Meter-Scale Thin-Walled Structure with Lattice Infill for Fuel Tank Supporting Component of Satellite:Multiscale Design and Experimental Verification

Lightweight thin-walled structures with lattice infill are widely desired in satellite for their high stiffness-to-weight ratio and superior buckling strength resulting fromthe sandwich effect.Such structures can be fabricated bymetallic additive manufacturing technique,such as selective laser melting(SLM).However,the maximum dimensions of actual structures are usually in a sub-meter scale,which results in restrictions on their appliance in aerospace and other fields.In this work,a meter-scale thin-walled structure with lattice infill is designed for the fuel tank supporting component of the satellite by integrating a self-supporting lattice into the thickness optimization of the thin-wall.The designed structure is fabricated by SLM of AlSi10Mg and cold metal transfer welding technique.Quasi-static mechanical tests and vibration tests are both conducted to verify the mechanical strength of the designed large-scale lattice thin-walled structure.The experimental results indicate that themeter-scale thin-walled structure with lattice infill could meet the dimension and lightweight requirements of most spacecrafts.

VIBRATION IN HIGH-SPEED MILLING OF THIN-WALLED COMPONENTS

To investigate the vibration principle in machining thin-walled components, a dynamic model for end milling of flexible structures is built based on considering the variations in the dynamic chip thickness and the differences between up-milling and down-milling. Two milling experiments verify the model. Experimental results show that the model can predict the milling force and displacements simultaneously in the dynamic milling process.

Fundamentals and Processes of Fluid Pressure Forming Technology for Complex Thin-Walled Components

A new generation of fluid pressure forming technology has been developed for the three typical structures of tubes,sheets,and shells,and hard-to-deform material components that are urgently needed for aerospace,aircraft,automobile,and high-speed train industries.in this paper,an over all review is introduced on the state of the art in fundamentals and processes for lower-pressure hydroforming of tubular components,double-sided pressure hydroforming of sheet components,die-less hydroforming of ellipsoidai shells,and dual hardening hot medium forming af hard-to-deform materiais Particular attention is paid to deformation behavior,stress state adjustment,defect prevention,and typical applications.In addition,future development directions of fluid pressure forming technology are discussed,including hyper lower-loading forming for ultra-large non-uniform components,precision for ming for intermetallic compound and high-entropy alloy components,intelligent process and equipment,and precise finite element simulation of inhomogeneous and strong anisotropic thin shells.

Topological Optimization Method for Aeronautical Thin-Walled Component Fixture Locating Layout

Fixture locating layout has a direct and influential impact on aeronautical thin-walled component(ATWC)manufacturing quality.The purpose is to develop a topological optimization method for ATWC fixture locating layout to minimize the manufacturing deformation.Firstly,a topological optimization model that takes the stiffness of ATWC as the objective function and the volume of the locating structure as the constraint is established.Secondly,ATWC and the locating structure are regarded as an integrated entity,and the variable-density method based topological optimization approach is adopted for the optimization of the locating structure using ABAQUS topology optimization module(ATOM).Thirdly,through a subsequent model reconstruction referring to the obtained topological structure,the optimal fixture locating layout is achieved.Finally,a case study is conducted to verify the proposed method and the comparison results with firefly algorithm(FA)coupled with finite element analysis(FEA)indicate that the number and positions of the locators for ATWC can be optimized simultaneously and successfully by the proposed topological optimization model.

High-efficiency forming processes for complex thin-walled titanium alloys components: state-of-the-art and perspectives

Complex thin-walled titanium alloy components play a key role in the aircraft,aerospace and marine industries,offering the advantages of reduced weight and increased thermal resistance.The geometrical complexity,dimensional accuracy and in-service properties are essential to fulfill the high-performance standards required in new transportation systems,which brings new challenges to titanium alloy forming technologies.Traditional forming processes,such as superplastic forming or hot pressing,cannot meet all demands of modern applications due to their limited properties,low productivity and high cost.This has encouraged industry and research groups to develop novel high-efficiency forming processes.Hot gas pressure forming and hot stamping-quenching technologies have been developed for the manufacture of tubular and panel components,and are believed to be the cut-edge processes guaranteeing dimensional accuracy,microstructure and mechanical properties.This article intends to provide a critical review of high-efficiency titanium alloy forming processes,concentrating on latest investigations of controlling dimensional accuracy,microstructure and properties.The advantages and limitations of individual forming process are comprehensively analyzed,through which,future research trends of high-efficiency forming are identified including trends in process integration,processing window design,full cycle and multi-objective optimization.This review aims to provide a guide for researchers and process designers on the manufacture of thin-walled titanium alloy components whilst achieving high dimensional accuracy and satisfying performance properties with high efficiency and low cost.

Sheet Bulk Forming of Thin-Walled Components with External Gearing through Upsetting Using Controllable Deformation Zone Method

Sheet-bulk metal forming(SBMF)is a promising process for manufacturing complex sheet components with functional elements.In this study,the entire forming process for a typical thin-walled component with external gearing is investigated,including sheet forming and bulk forming processes.Deep drawn cups are prepared during sheet forming;subsequently,upsetting is performed on the sidewall to form external gearing.The upsetting method performed is known as upsetting with a controllable deformation zone(U-CDZ).Compared with the conventional upsetting method,a floating counter punch with a counter force is used in the U-CDZ method such that the forming mechanism is changed into the accumulation of the deformation zone instead of deformation throughout the entire sidewall.The effects of the counter force and material flow are investigated to understand the mechanism.The forming quality,i.e.,the formfilling and effective strain distribution,improved,whereas a high forming load is avoided.In addition,a punch with a lock bead is used to prevent folding at the inner corner during the experiment.

Vibrations in High Speed Milling of Thin-walled Components

Thin-walled structures have been widely used in the aerospace industry.The dynamic interaction between the milling cutter and thin-walled workpiece can easily lead to vibration.This paper investigates the vibration caused during milling the thin-walled workpiece on the NC machining center,presents a theoretical milling vibration model of thin-walled beam.The model was verified by using milling experiments and numerical simulations.Some valuable conclusions are derived,this will be references to scientific research and guides to the vibration-free milling of thin-walled structures at different cutting speeds.

Recent Developments on Damage and Fracture of Thin-Walled Complex Components Produced by Spinning

The spinning technique has been widely used in the manufacture of aerospace thin-walled axisymmetric components because of its excellent formability. Damage and fracture,as the important defects that often occur and must be avoided in the forming and service stages of components,have attracted much attention of researchers. In this paper,the fracture behavior and laws of spinning components such as conical parts,tubular parts,and components with inner ribs are summarized,the typical coupled and uncoupled ductile fracture models are introduced,and their applications in spinning are analyzed. Meanwhile,the recent developments on the modified ductile fracture model in analyzing damage and fracture mechanisms of spinning are emphatically introduced. The results could provide guidance for the selection and establishment of appropriate ductile fracture models in the finite element simulation for the accurate prediction and analysis of fracture moment,location,form,damage mechanism,and evolution law,and help the development of precision spinning techniques for high-performance thin-walled complex components.

Collaborative manufacturing technologies of structure shape and surface integrity for complex thin-walled components of aero-engine:Status,challenge and tendency

Presently,the service performance of new-generation high-tech equipment is directly affected by the manufacturing quality of complex thin-walled components.A high-efficiency and quality manufacturing of these complex thin-walled components creates a bottleneck that needs to be solved urgently in machinery manufacturing.To address this problem,the collaborative manufacturing of structure shape and surface integrity has emerged as a new process that can shorten processing cycles,improve machining qualities,and reduce costs.This paper summarises the research status on the material removal mechanism,precision control of structure shape,machined surface integrity control and intelligent process control technology of complex thin-walled components.Numerous solutions and technical approaches are then put forward to solve the critical problems in the high-performance manufacturing of complex thin-wall components.The development status,challenge and tendency of collaborative manufacturing technologies in the high-efficiency and quality manufacturing of complex thin-wall components is also discussed.

Effect of assisted transverse magnetic field on distortion behavior of thin-walled components in WEDM process

Machining performance of thin-walled components made by aeronautical difficult-toprocess materials is a significant issue in the aviation manufacturing industry.Although wire electric discharge machining-low speed(WEDM-LS)is one of typical non-contact machining processes without macro cutting force,which does well in removing hardness and brittleness materials via pulsed discharge at high temperature,but few researchers have studied the thermal distortion behavior leading to a considerable geometric error in the WEDM-LS of thin-walled components.In this paper,a transverse magnetic field assisted method is applied for affecting the uniformity of discharge point distribution so as to reduce the distortion in WEDM-LS processing thin-wall component.First,the generation mechanism of this new distortion behavior and the impact mechanism of transverse magnetic field(TMF)on distortion are demonstrated by theoretical analysis.In order to further figure out the distortion behavior in the TMF-WEDM process,a new thermophysical model considering the discharge point distribution is established to simulate temperature field,residual stress field and distortion profiles.Then a large number of Taguchi experiments are carried out to investigate the influences of process parameters including pulse discharge energy(pulse on time,pulse off time,and current)and magnetic field strength on distortion in WEDM-LS.To comparatively analyze simulated and experimental results,the accuracy of established thermophysical model is verified within a relative error of 18.38%in distortion.Moreover,it can be revealed that transverse magnetic field contribute to significantly improve the longitudinal distribution uniformity with maximum increase of 12.32%at magnetic field strength:0.15 T,leading to significant reductions of 32.77%in distortion and 22.68%in recast layer.Eventually,we also presented the variation of residual stress and recast layer along thickness direction under different distortion behavior,which are in good agreement with that of distortion behavior.

小区小麦育种收获机锥型脱粒滚筒性能试验

小区小麦育种收获机锥型脱粒滚筒体积小、功耗低,可加快脱粒滚筒轴向物料输送,提高清机效率。为了进一步研究锥型脱粒滚筒作业性能,结合自行研制的纵轴流锥型滚筒脱粒装置,通过改变锥型滚筒主要结构参数进行对比试验,得出滚筒锥角及滚筒脱粒元件是影响滚筒作业性能的主要结构参数。在选取最优参数后研制出一种集钉齿、短纹杆-板齿于一体,锥角为13°的组合齿锥型滚筒,并进行试验。试验结果表明,该滚筒作业时种子破碎率为0.52%,滚筒脱粒损失率及籽粒含杂率分别为0.43%及6.23%,装置内部种子残留率为0,功耗为2.48kW,符合小区小麦育种收获要求。

端部方锥形薄壁构件的抗撞性尺寸优化

基于显式有限元技术,采用响应面法,以结构的比吸能为优化函数,以提高车辆吸能原件的抗撞性为目的,研究正方形截面金属薄壁构件的端部锥形尺寸对抗撞性的影响。经过数值分析,得出端部为方锥形的正方形截面薄壁构件的比吸能关于锥形长度和小锥边长的变化规律,这些规律可以用于实际吸能原件的设计,为进一步研究奠定基础。

锥形钛合金非骨水泥股骨柄全髋关节置换术34例随访一年X线结果分析

目的观察最新一代锥形钛合金非骨水泥股骨柄于术后1年是否稳定及股骨柄周围骨的重构方式。方法对采用最新一代锥形钛合金非骨水泥股骨柄全髋关节置换的34侧髋关节(28例),进行定期随访,平均随访15个月,对术前、术后近期及术后1年的X线片(股骨部分)进行测量,将测量结果进行统计分析。结果在股骨柄的中1/3普遍存在骨与假体之间的“焊接点”;没有假体移位、“筑基”形成,以及金属颗粒滑脱;除1例外,其余病例出现股骨距的重吸收;27髋出现股骨距松质化;在非涂层部分出现反应线的有19髋;非骨水泥股骨柄固定及稳定评分,平均总分为+24.1分。结论所有股骨柄于术后1年X线片上都被确认有骨长入。

端部圆锥形薄壁构件的抗撞性设计优化

基于显式有限元技术,采用响应面法,以结构的比吸能为优化函数,研究了圆形截面金属薄壁构件的端部锥形尺寸对抗撞性的影响;经过数值分析,得出了端部为锥形的圆形截面薄壁构件的比吸能关于锥形长度和锥边直径的变化规律,这些规律可以用于实际吸能原件的设计,并为进一步研究奠定了基础.

锥形件拉深压边力数学模型的建立

本文用逐步选择因素组合法，对锥形件拉深临界压边力试验数据进行了处理，所得数学模型比一般逐步回归法具有更高的精度和可靠性，模型更为完善。

锥形光纤装置研究(英文)

基于锥形光纤制造过程的复杂性及其传像束的传输性能,利用微机与步进电机相结合,同时控制常用的双坩埚光纤拉丝机出丝管口的直径大小和鼓轮转速快慢,实现了数控拉制1m长锥形光纤的新方法,并且集束制作出了两种两端不同半径比的锥形光纤传像束.与常用的增大鼓轮体积的方法相比,该装置具有体积小,便于操作,两端半径比可自由控制,断丝率低等特点.分析了这两种锥形光纤传像束的模式损耗。

暖风机除霜接口冲压工艺设计

分析了暖风机除霜接口零件的冲压生产工艺,在生产技术准备工作中用倒推法对工艺顺序进行了合理编排,对各工序的形状和尺寸进行了分析和计算,对宽凸缘零件拉深进行了详细计算;各工序间的坯料尺寸计算较为关键,它对其后工序的形状会产生较大影响;修边工序的准确轮廓尺寸可通过试验获得,以保证最终产品口部平直的要求;在成形锥度形状时,从模具结构上尽量保证制件坯料处于径向、切向受拉厚度方向受压的应力状态。本零件结构独特,工艺方案复杂,工序较长,对同类型产品工艺制定具有借鉴作用和参考价值。

A study on bearing characteristic and failure mechanism of thin-walled structure of a prefabricated subway station

In order to study the bearing performance of a new type of prefabricated subway station structure(PSSS),firstly,a three-dimensional finite element model of the PSSS was established to study the nonlinear mechanics and deformation performance.Secondly,the bearing mechanism of a PSSS was investigated in detail.Finally,the development law of damages to a thin-walled prefabricated component and the failure evolution mechanism of a PSSS were discussed.The results showed that this new type of the PSSS had good bearing capacity.The top arch structure was a three-hinged arch bearing system,and the enclosure structure and the substructure were respectively used as the horizontal and vertical support systems of the three-hinged arch structure to ensure the integrity and stability of the overall structure.Moreover,the tongue-and-groove joints could effectively transmit the internal force between the components and keep the components deformed in harmony.The rigidity degradation of the PSSS caused by the accumulation of damages to the spandrel,hance,arch foot,and enclosure structure was the main reason of its loss of bearing capacity.The existing thin-walled components design had significant advantages in weight reduction,concrete temperature control,components hoisting,transportation and assembly construction,which achieved a good balance between safety,usability and economy.

圆锥滚子轴承摩擦力矩理论计算和试验分析

深入了解圆锥滚子轴承内部组件间的复杂接触及运动特性,构建其摩擦损耗预估模型。考虑到轴承腔体内部润滑油影响,引入滑动权重系数考虑边界润滑对损耗影响,采用切入发热及贫油回填系数考虑润滑成膜对滚动摩擦影响。通过对比理论预测与实验测试发现:二者最大误差不超过25%。最后,解析了圆锥滚子轴承摩擦力矩的影响机制,结果表明:轴承总摩擦力矩随着载荷的增大而增大,并趋于平稳;滚动摩擦分量变化趋势与总体摩擦力矩相同。

锥形冷挤压件的工艺计算

提出了以相对深度和断面缩减率两个指标来综合分析锥形冷挤压件变形程度的方法。通过工艺实践证明 ,该工艺计算方法基本可行。