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.

Aerospace Medicine and Human Performance更名前后对比分析及启示

目的研究Aerospace Medicine and Human Performance更名前后的主要报道方向、国别、发文机构的变化情况等,以期为国内同行提供参考。方法主要利用CiteSpace的共词网络功能来对期刊报道方向、发刊国别、发文机构等变化进行分析。数据来自Web of Science核心合集的SCI拓展版,以期刊名“Aviation Space and Environmental Medicine”检索,时间跨度为1991年1月1日至2014年12月31日,剔除征稿启事、会议通知等非学术文献。导入NoteExpress软件进行去重,共有4830篇文章。该刊于2015年更名为“Aerospace Medicine and Human Performance”,检索策略为:时间跨度为2015年1月1日至2023年6月13日,数据清洗方法同上,共检索到1076篇文章。结果(1)主要发文机构:更名前主要供稿机构为美国空军(160篇)、美国国防部(93篇)和美国宇航局(NASA,77篇);更名后主要供稿机构未发生变化,但发文数量均较更名前减少,美国空军47篇,美国国防部24篇,NASA 24篇。(2)主要关键词对比:更名后主要关键词与飞行、航天相关的连接强度显著增加,而对一般健康问题的关注相对减少,出现了spaceflight、air travel等直接与飞行行为相关的内容。(3)主要国别:更名前美国发文2411篇(49.91%)、加拿大发文314篇(6.50%)、英国发文279篇(5.77%)、法国发文167篇(3.45%)、德国发文160篇(3.31%);更名后美国发文501篇(46.56%)、英国发文98篇(9.10%)、中国发文54篇(5.01%)、加拿大发文53篇(4.92%)、法国发文42篇(3.90%)。(4)年均发文量:根据检索结果,更名前共24年,年均发文201篇;更名后从2015年至本文检索截止时间共8.5年,年均发文127篇,年均报道量下降较多。(5)影响因子:截止2014年更名前共发文164篇,影响因子1.0051(含自引);2016年是该刊更名有影响因子等统计数据的第一年,共发文132篇,影响因子0.8250;2022年发文109篇,影响因子1.0001(含自引)。综合考量发文量和影响因子,该刊的综合影响力更名后并无显著提升。结论该刊在更名后,对于飞行环境的影响报道有所减少,主要讨论范围从之前的所有飞行类型聚焦为以太空飞行为主,关于飞行行为对人体健康的影响和绩效表现的报道大幅增长,同时也增加了关于飞行装备对飞行安全影响的讨论。随着航空航天技术的进步和航空装备的发展,更深入地探讨航空活动中环境因素对人体长时间复合作用的影响是必然。在该刊更名后,我国的发文数量排名第三,也在一定程度上说明存在高质量原创性成果外流的情况。我国期刊在坚持刊物原有特色的前提下,根据领域研究的发展,与时俱进,探索可持续发展的办刊模式;要进一步明确期刊定位与服务对象,以国家重大需求为导向,聚焦航空航天领域前沿、热点,适时调整栏目设置,提升期刊的学术质量和学科影响力,打造高质量的学术交流平台。

Energy Consumption Analysis and Characterization of Aerospace Manufacturing Facilities in the United States–A Step towards Sustainable Development

In this study,information on energy usage in the United States(U.S.)aerospace manufacturing sector has been analyzed and then represented as energy intensities(kWh/m2)to establish benchmark data and to compare facilities of varying sizes.First,public sources were identified and the data from these previously published sources were aggregated to determine the energy usage of aerospace manufacturing facilities within the U.S.From this dataset,a sample of 28 buildings were selected and the energy intensity for each building was estimated from the data.Next,as a part of this study the energy data for three additional aerospace manufacturing facilities in the U.S.were collected firsthand.That data was analyzed and the energy intensity(kWh/m2)for each facility was calculated and then compared with the energy intensities of the 28 buildings from the sample.Three different indicators of energy consumption in aerospace manufacturing facilities were used as comparators to assist facility managers with determining potential energy savings and help in the decision-making process.On average,aerospace manufacturing facilities in the United States spent 4 cents for each dollar of sale on energy.The energy intensity(kWh/m2)and the power intensity(W/m2)for each facility were calculated based on the actual facility energy bills.The power intensity for these facilities ranges from 34 to 134 W/m2.The energy intensity ranged from 232 to 949 kWh/m2.We found that the power intensity could be used to estimate energy consumption when the annual operating hours of the facility are considered.and to estimate the energy-related carbon dioxide emissions.

Applications of magnesium alloys for aerospace:A review

With the increasingly excellent performance of magnesium alloy materials, magnesium alloys are increasingly widely used under the urgent need for weight reduction in aerospace applications. However, due to the severe aviation environment, the strength, corrosion resistance and electrical conductivity of magnesium alloy materials need to be further improved. Many scholars are committed to studying higher comprehensive mechanical properties. Besides, they have studied surface treatment processes with space application characteristics, such as high emissivity oxidation and high anti-corrosion electroplating. To further improve the safety and reliability of magnesium alloys and expand their applications, this paper discusses several kinds of magnesium alloys and summarizes their research progress. The whole manuscript should be revised by an expert who has more experience on English writing. At the same time, the surface treatments of magnesium alloy materials for aerospace are analyzed. Besides, the application of magnesium alloy in aerospace field is summarized. With the in-depth research of many scholars, the improvement of material properties and the development of surface protection and functional technology, it is believed that magnesium alloys will be used in more and more aerospace applications and make more contributions to the aerospace field.

Durability Testing of Composite Aerospace Materials Based on a New Polymer Carbon Fiber-Reinforced Epoxy Resin

In this study,the durability of a new polymer carbonfiber-reinforced epoxy resin used to produce composite material in the aerospacefield is investigated through analysis of the corrosion phenomena occurring at the microscopic scale,and the related infrared spectra and thermal properties.It is found that light and heat can con-tribute to the aging process.In particular,the longitudinal tensile strength displays a non-monotonic trend,i.e.,itfirst increases and then decreases over time.By contrast,the longitudinal compressive and inter-laminar shear strengths do not show significant changes.It is also shown that the inter-laminar shear strength of carbonfiber/epoxy resin composites with inter-laminar hybrid structure is better than that of pure carbonfiber materials.The related resistance to corrosion can be improved by more than 41%.

Autonomous Control Reconfiguration of Aerospace Vehicle Based on Control Effectiveness Estimation

Future aerospace vehicles （ASV） are designed to fly in both inner and extra atmospheric fields, which requires autonomous adaptability to the uncertainties emanated from abrupt faults and continuously time-varying environments. An autonomous control reconfiguration scheme is presented for ASV to deal with the uncertainties on the base of control effectiveness estimation. The on-line estimation methods for the time-varying control effectiveness of linear control system are investigated. Some sufficient conditions for the estimable system are given for different cases. There are proposed corresponding on-line estimation algorithms which are proved to be convergent and robust to noise using the least-square-based methods. On the ground of fuzzy logic and linear programming, the control allocation algorithms, which are able to implement the autonomous control reconfiguration through the redundant actuators, are put forward. Finally, an integrated system is developed to verify the scheme and algorithms by way of numerical simulation and analysis.

Non-traditional Machining Techniques for Fabricating Metal Aerospace Filters

Thanks to recent advances in manufacturing technology, aerospace system designers have many more options to fabricate high-quality, low-weight, high-capacity, cost-effective filters. Aside from traditional methods such as stamping, drilling and milling, many new approaches have been widely used in filter-manufacturing practices on account of their increased processing abilities. How- ever, the restrictions on costs, the need for studying under stricter conditions such as in aggressive fluids, the complicity in design, the workability of materials, and others have made it difficult to choose a satisfactory method from the newly developed processes, such as, photochemical machining （PCM）, photo electroforming （PEF） and laser beam machining （LBM） to produce small, inexpensive, lightweight aerospace filters. This article appraises the technical and economical viability of PCM, PEF, and LBM to help engineers choose the fittest approach to turn out aerospace filters.

Development of the Supply Chain Oriented Quality Assurance System for Aerospace Manufacturing SMEs and Its Implementation Perspectives

Aerospace manufacturing SMEs are continuously facing the challenge on managing their supply chain and complying with the aerospace manufacturing quality standard requirement due to their lack of resources and the nature of business. In this paper, the ERP system based approach is presented to quality control and assurance work in light of seamless integration of in-process production data and information internally and therefore managing suppliers more effectively and efficiently. The Aerospace Manufacturing Quality Assurance Standard （BS/EN9100） is one of the most recognised and essential protocols for developing the industry-operated-and-driven quality assurance systems. The research investigates using the ERP based system as an enabler to implement BS/EN9100 quality management system at manufacturing SMEs and the associated implementation and application perspectives. An application case study on a manufacturing SME is presented by using the SAP based implementation, which helps fiarther evaluate and validate the approach and application system development.

An Overview of Performance Characteristics, Experiencesand Trends of Aerospace Engine Bearings Technologies

In this paper, the operating conditions, technical requirements, performance characteristics, design ideas, application experiences and development trends of aerospace engine bearings, including material technology, integration design and reliability, are reviewed. The development history of aerospace engine bearing is recalled briefly at first. Then today＇s material technologies and the high bearing performances of the bearings obtained through the new materials are introduced, which play important roils in the aeroengine bearing developments. The integration design ideas and practices are explained to indicate its significant advantages and importance to the aerospace engine bearings. And the reliability of the shaft-bearing system is pointed out and treated as the key requirement with goals for both engine and bearing. Finally, as it is believed that the correct design comes from practice, the pre-qualification rig testing conducted by FAG Aerospace GmbH ＆ Co. KG is briefly illustrated as an example. All these lead to the development trends of aerospace engine bearings from different aspects.

Research on Auto-detection for Remainder Particles of Aerospace Relay Based on Wavelet Analysis

Aerospace relay is one kind of electronic components which is used widely in national defense system and aerospace system. The existence of remainder particles induces the reliability declining, which has become a severe problem in the development of aerospace relay. Traditional particle impact noise detection （PIND） method for remainder detection is ineffective for small particles, due to its low precision and involvement of subjective factors. An auto-detection method for PIND output signals is proposed in this paper, which is based on direct wavelet de-noising （DWD）, cross-correlation analysis （CCA） and homo-filtering （HF）, the method enhances the affectivity of PIND test about the small particles. In the end, some practical PIND output signals are analysed, and the validity of this new method is proved.

Polymer composite for antistatic application in aerospace

The pheno menon of static electricity is unpredictable,particulariy when an aircraft flying at high altitude that causes the accumulation of static charges beyond a threshold value leading to the failure of its parts and systems including severe explosion and radio communication failure.The accumulation of static charges on aircraft is generated by the virtue of interaction between the outer surface of aircraft and the external environmental attributes encompasses air particles,ice,hail,dust,volcanic ash in addition to its triboelectric charging.In the recent years,advanced polymer-based composites or nanocomposites are preferred structural constituents for aircrafts due to their light weight and comparable mechanical properties,but such composite systems do not render low impedance path for charge flow and are subsequently vulnerable to effect of lightning strike and precipitation static.In this context,it is essential to develop conductive composite systems from non-co nductive polymer natrix by nano fillerembodime nts.The advent of carbon-based nanocomposite/nano materials have adequately addressed such issues related to the nonco nductive polymer matrix and further turned into an avant-garde genre of materials.The current review envisioned to illustrate the detailed exploitation of various polymer nanocomposites in addition to especially mentioned epoxy composites based on carbon fillers like carbon black,carbon nanotube(single walled carbon nanotube and multi walled carbon nanotube) and graphene the development of antistatic application in aircra ft in addition to the static charge phenomenon and condition for its prevalence in avionic systems.

Adaptive augmentation of gain-scheduled controller for aerospace vehicles

This paper proposes an adaptive augmentation control design approach of the gain-scheduled controller.This extension is motivated by the need for augmentation of the baseline gainscheduled controller.The proposed approach can be utilized to design flight control systems for advanced aerospace vehicles with a large parameter variation.The flight dynamics within the flight envelope is described by a switched nonlinear system,which is essentially a switched polytopic system with uncertainties.The flight control system consists of a baseline gain-scheduled controller and a model reference adaptive augmentation controller,while the latter can recover the nominal performance of the gainscheduled controlled system under large uncertainties.By the multiple Lyapunov functions method,it is proved that the switched nonlinear system is uniformly ultimately bounded.To validate the effectiveness of the proposed approach,this approach is applied to a generic hypersonic vehicle,and the simulation results show that the system output tracks the command signal well even when large uncertainties exist.

Research on Feature Extraction of Remnant Particles of Aerospace Relays

The existence of remnant particles, which significantly reduce the reliability of relays, is a serious problem for aerospace relays. The traditional method for detecting remnant particles-particle impact noise detection （PIND）-can be used merely to detect the existence of the particle; it is not able to provide any information about the particles＇ material. However, information on the material of the particles is very helpful for analyzing the causes of remnants. By analyzing the output acoustic signals from a PIND tester, this paper proposes three feature extraction methods： unit energy average pulse durative time, shape parameter of signal power spectral density （PSD）, and pulse linear predictive coding coefficient sequence. These methods allow identified remnants to be classified into four categories based on their material. Furthermore, we prove the validity of this new method by processing P1ND signals from actual tests.

Research on the Reliability Tolerance Analysis Method of Electromagnetic Relay in Aerospace

Electromagnetic relay in aerospace is one of the main electronic components in aerospace electronic systems for information transfer, control and power distribution, and its reliability will influence the reliability of the whole aerospace electronic systems. Reliability design is the key technique of electromagnetic relay reliability engineering. This paper synthetically analyzes the present reliability design methods, and presents the reliability tolerance analyzing mathematic models of electromagnetic force basing on orthogonal design, mechanical spring force basing on probability statistics theory, and matching characteristics of electromagnetic force and mechanical spring force basing on method of stressstrength interference. Some instructive conclusions are draw by researching on the reliability tolerance of some type electromagnetic relay in aerospace.

Trajectory linearization control of an aerospace vehicle based on RBF neural network

An enhanced trajectory linearization control （TLC） structure based on radial basis function neural network （RBFNN） and its application on an aerospace vehicle （ASV） flight control system are presensted. The influence of unknown disturbances and uncertainties is reduced by RBFNN thanks to its approaching ability, and a robustifying itera is used to overcome the approximate error of RBFNN. The parameters adaptive adjusting laws are designed on the Lyapunov theory. The uniform ultimate boundedness of all signals of the composite closed-loop system is proved based on Lyapunov theory. Finally, the flight control system of an ASV is designed based on the proposed method. Simulation results demonstrate the effectiveness and robustness of the designed approach.

Standardization for Additive Manufacturing in Aerospace

Additive manufacturing （AM）--the process of joining materials to make parts from three-dimensional （3D） model data, usually layer upon layer-is an emerging field with a strong need for standardization. Standards serve to develop a common set of basic requirements along the value chain for a harmonized supplier-customer relationship. The benefits of standardization are experienced on both the quality and the commercial sides.

Orbital Milling Hole of Aerospace Al-Alloy with Big Pitch

To improve the processing efficiency and the quality of orbital milling hole of aerospace Al-alloy, the big-pitch influence on cutting force and hole quality was studied experimentally. First, a program based on horizontal lathe was proposed based on kinematics analysis of orbital milling. Then, the cutting force at different stages and the hole quality with different pitches were measured. Results show that the axial force and radial force increase with the pitch amplification during orbital milling. However, the axial force in the orbital milling hole is about 8—10 times smaller than that in the conventional drilling. The diameter error of milling hole is 48—93 μm, and the surface roughness of milling hole is 1.2—1.7 μm. Finally, an orbital milling device with big pitch was designed.

Development of High-Energy-Density Liquid Aerospace Fuel:A Perspective

Aerospace aircraft has significantly improved the life quality of human beings and extended the capability of space explosion since its appearance in 1903,in which liquid propellants or fuels provide the key power source.For jet fuels,its property of energy density plays an important role in determining the flight range,load,and performance of the aircraft.Therefore,the design and fabrication of high-energy-density(HED)fuels attract more and more attention from researchers all over the world.Herein,we briefly introduce the development of liquid jet fuels and HED fuels and demonstrate the future development of HED fuels.To further improve the energy density of fuel,the approaches of design and construction of multi-cyclic and stained molecule structures are proposed.To break through the density limit of hydrocarbon fuels,the addition of energetic nanoparticles in HED fuels to produce nanofluid or gelled fuels may provide a facile and effective method to significantly increase the energy density.This work provides the perspective for the development of HED fuels for advanced aircrafts.

Influence of Shim Layers on Progressive Failure of a Composite Componentin Composite-Aluminum Bolted Joint in Aerospace Structural Assembly

The influence of varying shim layers on the progressive damage/failure of a composite component in a bolted composite-aluminum aerospace structural assembly was investigated using a non-linear three-dimensional(3 D)structural solid elements assembled model of a carbon fiber-reinforced polymer(CFRP)-aluminum single-lap joint with a titanium(Ti-6 Al-4 V)fastener and a washer generated with the commercial finite element(FE)software package,ABAQUS/Standard.A progressive failure algorithm written in Fortran code with a set of appropriate degradation rules was incorporated as a user subroutine in ABAQUS to simulate the non-linear damage behavior of the composite component in the composite-aluminum bolted aerospace structure.The assembled 3 DFE model simulated,as well as the specimen for the experimental testing consisted of a carbon-epoxy IMS-977-2 substrate,aluminum alloy 7075-T651 substrate,liquid shim(Hysol EA 9394),solid peelable fiberglass shim,a titanium fastener,and a washer.In distinction to previous investigations,the influence of shim layers(liquid shim and solid peelable fiberglass shim)inserted in-between the faying surfaces(CFRP and aluminum alloy substrates)were investigated by both numerical simulations and experimental work.The simulated model and test specimens conformed to the standard test configurations for both civil and military standards.The numerical simulations correlated well with the experimental results and it has been found that:(1)The shimming procedure as agreed upon by the aerospace industry for the resolution of assembly gaps in bolted joints for composite materials is the same for a composite-aluminum structure;liquid shim series(0.3,0.5 and 0.7 mm thicknesses)prolonged the service life of the composite component whereas a solid peelable fiberglass shim most definitely had a better influence on the 0.9 assembly gap compared with the liquid shim;(2)The shim layers considerably influenced the structural strength of the composite component by delaying its ultimate failure thereby increasing its service life;and(3)Increasing the shim layer′s thickness led to a significant corresponding effect on the stiffness but with minimal effect on the ultimate load.

Digital Twin-based Quality Management Method for the Assembly Process of Aerospace Products with the Grey-Markov Model and Apriori Algorithm

The assembly process of aerospace products such as satellites and rockets has the characteristics of single-or small-batch production,a long development period,high reliability,and frequent disturbances.How to predict and avoid quality abnormalities,quickly locate their causes,and improve product assembly quality and efficiency are urgent engineering issues.As the core technology to realize the integration of virtual and physical space,digital twin(DT)technology can make full use of the low cost,high efficiency,and predictable advantages of digital space to provide a feasible solution to such problems.Hence,a quality management method for the assembly process of aerospace products based on DT is proposed.Given that traditional quality control methods for the assembly process of aerospace products are mostly post-inspection,the Grey-Markov model and T-K control chart are used with a small sample of assembly quality data to predict the value of quality data and the status of an assembly system.The Apriori algorithm is applied to mine the strong association rules related to quality data anomalies and uncontrolled assembly systems so as to solve the issue that the causes of abnormal quality are complicated and difficult to trace.The implementation of the proposed approach is described,taking the collected centroid data of an aerospace product’s cabin,one of the key quality data in the assembly process of aerospace products,as an example.A DT-based quality management system for the assembly process of aerospace products is developed,which can effectively improve the efficiency of quality management for the assembly process of aerospace products and reduce quality abnormalities.