300M超高强度钢在模拟积水环境中的腐蚀行为

 针对飞机结构部件在服役过程中存在的缝隙积水导致结构材料腐蚀的问题,通过研究腐蚀产物、形貌、失重、腐蚀速率、腐蚀损伤度以及积水溶液与暴露金属的面容比、pH值等的变化,探讨了300M超高强度钢在模拟积水环境中的腐蚀行为。结果表明,300M钢在模拟积水中的腐蚀是从点蚀开始,然后点蚀坑扩展合并,逐渐发展为全面腐蚀,其腐蚀失重和腐蚀损伤度随腐蚀时间的增加而增大,腐蚀损伤度则呈现出幂函数变化趋势;随腐蚀时间的延长,模拟积水环境中的pH值从初期的4.2升到5.2再下降到4.8～5.0,平均腐蚀速率也从0.289 g/(m²·h)线性减小到0.120 g/(m²·h);电化学交流阻抗结果表明随腐蚀时间的延长,容抗弧半径逐渐增大,说明腐蚀产物对基体起到一定的保护作用,这与腐蚀速率变化规律一致;另外,不同的面容比(腐蚀介质体积与300M钢暴露面积之比)对腐蚀过程的影响是:随面容比的增加,腐蚀失重与腐蚀速率均增大。     

基于非线性静力学模型的飞机系留载荷计算方法研究

由于飞机在强风下系留时,机体承受各方向的载荷较大,因此需对系留结构及系留索是否具有足够的承载能力进行分析,而其中系留载荷的计算就显得异常重要。采用MSC．Nastran软件,针对飞机存系留情况下,系留索的单向承载性及起落架与地面的非线性接触特性,通过应用非线性间隙单元,建立了非线性静力仿真模型,并计算了飞机在系留状况下,各系留索承受的张力及各系留点所受的载荷,计算中同时考虑了起落架缓冲支柱空气弹簧力对于系留载荷的影响,从而为飞机系留载荷提供了一种新的有限元计算方法。     

摩托车发动机机加柔性生产线工艺设计

技术改造实施成功与否,很大程度取决于该项目的工艺设计水平。本文从柔性生产线工艺设计依据、指导思想、主要设计内容,以及生产线总体技术水平和经验教训等方面,较详细地介绍了摩托车发动机机加柔性生产线工艺设计的全过程。     

潜射导弹级间段密封圈动态密封性能模拟试验方法

根据潜射导弹级间段密封圈在出水过程中的动态变形参数设计了一套模拟试验件和加载、加水及测量装置,采用摆锤冲击加载方式和裂纹动态张开位移测量方法再现了密封圈在导弹出水过程中的使用条件,证明密封圈在规定的开缝宽度、开缝时间和弹体内外压差的使用环境下能够保证防水和密封效果。利用两自由度冲击响应模型分析了试验的动响应曲线,给出了试验系统模态参数的识别结果。     

Machining of SiC ceramic matrix composites: A review

Continuous fiber reinforced SiC ceramic matrix composites (FRCMCs-SiC) are currently the preferred material for hot section components, safety–critical components and braking components (in the aerospace, energy, transportation) with high value, and have triggered the demand for machining. However, the high brittleness, anisotropy, and heterogeneity of materials bring great challenges to machining, due to high mechanical and thermal loads, severe tool wear, and poor machining quality. With the increasing demand of FRCMCs-SiC parts, high-quality and high-efficient machining has become a hot issue. This review paper provides a detailed literature survey on the machining of FRCMCs-SiC. The material removal mechanism, defect form, and interfacial mechanical properties of FRCMCs-SiC were summarized. The machining processes of FRCMCs-SiC were introduced, and their respective advantages and disadvantages were compared. Given the low machinability (high hardness, high brittleness, anisotropy, and heterogeneity) of FRCMCs-SiC, preliminary experiments have proved that ultrasonic-assisted machining and laser-assisted machining have shown unique advantages in reducing force and tool wear, improving machining quality and machining efficiency. The machined surface integrity was discussed, the influence of process parameters on the machined surface quality was analyzed, and the machining defects of FRCMCs-SiC were summarized. But for FRCMCs-SiC, the existing quantitative evaluation of the machined surface integrity was weak and unsystematic.     

切向结构永磁同步电机中磁钢厚度对性能的影响

提出了切向结构永磁同步电机中磁钢厚度的约束条件;依据电机学理论并结合有限元计算方法,研究了气隙长度恒定时不同极对数下气隙磁密、每极磁通与磁钢厚度的关系,探讨了磁钢厚度对电机的过载能力、铁耗等性能的影响;在气隙长度发生变化时,为了保证漏磁大小不变,讨论了气隙与非导磁衬套厚度、磁钢厚度的关系。并指出:(1)气隙恒定时,随着磁钢厚度的增加,不同极对数时磁钢体积增大所提供的磁势对每极磁通的影响有所不同;铁耗和过载能力随磁钢厚度的增加而增大。(2)气隙增大时,为了保证气隙磁密和漏磁不变,必须增加非导磁衬套的厚度。(3)极对数增加时,减小磁钢厚度能提高电机的性价比。     

基于动力学仿真技术的TC4整体叶轮铣削参数优化

针对某航空发动机TC4整体叶轮在数控加工过程中存在颤振、加工效率低及因加工变形而导致局部超差等问题,提出了相应的铣削参数优化解决方案。在进行切削力系数辨识试验获取TC4材料的切削力系数及锤击试验获取加工系统动力学特性参数的基础上,通过综合使用自行开发的铣削加工动力学仿真软件SimuCut和国外的CutPro软件进行动力学仿真与优化,获得了优化的切削参数。使用优化的切削参数进行加工,有效地消除了颤振和因加工变形引起的局部超差,提高了加工效率。     

Four-axis trochoidal toolpath planning for rough milling of aero-engine blisks

The Blade Integrated Disk (Blisk) is one of the key components in the aero-engine, it is generally manufactured by the multi-axis milling and almost 90% raw materials are removed. To avoid the full immersion of a cutter in the rough machining of a blisk channel, the trochoidal milling is a promising strategy since it can keep a small immersion angle in the rough milling process while maintaining the high machining efficiency. However, while toolpaths are being planned for the trochoidal milling process, the conventional methods are mainly for the planar machining area with fixed tool orientations, which cannot be used for complex channels where the multi-axis machining should be employed. To this end, this paper presents a four-axis trochoidal toolpath planning method with a ball-end cutter, and thus the blisk channel can be machined efficiently. For this to happen, the trochoidal paths are planned in the parametric domain and then mapped into the physical domain, with tool orientations controlled by the quaternion interpolation method to have smooth tool movement along the toolpaths. Both geometric simulation and physical milling experiments of the proposed method have convincingly demonstrated the validation of the proposed method.     

Investigation on the interface damage in drilling low-stiffness CFRP/Ti stacks

Carbon fiber reinforced plastic and titanium alloy (CFRP/Ti) stacks have been widely used as aerospace structures because of their excellent combination of physical properties. Interface damage caused by interface gaps, significantly different from that of metal/metal stacks, is a common problem in the through-hole drilling of CFRP/Ti stacks with low stiffness. In this study, a force–deformation coupling model was developed to further examine the formation mechanism and the control method of interface damage. Firstly, the coupling model was built considering the interaction between the thrust force and the deformation. To solve this model, a numerical method was proposed in which specific cutting coefficients were calibrated using only the thrust force of rigid stacks. Secondly, drilling experiments were performed with different feed rates and bending stiffness. Experimental results indicate that interface damage mainly includes interlayer chips and surface damage of CFRP layers. The surface damage, which is irreparable, is caused by the rotary extension of metal chips along the interlayer gap. Thirdly, variations of the interface gap were calculated with the coupling model that had been verified by measured thrust forces. The damage area was found to have a linear dependence relation with the interlayer gap. However, in conditions of large gap sizes, the interface damage areas increased with the interlayer gap at high feed rates, while decreasing slightly at low feed rates. This phenomenon was satisfactorily explained by the presented model. Finally, a method was proposed to determine the appropriate pressure exceeding which no interlayer damage will occur. Additional drilling experiments proved the method effective. This study leads to further understanding of the forming mechanism of interlayer damage and of selecting appropriate parameters in drilling low-stiffness composite/metal stacks.     

Vibration suppression of thin-walled workpiece machining considering external damping properties based on magnetorheological fluids flexible fixture

Milling of the thin-walled workpiece in the aerospace industry is a critical process due to the high flexibility of the workpiece. In this paper, a flexible fixture based on the magnetorheological(MR) fluids is designed to investigate the regenerative chatter suppression during the machining.Based on the analysis of typical structural components in the aerospace industry, a general complex thin-walled workpiece with fixture and damping constraint can be equivalent as a rectangular cantilever beam. On the basis of the equivalent models, natural frequency and mode shape function of the thin-walled workpiece is obtained according to the Euler–Bernoulli beam assumptions. Then,the displacement response function of the bending vibration of the beam is represented by the product of all the mode shape function and the generalized coordinate. Furthermore, a dynamic equation of the workpiece-fixture system considering the external damping factor is proposed using the Lagrangian method in terms of all the mode shape function and the generalized coordinate, and the response of system under the dynamic cutting force is calculated to evaluate the stability of the milling process under damping control. Finally, the feasibility and effectiveness of the proposed approach are validated by the impact hammer experiments and several machining tests.