数控机床及工装的发展与创新设计

在现代数控加工中,由于被加工件的精度要求以及复杂度不断提高,传统加工系统无法满足使用需求,为解决这一问题,数字控制系统的核心算法以及驱动系统得到了快速发展,一些创新机构也应用到了数控机床的整机结构设计中.这些解决措施大幅提升了被加工件的精度和表面质量,促进了市场上一系列新型数控机床的出现,如复合机床、镜像铣削机床等,与之配合的新型加工工装技术也取得了相应的突破.     

Advances in fabrication of ceramic corundum abrasives based on sol–gel process

Corundum abrasives with good chemical stability can be fabricated into various free abrasives and bonded abrasive tools that are widely used in the precision machining of various parts. However, these abrasives cannot satisfy the machining requirements of difficult-to-machine materials with high hardness, high strength, and strong wearing resistance. Although superhard abrasives can machine the above-mentioned materials, their dressing and manufacturing costs are high. By contrast, ceramic corundum abrasives fabricated by sol–gel method is a cost-effective product between conventional and superhard abrasives. Ceramic corundum abrasives exhibit self-sharpening and high toughness. In this review, the optimization methods of ceramic corundum abrasive properties are introduced from three aspects: precursor synthesis, particle shaping, and sintering. Firstly, the functional mechanism of seeds and additives on the microstructural and mechanical properties of abrasives is analyzed. Specifically, seeds can reduce the phase transition temperature and improve fracture toughness. The grain size and uniformly dense structure can be controlled by applying an appropriate amount of multicomponent additives. Then, the urgent need of engineering application and machinability of special shape ceramic corundum abrasives is reviewed, and three methods of abrasive shaping are summarized. The micromold replication technique is highly advanced and can be used to prepare functional abrasives. Additionally, the influence of a new sintering method, namely, two-step sintering technique, on the microstructural and mechanical performance of ceramic corundum abrasives is summarized. Finally, the challenge and developmental trend of the optimization of ceramic corundum abrasives are prospected.     

Machining of a film-cooling hole in a single-crystal superalloy by high-speed electrochemical discharge drilling

Single-crystal superalloys are typical advanced materials used for manufacturing aeroengine turbine blades. Their unique characteristics of high hardness and strength make them exceedingly difficult to machine. However, a key structure of a turbine blade, the film-cooling hole,needs to be machined in a single-crystal superalloy; such machining is challenging, especially considering the increasing levels of machining efficiency and quality demanded by the aeroengine industry. Tube electrode high-speed electrochemical discharge drilling(TSECDD), a hybrid technique of high-speed electrical discharge drilling and electrochemical machining, provides high machining efficiency and accuracy, as well as eliminating the recast layer. In this study, TSECDD is used to machine a film-cooling hole in a nickel-based single-crystal superalloy(DD6). The Taguchi methods of experiment are used to optimise the machining parameters. Experimental results show that TSECDD can effectively drill the film-cooling hole; the optimum parameters that give the best performance are as follows: pulse duration: 12 ls, pulse interval: 30 ls, peak current:6 A, and salt solution conductivity: 3 m S/cm. Finally, a hole is machined by TSECDD, and the results are compared with those obtained by electrical discharge machining. TSECDD is found to be promising for improving the surface quality and eliminating the recast layer.     

Advances in critical technologies for hypersonic and high-enthalpy wind tunnel

Hypersonic and high-enthalpy wind tunnels and their measurement techniques are the cornerstone of the hypersonic flight era that is a dream for human beings to fly faster, higher and further. The great progress has been achieved during the recent years and their critical technologies are still in an urgent need for further development. There are at least four kinds of hypersonic and high-enthalpy wind tunnels that are widely applied over the world and can be classified according to their operation modes. These wind tunnels are named as air-directly-heated hypersonic wind tunnel, light-gas-heated shock tunnel, free-piston-driven shock tunnel and detonation-driven shock tunnel, respectively. The critical technologies for developing the wind tunnels are introduced in this paper, and their merits and weakness are discussed based on wind tunnel performance evaluation. Measurement techniques especially developed for high-enthalpy flows are a part of the hypersonic wind tunnel technology because the flow is a chemically reacting gas motion and its diagnosis needs specially designed instruments. Three kinds of the measurement techniques considered to be of primary importance are introduced here, including the heat flux sensor, the aerodynamic balance, and optical diagnosis techniques. The techniques are developed usually for conventional wind tunnels, but further improved for hypersonic and high-enthalpy tunnels. The hypersonic ground test facilities have provided us with most of valuable experimental data on high-enthalpy flows and will play a more important role in hypersonic research area in the future. Therefore, several prospects for developing hypersonic and high-enthalpy wind tunnels are presented from our point of view.     

PLC构成电梯控制系统特性分析

分析了电梯的负载特性,阐述了采用梯形加速曲线的电梯理想速度曲线,结合变频器和PLC的性能,论述了电梯控制系统的构成和工作特性,以及电梯速度曲线产生的方法,归纳了由PLC构成的控制系统软件设计的特点。     

基于位移和力值组合的静重式力标准机砝码加卸载控制方法研究

介绍了一种基于位移和力值组合的静重式力标准机砝码加卸载的控制方法,通过监测砝码的移动量和参考力传感器叠加系统的力值量,实时调整加卸载机构的加卸载速度,以实现对被检力传感器的平滑加卸载的目的。该方法有效解决了吊挂在加载过程中产生较大摆动,影响力标准机复现力值准确度的问题,同时也消除了力值过冲现象,避免了因逆程效应而导致的力传感器输出偏差。     

运载火箭并联双机姿控配平策略研究

运载火箭并联双机是一种常见的发动机推力矢量控制(Thrust Vector Control, TVC)方案,发动机与伺服机构可组合出不同的控制布局。针对液体运载火箭典型的4种并联双机摆发动机控制布局,开展了故障动力学建模仿真研究,基于运载火箭比例微分(Proportional Differential, PD)姿控方法,比对分析了不同故障模式的姿控配平结果,优选了并联双机摆发动机控制布局,最后应用控制重分配技术验证了故障下放宽滚动通道性能策略的有效性,结果表明不同的推力矢量布局故障适应能力不同,姿态重构技术在发动机推力较大故障下仍可保证运载火箭良好的姿控性能与稳定能力。     

基于SMP机群的航空CFD并行技术应用研究

针对SMP机群的双层并行体系结构,研制出一种双层并行技术--在计算节点间采用MPI消息传递模式并行,而在计算节点内部采用OpenMP编译器指令模式并行.通过算例测试证明,采用该技术的航空CFD程序,并结合贪婪负载平衡分配技术进行并行计算,其效率可达94%,计算结果与实验值吻合.     

一种实时测控集群数据处理进程软件控制方法

在基于集群架构的实时测控系统上,通过软件设计实现一种满足数据处理实时性和系统高可用的集群数据处理进程控制方法。计算节点运行的数据处理进程采用多线程设计,对时间驱动线程和数据驱动线程分别设计了工作信号处理流程。实践证明方法不但能够保证计算节点完成数据处理任务的实时性和可靠性,还能动态完成集群节点的任务迁移和故障恢复,提高了测控集群系统的实时性和可用性,从而有效发挥集群系统架构在测控系统中应用的优势。     

2.4米跨声速风洞大展弦比飞机测力试验技术研究

针对大展弦比飞机的气动布局特点,在2.4米跨声速风洞中开展了大展弦比飞机测力试验技术研究。该项研究建立了大升阻比高精度天平设计技术和模型支撑系统设计平台,研制了专用大升阻比高精度测力天平和模型支撑系统。在国内高速风洞中建立了大型跨声速风洞模型设计新准则。研究结果表明:所提出和制定的方案是科学合理的,为我国大飞机研制提供了可靠的技术支撑。