5005铝合金分流模挤压过程有限元模拟

采用DEFORM-3D有限元商业软件,利用焊合面重构技术实现了空心型材分流组合模挤压过程模拟,获取了挤压过程中的材料流动行为与流动速度场的规律,结合型材挤出时模拟的应力场和应变场的分布,研究型材挤压的晶粒分布规律并其成因。结果表明:挤压型材的横截面上的应力应变分布与实际晶粒尺寸分布有对应关系,型材挤压成形过程中应力应变集中分布是造成型材边部晶粒尺寸比中心部细小,拐角区域晶粒比直边区域细小的原因。     

GH4169合金反挤压成形模具磨损

基于修正 Archard 磨损模型,采用数值模拟方法系统分析了 GH4169合金反挤压成形过程中各挤压工艺参数对模具磨损的影响规律。结果表明：在选取的参数范围内,挤压凸模最易产生磨损失效的区域为凸模圆角处,模具最大磨损深度随凸模圆角半径及坯料预热温度的增大而降低,随摩擦系数的增大而增大;当挤压速率小于100 mm ／s时,模具最大磨损深度随挤压速率的增大而减小,当挤压速率大于100mm ／s 时,模具最大磨损深度随挤压速率的增大先增大后减小。最佳工艺参数坯料预热温度1020℃,摩擦系数0．05,变形速率100mm ／s,模具预热温度300℃时模具磨损量最小,为9．28×10－3 mm。     

Radially loading rotary extrusion for manufacturing large-size conical cylinders with inner transverse high ribs

The Large-size Conical Cylinders with Inner Transverse High Ribs (LCCWITHR) can reduce the weight of the parts while maintaining high rigidity and strength. Radially Loading Rotary Extrusion (RLRE) forming technology can achieve integral forming of LCCWITHR through the synergy of radial and rotary movements of dies. The flow law of the material during the forming process is the key to forming large-size inner ribs. At present, there is no unified understanding of the metal flow law of RLRE forming technology. An analytical expression was derived to predict the Radial Direction (RD) deformation loads. The FE simulation and process experiment were carried out to investigate the effects of the inclination angle, thickness factor and transition arc radius of the split top dies on the spacing of the metal diversion plane, the metal flow velocity of the rib area and the final radius of the inner rib. The influence of the split top dies loading distance and the bottom die rotation angle of each pass on the inner radius of the inner rib was verified. And the optimal combination of dies shape parameters and loading paths which can make the metal flow orderly was obtained: the inclination angle is 140°, the thickness factor is 3.64, the transition arc radius is 16 mm; the top dies loading distance is 15 mm, the bottom die rotation angle is 45°. The FE simulation results have been found to be in close agreement with physics experiment. The research results reveal the metal flow law of rib growth in the RLRE of LCCWITHR, which lays a theoretical foundation for subsequent thorough research and process optimization.     

双旋翼微型飞行器的非定常气动特性

发展了一种基于计算流体力学(CFD)的非定常气动特性预测方法,计算方法包括了动量源模型、预处理方法、非结构嵌套网格和Spalart-Allmaras(S-A)湍流模型等技术.通过计算悬停Caradonna-Tung算例和俯仰振荡NACA0012算例,验证了计算方法模拟双旋翼微型飞行器动态流场的有效性.数值模拟了双旋翼微型飞行器动态流场,给出了非定常气动系数的迟滞曲线,分析了缩减频率、前飞速度和螺旋桨转速对非定常气动特性的影响.计算结果表明:力矩系数迟滞效应随缩减频率、前飞速度和螺旋桨转速增大而增大,升力系数迟滞效应随缩减频率和前飞速度增大而增大,但基本不随螺旋桨转速变化而变化.      

TC4 钛合金框类零件热挤压数值模拟及工艺优化

为了获得TC4某框类零件热挤压成形工艺方案及其合适的工艺参数,利用有限元软件Msc/su-perforge对零件整体热挤压成形和分段热挤压成形两工艺方案进行数值模拟,得出:整体热挤压成形工艺所需挤压力过高,成形困难,不适合该零件;分段热挤压成形工艺所需挤压力低、成形状况良好适合该零件,并以初始挤压温度920℃、挤压速率3 mm/s为成形的合适条件。     

Mechanism analysis of hysteretic aerodynamic characteristics on variable-sweep wings

Variable-sweep wings have large shape-changing capabilities and wide flight envelops, which are considered as one of the most promising directions for intelligent morphing UAVs. Aerodynamic investigations always focus on several static states in the varying sweep process, which ignore the unsteady aerodynamic characteristics. However, deviations to static aerodynamic forces are inevitably caused by dynamic sweep motion. In this work, first, unsteady aerodynamic characteristics on a typical variable-sweep UAV with large aspect ratio were analyzed. Then, deep mechanism of unsteady aerodynamic characteristics in the varying sweep process was studied. Finally, numerical simulation method integrated with structured moving overset grids was applied to solve the unsteady fluid of varying sweep process. The simulation results of a sweep forward-backward circle show a distinct dynamic hysteresis loop surrounding the static data for the aerodynamic forces. Compared with the static lift coefficients , at the same sweep angles, dynamic  lift coefficient in sweep forward process are all smaller, while dynamic sweep backward  lift coefficient are all larger. In addition, dynamic deviations to static  lift coefficient are positively related with the varying sweep speeds. Mechanism study on the unsteady aerodynamic characteristics indicates that three key factors lead to the dynamic hysteresis loop in varying sweep process. They are the effects of additional velocity caused by varying sweep motion, the effects of flow hysteresis and viscosity. The additional velocity induced by sweep motion affects the transversal flow direction along the wing and the effective angle of attack at the airfoil profile. The physical properties of flow, the hysteresis and viscosity affect the unsteady aerodynamic characteristics by flow separation and induced vortexes.     

圆棒热挤压过程研究

用抛物面速度场,对圆棒热挤压过程进行上限分析。经理论计算和有关试验数据比较,所求得的挤压力具有足够高的精度;并利用所建立的数学模型对挤压过程死区、最佳模角和挤压力进行了系统地研究。     

多点"三明治"成形及其在风洞收缩段形体制造中的应用

大型风洞收缩段形体板厚较大,成形较困难,而风洞收缩段形体制造精度对气流品质有很大影响,由于收缩形体中各个瓣片的形状差异较大,所以采用传统模压工艺需要很多模具,势必增加成本和制造周期,因此,提出了低速风洞收缩段型面制造的一种新方法,即多点"三明治"成形方法。通过对收缩段曲面坐标变换和曲面离散,确定出多点"三明治"成形模具顶杆的高度,为了确保瓣片的尺寸加工精度,减少实验工作量,成形前,需要通过数值模拟对弹复量进行预报,试压后,测量瓣片的实际尺寸,重新调节模具顶杆的高度。研究表明,多点"三明治"成形适于制造大曲率半径曲面工件。采用此种新工艺已在一套模具上为某风洞收缩段形体制成200多种双曲率瓣片。     

Hot deformation behavior and strain compensation constitutive model of equiaxed fine grain diffusion-welded micro-duplex TC4 titanium alloy

In this work, two-stage diffusion bonding of micro-duplex TC4 titanium alloy was carried out to study the flow behavior and constitutive models of the bonding joint and the base metal after the same thermal cycling during the hot forming process. Microstructure and mechanical properties test were used to verify the good quality of the equiaxed fine grain diffusion-welded TC4 alloy. Quasi-static tensile experiment was carried out at temperatures ranging from 750–900 °C and strain rates of 0.0001–0.1 s⁻¹. The joint showed the weak dynamic recovery at strain rates of 0.01–0.1 s⁻¹ and temperatures of 750–850 °C. At strain rates of 0.0001–0.001 s⁻¹ and temperatures of 850–900 °C, the flow stress of joint presented steady-state characteristics. Different deformation conditions lead to the remarkable difference of dynamic softening performance between the joint and heat-treated base metal, but the flow stress in elastic and strain hardening stages exhibited similar behavior. The strain compensated Arrhenius-type constitutive models of TC4 joint and heat-treated base metal were developed respectively. The fifth-order polynomial functions between the material property correlation coefficients and strain were obtained. The models have shown good correlation, with correlation coefficient values of 0.984 and 0.99. The percentage average absolute relative error for the models were found to be 10% and 9.46%, respectively.     

辅助进气激励器强化喷流混合的数值模拟

对采用高动量的辅助进气激励器和“常规”激励器强化的高速、大尺度喷流混合进行了数值模拟研究。对比了辅助进气激励器和“常规”激励器吹气射流对流向涡、喷流拍动、阻塞面积的影响,分析了合成射流强化喷流混合的流动滞后现象。结果表明:合成射流强化喷流混合中的辅助进气激励器在吹气时间、吹气动量、峰值动量比方面要明显优于“常规”激励器。合成射流强化喷流混合由激励器迟滞和流场迟滞两部分组成。“常规”激励器和辅助进气激励器射流峰值动量都滞后于活塞峰值速度时刻19.5%,流场滞后峰值动量时刻5%左右。相比于“常规”激励器,采用辅助进气激励器的“小突片”堵塞面积较大,强化喷流混合的效果更好。      

Numerical study on combustion efficiency of aluminum particles in solid rocket motor

The combustion of aluminum particles in solid rocket motor plays an important role in energy release of propellants. However, due to the limited residence time, aluminum particles may not be burned completely, thus hindering the improvement of specific impulse. This study aims to explore the characteristics of aluminum combustion efficiency and its influencing factors by experiments and numerical simulations, providing a guideline for engine performance improvement. As an input of simulation, the initial agglomerate size was measured by a high pressure system. Meanwhile, the size distribution of the particles in plume was measured by ground firing test to validate the numerical model. Then, a two-phase flow model coupling combustion of micro aluminum particle was developed, by which the detailed effects of particle size, detaching position and nozzle convergent section structure on aluminum combustion efficiency were explored. The results suggest that the average combustion temperature in the chamber drops with increasing initial particle size, while the maximum temperature increases slightly. In the tested motors, the aluminum particle burns completely as its diameter is smaller than 50 μm, and beyond 50 μm the combustion efficiency decreases obviously with the increase of initial size. As the diameter approaches to 75 μm, the combustion efficiency becomes more sensitive to particle size. The combustion efficiency of aluminum particle escaping from end-burning surfaces is significantly higher than that from internal burning surface, where the particle combustion efficiency decreases during approaching the convergent section. Furthermore, the combustion efficiency decreases slightly with increasing nozzle convergent section angle. And theoretically it is feasible to improve combustion efficiency of aluminum particles by designing the convergent profile of nozzle.     

串联式TBCC发动机风车冲压模态性能模拟

建立了基于部件低转速特性匹配的串联式涡轮基组合循环（TBCC）发动机风车冲压模态性能计算模型,提出了压气机低转速大流量特性扩展方法,由换算扭矩代替等熵效率表示旋转部件特性,解决了低转速部件效率不连续相关问题。分析了冲压外涵面积变化和涡轮功率提取对风车冲压模态性能及部件匹配的影响规律,并基于推力、流量连续准则设计了涡轮模态至冲压模态转换过程（含风车冲压模态）的参数调节规律。计算结果表明:在风车冲压模态下,冲压外涵面积变化对风扇工作状态有显著影响,对压气机影响较小;涡轮可提取功率随着风车转速的减小先增加后降低,比冲随提取功率的增加基本呈线性降低趋势,功率提取位置（高、低压涡轮）对部件匹配有显著影响。      

MB26 镁合金复杂结构件等温模锻过程的数值模拟与缺陷控制

采用DEFORM-3D有限元软件对MB26镁合金复杂结构件等温模锻工艺过程进行了数值模拟,直观地反映了锻件成形过程中的应力分布、金属流动趋势以及成形效果,分析了折叠、流线不顺等缺陷产生的原因.通过数值分析得出了合理的坯料形状、模具形式及成形工艺参数,消除了成形中可能出现的缺陷.     

SiCw/Al复合材料热挤压模具设计及其对挤压棒材组织和性能的影响

用具有宏观夹铝带的ＳｉＣｗ／Ａｌ复合材料的热挤压余,对热挤压压余中的金属流线进行了观察并建立了金属流线方程,为抗日夺模具的设计提供了指导原则。本文用曲线形状较金属流线形状陆的流线凹模进行挤压,结果表明,使用该种凹模能够有效地消除金属“死区”并在一定程度上减少了晶须折断,从而提高了挤压棒的强度。     

2060铝锂合金冷模热成形界面换热系数确定的实验与算法

2060铝锂合金具有密度低、比强度高等优势,在航空航天零件制造领域已得到广泛应用。通过冷模热成形工艺可以提高2060铝锂合金成形性,减少开裂、拉毛、回弹等缺陷的发生,后续时效处理可以提高零件整体刚度。然而在实际成形过程中缺乏对温度场的准确预测,即缺乏2060铝锂合金在变压强下界面换热行为的准确描述,无法对成形效果进行评估。本文利用冷模热成形界面换热测试平台,对不同压强下2060铝锂合金与H13热作模具钢的换热行为进行测试研究,基于考虑模具钢变热物性参数的显式有限差分法反算模具表面温度,计算得到不同压强下的界面换热系数,并与Beck反传热算法进行对比,两者计算结果相近。实验结果显示2060铝锂合金IHTC随压强增大而增大,在20 MPa下IHTC=1.906 6 kW/（m²·K）。改进的有限差分法具有计算效率高、速度快、反映实际模具内部温度场、误差较低等优点,可拓展应用于其他薄板材料在冷模热成形条件下的界面换热系数求解。     

可调桨距冲压空气涡轮气动特性实验与数值分析

冲压空气涡轮风洞实验主要目的是采用相似准则,模拟空中加油工作状态,测量涡轮输出功率,分析涡轮气动特性。实验分别使用励磁发电机和加油泵作为测功器,通过调桨变距并测量最大输出功率。气动特性实验表明在风洞气流速度比加油机最小飞行速度低16%的条件下,冲压涡轮输出功率即可满足加油需要。论文还采用高数值稳定性代数Baldwin-Lomax湍流模型模拟冲压涡轮全三维混合型流场,分析流场主要气动特性,讨论桨叶表面载荷的分布。数值模拟结果显示在冲压空气涡轮桨叶近轮毂区域需要进一步优化。      

A hybrid chemical modification strategy for monocrystalline silicon micro-grinding: Experimental investigation and synergistic mechanism

For high performance manufacturing of micro parts and features, a hybrid chemical modification strategy is proposed to decrease critical energy barrier of mechanical removal of hard and brittle crystal material by refining localized machining condition. The strategy, namely UV-light and IR-laser hybrid chemical modification (UVIR-CM) strategy, includes two steps, an ultraviolet light (UV-light) catalytic advanced oxidation and an infrared laser (IR-laser) assisted selective modification based on Fenton liquid–solid reaction for monocrystalline silicon. The modification effects of UVIR-CM strategy were investigated by surface morphology micro-observation, cross-section transmission electron microscopy (TEM) observation, Raman spectroscopy analysis and nanoindentation test. Experimental results demonstrated that varied degrees of laser texturing appeared on different strategy samples’ IR-laser scanned area. And the IR-laser thermal damage has been successfully inhibited due to the refraction and reflection of energy by bubbles in liquid medium. But for the UVIR-CM strategy, a uniform and amorphous silicate layer is detected in a certain boundary. The UV-light promotes oxidation cycle ability of the chemical solution and ensures sufficient oxide modified layer for subsequent step. Attributing to synergism of photochemical, photothermal and kinetic effects induced by IR-laser, the modified layer displays layered structure with about 600 nm thickness, (2.7 ± 0.60) GPa nanohardness, and (93.7 ± 22.9) GPa indentation modulus. And the layered structure is amorphous layer, nanocrystal and micro-twins layer from the surface to the interior of sample. Consequently, it reveals that the subsequent mechanical removal will become easy due to decreasing energy barrier of monocrystalline silicon in selective area. Meanwhile, its original excellent mechanical properties also are maintained under a certain depth. The results contribute to develop a novel combined micro-machining technology to achieve collaborative manufacturing of structure shape and surface integrity for micro parts and feature.     

Temperature measurements by coherent anti-Stokes Raman spectroscopy in hydrogen-fuelled scramjet combustor

Instantaneous temperature measurements in two dimensional stepped dual-mode hydrogen-fuelled scramjet combustor were performed by the broad-band CARS technique. The experiment consisted of a direct-connect test of a Mach 3 combustor with three fin fuel injectors. The freestream flow was combustion heated to total temperature T_t=1600–1700 K. Temperature measurements with repetition rate of 10 Hz during run duration of 10 s and hydrogen combustion duration of 5 s were carried out at one spatial point located downstream of a rearward-facing step. For scramjet mode of operation (combustion in supersonic flow) the temperatures derived from single shot measurements were in the range 600–900 K. For ramjet mode (combustion in subsonic flow in pseudo-shock) the temperatures increased to 1200–1600 K. The temperature values in the last case were grouped around both 600 K and 1500 K, making the shape of the temperature probability density function bimodal. The nature of such a probability distribution is discussed.     

Frictional resistance of supercritical pressure RP-3 flowing in a vertically downward tube at constant heat fluxes

Based on the demands of compact heat exchangers and micro cooling channels applied for aviation thermal protection, the flow resistance characteristics of aviation kerosene RP-3 were experimentally studied in a vertically downward circular miniature tube with an inner diameter of 1.86 mm at supercritical pressures and constant heat fluxes. A long and short tube method was used to accurately calculate the frictional pressure drop, and experimental conditions are supercritical pressures of 4 MPa, mass flow rates of 2–4 g/s (i.e., mass fluxes of 736–1472 kg/(m²?s)), heat fluxes of 100–500 kW/m², and inlet temperatures of 373–673 K. Results show that the sharp variations of thermophysical properties, especially density, have significant influences on frictional resistances. Generally, the frictional pressure drop and the friction factor increase with increasing inlet temperatures, and this trend speeds up in the relatively high-temperature region. However, the friction factor has a sudden decline when the fuel outlet temperature exceeds the pseudo-critical temperature. The frictional pressure drop and the friction factor basically remain unchanged with increasing heat flux when the inlet temperature is relatively low, but increase quickly when the inlet temperature is relatively high. Besides, a larger mass flux yields a higher pressure drop but does not necessarily yield a higher friction factor. Finally, an empirical friction factor correlation is proposed and shows better predictive performance than those of previous models.     

Substructure evolution in two phases based constitutive model for hot deformation of TC18 in α + β phase region

The α + β dual phase titanium alloys are key structural materials in aviation and aerospace industries, and the complicated flow behavior of these titanium alloys during hot deformation requires to establish a constitutive model incorporating physical mechanism for optimizing processing parameters and designing forming tools. This work aims to establish a constitutive model incorporating physical mechanism for hot deformation of TC18 in α + β phase region. Firstly, the flow behavior and microstructure evolution for hot deformation of TC18 in α + β phase region are characterized. The TC18 shows significant strain hardening rate and negative strain hardening exponent around and after peak flow stress, respectively. After peak flow stress, Dynamic Recovery (DRV) mechanism dominates the evolution of α and β phases according to the results of substructure evolution. Then, the internal state variables method is applied to establish a constitutive model incorporating physical mechanism for hot deformation of dual phase titanium alloys. The variation of dislocation density during the hot deformation of titanium alloys is modeled by considering the accumulation of dislocation due to the impediment to dislocation movement by substructure obstacles and the annihilation of dislocation due to the dynamic restoration effect. The interaction between dislocations, the subgrain boundaries and the grain/phase boundaries obstruct the dislocation movement in the α phase, and the first two obstructs the dislocation movement in the β phase during the hot deformation of TC18. The dislocation annihilation process in the α and β phases during the hot deformation of TC18 is dominated by DRV. Finally, the substructure evolution in the two phases based constitutive model for hot deformation of TC18 in α + β phase region is presented. This model is well applied to predict the flow stress and quantitively analyze the role of DRV effect in the evolution of α and β phases during the hot deformation of TC18.