Stability analysis of robotic longitudinal-torsional composite ultrasonic milling

Currently, industrial robots are considered as an alternative towards traditional machine tools. Especially for the large-scale parts milling, robotic flexibility and low cost make it possess the irreplaceability. However, the milling chatter caused by its weak rigidity hampers robotic application and promotion severely in aviation industry. Rotary ultrasonic milling (RUM) technology with one-dimensional axial vibration has been proven and approved on avoiding robotic chatter. Based on this, the research of project team demonstrates that longitudinal-torsional composite ultrasonic milling (CUM-LT) involving separation characteristic has a greater advantage than RUM in terms of chatter suppression. Thereby, the CUM-LT as a new means is applied to avoid processing vibration of robotic milling system. And its influence mechanism on stability improvement of weak stiffness processing system is clarified. Meanwhile, the approaches to strengthen separation effect are provided innovatively. Moreover, a new analysis method of robotic CUM-LT (RCUM-LT) stability is proposed on the basis of ultrasonic function angles. The simulation and experimental results indicate that compared with robotic RUM (RRUM), stability regions of separated RCUM-LT (SRCUM-LT) and unseparated RCUM-LT (URCUM-LT) are improved by 124.42% and 39.20%, respectively. The addition of torsional ultrasonic energy has a wonderful effect on the milling chatter suppression of low stiffness robots.     

Visual inspection of aircraft skin: Automated pixel-level defect detection by instance segmentation

Skin defect inspection is one of the most significant tasks in the conventional process of aircraft inspection. This paper proposes a vision-based method of pixel-level defect detection, which is based on the Mask Scoring R-CNN. First, an attention mechanism and a feature fusion module are introduced, to improve feature representation. Second, a new classifier head—consisting of four convolutional layers and a fully connected layer—is proposed, to reduce the influence of information around the area of the defect. Third, to evaluate the proposed method, a dataset of aircraft skin defects was constructed, containing 276 images with a resolution of 960 × 720 pixels. Experimental results show that the proposed classifier head improves the detection and segmentation accuracy, for aircraft skin defect inspection, more effectively than the attention mechanism and feature fusion module. Compared with the Mask R-CNN and Mask Scoring R-CNN, the proposed method increased the segmentation precision by approximately 21% and 19.59%, respectively. These results demonstrate that the proposed method performs favorably against the other two methods of pixel-level aircraft skin defect detection.     

涡扇发动机全包线加速控制计划改进方法研究

加速控制计划直接影响了发动机的响应速度以及运行安全。为了提高发动机响应能力,提出了一种基于等温度线的发动机全包线加速控制计划。分别针对稳态和动态过程开展相似换算误差分析,证明并验证了关键参数在等风扇进口温度时,具有较高相似换算精度的规律。基于此换算误差理论,提出全包线加速控制计划改进方法,该方法在不同等风扇进口温度下设计多条加速控制计划,再通过线性插值得到包线内不同等温线下的加速控制计划。结果表明,改进后的加速控制计划相比于传统单点优化得到的加速控制计划,发动机加速至最大转速的98%所需的时间减少了7.2%,最大转速提升了1%,且风扇、压气机喘振裕度和涡轮前温度等均未超出限制值。因此,该方法相比于传统单点优化方法既提升了在包线内获取的加速控制计划的精度,又确保了发动机在包线内安全稳定工作的前提下更好的发挥加速性能。     

涡轮动叶表面换热特性的试验研究

航空发动机性能的提高对涡轮叶片耐热极限提出了更高的要求,为了更准确地分析涡轮叶片的传热特性,选取某型气冷涡轮动叶10%、50%和90%叶高的特征型面通过低导热光敏树脂材料经过3D打印而成,通过叶片表面粘贴厚度为0.02mm康铜加热膜接通恒定电流加热,使用红外热像系统精确测量叶片壁面温度,在平面叶栅中研究了吹风比(M)和雷诺数(Re)对气膜绝热冷却效率和努塞尔数(Nu)的影响(试验中基于弦长的进口雷诺数Re为8.0×10⁴-16.7×10⁴,吹风比M为1-3)。试验结果表明：M=1时气膜能够较好附着在叶片表面,叶片表面得到较好冷却;随着主流雷诺数的增加,绝热壁面温度逐渐升高,绝热效率逐渐降低;吹风比对涡轮叶片的传热特性的影响与气膜孔出流角度有关,随着吹风比的增大,压力面绝热冷却效率逐渐增大,由于吸力面的气膜孔出流角较大,吹风比增大使得吸力面的绝热冷却效率逐渐减小;随着吹风比的增加,对流换热系数增大。     

航空发动机设计任务循环的选取

由某型发动机的未来使用任务推导了其设计飞行任务剖面和飞行任务混频,然后根据该发动机的高度－速度特性得出了其转速剖面。在该转速剖面下对发动机的压气机盘进行了应力和疲劳寿命计算,由计算结果得出该发动机设计任务循环的选取范围,认为：航空发动机的设计任务循环除0－最大－0、慢车－最大－慢车和巡航－最大－巡航3类循环以外,还应当包括对发动机构件疲劳寿命有较大影响的其它载荷循环,否则将造成设计载荷估计精度大大降低。     

一种用于飞机试验台的三分力传感器

多分力载荷传感器是一种常用的传感器,但通常当各分力的量程相差太大时难以取得良好的效果。提出了一种新型传感器结构形式,减少了各分力之间的耦合,使得在各分力量程不匹配的情况下亦可获得较高的测量精度。     

三维不可压边界层抛物化稳定性方程的椭圆特性研究

针对三维平行不可压边界层流动的抛物化稳定性方程,研究其剩余的椭圆特性,提出了消除该特性的具体方法,并对抛物化稳定性方程解与全椭圆问题解的一致性进行了证明。     

求解具有多层试验数据成败型单元混联系统可靠性近似限的信息论方法

研究了求解具有多层成败型试验数据时,系统可靠性置信下限近似解的信息论方法,给出了各层试验数据综合的方法和步骤,推导了各层数据信息论方法折合及综合的计算公式。根据单元试验信息提供的信息量与系统折合试验应提供的信息量相等的原则,将多层试验数据逐级折合为系统的等效成败型数据,导出了等效成败型数据信息论方法折合的基本公式;结合可靠性工程的基本原理,根据单个成败型单元可靠性评定的经典精确置信限方法,给出了系统可靠性置信下限的近似解。并以实例形式说明了该方法的具体应用。     

基于自联想网络的发动机传感器解析余度技术

本文提出了一种基于自联想神经网络的传感器解析余度技术。在这种网络中,冗余传感器的信息被压缩、重组进入网络的第一部分,网络的第二部分将压缩信息恢复出来。基于数据融合原理,若一个传感器发生故障,其它传感器仍可提供足够的信息代替发生故障的传感器。理论分析和用于涡轴发动机的仿真结果表明,这种特殊结构的自联想网络具有良好的过滤噪声和故障信号的作用,特别适合于用作不易建模的复杂对象的传感器信号重构     

奥氏体合金熔焊接头形变再结晶态的疲劳性能

焊接接头的微观组织和力学性能不均匀性影响疲劳性能,常用焊后热处理等工艺方法来改善。但奥氏体型合金固态无同素异构转变,焊后热处理难以明显地改善其微观组织和疲劳性能。形变再结晶工艺可以同时改善其微观组织和力学性能,进而可以非常显著地提高该焊接接头的抗疲劳断裂能力。本文主要讨论１Ｃｒ１８Ｎｉ９Ｔｉ熔焊接头形变再结晶态的微观组织和疲劳性能,并以该焊接接头的低循环疲劳性能来验证