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.

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.

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.

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.

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.

An electromagnetic semi-active dynamic vibration absorber for thin-walled workpiece vibration suppression in mirror milling

As critical components of aircraft skins and rocket fuel storage tank shells,large thin-walled workpieces are susceptible to vibration and deformation during machining due to their weak local stiffness.To address these challenges,we propose a novel tunable electromagnetic semi-active dynamic vibration absorber(ESADVA),which integrates with a magnetic suction follower to form a followed ESADVA(follow-ESADVA)for mirror milling.This system combines a tunable magnet oscillator with a follower,enabling real-time vibration absorption and condition feedback throughout the milling process.Additionally,the device supports self-sensing and frequency adjustment by providing feedback to a linear actuator,which alters the distance between magnets.This resolves the traditional issue of being unable to directly monitor vibration at the machining point due to space constraints and tool interference.The frequency shift characteristics and vibration absorption performance are comprehensively investigated.Theoretical and experimental results demonstrate that the prototyped follow-ESADVA achieves frequency synchronization with the milling tool,resulting in a vibration suppression rate of approximately 47.57%.Moreover,the roughness of the machined surface decreases by18.95%,significantly enhancing the surface quality.The results of this work pave the way for higher-quality machined surfaces and a more stable mirror milling process.

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.

Boundary Element Analysis forModeⅢCrack Problems of Thin-Walled Structures from Micro-to Nano-Scales

This paper develops a new numerical framework for modeⅢcrack problems of thin-walled structures by integrating multiple advanced techniques in the boundary element literature.The details of special crack-tip elements for displacement and stress are derived.An exponential transformation technique is introduced to accurately calculate the nearly singular integral,which is the key task of the boundary element simulation of thin-walled structures.Three numerical experiments with different types of cracks are provided to verify the performance of the present numerical framework.Numerical results demonstrate that the present scheme is valid for modeⅢcrack problems of thin-walled structures with the thickness-to-length ratio in the microscale,even nanoscale,regime.

Springback analysis and strategy for multi-stage thin-walled parts with complex geometries

Springback of a SUS321 complex geometry part formed by the multi-stage rigid-flexible compound process was studied through numerical simulations and laboratory experiments in this work.The sensitivity analysis was provided to have an insight in the effect of the evaluated process parameters.Furthermore,in order to minimize the springback problem,an accurate springback simulation model of the part was established and validated.The effects of the element size and timesteps on springback model were further investigated.Results indicate that the custom mesh size is beneficial for the springback simulation,and the four timesteps are found suited for the springback analysis for the complex geometry part.Finally,a strategy for reducing the springback by changing the geometry of the blank is proposed.The optimal blank geometry is obtained and used for manufacturing the part.

Geometric Accuracy and Energy Absorption Characteristics of 3D Printed Continuous Ramie Fiber Reinforced Thin-Walled Composite Structures

The application of continuous natural fibers as reinforcement in composite thin-walled structures offers a feasible approach to achieve light weight and high strength while remaining environmentally friendly.In addition,additive manufacturing technology provides a favorable process foundation for its realization.In this study,the printability and energy absorption properties of 3D printed continuous fiber reinforced thin-walled structures with different configurations were investigated.The results suggested that a low printing speed and a proper layer thickness would mitigate the printing defects within the structures.The printing geometry accuracy of the structures could be further improved by rounding the sharp corners with appropriate radii.This study successfully fabricated structures with vari-ous configurations characterized by high geometric accuracy through printing parameters optimization and path smoothing.Moreover,the compressive property and energy absorption characteristics of the structures under quasi-static axial compression were evaluated and compared.It was found that all studied thin-walled structures exhibited progressive folding deformation patterns during compression.In particular,energy absorption process was achieved through the combined damage modes of plastic deformation,fiber pullout and delamination.Furthermore,the com-parison results showed that the hexagonal structure exhibited the best energy absorption performance.The study revealed the structure-mechanical property relationship of 3D printed continuous fiber reinforced composite thin-walled structures through the analysis of multiscale failure characteristics and load response,which is valuable for broadening their applications.

Modeling time-dependent mechanical behavior of hard rock considering excavation-induced damage and complex 3D stress states

To investigate the long-term stability of deep rocks,a three-dimensional(3D)time-dependent model that accounts for excavation-induced damage and complex stress state is developed.This model comprises three main components:a 3D viscoplastic isotropic constitutive relation that considers excavation damage and complex stress state,a quantitative relationship between critical irreversible deformation and complex stress state,and evolution characteristics of strength parameters.The proposed model is implemented in a self-developed numerical code,i.e.CASRock.The reliability of the model is validated through experiments.It is indicated that the time-dependent fracturing potential index(xTFPI)at a given time during the attenuation creep stage shows a negative correlation with the extent of excavationinduced damage.The time-dependent fracturing process of rock demonstrates a distinct interval effect of the intermediate principal stress,thereby highlighting the 3D stress-dependent characteristic of the model.Finally,the influence of excavation-induced damage and intermediate principal stress on the time-dependent fracturing characteristics of the surrounding rocks around the tunnel is discussed.

Saturation Estimation with Complex Electrical Conductivity for Hydrate-Bearing Clayey Sediments:An Experimental Study

Clays have considerable influence on the electrical properties of hydrate-bearing sediments.It is desirable to understand the electrical properties of hydrate-bearing clayey sediments and to build hydrate saturation(S_(h))models for reservoir evaluation and monitoring.The electrical properties of tetrahydrofuran-hydrate-bearing sediments with montmorillonite are characterized by complex conductivity at frequencies from 0.01 Hz to 1 kHz.The effects of clay and Sh on the complex conductivity were analyzed.A decrease and increase in electrical conductance result from the clay-swelling-induced blockage and ion migration in the electrical double layer(EDL),respectively.The quadrature conductivity increases with the clay content up to 10%because of the increased surface site density of counterions in EDL.Both the in-phase conductivity and quadrature conductivity decrease consistently with increasing Sh from 0.50 to 0.90.Three sets of models for Sh evaluation were developed.The model based on the Simandoux equation outperforms Archie’s formula,with a root-mean-square error(E_(RMS))of 1.8%and 3.9%,respectively,highlighting the clay effects on the in-phase conductivity.The fre-quency effect correlations based on in-phase and quadrature conductivities exhibit inferior performance(E_(RMS)=11.6%and 13.2%,re-spectively)due to the challenge of choosing an appropriate pair of frequencies and intrinsic uncertainties from two measurements.The second-order Cole-Cole formula can be used to fit the complex-conductivity spectra.One pair of inverted Cole-Cole parameters,i.e.,characteristic time and chargeability,is employed to predict S_(h) with an E_(RMS) of 5.05%and 9.05%,respectively.

Experimental Study on Entropy Features in Machining Vibrations of A Thin-Walled Tubular Workpiece

In machining processes,chatter vibrations are always regarded as one of the major limitations for production quality and efficiency.Accurate and timely monitoring of chatter is helpful to maintain stable machining operations.At present,most chatter monitoring methods are based on the energy level at specified chatter frequencies or frequency bands.However,the spectral features of chatter could change during machining operations due to complexity and time-varying dynamics of the physical machining process.The purpose of this paper is to investigate the time-varying chatter features in turning of thin-walled tubular workpieces from the perspective of entropy.The airborne acoustics was selected as the source of information for machining condition monitoring.First,corresponding to the distinguishing surface topographies relevant to machining conditions,the features of the sound signal emitted during turning of the thin-walled cylindrical workpieces were extracted using the spectral analysis and wavelet packet transform,respectively.It was shown that the dominant vibration frequency as well as the energy distribution could shift with the transition of the machining status.After that,two relative entropy indicators based on the spectrum and the wavelet packet energy were constructed to identify chattering events in turning of the thin-walled tubes.The experimental results demonstrate that the proposed indicators could accurately reflect the transition of machining conditions with high sensitivity and robustness in comparison with the traditional FFT-based methods.The achievement of this study lays the foundations of the online chatter monitoring and control technique for turning of the thin-walled tubular workpieces.

A novel complex-high-order graph convolutional network paradigm:ChyGCN

In recent years,there has been a growing interest in graph convolutional networks(GCN).However,existing GCN and variants are predominantly based on simple graph or hypergraph structures,which restricts their ability to handle complex data correlations in practical applications.These limitations stem from the difficulty in establishing multiple hierarchies and acquiring adaptive weights for each of them.To address this issue,this paper introduces the latest concept of complex hypergraphs and constructs a versatile high-order multi-level data correlation model.This model is realized by establishing a three-tier structure of complexes-hypergraphs-vertices.Specifically,we start by establishing hyperedge clusters on a foundational network,utilizing a second-order hypergraph structure to depict potential correlations.For this second-order structure,truncation methods are used to assess and generate a three-layer composite structure.During the construction of the composite structure,an adaptive learning strategy is implemented to merge correlations across different levels.We evaluate this model on several popular datasets and compare it with recent state-of-the-art methods.The comprehensive assessment results demonstrate that the proposed model surpasses the existing methods,particularly in modeling implicit data correlations(the classification accuracy of nodes on five public datasets Cora,Citeseer,Pubmed,Github Web ML,and Facebook are 86.1±0.33,79.2±0.35,83.1±0.46,83.8±0.23,and 80.1±0.37,respectively).This indicates that our approach possesses advantages in handling datasets with implicit multi-level structures.

Discovery of nano organo-clay complex pore-fractures in shale and its scientific significance:A case study of Cretaceous Qingshankou Formation shale,Songliao Basin,NE China

A new pore type,nano-scale organo-clay complex pore-fracture was first discovered based on argon ion polishing-field emission scanning electron microscopy,energy dispersive spectroscopy and three-dimensional reconstruction by focused ion-scanning electron in combination with analysis of TOC,R_(o)values,X-ray diffraction etc.in the Cretaceous Qingshankou Formation shale in the Songliao Basin,NE China.Such pore characteristics and evolution study show that:(1)Organo-clay complex pore-fractures are developed in the shale matrix and in the form of spongy and reticular aggregates.Different from circular or oval organic pores discovered in other shales,a single organo-clay complex pore is square,rectangular,rhombic or slaty,with the pore diameter generally less than 200 nm.(2)With thermal maturity increasing,the elements(C,Si,Al,O,Mg,Fe,etc.)in organo-clay complex change accordingly,showing that organic matter shrinkage due to hydrocarbon generation and clay mineral transformation both affect organo-clay complex pore-fracture formation.(3)At high thermal maturity,the Qingshankou Formation shale is dominated by nano-scale organo-clay complex pore-fractures with the percentage reaching more than 70%of total pore space.The spatial connectivity of organo-clay complex pore-fractures is significantly better than that of organic pores.It is suggested that organo-complex pore-fractures are the main pore space of laminar shale at high thermal maturity and are the main oil and gas accumulation space in the core area of continental shale oil.The discovery of nano-scale organo-clay complex pore-fractures changes the conventional view that inorganic pores are the main reservoir space and has scientific significance for the study of shale oil formation and accumulation laws.

Complexity Considerations in the Heisenberg Uncertainty Principle

This work introduces a modification to the Heisenberg Uncertainty Principle (HUP) by incorporating quantum complexity, including potential nonlinear effects. Our theoretical framework extends the traditional HUP to consider the complexity of quantum states, offering a more nuanced understanding of measurement precision. By adding a complexity term to the uncertainty relation, we explore nonlinear modifications such as polynomial, exponential, and logarithmic functions. Rigorous mathematical derivations demonstrate the consistency of the modified principle with classical quantum mechanics and quantum information theory. We investigate the implications of this modified HUP for various aspects of quantum mechanics, including quantum metrology, quantum algorithms, quantum error correction, and quantum chaos. Additionally, we propose experimental protocols to test the validity of the modified HUP, evaluating their feasibility with current and near-term quantum technologies. This work highlights the importance of quantum complexity in quantum mechanics and provides a refined perspective on the interplay between complexity, entanglement, and uncertainty in quantum systems. The modified HUP has the potential to stimulate interdisciplinary research at the intersection of quantum physics, information theory, and complexity theory, with significant implications for the development of quantum technologies and the understanding of the quantum-to-classical transition.

Three-dimensional magnetic reconnection in complex multiple X-point configurations in an ancient solar-lunar terrestrial system

Magnetic reconnection processes in three-dimensional(3D)complex field configurations have been investigated in different magneto-plasma systems in space,laboratory,and astrophysical systems.Two-dimensional(2D)features of magnetic reconnection have been well developed and applied successfully to systems with symmetrical property,such as toroidal fusion plasmas and laboratory experiments with an axial symmetry.But in asymmetric systems,the 3D features are inevitably different from those in the 2D case.Magnetic reconnection structures in multiple celestial body systems,particularly star-planet-Moon systems,bring fresh insights to the understanding of the 3D geometry of reconnection.Thus,we take magnetic reconnection in an ancient solar-lunar terrestrial magneto-plasma system as an example by using its crucial parameters approximately estimated already and also some specific applications in pathways for energy and matter transports among Earth,ancient Moon,and the interplanetary magnetic field(IMF).Then,magnetic reconnection of the ancient lunar-terrestrial magnetospheres with the IMF is investigated numerically in this work.In a 3D simulation for the Earth-Moon-IMF system,topological features of complex magnetic reconnection configurations and dynamical characteristics of magnetic reconnection processes are studied.It is found that a coupled lunar-terrestrial magnetosphere is formed,and under various IMF orientations,multiple X-points emerge at distinct locations,showing three typical magnetic reconnection structures in such a geometry,i.e.,the X-line,the triple current sheets,and the A-B null pairs.The results can conduce to further understanding of reconnection physics in 3D for plasmas in complex magnetic configurations,and also a possible mechanism for energy and matters transport in evolutions of similar astrophysical systems.

Synthesis and Physico-Chemical Characterizations of Novel Hydrazone Ligands and Their Metal Complexes against Hormone-Dependent and Independent Cancers

This work deals with the synthesis and physicochemical characterizations of a new group of novel retinoidal ligands and their metal complexes. Their in vitro anti-proliferative activities have shown that ligand L1 is effective against human breast cancer BT-20 and MCF-7 cell lines. At the same time, compound L2 exerts its effect on human prostate cancer PC-3 and human breast cancer MDA-MB-231 and MCF-7 cell lines respectively. The retinoid ligands exert their pleiotropic action toward retinoic acid receptors (RARs) than their metal complexes but all compounds exhibit concentration-dependent.