一种新的微细精密航空制造技术—纯水微细电解加工的工艺研究(英文)

为了寻求航空精密微细制造新技术并实现绿色制造和精密微细制造,对一种新型微细电解加工方法——纯水微细电解加工进行了研究。基于水解离机理,在新研制的试验装置上,采用不同的试验条件,进行了一系列工艺试验,探索并揭示了实现纯水微细电解加工的必要工艺条件和工艺规律,加工了圆孔和字母"PW-ECM";还研究了超声振动—纯水电解复合加工新方法,进而在不锈钢薄片上加工出三角、方形盲孔、三角通孔;试验研究结果证明了纯水微细电解加工的可行性。     

A Comparative Study of the Influence of the Active Young Sun on the Early Atmospheres of Earth, Venus, and Mars

Because the solar radiation and particle environment plays a major role in all atmospheric processes such as ionization, dissociation, heating of the upper atmospheres, and thermal and non-thermal atmospheric loss processes, the long-time evolution of planetary atmospheres and their water inventories can only be understood within the context of the evolving Sun. We compare the effect of solar induced X-ray and EUV (XUV) heating on the upper atmospheres of Earth, Venus and Mars since the time when the Sun arrived at the Zero-Age-Main-Sequence (ZAMS) about 4.6 Gyr ago. We apply a diffusive-gravitational equilibrium and thermal balance model for studying heating of the early thermospheres by photodissociation and ionization processes, due to exothermic chemical reactions and cooling by IR-radiating molecules like CO₂, NO, OH, etc. Our model simulations result in extended thermospheres for early Earth, Venus and Mars. The exospheric temperatures obtained for all the three planets during this time period lead to diffusion-limited hydrodynamic escape of atomic hydrogen and high Jeans’ escape rates for heavier species like H₂, He, C, N, O, etc. The duration of this blow-off phase for atomic hydrogen depends essentially on the mixing ratios of CO₂, N₂ and H₂O in the atmospheres and could last from ∼100 to several hundred million years. Furthermore, we study the efficiency of various non-thermal atmospheric loss processes on Venus and Mars and investigate the possible protecting effect of the early martian magnetosphere against solar wind induced ion pick up erosion. We find that the early martian magnetic field could decrease the ion-related non-thermal escape rates by a great amount. It is possible that non-magnetized early Mars could have lost its whole atmosphere due to the combined effect of its extended upper atmosphere and a dense solar wind plasma flow of the young Sun during about 200 Myr after the Sun arrived at the ZAMS. Depending on the solar wind parameters, our model simulations for early Venus show that ion pick up by strong solar wind from a non-magnetized planet could erode up to an equivalent amount of ∼250 bar of O⁺ ions during the first several hundred million years. This accumulated loss corresponds to an equivalent mass of ∼1 terrestrial ocean (TO (1 TO ∼1.39×10²⁴ g or expressed as partial pressure, about 265 bar, which corresponds to ∼2900 m average depth)). Finally, we discuss and compare our findings with the results of preceding studies.     

Galactic Wind: Mass Fractionation and Cosmic Ray Acceleration

The dynamical and chemical effects of the Galactic Wind are discussed. This wind is primarily driven by the pressure gradient of the Cosmic Rays. Assuming the latter to be accelerated in the Supernova Remnants of the disk which at the same time produce the Hot Interstellar Medium, it is argued that the gas removed by the wind is enriched in the nucleosynthesis products of Supernova explosions. Therefore the moderate mass loss through this wind should still be able to remove a substantial amount of metals, opening the way for stars to produce more metals than observed in the disk, by e.g. assuming a Salpeter-type stellar initial mass function beyond a few Solar masses. The wind also allows a global, physically appealing interpretation of Cosmic Ray propagation and escape from the Galaxy. In addition the spiral structure of the disk induces periodic pressure waves in the expanding wind that become a sawtooth shock wave train at large distances which can re-accelerate “knee” particles coming from the disk sources. This new Galactic Cosmic Ray component can reach energies of a few×10¹⁸ eV and may contribute to the juncture between the particles of Galactic and extragalactic origin in the observed overall Cosmic Ray spectrum.     

Intelligent NURBS Interpolator Based on the Adaptive Feedrate Control

首先分析了NURBS曲线的特点和NURBS曲线插补的参数值的求取方法;其次,在可控弓高误差算法的基础上,提出了一种简单而实用的NURBS曲线的自适应插补算法,该算法充分考虑到了机床的实际加工能力,对曲线段进行提前预插补,提前预插补减速所需的最大插补周期数,实现了进给速度提前减速,能使加工进给速度自适应地随着曲率半径和曲率半径的变化率的变化而变化,使得加工运动更平滑;并且该方法还避免了因加工曲线终点的判断而带来的复杂计算;最后给出了快速求取插补点的三次NURBS曲线动态矩阵表示和曲线曲率的快速计算方法。     

30CrMnSiNi2A 双头螺栓断裂失效分析

分离装置静力试验后发现连接两个舱体的双头螺栓中有7 件发生断裂,螺栓表面进行了达克罗

处理。通过失效分析及相关试验综合分析认为,分离装置上7 件螺栓的断裂性质均为延迟性脆性断裂,断裂机

理为氢脆。导致发生氢脆断裂的原因除螺栓材料及组织具有较高的氢脆敏感性外,主要与静力试验过程中长

时间包覆湿泥有关;另外,原材料氢含量控制及达克罗涂层工艺处理虽然有效避免了产品表面处理过程中带来

的氢脆隐患,但是若使用环境中存在水及腐蚀性介质Cl、S 时,产品在拉应力作用下仍可能发生氢脆延迟断裂

而导致严重后果。

     

基于轮廓法测试铝合金拉弯成形残余应力研究

以2026-T3511铝合金T形结构件的拉弯成形件为研究对象,首先采用线切割将T形结构件分割成两块具有T形截面的试样,然后基于轮廓法测试应力原理应用激光位移传感器分别测试两个分割截面的轮廓变化,进而将两个截面的测量值拟合平均后与有限元模型结合以计算该试样的初始残余应力,从而获得该T形结构件的横截面法向应力并分析其分布特征。研究结果表明,基于轮廓法测得的应力分布与有限元仿真结果分布规律相近:峰值压应力为60MPa,峰值拉应力为40MPa;轮廓法在航空结构件应力测试中能够准确地获得其他测试方法无法获得的横截面完整的应力分布。     

整体叶盘叶型电解加工流场设计及实验

电解加工（ECM）是航空发动机整体叶盘制造的主要技术之一,其电解液流场稳定性是影响电解加工精度和表面质量的核心因素。本文在分析原有的二维流场基础上,针对流体在不同流道截面下的流场状态,提出了一种三维复合电解液流场模式,即三股电解液分别从毛坯进气边、叶盆叶根、叶背叶根流入,由排气边交汇流出。采用有限元法对三维复合流场及两类二维流场开展仿真分析,分析结果表明三维复合流场改善了流道突变区域流场状态,有效抑制了二维流场的流场缺陷,有助于提高流场稳定性。对加工区液体流态进行了判断,其结果显示三维复合流场可以满足电解加工要求。开展了3种流场模式的加工速度比较实验,三维复合流场达到的进给速度最高,较二维流场可显著提升加工效率。采用三维复合流场开展了多叶片扇段加工,获得了较好的重复精度与表面质量。     

7085铝合金残余应力及加工变形的数值仿真与试验

毛坯残余应力的测量以及零件的加工变形分析是航空整体结构件数控加工工艺研究的难题。应用MSC.Marc软件对某型飞机主起支撑接头的7085铝合金锻件毛坯的淬火-压缩工艺进行了数值仿真,获得了毛坯残余应力分布趋势;应用X射线衍射法与钻孔法测量了毛坯表层残余应力分布,提出了基于系数修正法的毛坯残余应力分析方法,通过最小二乘法（LSM）拟合仿真值与试验值以获得应力修正系数,并对毛坯残余应力分布的仿真结果进行修正,获得了实际毛坯的残余应力分布;由此进行了主起支撑接头缩比零件加工变形仿真与验证试验。研究结果表明：7085铝合金块状毛坯残余应力数值仿真结果与测试结果的趋势吻合,为应力修正提供了物理基础;相对于未修正的应力分布,基于修正后的应力分布仿真获得的变形结果精度提高了50%;7085-T7452铝合金的毛坯残余应力是导致主起支撑接头加工变形的主要因素。     

双喉道喷管与飞翼布局无人机气动数值研究

利用超椭圆方法,设计了双喉道射流矢量喷管的气动外形,并采用S-A湍流模型数值研究了次主流压比、次流方向及喷管外形参数对其气动特性的影响。研究表明,当确定次主流压比SPR=3时,可依次确定该型喷管外形参数分别为空腔长度l=3h,空腔扩张角θ1=10°,空腔收敛角θ2=30°,二次流注入角α=120°时,矢量喷管的气动特性最优。将设计的气动最优喷管与飞翼布局无人机后体进行一体化设计,数值模拟了喷管对飞翼布局无人机升阻特性的影响,结果表明,双喉道射流矢量喷管能够很好地运用于飞翼布局无人机。     

基于自适应差分进化算法的变循环发动机模型求解方法研究

为了降低传统迭代算法在求解变循环发动机非线性模型时对初值的依赖性,将模型的求解问题转换为求最小值的优化问题,引入差分进化算法进行模型的求解,并提出一种自适应差分进化算法(ADE)。ADE借助轮盘赌选择法,利用种群的进化经验可以自适应的选择最适合当前种群的差分策略与算法控制参数。针对变循环发动机四个典型工作点的模型求解问题,研究了标准差分进化算法(SDE)的控制参数对其性能的影响,获取了SDE在求解四个典型工作点时的最优控制参数组合,对比分析了ADE与SDE的性能差异,最后研究了种群规模对ADE性能的影响。结果表明：SDE在求解发动机模型时具有较好的鲁棒性,在求解不同工作点时算法的最优控制参数并不完全相同;相比于使用最优控制参数的SDE,ADE可以在不影响算法鲁棒性的情况下提升效率50%以上;减少ADE的种群规模会在提升算法效率的同时破坏鲁棒性。