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.     

金属弹簧管性能影响因素的仿真分析

为了研究高温密封组件金属弹簧性能,本文通过对波音公司编网状弹簧管结构和Streck心脏支架结构的研究,建立了编织弹簧的几何拓扑构型和数学模型,推导了弹簧直径计算公式。采用AUTODESK3D-MAX构建了编织弹簧的仿真模型,用ANSYS仿真软件分别从编织丝直径、编织密度以及编织方法 3方面探究不同测试对弹簧性能的影响。结果表明,增加弹簧丝直径、降低弹簧管轴向方向的编织密度、提高圆周方向的编织密度、向外的弹簧管编织方式可有效提高弹簧管的回弹性能。     

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.     

飞机高升力系统扭力管旋转角度测试方法

在飞机地面模拟试验环境下需要测试高升力系统襟翼扭力管旋转角度.由于扭力管属于系统试验件,在不改变试验环境构型的情况下不可截断或更换安装用于测试扭力管旋转角度的旋转编码器.本文利用同步轮法实现了在不破坏扭力管前提下安装旋转编码器测试扭力管旋转角度,方法简单、可靠,且容易实现,很好的满足了试验大纲要求.     

爆震管壁面热负荷实验

在一台内径61 mm、长度1140 mm的气动阀式脉冲爆震发动机(PDE)上,进行了爆震管热负荷的测量计算,主要采用了两种换热模型:一是自然对流和热辐射模型;二是强迫对流模型.在两种方式下,爆震管的热负荷随频率的变化关系基本相同,即随频率升高而热负荷增大,但频率增加两倍热负荷增加却不止两倍.此外,在方式二的情况下,还得到煤油蒸发率随频率的变化关系,为PDE蒸发器设计提供参考.      

周期结构电磁特性在高频真空器件中的应用

作为行波类真空电子器件的核心组件,慢波结构是一种周期结构,其场可以有无限多个模式,每个模式由无穷多个空间谐波构成.每个空间谐波有相应的色散曲线且曲线各段有不同的特性.提出了周期结构色散特性的全维度开发的概念,并以一种可用微电机系统(MEMS)技术加工的折叠波导(FWG)慢波结构为例,对其色散特性进行了分析,利用这些色散特性开展了行波管(TWT)、返波管(BWO)等传统器件的研究工作,同时提出了过模器件、带边振荡器(BO)和谐波放大器(THAT)等新型器件,这些器件的实验研究则以W波段及其以上频率为主,最后给出了突破的关键技术以及测试得到的器件的主要性能.      

水声管中传感器灵敏度标定的新方法

对声管双传感器传递函数法测量中由传感器灵敏度差异带来的误差进行了分析.根据已知确定界面反射系数可确定传感器传递函数,并可求其灵敏度比的原理提出了声管中双传感器灵敏度标定的新方法.空气声管中对刚背衬下已知传递函数进行了实验验证;水声管中气体背衬时,分别在常压和打压情况下对新方法进行了实验验证,说明了新方法的可靠性,克服了水声管中无法用交换传感器获得灵敏度补偿的困难.     

机翼热气防冰系统设计

利用热流体系统仿真分析平台Flowmaster和计算流体力学软件Fluent进行联合仿真,对机翼热气防冰系统进行了设计和性能分析.设计参数包括防冰系统笛形管热气喷口孔径、孔数及孔间距等参数.基于Flowmaster对所设计的供气管路进行供气流量分配计算.基于Fluent模拟防冰腔内流动与换热,计算了防冰腔的热效率.根据防冰热载荷及热效率结果预测每段缝翼防冰所需热气流量,引入参数供气余度来分析防冰系统热性能.所提出的热气防冰系统设计方法可为热气防冰系统的工程设计与优化提供重要的帮助.     

地下结构模型试验的光学激波管

光学激波管是进行抗爆结构试验研究的一种新型动载设备,它除具有常规激波管的通过电测手段测试试验结构物上一点或多点的应力、应变、速度等力学参数外,其突出的特点是通过光测手段能够拍摄试验结构物在冲击波动压作用下连续变化的过程和被破坏形态的清晰物理图像,进行地下结构的抗爆研究。本文较详细地介绍了用于地下结构抗爆试验研究用的光学激波管设备的构造和测试手段以及设备调试和应用试验的情况,最后还公布了用该设备拍摄到的激波进入通道后波后新物理现象的彩色波动照片及用该设备做的部分试验研究成果。     

几种流体壁面剪切力测压管的性能研究

对四种壁画型流体剪切力测量差压计Ｓｔａｎｔｏｎ管，Ｋ型管，穴型管，及微孔表面差压管在湍流边界层条件下进行试验并对其结构特点进行比较后表明，这四种差压计具有相同的特征，所测量的区差均为流量动量变化所致，其流体剪切力可以表示为τ＝Ｃ△Ｐ￣ｎ，为避免对标定数据过于繁复的多段拟会，并使差压计能在较大测量范围内保持拟合公式的精度，各类差压管在与固体壁画铅垂方向上的尺度值应尽量低，微孔表面差压管结构复杂，灵敏度低，但它具有线性特性。