Analysis of Chang’e-5 lunar core drilling process

Chang’e-5 explorer successfully acquired lunar regolith core samples from depths of greater than 1 m of lunar surface. This study analyzed the lunar core drilling process based on the telemetry data, image information, and returned samples to optimize the sampling device design and enhance the understanding of the lunar regolith. In particular, a prediction method for the projected drilling path and local terrain fitting of drilling dip angle was proposed based on the flight events recorded during the core drilling process and the image information acquired before, during, and after sampling. The results revealed that the drilling dip angle of Chang’e-5 was approximately 2.3°, and the deviation of the drilling length and depth was less than 2 mm. For continuous drilling, a fusion method based on telemetry data and image information was applied to determine the demarcation point of drilling with and without the lunar soil. The position of the demarcation point implied that the drilling point remained at approximately 6 mm loose soil, thereby lagging the action of the force response. Additionally, a characteristic parameter comparison method was proposed for the lunar and ground drilling to analyze the status of the lunar soil. Furthermore, the analysis results revealed that the majority of the Chang’e-5 drilling samples were derived from 0–73.8 cm below the lunar surface and few samples were extracted below 73.8 cm, as the drilling encountered several rocky regions. Moreover, the drilling point exhibited two prominent stratification variations at ～28.7 cm and ～70 cm below the lunar surface. Ultimately, the preliminary relationship between sample dissected position in soft tube and drilling displacement was analyzed. The segmented estimation results can support research on subsurface lunar soil.     

Experimental and modeling study of surface topography generation considering tool-workpiece vibration in high-precision turning

High-precision turning(HPT) is a main processing method for manufacturing rotary high-precision components, especially for metallic parts. However, the generated vibration between tool tip and workpiece during turning may seriously deteriorate the surface integrity. Therefore,exploring the effect of vibration on turning surface morphology and quality of copper parts using3D surface topography regeneration model is crucial for predicting HPT performance. This developed model can update the machin...     

CFRP钻削温度场的数值仿真与分析

为研究碳纤维增强树脂基复合材料(CFRP)钻削过程传热规律及温度分布特性,在对材料热物理特性均匀化处理的基础上,利用COMSOL Multiphysics建立单向CFRP钻削温度场数值仿真模型,探究钻削过程中热量传递及温度场分布规律.结果表明,出口处温度场呈椭圆形分布状态,椭圆形最小值离心率e为0.771,且椭圆的长轴...     

激光加工非金属复合材料的研究与应用进展

非金属复合材料是一种低密度、高强度、高模量的高性能材料，目前已经成为航天卫星上不可或缺的关键结构材料。但与此同时，该类材料也是一种极难加工的各向异性非均质材料，采用传统的接触式方法加工易产生崩边、分层、起毛、撕裂等问题。激光制造技术作为一种开始逐步走向实用化的先进制造技术，具有材料去除能力强、加工精度高、损伤可控等一系列优点，是一种实现非金属复合材料高性能加工、满足现有和未来需求的理想方法。本文围绕航空航天领域应用较为广泛的碳纤维复合材料、芳纶纤维复合材料和陶瓷基复合材料，系统地综述了国内外激光加工非金属复合材料的研究与应用进展。其中技术分支涉及切割、制孔、铣削刻蚀、清洗等实体减材制造技术。最后对非金属复合材料激光加工方法的未来研究重点和工程应用前景进行了总结与展望。     

Breakthrough detection in electrochemical discharge drilling to enhance machining stability

Film cooling holes are widely used in aero-engine turbine blades. These blades feature large numbers of holes with complex angles and require a high level of surface integrity. Electrochemical discharge drilling(ECDD) combines the high efficiency of electrical discharge drilling(EDD) with high quality of electrochemical drilling(ECD). However, due to the existence of a variety of energy for material removal, accurate and timely detection of breakthroughs is fraught with difficulties. An insuffic...     

Influence of lunar regolith compressibility on sampling performance of thick wall spiral drills

A 2 m class robotic drill was sent to the Moon and successfully collected and returned regolith samples in late 2020 by China. It was a typical thick wall spiral drill (TWSD) with a hollow auger containing a complex coring system to retain subsurface regolith samples. Before the robotic drill was launched, a series of laboratory tests were carried out to investigate and predict the possible drilling loads it may encounter in the lunar environment. This work presents how the sampling performance of the TWSD is affected by the regolith compressibility. Experiments and analysis during the drilling and sampling process in a simulated lunar regolith environment were conducted. The compressibility of a typical lunar regolith simulant (LRS) was measured through uni-directional compression tests to study the relationship between its inner regolith stress and bulk density. A theoretical model was established to elucidate the cutting discharge behavior by auger flights based on the aforementioned relationship. Experiments were conducted with the LRS, and the results show that the sampling performance is greatly affected by the flux of the drilled cuttings into the spiral flight channels. This work helped in scheduling reasonable drilling parameters to promote the sampling performance of the robotic drill in the Chinese Chang'E 5 mission.     

碳纤维复合材料钻削温度测试与分析

利用热像仪对碳／环氧复合材料高速钻孔时的钻削温度及温度场分布进行了系统的试验研究。实验结果显示,钻削热主要是由刀具后刀面与已加工表面之间的摩擦产生的。转速越高,钻削温度赵高;进给量越大,钻削温度越低,但钻削温度一般不超过环氧树脂的玻璃化转变温度。     

拉伸载荷下正交三向机织复合材料接头失效多尺度渐进损伤分析

针对机械打孔三维机织复合材料耳片接头的单轴拉伸破坏性能，采用多尺度分析方法研究孔边纱线破坏过程。结果表明，正交三向（ORT）机织复合材料接头孔边的连续的经纱出现大量的纵向损伤；纬纱单元出现大量横向损伤，损伤沿着孔边45°方向逐渐扩展，纬纱发生剪切失效，最终接头的损伤形式为剪切破坏。数值模拟和试验结果的误差为1.14％，验证了多尺度有限元仿真方法的正确性。孔边细观区域的纱线损伤从孔边扩展到边接头边缘。孔边纱线的分布位置不同，纱线的破坏形式虽不一样，但是不影响破坏的扩展趋势。     

Review on residual stress and its effects on manufacturing of aluminium alloy structural panels with typical multi-processes

In the aerospace industry, integrated aluminium alloy plates and stiffened panels with high accuracy and performance attract significant interest. To manufacture these panels as integrity with high accuracy, multiple processes need to be utilised, such as machining, welding and forming. During the whole manufacturing chain, residual stresses can be generated and redistributed in the components among different processes. The residual stress would significantly affect the shapes and properties of the final products. Currently, these great effects are not well considered in the design and manufacturing processes. This paper aims to draw a general understanding of the residual stress generated in the pre-manufacturing processes and its effects on subsequent manufacturing processes. The mechanisms and distributions of residual stresses generated in typical pre-manufacturing processes of structural panels, including machining, welding and additive manufacturing (AM), are firstly summarised. The detailed effects of generated residual stresses on distortion and application properties in subsequent manufacturing processes are then concluded. In addition, current methods developed for the investigation of residual stress effect in multi-processes manufacturing are critically reviewed, including experimental, analytical, finite element (FE) and machine learning methods. Furthermore, the future development trend of methods for residual stress consideration and control in the design of manufacturing processes is summarised, providing comprehensive guidance to achieve the high accurate manufacturing of aluminium alloy structural components.