A review of topology optimization for additive manufacturing: Status and challenges

Topology optimization was developed as an advanced structural design methodology to generate innovative lightweight and high-performance configurations that are difficult to obtain with conventional ideas. Additive manufacturing is an advanced manufacturing technique building as-designed structures via layer-by-layer joining material, providing an alternative pattern for complex components. The integration of topology optimization and additive manufacturing can make the most of their advantages and potentials, and has wide application prospects in modern manufacturing. This article reviews the main content and applications of the research on the integration of topology optimization and additive manufacturing in recent years, including multi-scale or hierarchical structural optimization design and topology optimization considering additive manufacturing constraints. Meanwhile, some challenges of structural design approaches for additive manufacturing are discussed, such as the performance characterization and scale effects of additively manufactured lattice structures, the anisotropy and fatigue performance of additively manufactured material, and additively manufactured functionally graded material issues, etc. It is shown that in the research of topology optimization for additive manufacturing, the integration of material, structure, process and performance is important to pursue high-performance, multi-functional and lightweight production. This article provides a reference for further related research and aerospace applications.     

某型工程车多功能检测仪的硬件设计

设计的检测仪用于检测某型工程车的电控系统,以51单片机作为中央处理单元,以MAX392多路选择器实现多路选通,以CPLD扩展外围接口,可较好地实现信号的采集、存储和信息显示等功能。检测仪还具有代用功能,在紧急情况下可代替原车电控系统进行工作。     

用于航天器贮箱的复合材料层合板低速冲击损伤及其渗漏规律研究

得益于优异的力学性能和减质优势,贮箱复合材料化已成为新一代航天器的重要特征之一,而复合材料贮箱的冲击后渗漏问题须要重点关注。针对一种用于航天器贮箱的含表层机织布复合材料层合板,通过依次开展低速冲击试验、C扫描损伤检测和氦质谱渗漏检测,获取不同能量冲击后层合板的内部分层损伤和渗漏率,并对比分析了机织布分别置于冲击侧和背侧时层合板的渗漏规律。结果表明,将机织布层置于冲击背侧时,层合板的冲击渗漏门槛值显著提高,且发生渗漏时出现目视可见损伤。     

面向3D打印的设计制造一体化探索

紧密围绕航天结构未来发展需求,以增材制造复杂产品研发为研究对象,对实现设计制造一体化的技术路线和关键技术进行分析。把设计、仿真和制造有机统一起来,把工艺设计纳入结构设计流程,通过仿真驱动设计来提高产品质量、降低制造成本。研究成果可应用于航天领域增材制造产品研发,对传统设计制造模式向智能制造转型具有积极探索意义。     

一种未来大型天地往返运输系统平台气动方案

针对未来低运行成本、可直接水平起降、重复使用的大型天地往返运输系统平台飞行器研制所需重点解决的全速域气动力性能需求与气动热防护匹配等难题,分析了典型航天飞机方案所存在的能量运行缺陷等主要问题及可能的改善方案。基于放宽气动热防护设计、涡轮/冲压/火箭发动机三动力组合、嵌套式旋转机翼全速域变体、在爬升阶段将飞行动能转化为高度势能以及再入阶段“跳跃式”盘旋减速飞行轨迹控制等设计思想,从能量损失速率控制和回收利用等角度出发,开展了一种新型大型天地往返运输系统平台气动布局概念设计研究。全速域气动力/热性能工程估算以及内/外流整体气动效能初步分析结果表明,该方案可有效满足整个飞行包线内的升重平衡需求,相比航天飞机方案具有显著的整体气动效能优势,值得进一步开展深入研究。     

基于遗传优化算法的微通道紫铜热交换器扩散连接工艺

基于遗传优化算法,进行了T2紫铜同种材料扩散连接工艺研究。采用正交试验方法,结合BP神经网络和多目标遗传算法,以扩散连接时的温度、压力、保温时间为输入变量,以扩散连接后的试样焊合率和变形量为输出变量,对扩散连接工艺参数进行优化,并实施相应的扩散连接验证试验。结果表明:T2紫铜合适的扩散连接工艺参数为:温度780℃、压力7. 5 MPa、保温时间120 min,此条件下焊合率可达95. 26%,变形量为0. 166 mm。采用此工艺参数进行微通道热交换器零件制造,厚度方向变形量0. 162 mm,经超声C扫描后连接情况良好,经耐压防漏检测后满足密封性及设计要求。     

基于产业思维的航天发射服务研究

首先从核心驱动出发提出航天发展三阶段第一推动力,从产业要素出发分析航天产业进阶的市场、技术和产业政策三要素。而后从价值链出发研究航天产业产值分布和产业整合策略。最后分析了新兴航天发射服务公司的模式、产品和技术,为我国航天发射服务提供参考。     

基于微观图像及内聚力模型的复合材料裂纹扩展模拟

为研究材料微观结构及晶界强度对材料力学性能的影响,在晶界处引入内聚力单元模型,模拟晶间破坏过程。以ZrB_2-SiC复合材料为研究对象,将其扫描的微观结构图片进行矢量化处理,并导入ABAQUS有限元软件中建立模型,同时在其晶界处,设置内聚力单元模拟晶界破坏过程。通过改变Zr B2与Si C相界面强度,得到了晶界及材料不均匀对材料应力分布及裂纹扩展的影响。结果表明,由于晶界的存在,材料内部出现应力分布不均匀现象并产生应力集中。随着晶界强度的改变,裂纹起始位置及扩展方向发生改变,且裂纹沿低强度的界面进行扩展。随着ZrB_2-SiC界面强度增大,材料的强度提高,拉伸模量不变。     

弹性体运载火箭建模及控制器设计

考虑运载火箭飞行过程中的弹性振动特性,对运载火箭进行全量动力学建模以及控制器设计。首先将运载火箭考虑为一维梁模型并建立全量动力学模型,分别引入自适应滤波姿态控制算法和H_2范数鲁棒增益调度控制算法设计控制器。仿真结果表明:在考虑舵机非线性情况下两种控制方法均能够满足精度要求,在具有较大外部扰动情况下,鲁棒增益调度控制算法相较于自适应滤波算法具有较强的鲁棒性。     

Effects of in-track maneuver on Sun illumination conditions of near-circular low Earth orbits

By developing approximate analytical models considering the J₂ perturbation, the effects of an in-track maneuver on the orbital Sun illumination conditions of near-circular low Earth orbits are analyzed. First, two approximate models for the variations in orbital sunshine angles are developed, one for variations at a given time and the other for variations at a given argument of latitude. Next, two approximate models for variations in orbital arc in Earth shadow are developed, one considers the small eccentricity and the other uses the zero eccentricity. Finally, the developed approximate models are applied to analyzing the Sun illumination conditions of a typical in-track maneuver mission on a near-circular low Earth orbit. From the results obtained, three major conclusions can be drawn. First, the variations in orbital sunshine angles at a given time may reach tens of degrees when the drifting time reaches hundreds of orbital periods, and the approximate model for that situation cannot effectively approach the numerical results. Second, the variations in orbital sunshine angles for any given argument of latitude are only a couple of degrees even when the drifting time reaches 500 orbital periods, and the approximation model developed can effectively approach the numerical results. Third, for variations in orbital arc in Earth shadow, the approximate model considering the small eccentricity has simple expressions and can effectively approach the numerical results; in contrast, the approximate model using the zero eccentricity has relatively worse precision.