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.

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.

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.

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 blank quenching on shear spinning forming precision of 2219 aluminum alloy complex thin-walled components

The quenching-spinning(Q-S)process,i.e.,shear spinning after blank quenching,has been increasingly utilized to form 2219 aluminum alloy complex thin-walled components.However,the changes in material property,shape and stress of the blanks after quenching will affect the spin-ning forming precision.In this study,the rules and mechanisms of these effects are investigated based on a combined finite element(FE)model including blank quenching and component spinning process.The results indicate that the increase of material strength and the existence of distortion of the quenched blank lead to a notable increase in the non-uniformity of the circumferential compres-sive stress in the spinning area and the increase of the flange swing height during spinning.These changes result in an increase in the wall thickness and component-mandrel gap of the components.The quenching residual stress has little effect on wall thickness and roundness but can noticeably reduce the component-mandrel gap.This is because that the existence of quenching residual stress of the blank can lead to the decrease of the maximum circumferential compressive stress of the workpiece in spinning and an obvious drop in the maximum compressive stress after reaching the stress peak.Quenching distortion is the main factor affecting the roundness.Moreover,the opti-mized installation way of the blank for spinning is obtained.

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.

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.

Optimization of Fixture Number in Large Thin-Walled Parts Assembly Based on IPSO

There are lots of researches on fixture layout optimization for large thin-walled parts.Current researches focus on the positioning problem,i.e.,optimizing the positions of a constant number of fixtures.However,how to determine the number of fixtures is ignored.In most cases,the number of fixtures located on large thin-walled parts is determined based on engineering experience,which leads to huge fixture number and extra waste.Therefore,this paper constructs an optimization model to minimize the number of fixtures.The constraints are set in the optimization model to ensure that the part deformation is within the surface profile tolerance.In addition,the assembly gap between two parts is also controlled.To conduct the optimization,this paper develops an improved particle swarm optimization(IPSO)algorithm by integrating the shrinkage factor and adaptive inertia weight.In the algorithm,particles are encoded according to the fixture position.Each dimension of the particle is assigned to a sub-region by constraining the optional position range of each fixture to improve the optimization efficiency.Finally,a case study on ship curved panel assembly is provided to prove that our method can optimize the number of fixtures while meeting the assembly quality requirements.This research proposes a method to optimize the number of fixtures,which can reduce the number of fixtures and achieve deformation control at the same time.

Development of Fixture Layout Optimization for Thin-Walled Parts:A Review

An increasing number of researchers have researched fixture layout optimization for thin-walled part assembly during the past decades.However,few papers systematically review these researches.By analyzing existing literature,this paper summarizes the process of fixture layout optimization and the methods applied.The process of optimization is made up of optimization objective setting,assembly variation/deformation modeling,and fixture layout optimization.This paper makes a review of the fixture layout for thin-walled parts according to these three steps.First,two different kinds of optimization objectives are introduced.Researchers usually consider in-plane variations or out-of-plane deformations when designing objectives.Then,modeling methods for assembly variation and deformation are divided into two categories:Mechanism-based and data-based methods.Several common methods are discussed respectively.After that,optimization algorithms are reviewed systematically.There are two kinds of optimization algorithms:Traditional nonlinear programming and heuristic algorithms.Finally,discussions on the current situation are provided.The research direction of fixture layout optimization in the future is discussed from three aspects:Objective setting,improving modeling accuracy and optimization algorithms.Also,a new research point for fixture layout optimization is discussed.This paper systematically reviews the research on fixture layout optimization for thin-walled parts,and provides a reference for future research in this field.

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.

Multi-omics analyses provide insights into the evolutionary history and the synthesis of medicinal components of the Chinese wingnut

Chinese wingnut(Pterocarya stenoptera)is a medicinally and economically important tree species within the family Juglandaceae.However,the lack of high-quality reference genome has hindered its in-depth research.In this study,we successfully assembled its chromosome-level genome and performed multiomics analyses to address its evolutionary history and synthesis of medicinal components.A thorough examination of genomes has uncovered a significant expansion in the Lateral Organ Boundaries Domain gene family among the winged group in Juglandaceae.This notable increase may be attributed to their frequent exposure to flood-prone environments.After further differentiation between Chinese wingnut and Cyclocarya paliurus,significant positive selection occurred on the genes of NADH dehydrogenase related to mitochondrial aerobic respiration in Chinese wingnut,enhancing its ability to cope with waterlogging stress.Comparative genomic analysis revealed Chinese wingnut evolved more unique genes related to arginine synthesis,potentially endowing it with a higher capacity to purify nutrient-rich water bodies.Expansion of terpene synthase families enables the production of increased quantities of terpenoid volatiles,potentially serving as an evolved defense mechanism against herbivorous insects.Through combined transcriptomic and metabolomic analysis,we identified the candidate genes involved in the synthesis of terpenoid volatiles.Our study offers essential genetic resources for Chinese wingnut,unveiling its evolutionary history and identifying key genes linked to the production of terpenoid volatiles.

Numerical Analysis of Cold-Formed Thin-Walled Steel Short Columns with Pitting Corrosion during Bridge Construction

Pitting corrosion is harmful during bridge construction,which will lead to uneven roughness of steel surfaces and reduce the thickness of steel.Hence,the effect of pitting corrosion on the mechanical properties of cold-formed thin-walled steel stub columns is studied,and the empirical formulas are established through regression fitting to predict the ultimate load of web and flange under pitting corrosion.In detail,the failure modes and load-displacement curves of specimens with different locations,area ratios,and depths are obtained through a large number of non-linear finite element analysis.As for the specimens with pitting corrosion on the web,all the specimens are subject to local buckling failure,and the failure mode will not change with pitting corrosion,but the failure location will change with pitting corrosion location;the size,location,and area ratio of pitting corrosion have little influence on the ultimate load of cold-formed thin-walled steel short columns,but the loss rate of pitting corrosion section area has a greater impact on the ultimate bearing capacity.As for the specimen with flange pitting corrosion,the location and area ratio of pitting corrosion have less influence on the ultimate load of cold-formed thin-walled steel short columns,and the section area loss rate has greater influence on the ultimate bearing capacity;the impact of web pitting corrosion on the ultimate load is greater than that of flange pitting corrosion under the same condition of pitting corrosion section area.The prediction formulas of limit load which are suitable for pitting corrosion of web and flange are established,which can provide a reference for performance evaluation of corroded cold-formed thin-walled steel.

Effect of Planting Date on Yield and Yield Components of Grain Sorghum Hybrids

In Kansas, productivity of grain sorghum [Sorghum bicolor (L.) Moench] is affected by weather conditions at planting and during pollination. Planting date management and selection of hybrid maturity group can help to avoid severe environmental stresses during these sensitive stages. The hypothesis of the study was that late May planting improves grain sorghum yield and yield components compared with late June planting. The objectives of this research were to investigate the influence of planting dates yield and yield components of different grain sorghum hybrids, and to determine the optimal planting date and hybrid combination for maximum biomass and grains production. Three sorghum hybrids (early, medium, and late maturing) were planted in late May and late June without irrigation in Kansas at Manhattan/Ashland Bottom Research Station, and Hutchinson in 2010;and at Manhattan/North Farm and Hutchinson in 2011. Data on dry matter production, yield and yield components were collected. Grain yield and yield components were influenced by planting date depending on environmental conditions. At Manhattan (2010), greater grain yield, number of heads per plant, were obtained with late-June planting compared with late May planting, while at Hutchinson (2010) greater yield was obtained with late May planting for all hybrids. The yield component most affected at Hutchinson was the number of kernels∙panicle−1 and plant density. Late-May planting was favorable for late maturing hybrid (P84G62) in all locations. However, the yield of early maturing hybrid (DKS 28-05) and medium maturing hybrid (DKS 37-07) was less affected by delayed planting. The effects of planting dates on yield and yield components of grain sorghum hybrids were found to be variable among hybrid maturity groups and locations.

Simultaneous purification of minor components in natural products using twin-column recycling chromatography with a step solvent gradient

The isolation of minor components from complex natural product matrices presents a significant challenge in the field of purification science due to their low concentrations and the presence of structurally similar compounds.This study introduces an optimized twin-column recycling chromatography method for the efficient and simultaneous purification of these elusive constituents.By introducing water at a small flowing rate between the twin columns,a step solvent gradient is created,by which the leading edge of concentration band would migrate at a slower rate than the trailing edge as it flowing from the upstream to downstream column.Hence,the band broadening is counterbalanced,resulting in an enrichment effect for those minor components in separation process.Herein,two target substances,which showed similar peak position in high performance liquid chromatography(HPLC)and did not exceed 1.8%in crude paclitaxel were selected as target compounds for separation.By using the twin-column recycling chromatography with a step solvent gradient,a successful purification was achieved in getting the two with the purity almost 100%.We suggest this method is suitable for the separation of most components in natural produces,which shows higher precision and recovery rate compared with the common lab-operated separation ways for natural products(thin-layer chromatography and prep-HPLC).

Nontraditional energy-assisted mechanical machining of difficult-to-cut materials and components in aerospace community:a comparative analysis

The aerospace community widely uses difficult-to-cut materials,such as titanium alloys,high-temperature alloys,metal/ceramic/polymer matrix composites,hard and brittle materials,and geometrically complex components,such as thin-walled structures,microchannels,and complex surfaces.Mechanical machining is the main material removal process for the vast majority of aerospace components.However,many problems exist,including severe and rapid tool wear,low machining efficiency,and poor surface integrity.Nontraditional energy-assisted mechanical machining is a hybrid process that uses nontraditional energies(vibration,laser,electricity,etc)to improve the machinability of local materials and decrease the burden of mechanical machining.This provides a feasible and promising method to improve the material removal rate and surface quality,reduce process forces,and prolong tool life.However,systematic reviews of this technology are lacking with respect to the current research status and development direction.This paper reviews the recent progress in the nontraditional energy-assisted mechanical machining of difficult-to-cut materials and components in the aerospace community.In addition,this paper focuses on the processing principles,material responses under nontraditional energy,resultant forces and temperatures,material removal mechanisms,and applications of these processes,including vibration-,laser-,electric-,magnetic-,chemical-,advanced coolant-,and hybrid nontraditional energy-assisted mechanical machining.Finally,a comprehensive summary of the principles,advantages,and limitations of each hybrid process is provided,and future perspectives on forward design,device development,and sustainability of nontraditional energy-assisted mechanical machining processes are discussed.

Data Component:An Innovative Framework for Information Value Metrics in the Digital Economy

The increasing dependence on data highlights the need for a detailed understanding of its behavior,encompassing the challenges involved in processing and evaluating it.However,current research lacks a comprehensive structure for measuring the worth of data elements,hindering effective navigation of the changing digital environment.This paper aims to fill this research gap by introducing the innovative concept of“data components.”It proposes a graphtheoretic representation model that presents a clear mathematical definition and demonstrates the superiority of data components over traditional processing methods.Additionally,the paper introduces an information measurement model that provides a way to calculate the information entropy of data components and establish their increased informational value.The paper also assesses the value of information,suggesting a pricing mechanism based on its significance.In conclusion,this paper establishes a robust framework for understanding and quantifying the value of implicit information in data,laying the groundwork for future research and practical applications.

Transcriptomic analysis of Andrias davidianus meat and experimental validation for exploring its bioactive components as functional foods

Andrias davidianus(Chinese giant salamander,CGS)is the largest and oldest extant amphibian species in the world and is a source of prospective functional food in China.However,the progress of functional peptides mining was slow due to lack of reference genome and protein sequence data.In this study,we illustrated full-length transcriptome sequencing to interpret the proteome of CGS meat and obtain 10703 coding DNA sequences.By functional annotation and amino acid composition analysis,we have discovered various genes related to signal transduction,and 16 genes related to longevity.We have also found vast variety of functional peptides through protein coding sequence(CDS)analysis by comparing the data obtained with the functional peptide database.Val-Pro-Ile predicted by the CDS analysis was released from the CGS meat through enzymatic hydrolysis,suggesting that our approach is reliable.This study suggested that transcriptomic analysis can be used as a reference to guide polypeptide mining in CGS meat,thereby providing a powerful mining strategy for the bioresources with unknown genomic and proteomic sequences.

基于Visual Components的套筒类零件柔性制造单元的应用研究

为实现多品种中、小批量零件的智能化加工,以套筒类零件加工为研究对象,通过对零件工艺的分析,为满足单元加工、搬运、翻转等功能需求,对数控机床和工业机器人进行选型,实现柔性制造单元的设计。利用Visual Components软件进行单元搭建、仿真优化反馈以提高真实产线运行效率。利用Profinet实现制造单元真实搭建,完成单元安装调试。套筒类零件柔性制造单元的设计为生产线设计提供了新思路。