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.

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.

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.

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.

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.

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.

空天目标雷达智能识别仿真系统设计与实现

雷达智能识别方法训练、测试与评估通常需要构建大样本的数据集,如何快速获得有效的数据集是亟待解决的问题。分析了空天目标雷达智能识别系统应用场景,并结合应用需求给出了空天目标雷达智能识别仿真系统建设思路;采用组件化、模块化设计方法,设计空天目标雷达智能识别仿真系统框架,构建空天目标智能识别仿真系统,快速准确模拟空天目标电磁特性和动态回波,具有可扩展、可重构能力。仿真结果和初步应用表明,该系统可用于不同应用场景下空天目标雷达智能识别方法的测试与评估。

适用于航天控制系统零件精密内孔加工的高效电火花铣削技术

高效电火花铣削技术着眼于提升航天控制系统精密零件内孔加工的效率与精度,通过将高速电火花加工方法与传统铣削工艺相融合,突破传统电火花加工内孔需制备对应形状电极、加工效率低、几何精度差、再铸层厚度难以控制的限制,从电极损耗补偿和自适应过程控制、实时速度控制及轨迹规划、再铸层与表面质量控制方法等三方面出发,探索高效电火花铣削加工在复杂孔系壳体类、精密轴套类以及功能微孔类零件加工中的应用。该方法与传统电火花成形加工精密内孔相比,可将加工效率提升65%,同时最高可降低87.17%的再铸层厚度值,实现了精密内孔加工效率、质量与成本的多重提升。随着高效电火花铣削技术在精密加工中的广泛应用,将大幅提高航天控制系统关键零部件的制造能力,同时能够为日益增多的零件种类以及日益复杂的零件结构,提供更加全面的工艺解决方案。

基于FAHP方法的宇航元器件供应稳定性评价研究

宇航元器件是航天装备建设的基础性、战略性资源,对于实现装备自主发展具有重要影响,发挥着关键作用。在宇航元器件逐步实现国产化后,国产元器件能否实现稳定供应,将成为我国宇航元器件行业面临的一个新的紧迫性问题,以及制约国产元器件应用的重要因素。针对以上情况,运用模糊层次分析法(FAHP),从生产线、生产过程、核心零部件等9个影响因素维度,建立了国产宇航元器件供应稳定性评价指标体系,该体系有助于摸清宇航元器件供应现状,进而为我国宇航元器件领域精准施策奠定基础。

Multi-scale design and optimization for solid-lattice hybrid structures and their application to aerospace vehicle components

By integrating topology optimization and lattice-based optimization,a novel multi-scale design method is proposed to create solid-lattice hybrid structures and thus to improve the mechanical performance as well as reduce the structural weight.To achieve this purpose,a two-step procedure is developed to design and optimize the innovative structures.Initially,the classical topology optimization is utilized to find the optimal material layout and primary load carrying paths.Afterwards,the solid-lattice hybrid structures are reconstructed using the finite element mesh based modeling method.And lattice-based optimization is performed to obtain the optimal crosssection area of the lattice structures.Finally,two typical aerospace structures are optimized to demonstrate the effectiveness of the proposed optimization framework.The numerical results are quite encouraging since the solid-lattice hybrid structures obtained by the presented approach show remarkably improved performance when compared with traditional designs.

Recent progress in flexible supporting technology for aerospace thin-walled parts:A review

Thin-walled parts are widely used in the aerospace industry owing to their light weight and high specific strength.However,due to the low rigidity of thin-walled parts,elastic deformation and chatter easily occur,which seriously affect the machining accuracy and workpiece surface quality.To solve this problem,several supporting technologies have been reported in recent years.This paper reviews the recent research progress of flexible supporting technologies in the aerospace field by classifying them based on different principles and characteristics.The principle,progress,advantages,and limitations of the technologies are expounded by systematic comparison and summarized.Finally,the challenges and future development trends of flexible supporting technology,which will provide guidelines for further research,are 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.

基于光学部件制造的新时期航天工艺技术中心建设与管理实践

分析了新时期航天工艺技术中心建设的重要意义,介绍了航天光学部件制造工艺技术中心建设和管理模式、运行机制和取得的成效等。为持续提升航天工艺技术水平和制造能力,发展航天事业、建设航天强国,提出了加强航天工艺技术中心建设的若干建议。

宇航用元器件低成本高可靠技术探索和应用

基于测试可靠性的传统宇航元器件质量保证成本约占任务总成本的30%~40%且周期很长,难以满足快速组网星座和商业航天的发展需要,因而为了建立一种宇航用元器件低成本高可靠技术路线,提出了“面向任务和应用目标的宇航用元器件定量质量保证技术”路线。定量保证实现以下几个方面的突破:一是元器件可靠性要求从面向质量等级转变为面向任务和应用目标,实现元器件可靠性要求定量化;二是可靠性评价模式从测试可靠性模式转变为内建可靠性模式;三是提出定量评价低成本高可靠的方法。与传统质量保证相比,定量保证可将时间和成本降低至少2/3。定量保证在中国科学院空间科学卫星项目中进行了应用并得到了有效验证,具有一定的推广应用价值。

车规元器件宇航应用的质量保证要求研究

车规元器件的极限环境适应性、可靠性要求、质量保证方法等与军用和宇航用元器件有诸多相似之处,同时车规元器件具有技术新、性能高、产量大、成本低等优点,使得其在航天领域的应用被日益重视。基于车规元器件可靠性保证标准,从设计、验证、流片、封装测试等维度全面分析了车规元器件的1ppm质量目标达成策略,并提出定风险、认数据、补差距、降成本4项车规元器件宇航应用的质量保证措施,从而使车规元器件在宇航应用的成本与性能之间找到平衡点,有效促进了宇航电子产品的高可靠、低成本目标的达成。

模型与知识驱动的电缆加工工艺快速设计技术

为解决航天电缆组件设计工艺数据协同效率低、工艺知识积累应用不足、工艺准备重复性工作量大且周期长等问题,提出一种模型与知识驱动的航天电缆组件加工工艺快速设计技术。分析基于MBD的电缆结构化设计信息提取、电缆结构化工艺设计知识库构建、基于知识的电缆加工工艺智能生成等关键技术;构建B/S架构的软件系统并实现型号工程应用验证。结果表明:该系统能实现电缆工艺快速设计,大幅提高电缆组件加工工艺设计效率,提升文件规范性和工艺设计过程知识化、智能化水平。

宇航元器件极限评估技术研究

极限评估技术是一种元器件可靠性的新型评估方法,目的在于探求元器件的能力是否能够满足宇航特定的应用环境要求,极限评估对应用于高可靠领域内的元器件质量保证尤为重要。提出了极限评估技术相关概念和理论,总结了极限评估的一般方法,这对元器件的研制和应用具有实用价值并可有效指导元器件质量保证工作。