板筋型翼片件,在5×10~4kN液压机上采用等温模锻工艺方案的可行性和等温模锻的变形温度、应变速率等工艺参数。分析了翼片等温模锻时产生穿筋、缩孔、折叠和裂纹等各种缺陷的原因。经试验确定了消除各种缺陷的实用方法,选择合理的模具结构设计和最佳的坯料外形、尺寸制备等。用CAD方法可得到较为理想的等效高度坯料和模具型槽中设计较为实用而又经济的工艺余料孔。     

考虑动叶顶部间隙影响的跨音涡轮级的数值模拟

本文给出了一种基于区域分解算法的可考虑动叶顶部间隙和机匣刮削作用的涡轮级计算方法。并对NASA实验涡轮级进行了计算, 计算结果和实验结果吻合得很好。通过分析, 可以发现动叶顶部间隙流动将引起动叶顶部气流的欠偏转, 从而降低顶部的做功能力, 并且这一影响区域会达到一个相当大的范围。在动叶叶片顶部尾缘存在激波的情况下, 尾缘激波和顶部泄漏流动相互作用使激波结构变得十分复杂和无序, 这种无序的结构必然带来较大的损失。      

基于节流阀模型的变循环发动机风扇准稳态数值研究

为了研究变循环发动机风扇部件在模式转换过程中的气动性能及流场变化规律,在风扇三维数值仿真模型的外涵道出口采用节流阀模型给定出口特征边界,代替模式选择阀门形成了风扇高/低阶混合计算模型,计算过程中通过调节节流阀系数模拟模式选择阀门的开闭过程。在模式选择阀门单独作用时,对风扇部件、中介机匣和分流环在模式转换过程中的气动性能和流场变化进行了准稳态分析,得到了以下结论：在模式转换过程阀门关闭的前半段（阀门开度大于0.4）,第二级处于堵塞状态,此时第二级转子槽道正激波位于转子流道内部,并在阀门关闭过程中不断向前移动,第一级在此阶段流场及工作点几乎不发生变化;当第二级转子的槽道正激波被推至叶片前缘附近,第二级退出堵塞后,第一级转子流道内槽道激波开始移动,第一级气动性能才开始发生明显变化;在模式选择阀门从开到闭的过程中,分流环前缘气流攻角增大,内涵道上壁面附面层增厚造成内涵道进口流动出现径向畸变。     

三维设计思想在子午流道大扩张角条件下的应用

根据三维设计思想,提出了针对子午流道大扩张角条件下涡轮导向叶栅的设计思想.研究结果表明:在子午流道的设计上,采用减小内端壁扩张角及加大外端壁扩张角的方式,可有效保证内端壁附近气流的抗分离能力,并且导向叶片采用正倾斜设计,以降低通道涡的径向迁移,从而减小或消除导叶尖部气流的分离,增加尖部附近气流的抗分离能力,达到减少损失的目的.该方法现已在某航空发动机高性能低压涡轮气动设计中进行了成功的应用和验证.      

跨音速喷管流动的数值模拟

数值方法采用的差分格式是具有高分辨率和快速稳定收敛性质的全变差衰减(TVD)格式。喷管壁面形状和反压可任意给定,对于典型轴对称与二维喷管(即壁面由收缩角为45°,扩张角为15°的两条直线用圆弧光滑连接而成。圆弧的无量纲半径等于0.625,其参考长度为喉道半宽),进行了有激波与无激波流动的数值模拟。计算结果与实验结果以及其他计算结果符合良好,此法可推广到非定常跨音速喷管流动的计算,并可用于工程中喷管设计。