Development of Spaceborne Antenna for Circularly Polarized SAR Using Kevlar Honeycomb Core

This paper presents the development of circularly polarized microstrip antenna using Kevlar honeycomb core as the substrates for application of CP-SAR （circularly polarized synthetic aperture radar） which signal propagation is not affected by Faraday rotation effect in the ionosphere, as compared to linearly polarized systems especially at the L-band. The reason why Kevlar honeycomb core is used is because it is suitable for space environment in terms of lightweight and resistant to heat and shock. Measurements of the fabricated antenna were performed to confirm the simulation results. The results show good characteristics of the antennas except the axial ratio. The reason of insufficient axial ratio is assumed as fabrication error of the radiator and microstrip line.

Postprocessor development for ultrasonic cutting of honeycomb core curved surface with a straight blade

When ultrasonically cutting honeycomb core curved parts,the tool face of the straight blade must be along the curved surface’s tangent direction at all times to ensure high-quality machining of the curved surface.However,given that the straight blade is a nonstandard tool,the existing computer-aided manufacturing technology cannot directly realize the above action requirement.To solve this problem,this paper proposed an algorithm for extracting a straight blade real-time tool face vector from a 5-axis milling automatically programmed tool location file,which can realize the tool location point and tool axis vector conversion from the flat end mill to the straight blade.At the same time,for the multi-solution problem of the rotation axis,the dependent axis rotation minimization algorithm was introduced,and the spindle rotation algorithm was proposed for the tool edge orientation problem when the straight blade is used to machine the curved part.Finally,on the basis of the MATLAB platform,the dependent axis rotation minimization algorithm and spindle rotation algorithm were integrated and compiled,and the straight blade ultrasonic cutting honeycomb core postprocessor was then developed.The model of the machine tool and the definition of the straight blade were conducted in the VERICUT simulation software,and the simulation machining of the equivalent entity of the honeycomb core can then be realized.The correctness of the numerical control program generated by the postprocessor was verified by machining and accuracy testing of the two designed features.Observation and analysis of the simulation and experiment indicate that the tool pose is the same under each working condition,and the workpieces obtained by machining also meet the corresponding accuracy requirements.Therefore,the postprocessor developed in this paper can be well adapted to the honeycomb core ultrasonic cutting machine tool and realize high-quality and high-efficient machining of honeycomb core composites.

Effects of inclination angles of disc cutter on machining quality of Nomex honeycomb core in ultrasonic cutting

Ultrasonic cutting with a disc cutter is an advanced machining method for the high-quality processing of Nomex honeycomb core.The machining quality is influenced by ultrasonic cutting parameters,as well as tool orientations,which are determined by the multi-axis machining requirements and the angle control of the cutting system.However,in existing research,the effect of the disc cutter orientation on the machining quality has not been studied in depth,and practical guidance for the use of disc cutters is lacking.In this work,the inclined ultrasonic cutting process with a disc cutter was analyzed,and cutting experiments with different inclination angles were conducted.The theoretical residual height models of the honeycomb core,as a result of the lead and tilt angles,were established and verified with the results obtained by a linear laser displacement sensor.Research shows that the residual height of the honeycomb core,as a result of the tilt angle,is much larger than that as a result of the lead angle.Furthermore,the tearing of the cell wall on the machined surface was observed,and the effects of the ultrasonic vibration,lead angle,and tilt angle on the tear rate and tear length of the cell wall were studied.Experimental results revealed that ultrasonic vibration can effectively decrease the tearing of the cell wall and improve the machining quality.Changes in the tilt angle have less effect than changes in the lead angle on the tearing of the cell wall.The determination of inclination angles should consider the actual processing requirements for the residual height and the machining quality of the cell wall.This study investigates the influence of the inclination angles of a disc cutter on the machining quality of Nomex honeycomb core in ultrasonic cutting and provides guidelines for machining.

Anti-explosion performance and dynamic response of an innovative multi-layer composite explosion containment vessel

An innovative multi-layer composite explosion containment vessel(CECV)utilizing a sliding steel platealuminum honeycomb-fiber cloth sandwich is put forward to improve the anti-explosion capacity of a conventional single-layer explosion containment vessel(SECV).Firstly,a series of experiments and finite element(FE)simulations of internal explosions are implemented to understand the basic anti-explosion characteristics of a SECV and the rationality of the computational models and methods is verified by the comparison between the experimental results and simulation results.Based on this,the CECV is designed in detail and a variety of FE simulations are carried out to investigate effects of the sandwich structure,the explosive quantity and the laying mode of the fiber cloth on anti-explosion performance and dynamic response of the CECV under internal explosions.Simulation results indicate that the end cover is the critical position for both the SECV and CECV.The maximum pressure of the explosion shock wave and the maximum strain of the CECV can be extremely declined compared to those of the SECV.As a result,the explosive quantity the CECV can sustain is up to 20 times of that the SECV can sustain.Besides,as the explosive quantity increases,the internal pressure of the CECV keeps growing and the plastic deformation and failure of the sandwich structure become more and more severe,yielding plastic strain of the CECV in addition to elastic strain.The results also reveal that the laying angles of the fiber cloth's five layers have an impact on the anti-explosion performance of the CECV.For example,the CECV with fiber cloth layered in 0°/45°/90°/45°/0°mode has the optimal anti-capacity,compared to 0°/0°/0°/0°/0°and 0°/30°/60°/30°/0°modes.Overall,owing to remarkable anti-explosion capacity,this CECV can be regarded as a promising candidate for explosion resistance.

基于静态凝聚法的蜂窝芯轴向变胞元非均匀排布优化

为了有效改善蜂窝结构的强度与刚度,提出利用静态凝聚法实现变胞元的几何参数和非均匀排布同时优化的方法。根据卡氏定理,推导胞元的等效弹性模量和泊松比;沿轴向均匀划分蜂窝芯为若干列子结构,利用有限元法得到子结构的刚度矩阵;采用静态凝聚法建立超单元刚度矩阵,依据超单元节点编号装配获得蜂窝芯的整体刚度矩阵;计算蜂窝芯在剪切载荷作用下的结构变形,并与ANSYS结果比较分析。以子结构的个数以及胞元的夹角、夹板宽与斜壁长之比为设计变量,胞元的等效弹性模量最大和蜂窝芯的变形最小为设计目标,利用改进的粒子群算法进行优化并研究蜂窝芯优化前后的静、动态特性变化规律。结果表明:变胞元非均匀排布优化后,最大的位移、应力、应变均明显减小,且激励频率等于第二阶固有频率时振动最为强烈。研究结论可为蜂窝结构变胞元排布的优化设计提供指导。

复合材料油箱口盖零件的成型工艺研究

文章以某飞机油箱口盖为研究对象,通过材料设计、密封设计、耐火设计、雷电防火设计,对油箱口盖的复合材料成型工艺进行分析。通过工艺试验,合理选用油箱口盖零件原材料,设计铺层结构,优化工艺参数,采用热压罐成型工艺包括下料、铺贴、封装、固化、脱模、修整等具体过程完成复合材料油箱口盖的成型。

高温合金蜂窝芯加工振动分析与试验研究

高温合金蜂窝芯具有薄壁、多孔、面内弱刚性等特点,加工过程中易出现毛刺、撕裂、塌边等缺陷,采用冰固持加工后改善了加工质量,但仍然存在振动幅值较大的问题。针对高温合金蜂窝芯冰固持加工的振动问题,分析并确定冰固持条件下的高温合金蜂窝芯加工振动的主要形式是非谐波非周期性激励下的强迫振动,求解切入角变化导致的强迫振动激励间隔时间的变化规律。通过试验获得切削用量对高温合金蜂窝芯冰固持加工振动的影响规律,试验结果表明,当主轴转速为7000r/min、进给速度为4000mm/min、切削深度为0.5~1.5mm、切削宽度为0.5mm时,振动幅值较小,加工状态稳定,加工质量较好。

固化循环热历程对芳纶纸蜂窝芯材尺寸收缩的影响

在芳纶纸蜂窝夹芯结构的修理过程中,需对蜂窝零件进行多次加热固化,这可能会导致蜂窝芯材的尺寸收缩,从而导致零部件产生凹陷。因此,有必要研究固化循环热历程对芳纶纸蜂窝芯材尺寸收缩的影响规律,为飞机复合材料芳纶纸蜂窝夹芯结构的修理填补方案提供参考依据。研究了不同修理固化温度及固化循环次数对国产及国外几种芳纶纸蜂窝芯材尺寸收缩的影响。通过对每次固化后的蜂窝芯材尺寸进行测试,探究蜂窝芯材的收缩规律。结果表明,经中高温(121℃)和高温(177℃)下修理固化循环多次后,国产与国外的蜂窝芯材的尺寸收缩程度均明显高于经中低温(93℃)和低温(66℃)固化加热循环后的收缩程度;经5次修理加热循环后,几种蜂窝芯材的尺寸收缩程度均明显高于第1次修理固化后的收缩程度;对于相同厚度的国产和国外蜂窝芯材,经多次固化循环后,国产蜂窝芯材的收缩程度更低。总体而言,芳纶纸蜂窝芯材在常见修理温度下多次热历程循环后,蜂窝芯材加热后的收缩程度较小,具有良好的尺寸稳定性,能够较好地满足蜂窝夹芯结构多次修理填补的需求。

超轻型微球介电吸波材料性能及应用研究

为了实现吸波材料轻量化,本文通过设计材料微观结构及合成方法,将碳材料的介电特性与空心结构的低密度特性相结合,开发出一种超轻型材料,制备的碳空心球(C@air)材料具有优良的吸波性能。基于该材料分别制备吸波板材及可用于隐身飞机机翼前缘的吸波蜂窝芯,并对其进行电磁仿真及雷达反射截面积(RCS)测试,吸波蜂窝芯在同向水平极化下达到-32.3 dB,同向垂直极化下达到-27.2 dB。验证了该材料具有优秀的吸波性能及应用效果,为吸波材料的设计与应用提供思路。

地下车库蜂巢芯空心楼盖施工技术

结合泊里镇驻地改造施工现场情况,论述了蜂巢芯空心楼盖技术在地下车库施工过程中的应用。通过对蜂巢芯空心楼盖的施工技术要点描述,从降低工程造价;方便施工、减少模板;有效缩短施工工期;有效减少混凝土收缩裂缝;加强防水、防火性能及保温、隔声性能和抗震性能;相比一次性膜壳,蜂巢芯无脱落风险等方面分析地下车库顶板采用蜂巢芯空心楼盖的优势。

基于五轴高速铣削数控机床的航空用芳纶纸蜂窝加工工艺及试验研究

芳纶纸蜂窝是航空航天领域常用的减重复合材料,由韧性较大的芳纶纤维和含量较高的脆性树脂固化而成,固化成型后较难加工。为了满足某型号加工精度要求,根据该材料的组成成分和结构特点,结合需加工零件的形状尺寸,用五轴高速铣削数控机床进行加工工艺试验,通过单因素试验法,研究磨削速度、进给速度和刀具前倾角对其表面质量及形面精度的影响。试验结果表明:不同工艺参数对该型号芳纶纸蜂窝表面质量及形面精度差异较大。该型号蜂窝零件加工切削角速度最优参数为12000 rpm,参数可选区间为11000 rpm~13000 rpm之间;加工进给速度最优参数为1000 mm/min,为保证加工质量,参数可选区间为1000 mm/min~1200 mm/min之间;前倾角可选参数区间为10~30之间。

Analytical modeling and vibration analysis of fiber reinforced composite hexagon honeycomb sandwich cylindrical-spherical combined shells

This study analyzes and predicts the vibration characteristics of fiberreinforced composite sandwich(FRCS)cylindrical-spherical(CS)combined shells with hexagon honeycomb core(HHC)for the first time based on an analytical model developed,which makes good use of the advantage of the first-order shear deformation theory(FSDT),the multi-segment decomposition technique,the virtual spring technology,the Jacobi-Ritz approach,and the transfer function method.The equivalent material properties of HHC are firstly determined by the modified Gibson’s formula,and the related energy equations are derived for the HHC-FRCS-CS combined shells,from which the fundamental frequencies,the mode shapes,and the forced vibration responses are solved.The current model is verified through the discussion of convergence and comparative analysis with the associated published literature and finite element(FE)results.The effects of geometric parameters of HHC on the dynamic property of the structure are further investigated with the verified model.It reveals that the vibration suppression capability can be greatly enhanced by reducing the ratio of HHC thickness to total thickness and the ratio of wall thickness of honeycomb cell to overall radius,and by increasing the ratio of length of honeycomb cell to overall radius and honeycomb characteristic angle of HHC.

夹层结构斜削区蜂窝滑移机理及改善研究

基于蜂窝夹层结构固化原理分析和蜂窝在180℃高温下的力学性能分析,构建了蜂窝滑移受力模型,确定了影响蜂窝滑移的4个关键因素,分别为蜂窝侧向抗压能力、层间摩擦系数、蜂窝芯边缘倒角和固化压差。针对关键因素进一步分析,表明分别影响4个关键因素的子因素及其影响作用。同时提出了抑制蜂窝滑移的有效措施:1)最靠近蜂窝芯的铺层(推荐0/90°织物)延伸至零件边缘以便进行外力(防滑带、玻璃纤维等)拴系;2)工艺手段(浸胶法、胶膜法、隔膜法等稳定化方法)提高蜂窝侧向抗压能力。

A Study on Transmission Loss Characteristics of Honeycomb Panel for Offshore Structures

Honeycomb panel is consisted of 3 layers that are double-faced sheets and honeycomb-shaped core. It is highly desirable for ship, railway, and aerospace industry. The reason is that honeycomb panel excels in strength and in its weight. However in terms of insulation, it is a little bit insufficient to commonly use sandwich-panel. In this paper, Moor’s theory is used to predict sound transmission loss (STL). The theory is assumed that core layer is homogeneous orthotropic. And to calculate STL, it is evaluated in terms of the symmetric and anti-symmetric panel impedances, and the characteristic impedance of air. After that predicted data are compared with experiment data.

基于夹芯分层的碳纤维复材综框横梁仿真设计

为更好地适应现代织机的高速化发展要求,以一阶剪切变形理论为依据,将一种含夹芯分层的复材横梁应用于碳纤维综框技术升级。利用WorkBench/ACP模块开发复材横梁仿真模型,构建基于非对称纤维铺层的层压板设计方案,并通过配装铝合金板材对横梁结构进行强度加固。在考虑弹簧回综力和纱线张力影响的条件下,对复材横梁力学性能进行仿真分析。结果显示:复材横梁的自由振动模式以横向弯曲变形为主,应力集中区主要位于回综弹簧悬挂处;各纤维层的层间应力分布呈现一定对称性,靠近横梁两端区域的应力状态较为明显,而中间蜂窝芯材所受应力影响甚微;弹簧悬挂区各纤维层的失效顺序依次为0°、45°、-45°、90°;主应力S1是造成纤维层疲劳失效的主要因素。通过将夹芯分层与复材横梁结构设计相结合,有助于复合材料综框的轻量化实现与成本控制,为新型碳纤维综框的发展与性能提升提供了思路。

内嵌聚甲基丙烯酰亚胺泡沫的碳纤维增强复合材料蜂窝夹层结构水中抗爆试验研究

为了分析新型内嵌聚甲基丙烯酰亚胺(Polymethacrylimide,PMI)泡沫的碳纤维增强复合材料蜂窝夹层结构的水中抗爆性能,开展了水中爆炸作用下结构抗爆性能试验研究,对比了均质钢板、纯蜂窝夹芯夹层结构以及内嵌两种不同密度PMI泡沫蜂窝夹芯夹层结构的水中抗爆性能,分析了结构变形与破坏模式、结构表面压力特性以及结构后面板变形情况。结果表明,内嵌泡沫能够有效提升夹层结构的水中抗爆性能。研究结果可以为水中抗爆防护结构的轻量化设计及优化提供参考。

地雷爆炸载荷下防爆复合结构的动态响应研究

在现代城市巷战及未来战争中,地雷和简易爆炸装置(IEDs)将对装甲车辆构成严重威胁.传统的车辆底部防爆结构设计需要进行大量试验,成本高昂且准备周期长,因此防爆结构抗地雷仿真计算成为目前研究的重点.本文建立了三种防爆复合结构的有限元模型,通过LS-DYNA软件的ALE方法模拟地雷爆炸载荷作用下不同结构参数设置的防爆复合结构的动态响应,获得后效板中心点变形的位移-时间曲线.开展了防爆复合结构台架试验,测量后效板中心点的变形量并与有限元仿真结果进行对比,结果表明,后效板中心点最大塑性变形的仿真结果与试验结果误差均小于20%,可以通过有限元仿真进一步预测地雷爆炸载荷作用下后效板的塑性变形,提高防爆结构设计的工作效率.

纸木蜂窝板面外静态压缩有限元仿真分析

目的探究纸木蜂窝板的压溃模式和单个蜂窝单元的变形失效模式,为纸木蜂窝板内部失效机制提供一定的理论基础。方法通过有限元仿真模拟,分析面外静态压缩得到变形云图、应力–应变云图和应力–应变曲线。结果纸木蜂窝板的受压过程分为4个阶段,应力集中分布在蜂窝芯层,最外侧的蜂窝最早出现变形且变形较大,随后中间区域的蜂窝逐步变形增大。蜂窝芯层在受压时存在至多1个应力峰,蜂窝壁弯曲折叠了1~2次,产生了1~2个塑性铰,并在此过程中吸收能量。结论纸木蜂窝板的压溃失效趋势为由外侧蜂窝向内部蜂窝,由单层壁向双层壁,由最弱的压溃点向其余位置。

芳纶纸蜂窝芯结构件加工技术研究与应用进展

芳纶纸蜂窝芯材料是一类具有轴向比强度和比刚度高、轴向抗压能力强等优异性能的轻量化材料,在众多先进飞机、卫星、汽车中具有广泛应用,尤其是作为重要的轻量化结构件广泛应用于飞机的襟翼、舱门、地板等部位。在材料成型后,机械加工是必备的重要环节,以获得高精度的轮廓外形尺寸和装配特征。但芳纶纸蜂窝芯软质、脆性、非连续、薄壁等特性造成其加工难度极高。为解决极具挑战的加工难题,国内外研究团队进行了广泛且深入的探索,以实现芳纶纸蜂窝纸芯结构件高质高效加工。本文对芳纶纸蜂窝芯加工机理进行分析概述,系统性归纳总结蜂窝芯结构件加工固持方法、加工刀具、加工装备和加工工艺,介绍在典型结构件加工中的应用,并对未来发展方向进行展望。

开孔纸蜂窝芯层的面外静态压缩特性

针对双层侧壁开孔的纸蜂窝芯层的面外静态压缩特性,通过试验分析无孔和开孔纸蜂窝芯层在面外压缩量为85%时的压缩变形过程,研究相对湿度和圆孔直径对其强度性能的影响。基于蜂窝结构的对称性,利用两种基本单元模型,将面外受载的蜂窝胞壁视为无孔和开孔简支弹性薄板,推导出弹性屈曲临界应力和塑性屈曲平台应力的预测公式,结果表明理论计算与试验结果具有良好的一致性。结合纸基材的正交各向异性和纸蜂窝芯层的面外压缩特性,建立无孔、开孔纸蜂窝的有限元模型,仿真模拟蜂窝胞壁在弹性和塑性屈曲阶段的弯折变形演化过程,与静态压缩试验中所观察到的变形过程是一致的。