某型机超薄壁整体框数控加工技术

后机身30框板,是公司自行设计开发的L15新型高级教练机超薄壁整体框板.本文从工艺方法、工装设计、编程技术等方面,论述了该零件的数控加工技术关键,以及如何提高生产效率问题.     

Evolution of convex structure during counter-rotating electrochemical machining based on kinematic modeling

Counter-rotating electrochemical machining (CRECM) is a novel electrochemical machining (ECM) method, which can be used to machine convex structures with complex shapes on the outer surface of casings. In this study, the evolution of the convex structure during CRECM is studied. The complex motion form of CRECM is replaced by an equivalent kinematic model, in which the movement of the cathode tool is realized by matrix equations. The trajectory of the cathode tool center satisfies the Archimedes spiral equation, and the feed depth in adjacent cycles is a constant. The simulation results show that the variations of five quality indexes for the convex structure: as machining time increases, the height increases linearly, and the width reduces linearly, the fillets at the top and root fit the rational function, and the inclination angle of the convex satisfies the exponential function. The current density distributions with different rotation angles is investigated. Owing to the differential distribution of current density on workpiece surface, the convex is manufactured with the cathode window transferring into and out of the processing area. Experimental results agree very well with the simulation, which indicates that the proposed model is effective for prediction the evolution of the convex structure in CRECM.     

Magnetic connectivity and solar energetic proton event intensity profiles at deka-MeV energy

We present an analysis of the time-intensity profiles of 25 solar energetic proton events at 18.2 MeV, modelled by fitting an analytical function form (a modified Weibull function) to the observed intensities. Additionally relying on previous work that characterized the magnetic connectivity between the event-related solar flare and the observer in these events with three angular parameters, we investigate the fit function parameters, the connectivity parameters, and the iron-to-carbon ratio of the events for dependencies and correlations. We find that the fit parameter controlling the basic shape of the profile (parameter a) is not clearly dependent on the connectivity parameters or the Fe/C ratio, suggesting that the profile shapes of neither well and weakly connected nor generally “impulsive” and “gradual” events differ systematically during the early stages of the event at 1 AU. In contrast, the time scaling of the fit function (parameter b) is at least moderately correlated with both the magnetic connectivity parameters and the Fe/C ratio, in that well-connected and iron-rich events are typically shorter in relative duration than weakly connected and nominal-abundance events; intensity rise times display a similar correlation with the connectivity parameters. We interpret the former result as following from the combined effect of various transport processes acting on the particles in interplanetary space, while the latter is essentially consistent with established knowledge regarding the observed dependence of the time-intensity profile shapes of solar energetic particle events on their magnetic connectivity and heavy ion abundances. The desirability of modelling the particle transport effects in detail and extending the analysis to cover higher energies is indicated.     

轮廓度约束下近净成形叶片余量优化方法

针对近净成形的叶片在自适应精加工中余量不均这一问题,提出了考虑叶型截面线轮廓度公差约束的余量优化方法。在设计基准与加工基准配准的条件下,改变工件做刚性位移的余量优化思路,建立一种新的叶身优化模型,避免优化后叶片检测处的截面线超出轮廓度公差,提升叶片余量优化阶段寻找到目标加工曲面的能力。最后以某压气机叶片为例进行验证,此方法不仅能够保证叶身加工余量,还能同时满足型面检测处的轮廓度公差,为近净成形的叶片在自适应加工中提供一种新的余量优化方法。     

自由曲面侧铣刀具轮廓与轨迹同步优化方法

针对自由曲面侧铣加工中轨迹规划困难、加工精度难保证等问题，提出了一种自由曲线母线类刀具的外形轮廓设计方法。该方法在优化刀具轮廓的同时，充分考虑了加工过程中的工件精度和刀轴光顺性问题，实现了自由曲线母线类刀具的形状设计和对应侧铣加工轨迹的生成。首先，通过分别定义刀具轮廓母线和刀轴轨迹面实现对刀具形状和侧铣加工轨迹的表达，并由此计算切削行上刀具工件干涉量来评价加工误差，以刀轴轨迹面能量评价刀轴光顺性，建立了基于加工误差和刀轴光顺性的刀具轮廓与加工轨迹的同步优化模型；其次，为实现对同步优化模型的求解，给出了基于序列逼近法的求解策略，以及优化初值中刀轴轨迹面控制参数和刀具轮廓控制参数获取方法；最后，分别通过加工轨迹规划实验和刀具轮廓设计实验，验证了本文算法在在自由曲面四轴侧铣加工刀具轮廓设计与加工轨迹优化中的正确性及有效性。研究成果为提高自由曲面类零件侧铣加工精度、实现侧铣加工刀具轮廓设计及侧铣加工轨迹规划提供了一种有效的方法和手段。     

基于KNN的机床刀尖点频响函数预测

加工颤振是影响工件表面质量、加剧刀具磨损和降低机床寿命的重要原因,颤振抑制一直以来都是学术界和工业界关注的重点。稳定性叶瓣图是现有颤振抑制方法的重要依据,而机床刀尖点频响函数是绘制稳定性叶瓣图的主要输入。锤击试验法是目前获取刀尖模态参数最为准确的方法,但是在机床结构变化频繁的应用场景下,该方法效率低,机床需要长时间停机,难以满足实际生产要求。提出了基于KNN的机床刀尖点频响函数预测方法,将锤击试验法和KNN算法相结合,大幅减小了锤击试验的次数,同时准确获得机床刀尖点频响函数。在试验验证中,将该方法和传统RCSA方法进行对比,结果表明所提方法具有良好的准确度。     

Successes and challenges in non-destructive testing of aircraft composite structures

Composite materials are increasingly used in the aerospace industry. To fully realise the weight saving potential along with superior mechanical properties that composites offer in safety critical applications, reliable Non-Destructive Testing (NDT) methods are required to prevent catastrophic failures. This paper will review the state of the art in the field and point to highlight the success and challenges that different NDT methods are faced to evaluate the integrity of critical aerospace composites. The focus will be on advanced certificated NDT methods for damage detection and characterization in composite laminates for use in the aircraft primary and secondary structures.     

一种高超声速试飞器助推段主动弹性抑制方法

针对高超声速试飞器助推段由于其高静不稳定特性所引起的低频弹性模态与刚体高带宽控制之间动态耦合问题，具有低频模态和大静不稳定度等特征，引入主动弹性抑制技术，即在传统控制器的设计基础上引入弹性振动能量在线辨识技术相结合的改进自适应增广控制技术(Adaptive augmenting control, AAC)，动态改变开环系统控制增益，以降低弹性模态对舵机的影响，同时增加刚体控制系统的稳定性。仿真结果验证了该方法能够有效减小由干扰激励出的弹性模态所引起的附加舵机摆角，抑制伺服弹性耦合作用。该方法对高超声速试飞器助推段的控制具有重要的理论意义和工程应用价值。     

纵-扭复合超声钻削TC4钛合金振动系统设计与试验

螺旋沟槽变幅杆能够实现超声振动模式的转换，对单激励纵-扭复合振动的实现具有结构简单和操作可行的优点。基于弹性波场论对超声波在复合变幅杆中发生模式转换的原因及振动特性进行分析，并从超声波的入射角入手，分析入射角对振动模态的影响。在圆锥复合变幅杆的圆锥段开设螺旋沟槽，建立三维模型，并进行有限元仿真和试验验证，结果表明超声波入射角的改变对纵-扭复合变幅杆的扭-纵比影响显著。当入射角为46.5°和67.2°时，在变幅杆的输出端纵振模态和扭振模态发生明显的变化，实测的扭-纵比前者较后者提高约5.1倍。通过普通钻削与超声钻削实验对比，在不同的入射角条件下，超声钻削的平均钻削力均低于普通钻削力。与入射角为67.2°时对比，当入射角为46.5°时，平均钻削力降低约46%，并提高了制孔的质量，从而为模态转换的纵-扭复合变幅杆设计提供一定的理论依据。     

Reverberation time lags in the high luminosity quasar PG 1247+267

Virial estimates of the black hole mass in the center of AGNs, derived from single-epoch observations of luminosity and emission line widths, are now available for several thousands of objects at all redshifts and luminosities, so that studies of the cosmological evolution of the AGN mass function are becoming possible. These estimates are based on the empirical luminosity-size relation measured through reverberation mapping at low redshifts and luminosities. For this reason the spectrophotometric monitoring of 4 luminous quasars was started in 2003, with the 1.8 m telescope of the Asiago Observatory. To measure the reverberation time lag we adopt a method, recently introduced by Zu et al. (2011), which takes advantage of the available statistical information on variability autocorrelation and makes simple assumptions on the continuum-emission line transfer function. We present the estimate of the broad line region size for the quasar PG 1247+267, which is the most luminous object with reverberation measures to date. Virial products computed for C iv and C iii] emission lines provide consistent results. A possible flattening of the size-luminosity relation for C iv at high luminosity is suggested.