Theoretical and Experimental Investigation of Laser Milling Assisted with Jet Electrochemical Machining

In laser milling assisted with jet electrochemical machining （LMAJECM）, the source of energy is a pulsed laser beam aligned coaxially with a jet of electrolyte, which focuses optical energy on the surface of work- piece. The impact of jet of electrolyte develops a state-of-art work to perform operations such as electrolytic etch- ing, effective cooling, and transportation of debris. Therefore, a special jet cell is designed to obtain stable jet as to be a kind of noneontact tool, i. e. , electrode. According to the theoretical model of on-off pulse time process, laser machining and electrolytic anodization are simulated by finite element analysis （FEA） method. Grooves on a 0.5 mm thick 321 stainless steel sheet produced by LMAJECM is performed with pulsed Nd：YAG laser at the second harmonic wavelength. Compared with laser milling under ambient atmosphere conditions, the recast layer and burrs are effectively diminished. And the accuracy of depth is dedicated to laser milling, whilst that of width is dominated by jet electrochemical machining. It is demonstrated that LMAJECM can be a highly potential approach for fabricating 3-D micro components.     

整体叶盘电解加工阴极修正方法与试验

电解加工是航空发动机整体叶盘制造的主要技术之一,阴极修正是该加工技术的重要环节。为了提升阴极修正精度,提出了恒采样点空间法向修正方法。该方法将阴极型面设计、加工误差分析、工具阴极修正统一至阳极采样点空间法向的一维坐标系中,将复杂的三维曲面修正简化为离散的一维修正,消除了加工误差与修正量的错位。以某整体叶盘为例,在自行研制的整体叶盘型面电解加工机床上开展工具阴极修正试验,采用三坐标测量机对修正前后的加工样件进行检测,经过一次修正,叶片电解加工精度由0.25mm提高至0.04mm,试验结果表明该阴极修正方法合理有效,具有较强的可行性。     

可压缩平板边界层转捩的大涡模拟

入口利用层流速度型叠加二维和三维Tollmien-Schliting(T-S)波,应用动态亚格子模型、预处理技术以及高精度算法,采用大涡模拟(Large eddy simulation,LES)数值计算方法,对可压缩平板边界层空间模式的转捩机理及其拟序结构进行了研究。计算结果展示了T-S波经历线性、非线性发展阶段破碎形成发卡涡,最终演化成具有4个涡环的涡链结构的整个过程,并揭示了发卡涡涡腿并非完整对称及低速条带在涡环产生的位置不连续的现象,探讨了主流向涡与壁面相互作用诱导生成次流向涡的机理。     

基于微分Petri网的民机航迹演化通用模型构建

为实现对未来大流量、高密度、小间隔条件下的空域实施管理,在战略航迹规划阶段,提出了一种模块化的战略航迹演化通用模型。建立了不同航段之间航空器状态动态切换的一类宏观Petri网演化模型,以及同一航段内航空器速度和高度两种特征参数值连续变化的3类微观Petri网演化模型。根据航空器特征参数值转化的4种不同形式并基于航空器全飞行剖面的混杂运行特性,运用微分Petri网理论,定义了航空器的4种演化模式,通过组合各种演化模式得到了3种航空器基本演化模型。在满足航空器性能约束的前提下,通过设定10个航段及15个高度和速度预设值,得到了全飞行剖面下各特征参数的演化图。结果表明,所设计的演化模型增强了航迹预测模型的通用性,能够反映航空器在水平剖面和垂直剖面内的状态变化。     

钛合金宽弦空心风扇叶片数控切削加工关键技术

数控切削加工是最终保证钛合金宽弦空心风扇叶片制造精度的重要技术手段。分析了采用超塑成形/扩散连接技术制作的钛合金宽弦空心风扇叶片结构特征以及毛坯状态,指出了后续的数控切削加工应突破复杂曲面结构测量、加工变形控制以及切削加工误差补偿等关键技术。提出了开发集测量、分析和加工为一体的数控切削加工集成系统的研究思路,可为实现钛合金宽弦空心风扇叶片加工精度的精确控制提供指导。     

Evolution and History in a new “Mathematical SETI” model

In a recent paper (Maccone, 2011 [15]) and in a recent book (Maccone, 2012 [17]), this author proposed a new mathematical model capable of merging SETI and Darwinian Evolution into a single mathematical scheme. This model is based on exponentials and lognormal probability distributions, called “b-lognormals” if they start at any positive time b (“birth”) larger than zero. Indeed:

• 1.Darwinian evolution theory may be regarded as a part of SETI theory in that the factor f_l in the Drake equation represents the fraction of planets suitable for life on which life actually arose, as it happened on Earth.
• 2.In 2008 (Maccone, 2008 [9]) this author firstly provided a statistical generalization of the Drake equation where the number N of communicating ET civilizations in the Galaxy was shown to follow the lognormal probability distribution. This fact is a consequence of the Central Limit Theorem (CLT) of Statistics, stating that the product of a number of independent random variables whose probability densities are unknown and independent of each other approached the lognormal distribution if the number of factors is increased at will, i.e. it approaches infinity.
• 3.Also, in Maccone (2011 [15]), it was shown that the exponential growth of the number of species typical of Darwinian Evolution may be regarded as the geometric locus of the peaks of a one-parameter family of b-lognormal distributions constrained between the time axis and the exponential growth curve. This was a brand-new result. And one more new and far-reaching idea was to define Darwinian Evolution as a particular realization of a stochastic process called Geometric Brownian Motion (GBM) having the above exponential as its own mean value curve.
• 4.The b-lognormals may be also be interpreted as the lifespan of any living being, let it be a cell, or an animal, a plant, a human, or even the historic lifetime of any civilization. In Maccone, (2012 [17, Chapters 6, 7, 8 and 11]), as well as in the present paper, we give important exact equations yielding the b-lognormal when its birth time, senility-time (descending inflexion point) and death time (where the tangent at senility intercepts the time axis) are known. These also are brand-new results. In particular, the σ=1 b-lognormals are shown to be related to the golden ratio, so famous in the arts and in architecture, and these special b-lognormals we call “golden b-lognormals”.
• 5.Applying this new mathematical apparatus to Human History leads to the discovery of the exponential trend of progress between Ancient Greece and the current USA Empire as the envelope of the b-lognormals of all Western Civilizations over a period of 2500 years.
• 6.We then invoke Shannon's Information Theory. The entropy of the obtained b-lognormals turns out to be the index of “development level” reached by each historic civilization. As a consequence, we get a numerical estimate of the entropy difference (i.e. the difference in the evolution levels) between any two civilizations. In particular, this was the case when Spaniards first met with Aztecs in 1519, and we find the relevant entropy difference between Spaniards an Aztecs to be 3.84 bits/individual over a period of about 50 centuries of technological difference. In a similar calculation, the entropy difference between the first living organism on Earth (RNA?) and Humans turns out to equal 25.57 bits/individual over a period of 3.5 billion years of Darwinian Evolution.
• 7.Finally, we extrapolate our exponentials into the future, which is of course arbitrary, but is the best Humans can do before they get in touch with any alien civilization. The results are appalling: the entropy difference between aliens 1 million years more advanced than Humans is of the order of 1000 bits/individual, while 10,000 bits/individual would be requested to any Civilization wishing to colonize the whole Galaxy (Fermi Paradox).
• 8.In conclusion, we have derived a mathematical model capable of estimating how much more advanced than humans an alien civilization will be when SETI succeeds.

     

改善机床运动的五轴刀轨光顺方法

建立了五轴数控加工刀轨光顺优化模型,改善了线性插补方式下拐角过渡运动中的机床加速度情况。考虑了5个轴加速能力的差异,以轴加速度比,即轴实际达到的最大加速度与其允许最大加速度的比值,来衡量轴的加速度情况,以5个轴加速度比的平方平均数在整体上衡量机床的加速度情况,降低该值可提高机床运动平稳性。采用最短距离线法在初始刀轨的各切触点处建立了刀轴偏航角和俯仰角的可行域,使光顺后的刀轨满足残高和无过切要求。实例表明:该方法可有效光顺五轴数控加工刀轨,改善机床加速度情况,提高机床运动平稳性。      

飞机结构件轮廓特征加工自动分区算法

作为飞机结构件重要组成部分,轮廓特征包含大量复杂曲面,且与工艺凸台等干涉物相连接,使得轮廓特征编程需综合考虑复杂曲面及干涉物信息,在自动编程模式下,轮廓特征编程仍严重依赖人工经验,其编程周期占结构件编程周期的40%以上,严重影响了结构件编程效率。针对该问题,提出了一种综合考虑复杂曲面及干涉物信息的轮廓特征加工自动分区方法,基于相邻轮廓面连接边属性及凸边约束原则对轮廓面进行初分区,依据干涉物信息构建虚拟边界,并基于虚拟边界对轮廓面初分区结果进行横向和纵向加工区域划分,通过对划分区域进行合并得到轮廓特征加工分区结果。根据提出的方法开发了飞机结构件轮廓特征加工自动分区系统,经过多项典型飞机结构件测试,该方法稳定可靠,可为轮廓特征加工程序编制提供支撑。     

Characterization and life prediction of single-pass honing tool for fuel injection nozzle

Single-pass honing is an important machining method for finish machining of holes, which can meet the requirement for high efficiency and consistency of holes. Characterization and life prediction of single-pass honing tool are necessary to improve the machining accuracy of holes honed, especially dimension accuracy. Single-pass honing tool is a single layer abrasive tool with fixed dimension, which still remains problematic for characterization and life prediction. For fuel injection nozzles with bore diameter under 1 mm, the stiffness of the single-pass honing tool is poor. This article presents a novel analytical model that predicts life of the tool with poor stiffness. Firstly, according to the bore diameter and dimension tolerance, the single-pass honing tool is designed and manufactured. Based on the prepared single-pass honing tool, the measurement and characterization methods are established. Furthermore, the tool wear tests are carried out, and the tool contour evolution model is established to predict the tool life.     

Effects of traverse speed on weld formation,microstructure and mechanical properties of ZK60 Mg alloy joint by bobbin tool friction stir welding

ZK60B (Mg-6% Zn-0.6% Zr) alloy joints fabricated by bobbin tool friction stir welding (BTFSW) with various traverse speeds were investigated. The sound joint fabricated by the BTFSW was possible under the appropriate welding parameters. The severe plastic deformation during BTFSW resulted in dispersion and segregation of the Zr-rich particles within the stirred zone (SZ) followed by evolution of a bimodal grain structure with distributed bands of 0.8–1.7 μm ultrafine grains and 4.1–7.1 μm equiaxed grains. Micro-hardness of SZ is substantially reduced in contrast to that of parent metal (PM) in spite of the finer grain size owing to dissolution of Mg-Zn based precipitates having hardening effects on alpha-Mg matrix. With the decrease in traverse speed, randomization degree of the plasticized metal flow increases, which is evidenced by the randomized arc line pattern at the low traverse speed. Among all defect-free joints, the 200 mm/min joint exhibits the weakest isotropy of texture within SZ and the best tensile properties, which has reduced ultimate tensile strength and yield strength by 5.4% and by 22.2%, respectively, as compared to the PM. The randomized texture hinders the joint fracturing within SZ at low elongation. Therefore, a relatively high elongation of 10.8% was achieved, which corresponded to 72% of the PM value.