Effects of Loading Paths on Hydrodynamic Deep Drawing with Independent Radial Hydraulic Pressure of Aluminum Alloy Based on Numerical Simulation

In order to meet the forming demands for low plasticity materials and large height-diameter ratio parts, a new process of hydrodynamic deep drawing （HDD） with independent radial hydraulic pressure is proposed. To investigate the effects of loading paths on the HDD with independent radial hydraulic pressure, the forming process of 5A06 aluminum alloy cylindrical cup with a hemispherical bottom was studied by numerical simulation. By employing the dynamic explicit analytical software ETA/Dynaform based on LS-DYNA3D, the effects of loading paths on the sheet-thickness distribution and surface quality were analyzed. The corresponding relations of the radial hydraulic pressure loading paths and the part＇s strain status on the forming limit diagram （FLD） were also discussed. The results indicated that a sound match between liquid chamber pressure and independent radial hydraulic pressure could restrain the serious thinning at the hemisphere bottom and that through adjusting radial hydraulic pressure could reduce the radial tensile strain and change the strain paths. Therefore, the drawing limit of the aluminum cylindrical cup with a hemispherical bottom could be increased significantly.

Deformation and defects in hydroforming of 5A06 aluminum alloy dome with controllable radial pressure

A new process of hydroforming with controllable radial pressure was proposed to overcome difficulties in the forming of low plastic materials and large height-to-diameter ratio workpieces. A typical 5A06 aluminum alloy dome was numerically and experimentally investigated. The reasons for typical defects were analyzed under different radial pressures. Effects of radial pressure on the thickness distribution were discussed and optimal radial pressure was determined. It is shown by numerical simulations and experiment that a cup with a drawing ratio of 2.4 is formed by the new process of hydroforming with controllable radial pressure. It is significantly effective for the forming of low plastic materials and large height-to-diameter ratio workpieees. Two typical thinning points exit along the dome wall. With the radial pressure, thinning is decreased effectively at the two points, the dome forming is achieved and thickness distribution is more uniform.

Reliability and sensitivity analyses of HPT blade-tip radial running clearance using multiply response surface model

To reasonably design the blade-tip radial running clearance(BTRRC) of high pressure turbine and improve the performance and reliability of gas turbine, the multi-object multi-discipline reliability sensitivity analysis of BTRRC was accomplished from a probabilistic prospective by considering nonlinear material attributes and dynamic loads. Firstly, multiply response surface model(MRSM) was proposed and the mathematical model of this method was established based on quadratic function. Secondly, the BTRRC was decomposed into three sub-components(turbine disk, blade and casing), and then the single response surface functions(SRSFs) of three structures were built in line with the basic idea of MRSM. Thirdly, the response surface function(MRSM) of BTRRC was reshaped by coordinating SRSFs. From the analysis, it is acquired to probabilistic distribution characteristics of input-output variables, failure probabilities of blade-tip clearance under different static blade-tip clearances δ and major factors impacting BTRRC. Considering the reliability and efficiency of gas turbine, δ=1.87 mm is an optimally acceptable option for rational BTRRC. Through the comparison of three analysis methods(Monte Carlo method, traditional response surface method and MRSM), the results show that MRSM has higher accuracy and higher efficiency in reliability sensitivity analysis of BTRRC. These strengths are likely to become more prominent with the increasing times of simulations. The present study offers an effective and promising approach for reliability sensitivity analysis and optimal design of complex dynamic assembly relationship.

Hydrodynamic deep drawing of double layered conical cups

Hydrodynamic deep drawing assisted by radial pressure is an advanced sheet forming technology with great advantages such as higher drawing ratio, good surface quality and higher dimensional accuracy. In this process, both the bottom surface and the peripheral edge of sheets are under hydrodynamic pressure, so that the forming procedure is more uniform with low failure probability. Multi-layered sheets with complex geometries could be formed more easily with this technique compared with other traditional methods. Rupture is the main irrecoverable failure form in sheet forming processes. Prediction of rupture occurrence is of great importance for determining and optimizing the proper process parameters. In this research, a theoretical model was proposed to calculate the critical rupture pressure in production of double layered conical parts with hydrodynamic deep drawing process assisted by radial pressure. The effects of other process parameters on critical rupture pressure, such as punch tip radius, drawing ratio, coefficient of friction, sheet thickness and material properties were also discussed. The proposed model was compared with finite element simulation and validated by experiments on Al1050/St13 double layered sheets, where a good agreement was found with analytical results.

Formation of Aluminum-magnesium Alloy Cup by Hydrodynamic Deep Drawing with Twin-loading Paths

In order to overcome the limitation of hydro-rim deep drawing, a new process of hydrodynamic deep drawing （HDD） with independent radial hydraulic pressure was proposed. By employing the dynamic explicit analytical software ETA/DynaformS.5 which is based on LS-DYNA3D, the effects of independent radia! hydraulic pressure on the stress, strain and the sheet-thickness of aluminum-magnesium cylindrical cup with a hemispherical bottom were analyzed by numerical simulation. The feature of stress distribution is that there exists a stress-dividing circle in the flange, and the radius of dividing circle was determined by theoretical analysis and stimulation. The experimental results indicate that the reasonable match of independent radial hydraulic pressure and liquid chamber pressure can effectively reduce the thinning at the bottom of hemisphere, decrease the radial stress-strain, and improve the drawing limit of aiuminum-magnesium alloy cylindrical cup.

总压畸变对涵道推力风扇气动性能影响的研究

Inlet distortion is one of the main factors for the degradation of aerodynamic performance and stability margin of the compressor in practical operation. Due to the change of the inlet shape and the large amount of inhalation of the body Boundary Layer, the ducted thrust fan of the Boundary Layer Ingestion (BLI) propulsion system inevitably works in the intake distortion condition. In this paper, the ducted thrust fan in a BLI propulsion system is taken as the research object. The influence of radial and circumferential total pressure distortion on the inlet section of the ducted thrust fan caused by boundary layer suction and inlet shape is studied by steady single channel and fullloop numerical simulation. The influence law of distortion intensity and distortion range of the two types of distortion patterns of the distortion map is analyzed emphatically. The results show that :(1) the greater the range and intensity of the radial total pressure distortion are, the more affected the performance of the ducted thrust fan is;(2) The aero-dynamic performance decline amplitude of the ducted thrust fan increases with the increase of the intensity of the circumferential total pressure distortion;The transmission law of the circumferential total pressure distortion intensity along the inlet and outlet of the fan is almost the same. Different working conditions have influence on the attenuation degree of the circumferential total pressure distortion in the ducted thrust fan, and the attenuation range of the circumferential total pressure distortion in the design working condition is the largest.

Reliability of gas holdup measurements using the differential pressure method in a cyclone-static micro-bubble flotation column

Gas holdup is one of the key parameters in flotation process. Gas holdup as measured by a differential pressure method was investigated and the relative errors compared to the average gas holdup from the volume expansion method. The errors were used to establish optimum measurement positions. The results show that the measurement position should be in the middle of the column and in the region half way from the center to the wall (the half-radius). The gas holdup along the axial direction is lower at the bottom and higher at the top of the floatation column. The gas holdup along the radial direction is lower near the wall and higher near the center of the flotation column. The average gas holdup measure- ment can be replaced by regional gas holdup values.

Effect of Geometric Variation of Root Fillet on the Flow Characteristic of a Transonic Compressor Rotor

The effects of root fillet on the flow behavior of high loading compressor rotor tends to be much more crucial in practice,and it’s necessary to explore the internal relations between the geometric effects of root fillet and the flow behaviors of rotor blade.Therefore,eight types of root fillet with different radius were designed and installed around the blade root of NASA Rotor67.With the aids of fillet,the corner separation near suction side of blade root has been suppressed significantly in that the root fillet reconstructs the circumferential bending distributon of the suction-side curve from leading edge to trailing edge,and reduces the genmetric turning angle in the latter part of root section near trailing edge.However,apart from the improvement of corner flow characteristic caused by root fillet,both the tip flow deterioration and the decrease of stall margin occur in the new rotors,which indicates an indirect correlation between tip flow characteristic and root fillet exists indeed in the three-dimensional flowfields of transonic rotor.Actually,by means of the new radial pressure equilibrium affected by root fillet,a larger radius of root fillet contributes to much larger blade loading and stronger leakage flow in tip region of compressor rotor.As a result,a monotonic decrease of stall margin was present in the transonic rotor with increase of the root fillet radius.Subsequently,the positive bending of blade tip was introduced to deal with the negative effect caused by the root fillet indirectly.Combined with the effects of root fillet and positive tip-bending on the radial pressure equilibrium existing in channels,both the radial and streamwise loading distributions tend to be much more reasonable in new rotors,and the static pressure difference in former 1/3 chord of blade tip has decreased clearly which benefits to reduce the strength of leakage flow in tip region.Therefore,the flow deterioration in tip region of transonic rotor induced by root fillet has been well suppressed,with an obvious improvement of overall performance occurring in new rotors.

Compaction analysis and optimisation of convex-faced pharmaceutical tablets using numerical techniques

Capping failure,edge chipping,and non-uniform mechanical properties of convex-faced pharmaceutical tablets are common problems in the pharma industry.In this paper,the finite element method(FEM)and design of experiment techniques are used to determine the optimal shape of convex-faced(CF)pharmaceutical tablet which has more uniform mechanical properties and less capping and chipping tendency.The effects of different geometrical parameters and friction on the compaction responses of convex-faced pharmaceutical tablets were first identified and analysed.An FEM model of the tabletting process was generated using the implicit code ABAQUS and validated against experimental measurements.Response surface methodology was used to establish the relationship between the design variables,represented by the geometrical parameters and friction coefficient,and compaction responses of interest including residual die pressure,relative density variation within a tablet,and relative shear stress at the edge of a tablet.A statistical-based optimisation approach was then used to optimise the shape of CF tablets.The obtained results demonstrated how the geometrical parameters and friction coefficient of CF pharmaceutical tablets strongly affect their compaction behaviour and quality.