基于声发射技术的搅拌摩擦焊接工具磨损监测

为在线监测搅拌摩擦焊接过程工具磨损状态,本文基于虚拟仪器技术设计了一套声发射在线监测系统,结合声发射传感器、数据采集卡及信号调理器实现了对搅拌摩擦焊接加工过程中声发射信号的采集。实验中采用带有螺纹的搅拌针工具来焊接7075铝合金,并利用自主开发的在线监测系统采集焊接过程中的声发射信号。然后对采集到的声发射信号进行小波包分解处理,计算分解后各频段能量所占百分比,并提取能量分布规律作为信号特征。研究表明:搅拌摩擦焊接工具在不同磨损情况下具有不同的声发射信号特征,小波包分解处理表明搅拌头磨损轻微时,低频段能量占比较高;相反,搅拌头磨损严重时,低频段能量占比较低。     

Minimizing airfoil drag at low angles of attack with DBD-based turbulent drag reduction methods

Dielectric Barrier Discharge (DBD) based turbulent drag reduction methods are used to reduce the total drag on a NACA 0012 airfoil at low angels of attack. The interaction of DBD with turbulent boundary layer was investigated, based on which the drag reduction experiments were conducted. The results show that unidirectional steady discharge is more effective than oscillating discharge in terms of drag reduction, while steady impinging discharge fails to finish the mission (i.e. drag increase). In the best scenario, a maximum relative drag reduction as high as 64 % is achieved at the freestream velocity of 5 m/s, and a drag reduction of 13.7 % keeps existing at the freestream velocity of 20 m/s. For unidirectional discharge, the jet velocity ratio and the dimensionless actuator spacing are the two key parameters affecting the effectiveness. The drag reduction magnitude varies inversely with the dimensionless spacing, and a threshold value of the dimensionless actuator spacing of 540 (approximately five times of the low-speed streak spacing) exists, above which the drag increases. When the jet velocity ratio smaller than 0.05, marginal drag variation is observed. In contrast, when the jet velocity ratio larger than 0.05, the experimental data bifurcates, one into the drag increase zone and the other into the drag reduction zone, depending on the value of dimensionless actuator spacing. In both zones, the drag variation magnitude increases with the jet velocity ratio. The total drag reduction can be divided into the reduction in pressure drag and turbulent friction drag, as well as the increase in friction drag brought by transition promotion. The reduction in turbulent friction drag plays an important role in the total drag reduction.     

Mechanism of interconnected synchronized switch damping for vibration control of blades

The Synchronized Switch Damping (SSD) is regarded as a promising alternative to mitigate the vibration of thin-walled structures in aero-engines, especially for blades or bladed disks. The common manner is to shunt the switch circuit independently to a single piezoelectric structure. This paper is aimed at exploring a novel way of using the SSD, i.e., the SSD is interconnected between two piezoelectric structures or substructures. The damping mechanism, performance, and effective range of the interconnected SSD are studied numerically and experimentally. First, based on a dual cantilever beam finite element model, the time domain and frequency domain modeling and solving methods of the interconnected SSD are deduced and validated. Then, the influence of the amplitude and phase relationship on the damping effect of the interconnected SSD is numerically studied and compared with the shunted SSD. A self-sensing SSD control board is developed, and experimental studies are carried out. The results show that the interconnected SSD establishes an additional energy channel between the corresponding piezoelectric structures. When the amplitudes of the two cantilever beams are different, the interconnected SSD balances the vibration level of each beam. When the amplitudes of the two cantilever beams are the same, if the appropriate interconnection manner is selected according to the phase, the resonance peak can be reduced by more than 30%. When the vibration is in-phase/out-of-phase, the damping generated by the interconnected SSD in a cross/parallel manner is even more significant than the shunted SSD. Furthermore, this novel connection scheme reduces the number of SSD circuits in half. Finally, for engineering applications, we implement the proposed damping technology to the finite element model of a typical dummy bladed disk. A piezoelectric damping ratio of 13.7% is achieved when the amount of piezo material is only 10% of blade mass. Compared with traditional friction dampers, the major advancements of the interconnected SSD are: (A) it can reduce the vibration level of blades without friction interface; (B) the space constraint is overcome, i.e., the vibration energy is not necessarily dissipated independently in one sector or through physically adjacent blades, and instead, the dissipation and transfer of vibrational energy can be realized between any blade pair. If a specific gating circuit is adopted to adjust the interconnection manner of the SSD, vibration mitigation under variable working conditions with different engine orders will be expected; (C) designers do not need to worry about the annoying nonlinearities related to working conditions anymore.     

Hypersonic shock wave and turbulent boundary layer interaction in a sharp cone/flare model

A direct numerical simulation of hypersonic Shock wave and Turbulent Boundary Layer Interaction(STBLI) at Mach 6.0 on a sharp 7° half-angle circular cone/flare configuration at zero angle of attack is performed. The flare angle is 34° and the momentum thickness Reynolds number based on the incoming turbulent boundary layer on the sharp circular cone is Re_θ = 2506. It is found that the mean flow is separated and the separation bubble occurring near the corner exhibits unsteadiness. The Reynolds analogy factor changes dramatically across the interaction, and varies between 1.06 and 1.27 in the downstream region, while the QP85 scaling factor has a nearly constant value of 0.5 across the interaction. The evolution of the reattached boundary layer is characterized in terms of the mean profiles, the Reynolds stress components, the anisotropy tensor and the turbulence kinetic energy. It is argued that the recovery is incomplete and the near-wall asymptotic behavior does not occur for the hypersonic interaction. In addition, mean skin friction decomposition in an axisymmetric turbulent boundary layer is carried out for the first time. Downstream of the interaction, the contributions of transverse curvature and body divergence are negligible, whereas the positive contribution associated with the turbulence kinetic energy production and the negative spatial-growth contribution are dominant. Based on scale decomposition, the positive contribution is further divided into terms with different spanwise length scales. The negative contribution is analyzed by comparing the convective term, the streamwise-heterogeneity term and the pressure gradient term.     

高温环境下角接触球轴承磨损寿命分析

针对高温环境下轴承材料性质和润滑状态变化，造成轴承磨损加剧，过早丧失精度的问题。首先开展高温环境下轴承用材料的摩擦磨损试验，获取材料的磨损系数。在此基础上，考虑温度、润滑、轴承材料属性等对轴承磨损性能的影响，建立高温角接触球轴承磨损模型，通过数值求解探讨工况参数和结构参数等对轴承磨损性能的影响，并评估轴承的磨损寿命。结果表明：对于高温轴承材料无磁合金GH05，在高温300 ℃摩擦状态下平均磨损系数为2.5×10^-7 mm²/N；随着载荷、转速、温度的增加，轴承内、外滚道的磨损率均不断增大，其中内圈磨损率大于外圈，内圈磨损特性决定着轴承的磨损寿命；载荷和转速是决定轴承磨损寿命的主要因素，轴承主结构参数对磨损寿命具有重要影响，通过结构优化可提高轴承磨损寿命。     

搅拌摩擦加工调控镁合金组织与耐腐蚀性能的发展现状与趋势

近年来，航空航天领域轻量化进程发展迅速，镁合金在其中扮演着越来越重要的角色。然而，镁合金耐腐蚀性不佳的特点制约了镁合金的应用范围。本文综述了搅拌摩擦加工技术调控含第二相镁合金耐腐蚀性能的研究现状，从动态再结晶和加速第二相破碎、固溶两个角度，论述了搅拌摩擦加工调控镁合金组织的基本原理，并分析了搅拌摩擦加工改善含粗大第二相镁合金耐腐蚀性的原因，为改善含粗大第二相镁合金的耐蚀性提供了技术途径和研究方向。     

Design and analysis of a novel hybrid cooling method of high-speed high-power permanent magnet assisted synchronous reluctance starter/generator in aviation applications

To improve the heat dissipation performance, this paper proposes a novel hybrid cooling method for high-speed high-power Permanent Magnet assisted Synchronous Reluctance Starter/Generator (PMaSynR S/G) in aerospace applications. The hybrid cooling structure with oil circulation in the housing, oil spray at winding ends and rotor end surface is firstly proposed for the PMaSynR S/G. Then the accurate loss calculation of the PMaSynR S/G is proposed, which includes air gap friction loss under oil spray cooling, copper loss, stator and rotor core loss, permanent magnet eddy current loss and bearing loss. The parameter sensitivity analysis of the hybrid cooling structure is proposed, while the equivalent thermal network model of the PMaSynR S/G is established considering the uneven spraying at the winding ends. Finally, the effectiveness of the proposed hybrid cooling method is demonstrated on a 40 kW/24000 r/min PMaSynR S/G experimental platform.     

基于智能差分算法的摩擦力补偿方法研究

针对光电平台低速转动时，受摩擦力影响较大，使得速度跟随曲线出现“死区”现象，导致跟踪性能明显下降这一问题，提出了一种基于智能差分进化算法和Lurge摩擦模型的摩擦力补偿控制方法。通过采集记录光电转台正、反向匀速运动时的摩擦力大小，建立转台不同速度和摩擦力之间的对应关系。通过最小二乘法对摩擦模型静态参数进行分段拟合，采用智能差分进化算法辨识摩擦模型动态参数，并基于反馈的速度信息和获得的摩擦模型等效为摩擦补偿力矩输入到电流环控制输入端，实现平台平稳低速运行。实验结果表明：摩擦力补偿后速度响应误差由补偿前的±0.1°/s减小到±0.04 °/s，提出方法效果显著。