Developments and perspectives on the precision forming processes for ultra-large size integrated components

In order to meet the requirements of high reliability,long-lifetime and lightweight in a new generation of aerospace,aviation,high-speed train,and energy power equipment,integrated components are urgently needed to replace traditional multi-piece,welded components.The applications of integrated components involve in a series of large-size,complex-shaped,highperformance components made of difficult-to-deform materials,which present a huge challenge for forming ultra-large size integrated components.In this paper,the developments and perspectives of several extreme forming technologies are reviewed,including the sheet hydroforming of ultra-large curved components,dieless hydroforming of ellipsoidal shells,radial-axial ring rolling of rings,in situ manufacturing process of flanges,and local isothermal forging of titanium alloy components.The principle and processes for controlling deformation are briefly illustrated.The forming of typical ultra-large size integrated components and industrial applications are introduced,such as the high strength aluminum alloy,3m in diameter,integrated tank dome first formed by using a sheet blank with a thickness the same as the final component,and a 16m diameter,integrated steel ring rolled by using a single billet.The trends for extreme forming of ultra-large size integrated components are discussed with a goal of providing ideas and fundamental guidance for the further development of new forming processes for extreme-size integrated components in the future.

Influence of Component Size on the Corrosion Behavior of Ti6Al4V Alloy Fabricated by Electron Beam Powder Bed Fusion

The electrochemical behavior of Ti-6Al-4V with 1 mm and 16 mm thickness prepared by electron beam powder bed fusion(EB-PBF)was investigated in phosphate buffered saline.Electrochemical results showed that EB-PBF Ti-6Al-4V with a larger component size was more resistant to corrosion compared to the smaller component,because of less acicularαʹphase content and moreβphase content.As a non-equilibrium phase in the“high-energy state”,αʹphase has a greater susceptibility to corrode and reduces the corrosion resistance of the material,whileβphase improves corrosion resistance of titanium alloys.The results show that the phase composition has a more significant effect on the corrosion performance than the grain size.

OPTIMIZATION APPROACH FOR HYBRID ELECTRIC VEHICLE POWERTRAIN DESIGN

According to bench test results of fuel economy and engine emission for thereal power-train system of EQ7200HEV car. a 3-D performance map oriented quasi-linear model isdeveloped for the configuration of the powertrain components such as internal combustion engine,traction electric motor, transmission, main retarder and energy storage unit. A genetic algorithmbased on optimization procedure is proposed and applied for parametric optimization of the keycomponents by consideration of requirements of some driving cycles. Through comparison of numericalresults obtained by the genetic algorithm with those by traditional optimization methods, it isshown that the present approach is quite effective and efficient in emission reduction and fueleconomy for the design of the hybrid electric car powertrain.

Geographical classification of Nanfeng mandarin by near infrared spectroscopy coupled with chemometrics methods

Near infrared spectroscopy(NIRS),coupled with principal component analysis and wavelength selection techniques,has been sed to develop a robust and reliable reduced-spectrum classifi-cation model for determining the geographical origins of Nanfeng mandarins.The application of the changeable size moving window principal component analysis(CSMWPCA)provided a notably improved lassification model,with correct classification rates of 92.00%,100.00%,90.00%,100.00%,100.00%,100.00%and 100.00%for Fujian,Guangxi,Hunan,Baishe,Baofeng,Qiawan,Sanxi samples,respectively,as well as,a total dassification rate of 97.52%in the wavelength range from 1007 to 1296 nm.To test and apply the proposed method,the procedure was applied to the analysis of 59 samples in an independent test set.Good identification results(correct rate of 96.61%)were also received.The improvement achieved by the application of CSMWPCA method was particularly remarkable when taking the low complexities of the final model(290 variables)into account.The results of the study showed the great potential of NIRS as a fast,nondestructive and environmentally acceptable method for the rapid and reliable determination for geographical classifcation of Nanfeng mandarins.

Design of a Regenerative Auxiliary Power System for Service Vehicles

This paper presents a RAPS,namely the regenerative auxiliary power system,for the vehicle with special accessory power systems.Taking city buses and delivery trucks as examples,service vehicles keep engines idling to power their auxiliary devices(e.g.,refrigeration systems and hydraulic pumps).The potential fuel savings brought on by the electrification of these auxiliary systems are first quantitatively analyzed over a typical drive cycle for a delivery truck.The RAPS is then designed,and its components are sized in accordance with the objectives of compactness and cost-effectiveness.By introducing the proposed RAPS into a conventional delivery truck with an internal combustion engine,the powertrain can be treated as a hybrid because of adding an extra battery.As a result,to pursue a high overall efficiency,a holistic controller is presented for determining how and when to recharge the battery while minimizing the auxiliary system’s power consumption.More importantly,the proposed RAPS saves about 7%fuel when compared with consumption by conventional service vehicles.

Chemical characterization of size-resolved aerosols in four seasons and hazy days in the megacity Beijing of China

Size-resolved aerosol samples were collected by MOUDI in four seasons in 2007 in Beijing. The PM10 and PM1.8mass concentrations were 166.0 ± 120.5 and 91.6 ± 69.7 μg/m^3, respectively,throughout the measurement, with seasonal variation： nearly two times higher in autumn than in summer and spring. Serious fine particle pollution occurred in winter with the PM1.8/PM10 ratio of 0.63, which was higher than other seasons. The size distribution of PM showed obvious seasonal and diurnal variation, with a smaller fine mode peak in spring and in the daytime. OM（organic matter = 1.6 × OC（organic carbon）） and SIA（secondary inorganic aerosol） were major components of fine particles, while OM, SIA and Ca^2＋were major components in coarse particles. Moreover, secondary components, mainly SOA（secondary organic aerosol） and SIA,accounted for 46%-96% of each size bin in fine particles, which meant that secondary pollution existed all year. Sulfates and nitrates, primarily in the form of（NH4）2SO4, NH4NO3, Ca SO4, Na2SO4 and K2SO4, calculated by the model ISORROPIA II, were major components of the solid phase in fine particles. The PM concentration and size distribution were similar in the four seasons on non-haze days, while large differences occurred on haze days, which indicated seasonal variation of PM concentration and size distribution were dominated by haze days. The SIA concentrations and fractions of nearly all size bins were higher on haze days than on non-haze days, which was attributed to heterogeneous aqueous reactions on haze days in the four seasons.

Research on uncertainty in measurement assisted alignment in aircraft assembly

Operations in assembling and joining large size aircraft components are changed to novel digital and flexible ways by digital measurement assisted alignment.Positions and orientations（P＆O）of aligned components are critical characters which assure geometrical positions and relationships of those components.Therefore,evaluating the P＆O of a component is considered necessary and critical for ensuring accuracy in aircraft assembly.Uncertainty of position and orientation（U-P＆O）,as a part of the evaluating result of P＆O,needs to be given for ensuring the integrity and credibility of the result;furthermore,U-P＆O is necessary for error tracing and quality evaluating of measurement assisted aircraft assembly.However,current research mainly focuses on the process integration of measurement with assembly,and usually ignores the uncertainty of measured result and its influence on quality evaluation.This paper focuses on the expression,analysis,and application of U-P＆O in measurement assisted alignment.The geometrical and algebraical connotations of U-P＆O are presented.Then,an analytical algorithm for evaluating the multi-dimensional U-P＆O is given,and the effect factors and characteristics of U-P＆O are discussed.Finally,U-P＆O is used to evaluate alignment in aircraft assembly for quality evaluating and improving.Cases are introduced with the methodology.