长板件数控加工技术的探索与研究

结合某型机板件在数控加工中的研制生产状况和存在的问题,论述了实现各种长板件类结构零件装夹定位、刀具及其参数、加工方案及程编策略.通过这些技术措施的实施,在一定程度上解决了在加工长板类零件装夹和定位时出现的零件变形、让刀效率低、质量不稳定等问题.     

负游隙对高速高温薄壁圆柱滚子轴承动态性能的影响分析

计算了圆柱滚子轴承径向游隙为负值时的等效径向预紧载荷,并考虑等效径向预紧载荷下的套圈弹性变形,通过求解包含套圈弹性变形接触变形等效径向预紧载荷的非线性方程组,得到负游隙圆柱滚子轴承内部的载荷分布情况,以及负径向游隙带来的套圈周向应力.以此分析了负游隙对轴承承载性能及疲劳寿命的影响.结果表明:负径向游隙能够有效降低轴承打滑率,但同时也会降低轴承疲劳寿命,因此在负游隙设计时需同时考虑打滑率和轴承寿命,选择恰当的负游隙.     

平箔片楔形高度对气体止推箔片轴承特性影响

针对波箔型气体止推箔片轴承,建立了箔片结构二维薄板模型,并通过有限差分法和有限元法耦合求解可压缩气体Reynolds方程和气膜厚度方程,获得了给定轴承载荷条件下轴承气膜压力分布、气膜厚度分布、平箔片变形量和功率损耗等轴承特性.通过对比楔形高度分别为25,70,100,200,300μm时的轴承特性仿真结果研究了楔形高度对轴承性能的影响.结果表明:降低楔形高度使轴承气膜压力分布更均匀,并降低了平箔片的局部集中载荷.但楔形高度存在一个最佳值,使得达到相同轴承载荷所需的最小气膜厚度最大,并且轴承具有最小功率损耗,提高了轴承的工作效率.该结果为气体止推箔片轴承的结构设计提供的理论参考.      

Advances and trends in plastic forming technologies for welded tubes

With the implementation of environmental protection, sustainable development and conservation-oriented policies, components and parts of thin-walled welded tubes have gained increasing application in the aircraft and automotive industries because of their advantages: easily achieving forming and manufacturing process at low cost and in a short time. The current research on welded tube plastic forming is mainly concentrated on tube internal high-pressure forming, tube bending forming, and tube spinning forming. The focuses are on the material properties and characterization of welded tubes, finite element modeling for welded tube forming, and inhomogeneous deformation behavior and the mechanism and rules of deformation coordination in welded tube plastic forming. This paper summarizes the research progress in welded tube plastic forming from these aspects. Finally, with a focus on the urgent demand of the aviation, aerospace and automotive industries for high-strength and light-weight tubes, this paper discusses the development trends and challenges in the theory and technology of welded tube plastic forming in the future. Among them,laser tailor-welded technology will find application in the manufacture of high-strength steel tubes.Tube-end forming technology, such as tube flaring and flanging technology, will expand its application in welded tubes. Therefore, future studies will focus on the FE modeling regarding how to consider effects of welding on residual stresses, welding distortions and microstructure, the inhomogeneous deformation and coordination mechanism of the plastic forming process of tailor-welded tubes, and some end-forming processes of welded tubes, and more comprehensive research on the forming mechanism and limit of welded tubes.     

Cross-sectional deformation behavior of double-ridged rectangular tube with fillers in different stages of H-typed bending

The bent double-ridged rectangular tube (DRRT) with high forming quality is helpful to improve the microwave transmission accuracy. For reducing the cross-sectional deformation in the H-typed bending process, in addition to using rigid mandrel to support the inside of tube, ridge groove fillers are also added to restrict the deformation of ridge grooves. Because of the change of stress and strain state of bent tube in bending, rigid mandrel retracting and specially twice-springback stages, and the springback of fillers, the cross-sectional deformation of tube in each stage may be different. Therefore, based on the ABAQUS platform, the finite element models (FEM) for H-typed bending, mandrel retracting and twice-springback stages of H96 DRRT with fillers were established and validated. It is found that, for the height and width deformation of tube and spacing deformation of ridge grooves, retraction of mandrel can make the distribution of these deformations more uniform along the bending direction. The first springback can reduce these deformations significantly, which should be emphasized. But the second springback only increases them by less amount, which can be ignored. The smaller height deformation of ridge groove and filler can be neglected.     

整体弹性结构法及在叶片流固耦合分析中的应用

针对三维叶片时域流固耦合振动响应计算普遍耗时的问题,采用一种假设整体结构的模态位移,求解固体时域响应和实现高效网格变形,发展了一种3维时域流固耦合分析的整体弹性结构方法,并应用于压气机叶片0°和180°相位角的气动稳定性分析中。结果表明,所发展方法的计算结果与传统双向时域算法和文献的结果较为吻合,而计算效率相比于传统算法显著提升;在所分析的两个相位角下,叶片振动的气动阻尼均随流量减小先增大后降低,相比于0°相位角,180°下叶片的气动稳定性大幅提高,表明该方法能有效应用于叶片的工程流固耦合研究。     

针栓式喷注单元膜束撞击雾化混合过程数值模拟

为了全面认识针栓式喷注器喷雾场结构，基于自适应网格加密技术和分三相计算的PLIC VOF（Piecewise Linear Interface Calculation Volume of Fluid）方法对针栓式喷注单元膜束撞击雾化混合过程进行了仿真分析，通过对两路推进剂分别进行界面追踪，获得了膜束撞击雾化混合过程的详细结构特征，与高速摄影试验结果定性定量对比均吻合较好，验证了数值方法的准确性。以此为基础对膜束撞击的喷雾场结构、撞击变形过程、流场涡结构、雾化破碎典型特征及破碎后的雾化混合分布特征进行了识别分析，结果表明：膜束撞击形成了液束未穿透液膜和液束穿透液膜2种不同的喷雾扇结构。膜束撞击形成的喷雾扇呈"Ω"形，膜束同时发生弯曲变形和横截面变形。另外，膜束撞击同时受到正压和剪切应力作用，导致了一系列复杂涡流现象，使得相互作用增强，雾化混合均增强，这也是膜束撞击喷注构型优于膜膜撞击的本质原因。最后，还发现膜束撞击喷雾场液滴分布呈现分区结构特征，分别是液束控制主导的上雾化区、液膜控制主导的下雾化区及夹在中间的混合区，实际中应兼顾雾化特性和混合特性，选取中等动量比膜束撞击，这可为针栓式喷注器的理论研究和工程设计提供重要参考。     

基于全局Newton-Raphaon方法的弹流润滑分析

基于全局Newton-Raphaon方法对滑动轴承的弹流润滑性能进行了数值摸拟。比较了弹性变形对连杆大头轴承最小油膜厚度和最大油膜压力的影响。结果表明:全局Newton-Raphaon方法很好的解决了收敛困难,程序运行时间长的问题;考虑表面弹性变形的连杆大头轴承与刚性轴承相比,最小油膜厚度与最大油膜压力的变化趋势相同;一个工作循环内,弹性轴承的最小油膜厚度略大于刚性轴承,而最大油膜压力则明显减小。     

BTA 深孔钻削切屑变形与刀齿切削力分布规律仿真

采用ABAQUS有限元分析软件,建立了错齿BTA钻头钻削环状工件单元切削仿真模型,以45#钢为工件材料,对错齿BTA钻头各刀齿切削不同直径的环状工件进行了模拟仿真,分析了钻削过程中错齿BTA钻头各个刀齿切屑的形成过程与变形特点,研究了环状单元切削力三分量随工件半径的受力分布规律.结果表明,错齿BTA钻头各刀齿切削力分量呈现出随半径增大而增大的非均匀分布规律,并且切削速度和进给量对切削力分布规律几乎没有影响.     

有限变形塑性的指数算法

基于不同的应力测量方式，将得到不同形式的有限变形塑性的算法列式。本文基于柯西应力来表示屈服准则，给出了以柯西应力表示的有限变形塑性的指数算法列式。利用对数应变，在主轴下建立了返回映射算法，得到了一种非对称的算法切线模量。它保持了在无穷小理论中返回映射的算法结构。算例表明，对于静水压力相关的塑性材料，应力测量形式的选择对数值结果有较大的影响，柯西应力列式得到了合理的结果。