Turbine blade is one of the critical components of aircraft engine.The performance of the engine depends on the shape and dimensions of components,but superalloy blade material cannot be easily machined.Although inves...Turbine blade is one of the critical components of aircraft engine.The performance of the engine depends on the shape and dimensions of components,but superalloy blade material cannot be easily machined.Although investment casting is an ideal process for such net-shape components,it requires an accurate determination of the casting-die profile.In this paper,a reversing design methodology for investment casting die using ProCAST is proposed.By combining the methods of simplifying grid files and quick sorting,the efficiency of sorting and matching can be largely improved.Further,the mould/die cavity anti-deformation system can be easily built.With ProCAST,the optimized die profile for investment casting can be established.展开更多
To verify the effectiveness of the integrated importance measure (IIM) for multi-state coherent systems of k level,the definition and physical meaning of IIM are demonstrated.Then,the improvement potential and Δ-impo...To verify the effectiveness of the integrated importance measure (IIM) for multi-state coherent systems of k level,the definition and physical meaning of IIM are demonstrated.Then,the improvement potential and Δ-importance measures are generalized to multi-state coherent systems based on the system performance level,and the relationships between IIM and traditional importance measures are discussed.The characteristics of IIM are demonstrated in both series and parallel systems.Also,an application to an oil transportation system is given.The comparison results show that: (i) IIM has some useful properties that are not possessed by traditional importance measures; (ii) IIM is effective in evaluating the component role in multi-state systems when the component reliability and the failure rate are simultaneously considered.展开更多
The nature of networked manufacturing and agile manufacturing is to recognize enterprise resources timely and accurately. This paper mainly discusses an enterprise resource model method and the construction process. F...The nature of networked manufacturing and agile manufacturing is to recognize enterprise resources timely and accurately. This paper mainly discusses an enterprise resource model method and the construction process. Furthermore, the system frameworks of software and application are put forward to realize various enterprise resources management based on a resource business process. Thus, we ensure the integration and sharing of enterprise resources for the requirement of networked manufacturing.展开更多
The existing methods for blade polishing mainly focus on robot polishing and manual grinding.Due to the difficulty in high-precision control of the polishing force,the blade surface precision is very low in robot poli...The existing methods for blade polishing mainly focus on robot polishing and manual grinding.Due to the difficulty in high-precision control of the polishing force,the blade surface precision is very low in robot polishing,in particular,quality of the inlet and exhaust edges can not satisfy the processing requirements.Manual grinding has low efficiency,high labor intensity and unstable processing quality,moreover,the polished surface is vulnerable to burn,and the surface precision and integrity are difficult to ensure.In order to further improve the profile accuracy and surface quality,a pneumatic flexible polishing force-exerting mechanism is designed and a dual-mode switching composite adaptive control(DSCAC) strategy is proposed,which combines Bang-Bang control and model reference adaptive control based on fuzzy neural network(MRACFNN) together.By the mode decision-making mechanism,Bang-Bang control is used to track the control command signal quickly when the actual polishing force is far away from the target value,and MRACFNN is utilized in smaller error ranges to improve the system robustness and control precision.Based on the mathematical model of the force-exerting mechanism,simulation analysis is implemented on DSCAC.Simulation results show that the output polishing force can better track the given signal.Finally,the blade polishing experiments are carried out on the designed polishing equipment.Experimental results show that DSCAC can effectively mitigate the influence of gas compressibility,valve dead-time effect,valve nonlinear flow,cylinder friction,measurement noise and other interference on the control precision of polishing force,which has high control precision,strong robustness,strong anti-interference ability and other advantages compared with MRACFNN.The proposed research achieves high-precision control of the polishing force,effectively improves the blade machining precision and surface consistency,and significantly reduces the surface roughness.展开更多
Titanium alloy is a kind of typical hard-to-cut material due to its low thermal conductivity and high strength at elevated temperatures, this contributes to the fast tool wear in the milling of titanium alloys. The in...Titanium alloy is a kind of typical hard-to-cut material due to its low thermal conductivity and high strength at elevated temperatures, this contributes to the fast tool wear in the milling of titanium alloys. The influence of cutting conditions on tool wear has been focused on the turning process, and their influence on tool wear in milling process as well as the influence of tool wear on cutting force coefficients has not been investigated comprehensively. To fully understand the tool wear behavior in milling process with inserts, the influence of cutting parameters on tool wear in the milling of titanium alloys Ti6Al4 V by using indexable cutters is investigated. The tool wear rate and trends under different feed per tooth, cutting speed, axial depth of cut and radial depth of cut are analyzed. The results show that the feed rate per tooth and the radial depth of cut have a large influence on tool wear in milling Ti6Al4 V with coated insert. To reduce tool wear, cutting parameters for coated inserts under experimental cutting conditions are set as: feed rate per tooth less than 0.07 mm, radial depth of cut less than 1.0 mm, and cutting speed sets between 60 and 150 m/min. Investigation on the relationship between tool wear and cutting force coefficients shows that tangential edge constant increases with tool wear and cutter edge chipping can lead to a great variety of tangential cutting force coefficient. The proposed research provides the basic data for evaluating the machinability of milling Ti6Al4 V alloy with coated inserts, and the recommend cutting parameters can be immediately applied in practical production.展开更多
Discontinuous tape winding, which has obvious advantages in large extension ratio winding, is widely used in the molding of composites. Therefore, the research on technological parameters becomes the focus of many sch...Discontinuous tape winding, which has obvious advantages in large extension ratio winding, is widely used in the molding of composites. Therefore, the research on technological parameters becomes the focus of many scholars. However, how to accomplish the variable tension control is usually not fully considered. Accordingly, the constant extension ratio and the smoothness of winding process cannot be ensured. Aiming at the problem of tension control, this paper first gives a comparatively deep research on the control method and the interaction mechanism of tension, extension ratio, automatic lap and automatic rectification. Then, according to the winding process features, the mechanical device and the mathematical model of tension control system are established respectively. With regard to the characteristics of PID controller and fuzzy controller, the fuzzy self-tuning PID controller is designed. As a result, the variable tension control is realized during the winding and lapping process, and the constant extension ratio is guaranteed. Finally, a sample application is presented for demonstration. By presenting the variable tension control techniques for discontinuous tape winding, the constant extension ratio of tapes is achieved, the consecution and the automation degree of winding process is improved as well. Thus, the quality of wound products is guaranteed.展开更多
A turbine blade is one of the key components of the aero-engine. Its geometric shape should be inspected carefully in the production stage to ensure that it meets the tolerance specification. In the present paper, an ...A turbine blade is one of the key components of the aero-engine. Its geometric shape should be inspected carefully in the production stage to ensure that it meets the tolerance specification. In the present paper, an approach for investment turbine blade geometric shape analysis based on multi-source digital measurement is presented. Its key technologies, such as measurement data collection, blade model reliable alignment, geometric shape deviation fast calculation and visualization, were investigated. Actual measurement data from a structure light measurement device and a Coordinate Measuring Machine(CMM) for turbine blades were used to validate the presented method. The experimental results show that the proposed method is accurate, quick and effective to implement.展开更多
The large warping deformation at platform of turbine blade directly affects the forming precision. In the present research, equivalent warping deformation was firstly presented to describe the extent of deformation at...The large warping deformation at platform of turbine blade directly affects the forming precision. In the present research, equivalent warping deformation was firstly presented to describe the extent of deformation at platform. To optimize the process parameters during investment casting to minimize the warping deformation of the platform, based on simulation with Pro CAST, the single factor method, orthogonal test, neural network and genetic algorithm were subsequently used to analyze the influence of pouring temperature, shell mold preheating temperature, furnace temperature and withdrawal velocity on dimensional accuracy of the platform of superalloyDD6 turbine blade. The accuracy of investment casting simulation was verified by measurement of platform at blade casting. The simulation results with the optimal process parameters illustrate that the equivalent warping deformation was dramatically reduced by 21.8% from 0.232295 mm to 0.181698 mm.展开更多
Finite element(FE) simulation is a powerful tool for investigating the mechanism of machining fiber?reinforced polymer composite(FRP). However in existing FE machining simulation works,the two?dimensional(2 D) progres...Finite element(FE) simulation is a powerful tool for investigating the mechanism of machining fiber?reinforced polymer composite(FRP). However in existing FE machining simulation works,the two?dimensional(2 D) progressive damage models only describe material behavior in plane stress,while the three?dimensional(3 D) damage models always assume an instantaneous sti ness reduction pattern. So the chip formation mechanism of FRP under machin?ing is not fully analyzed in general stress state. A 3 D macro?mechanical based FE simulation model was developed for the machining of unidirectional glass fiber reinforced plastic. An energy based 3 D progressive damage model was proposed for damage evolution and continuous sti ness degradation. The damage model was implemented for the Hashin?type criterion and Maximum stress criterion. The influences of the failure criterion and fracture energy dissipa?tion on the simulation results were studied. The simulated chip shapes,cutting forces and sub?surface damages were verified by those obtained in the reference experiment. The simulation results also show consistency with previous 2 D FE models in the reference. The proposed research provides a model for simulating FRP material behavior and the machining process in 3 D stress state.展开更多
The optimal material removal strategy can improve a geometric accuracy and surface quality of thin-walled parts such as turbine blades and blisks in high-speed ball end milling.The dominant conception in the material ...The optimal material removal strategy can improve a geometric accuracy and surface quality of thin-walled parts such as turbine blades and blisks in high-speed ball end milling.The dominant conception in the material removal represents the persistence of the workpiece cutting stiffness in operation to advance the machining accuracy and machining efficiency.On the basis of theoretical models of cutting stiffness and deformation,finite element method (FEM) is applied to calculate the virtual displacements of the thin-walled part under given virtual loads at the nodes of the discrete surface.With the reference of deformation distribution of the thin-walled part,the milling material removal strategy is optimized to make the best of bracing ability of still uncut material.This material removal method is summarized as the lower stiffness region removed firstly and the higher stiffness region removed next.Analytical and experimental results show the availability,which has been verified by the blade machining test in this work,for thin-walled parts to reduce cutting deformation and meliorate machining quality.展开更多
Extended finite element method(XFEM) is proposed to simulate the discontinuous interface in the liquid-solid forming process.The discontinuous interface is an important phenomenon happening in the liquid-solid forming...Extended finite element method(XFEM) is proposed to simulate the discontinuous interface in the liquid-solid forming process.The discontinuous interface is an important phenomenon happening in the liquid-solid forming processes and it is difficult to be simulated accurately with conventional finite element method(CFEM) because it involves solid phase and liquid phase simultaneously.XFEM is becoming more and more popular with the need of solving the discontinuous problem happening in engineering field.The implementation method of XFEM is proposed on Abaqus code by using UEL(user element) with the flowchart.The key is to modify the element stiffness in the proposed method by using UEL on the platform of Abaqus code.In contrast to XFEM used in the simulation of solidification,the geometrical and physical properties of elements were modified at the same time in our method that is beneficial to getting smooth interface transition and precise analysis results.The analysis is simplified significantly with XFEM.展开更多
Recent development and recognition methods of raster to vector conversion for engineering drawings are presented. The advantages and disadvantages of all existing models are analyzed. Some research challenges and futu...Recent development and recognition methods of raster to vector conversion for engineering drawings are presented. The advantages and disadvantages of all existing models are analyzed. Some research challenges and future directions are discussed.展开更多
As a key assembly in the 5-axis CNC machine tools, positioning precision of the A-axis directly affects the machining accuracy and surface quality of the parts. First of all, mechanical structure and control system of...As a key assembly in the 5-axis CNC machine tools, positioning precision of the A-axis directly affects the machining accuracy and surface quality of the parts. First of all, mechanical structure and control system of the A-axis are designed. Then, considering the influence of nonlinear friction, backlash, unmodeled dynamics, uncertain cutting force and other external disturbance on the control precision of the A-axis, an adaptive sliding mode control(ASMC) based on extended state observer(ESO) is proposed. ESO is employed to estimate the state variables of the unknown system and an adaptive law is adopted to compensate for the input dead-zone caused by friction,backlash and other nonlinear characteristics. Finally, stability of the closed-loop system is guaranteed by the Lyapunov theory. Positioning experiments illustrate the perfect estimation of ESO and the stronger anti-interference and robustness of ASMC, which can improve the control precision of the A-axis by about 40 times. Processing experiments show that the ASMC can reduce the waviness,average error and roughness of the processed surface by 35.63%, 31.31% and 30.35%, respectively.展开更多
The purpose of this paper is to present an extended topology optimization method for the stiffeners layout design of aircraft assembled structures. Multi-fastener joint loads and manufacturing constraints are consider...The purpose of this paper is to present an extended topology optimization method for the stiffeners layout design of aircraft assembled structures. Multi-fastener joint loads and manufacturing constraints are considered simultaneously. On one hand, the joint loads are calculated and constrained within a limited value to avoid the failure of fasteners. On the other hand, the manufacturing constraints of the material distribution in the machining directions of stiffeners are implemented by an improved piecewise interpolation based on a beveled cut-surface. It is proven that the objective function is strictly continuous and differentiable with respect to the piecewise interpolation. The effects of the extended method with two different constraints are highlighted by typical numerical examples. Compared with the standard topology optimization, the final designs have clearly shown the layout of stiffeners and the joint loads have been perfectly constrained to a satisfying level.展开更多
A damage prediction method based on FE simulation was proposed to predict the occurrence of hot shortness cracks and surface cracks in liquid-solid extrusion process.This method integrated the critical temperature cri...A damage prediction method based on FE simulation was proposed to predict the occurrence of hot shortness cracks and surface cracks in liquid-solid extrusion process.This method integrated the critical temperature criterion and Cockcroft & Latham ductile damage model, which were used to predict the initiation of hot shortness cracks and surface cracks of products, respectively.A coupling simulation of deformation with heat transfer as well as ductile damage was carried out to investigate the effect of extrusion temperature and extrusion speed on the damage behavior of Csf/AZ91D composites.It is concluded that the semisolid zone moves gradually toward deformation zone with the punch descending.The amplitude of the temperature rise at the exit of die from the initial billet temperature increases with the increase of extrusion speed during steady-state extrusion at a given punch displacement.In order to prevent the surface temperature of products beyond the incipient melting temperature of composites, the critical extrusion speed is decreased with the increase of extrusion temperature, otherwise the hot shortness cracks will occur.The maximum damage values increase with increasing extrusion speed or extrusion temperature.Theoretical results obtained by the DeformTM-2D simulation agree well with the experiments.展开更多
To investigate the influence of real leading-edge manufacturing error on aerodynamic performance of high subsonic compressor blades,a family of leading-edge manufacturing error data were obtained from measured compres...To investigate the influence of real leading-edge manufacturing error on aerodynamic performance of high subsonic compressor blades,a family of leading-edge manufacturing error data were obtained from measured compressor cascades.Considering the limited samples,the leadingedge angle and leading-edge radius distribution forms were evaluated by Shapiro-Wilk test and quantile–quantile plot.Their statistical characteristics provided can be introduced to later related researches.The parameterization design method B-spline and Bezier are adopted to create geometry models with manufacturing error based on leading-edge angle and leading-edge radius.The influence of real manufacturing error is quantified and analyzed by self-developed non-intrusive polynomial chaos and Sobol’indices.The mechanism of leading-edge manufacturing error on aerodynamic performance is discussed.The results show that the total pressure loss coefficient is sensitive to the leading-edge manufacturing error compared with the static pressure ratio,especially at high incidence.Specifically,manufacturing error of the leading edge will influence the local flow acceleration and subsequently cause fluctuation of the downstream flow.The aerodynamic performance is sensitive to the manufacturing error of leading-edge radius at the design and negative incidences,while it is sensitive to the manufacturing error of leading-edge angle under the operation conditions with high incidences.展开更多
For aircraft manufacturing industries, the analyses and prediction of part machining error during machining process are very important to control and improve part machining quality. In order to effectively control mac...For aircraft manufacturing industries, the analyses and prediction of part machining error during machining process are very important to control and improve part machining quality. In order to effectively control machining error, the method of integrating multivariate statistical process control (MSPC) and stream of variations (SoV) is proposed. Firstly, machining error is modeled by multi-operation approaches for part machining process. SoV is adopted to establish the mathematic model of the relationship between the error of upstream operations and the error of downstream operations. Here error sources not only include the influence of upstream operations but also include many of other error sources. The standard model and the predicted model about SoV are built respectively by whether the operation is done or not to satisfy different requests during part machining process. Secondly, the method of one-step ahead forecast error (OSFE) is used to eliminate autocorrelativity of the sample data from the SoV model, and the T2 control chart in MSPC is built to realize machining error detection according to the data characteristics of the above error model, which can judge whether the operation is out of control or not. If it is, then feedback is sent to the operations. The error model is modified by adjusting the operation out of control, and continually it is used to monitor operations. Finally, a machining instance containing two operations demonstrates the effectiveness of the machining error control method presented in this paper.展开更多
基金National Natural Science Foundation of China (90405016, 10676028) 973 Program (2006CB601205)+1 种基金 863 Project (2006AA04Z 122) Aeronautical Science Foundation (04B53080, 2006ZA 53006) and 111 Project (B07050)
基金supported by National Key Technologies R&D Program under Grant No. 2006BAF04B02
文摘Turbine blade is one of the critical components of aircraft engine.The performance of the engine depends on the shape and dimensions of components,but superalloy blade material cannot be easily machined.Although investment casting is an ideal process for such net-shape components,it requires an accurate determination of the casting-die profile.In this paper,a reversing design methodology for investment casting die using ProCAST is proposed.By combining the methods of simplifying grid files and quick sorting,the efficiency of sorting and matching can be largely improved.Further,the mould/die cavity anti-deformation system can be easily built.With ProCAST,the optimized die profile for investment casting can be established.
基金supported by the National Natural Science Foundation of China (7110111671271170)+2 种基金the National Basic Research Program of China (973 Progrom) (2010CB328000)the National High Technology Research and Development Program of China (863 Progrom) (2012AA040914)the Basic Research Foundation of Northwestern Polytechnical University (JC20120228)
文摘To verify the effectiveness of the integrated importance measure (IIM) for multi-state coherent systems of k level,the definition and physical meaning of IIM are demonstrated.Then,the improvement potential and Δ-importance measures are generalized to multi-state coherent systems based on the system performance level,and the relationships between IIM and traditional importance measures are discussed.The characteristics of IIM are demonstrated in both series and parallel systems.Also,an application to an oil transportation system is given.The comparison results show that: (i) IIM has some useful properties that are not possessed by traditional importance measures; (ii) IIM is effective in evaluating the component role in multi-state systems when the component reliability and the failure rate are simultaneously considered.
文摘The nature of networked manufacturing and agile manufacturing is to recognize enterprise resources timely and accurately. This paper mainly discusses an enterprise resource model method and the construction process. Furthermore, the system frameworks of software and application are put forward to realize various enterprise resources management based on a resource business process. Thus, we ensure the integration and sharing of enterprise resources for the requirement of networked manufacturing.
基金supported by National Natural Science Foundation of China(Grant No.51005184)National Science and Technology Major Project of Ministry of Science and Technology of China(Grant No.2009ZX04014-053)
文摘The existing methods for blade polishing mainly focus on robot polishing and manual grinding.Due to the difficulty in high-precision control of the polishing force,the blade surface precision is very low in robot polishing,in particular,quality of the inlet and exhaust edges can not satisfy the processing requirements.Manual grinding has low efficiency,high labor intensity and unstable processing quality,moreover,the polished surface is vulnerable to burn,and the surface precision and integrity are difficult to ensure.In order to further improve the profile accuracy and surface quality,a pneumatic flexible polishing force-exerting mechanism is designed and a dual-mode switching composite adaptive control(DSCAC) strategy is proposed,which combines Bang-Bang control and model reference adaptive control based on fuzzy neural network(MRACFNN) together.By the mode decision-making mechanism,Bang-Bang control is used to track the control command signal quickly when the actual polishing force is far away from the target value,and MRACFNN is utilized in smaller error ranges to improve the system robustness and control precision.Based on the mathematical model of the force-exerting mechanism,simulation analysis is implemented on DSCAC.Simulation results show that the output polishing force can better track the given signal.Finally,the blade polishing experiments are carried out on the designed polishing equipment.Experimental results show that DSCAC can effectively mitigate the influence of gas compressibility,valve dead-time effect,valve nonlinear flow,cylinder friction,measurement noise and other interference on the control precision of polishing force,which has high control precision,strong robustness,strong anti-interference ability and other advantages compared with MRACFNN.The proposed research achieves high-precision control of the polishing force,effectively improves the blade machining precision and surface consistency,and significantly reduces the surface roughness.
基金Supported by National Basic Research Program of China(973 Program,Grant No.2013CB035802)National Natural Science Foundation of China(Grant No.51575453)+1 种基金Fundamental Research Funds for the Central Universities(Grant No.3102015JCS05002)the 111 Project,China(Grant No.B13044)
文摘Titanium alloy is a kind of typical hard-to-cut material due to its low thermal conductivity and high strength at elevated temperatures, this contributes to the fast tool wear in the milling of titanium alloys. The influence of cutting conditions on tool wear has been focused on the turning process, and their influence on tool wear in milling process as well as the influence of tool wear on cutting force coefficients has not been investigated comprehensively. To fully understand the tool wear behavior in milling process with inserts, the influence of cutting parameters on tool wear in the milling of titanium alloys Ti6Al4 V by using indexable cutters is investigated. The tool wear rate and trends under different feed per tooth, cutting speed, axial depth of cut and radial depth of cut are analyzed. The results show that the feed rate per tooth and the radial depth of cut have a large influence on tool wear in milling Ti6Al4 V with coated insert. To reduce tool wear, cutting parameters for coated inserts under experimental cutting conditions are set as: feed rate per tooth less than 0.07 mm, radial depth of cut less than 1.0 mm, and cutting speed sets between 60 and 150 m/min. Investigation on the relationship between tool wear and cutting force coefficients shows that tangential edge constant increases with tool wear and cutter edge chipping can lead to a great variety of tangential cutting force coefficient. The proposed research provides the basic data for evaluating the machinability of milling Ti6Al4 V alloy with coated inserts, and the recommend cutting parameters can be immediately applied in practical production.
基金supported by Shaanxi Provincial "13115" Important Scientific and Technological Innovation Fund of China (Grant No. 2009ZDKG-27)
文摘Discontinuous tape winding, which has obvious advantages in large extension ratio winding, is widely used in the molding of composites. Therefore, the research on technological parameters becomes the focus of many scholars. However, how to accomplish the variable tension control is usually not fully considered. Accordingly, the constant extension ratio and the smoothness of winding process cannot be ensured. Aiming at the problem of tension control, this paper first gives a comparatively deep research on the control method and the interaction mechanism of tension, extension ratio, automatic lap and automatic rectification. Then, according to the winding process features, the mechanical device and the mathematical model of tension control system are established respectively. With regard to the characteristics of PID controller and fuzzy controller, the fuzzy self-tuning PID controller is designed. As a result, the variable tension control is realized during the winding and lapping process, and the constant extension ratio is guaranteed. Finally, a sample application is presented for demonstration. By presenting the variable tension control techniques for discontinuous tape winding, the constant extension ratio of tapes is achieved, the consecution and the automation degree of winding process is improved as well. Thus, the quality of wound products is guaranteed.
基金financially supported by the Major National S&T Project(No.2012ZX04007021)Doctoral fund of China(No.2013YD050008)
文摘A turbine blade is one of the key components of the aero-engine. Its geometric shape should be inspected carefully in the production stage to ensure that it meets the tolerance specification. In the present paper, an approach for investment turbine blade geometric shape analysis based on multi-source digital measurement is presented. Its key technologies, such as measurement data collection, blade model reliable alignment, geometric shape deviation fast calculation and visualization, were investigated. Actual measurement data from a structure light measurement device and a Coordinate Measuring Machine(CMM) for turbine blades were used to validate the presented method. The experimental results show that the proposed method is accurate, quick and effective to implement.
基金financially supported by the National Natural Science Foundation of China(No.51371152)
文摘The large warping deformation at platform of turbine blade directly affects the forming precision. In the present research, equivalent warping deformation was firstly presented to describe the extent of deformation at platform. To optimize the process parameters during investment casting to minimize the warping deformation of the platform, based on simulation with Pro CAST, the single factor method, orthogonal test, neural network and genetic algorithm were subsequently used to analyze the influence of pouring temperature, shell mold preheating temperature, furnace temperature and withdrawal velocity on dimensional accuracy of the platform of superalloyDD6 turbine blade. The accuracy of investment casting simulation was verified by measurement of platform at blade casting. The simulation results with the optimal process parameters illustrate that the equivalent warping deformation was dramatically reduced by 21.8% from 0.232295 mm to 0.181698 mm.
基金Supported by Science Foundation of NPU(Grant No.3102015JCS05009)Chinese Foreign Talents Introduction and Academic Exchange Program(Grant No.B13044)
文摘Finite element(FE) simulation is a powerful tool for investigating the mechanism of machining fiber?reinforced polymer composite(FRP). However in existing FE machining simulation works,the two?dimensional(2 D) progressive damage models only describe material behavior in plane stress,while the three?dimensional(3 D) damage models always assume an instantaneous sti ness reduction pattern. So the chip formation mechanism of FRP under machin?ing is not fully analyzed in general stress state. A 3 D macro?mechanical based FE simulation model was developed for the machining of unidirectional glass fiber reinforced plastic. An energy based 3 D progressive damage model was proposed for damage evolution and continuous sti ness degradation. The damage model was implemented for the Hashin?type criterion and Maximum stress criterion. The influences of the failure criterion and fracture energy dissipa?tion on the simulation results were studied. The simulated chip shapes,cutting forces and sub?surface damages were verified by those obtained in the reference experiment. The simulation results also show consistency with previous 2 D FE models in the reference. The proposed research provides a model for simulating FRP material behavior and the machining process in 3 D stress state.
基金Sponsored by the Major National Science and Technology Special Project of China (Grant No.2009ZX04014-053)the National Natural Science Foundation of China (Grant No.51005183)
文摘The optimal material removal strategy can improve a geometric accuracy and surface quality of thin-walled parts such as turbine blades and blisks in high-speed ball end milling.The dominant conception in the material removal represents the persistence of the workpiece cutting stiffness in operation to advance the machining accuracy and machining efficiency.On the basis of theoretical models of cutting stiffness and deformation,finite element method (FEM) is applied to calculate the virtual displacements of the thin-walled part under given virtual loads at the nodes of the discrete surface.With the reference of deformation distribution of the thin-walled part,the milling material removal strategy is optimized to make the best of bracing ability of still uncut material.This material removal method is summarized as the lower stiffness region removed firstly and the higher stiffness region removed next.Analytical and experimental results show the availability,which has been verified by the blade machining test in this work,for thin-walled parts to reduce cutting deformation and meliorate machining quality.
基金Project(50972121) supported by the National Nature Science Foundation of ChinaProject(20080004) supported by the Foundation of Key Laboratory for Advanced Materials Processing Technology,Ministry of Education,China
文摘Extended finite element method(XFEM) is proposed to simulate the discontinuous interface in the liquid-solid forming process.The discontinuous interface is an important phenomenon happening in the liquid-solid forming processes and it is difficult to be simulated accurately with conventional finite element method(CFEM) because it involves solid phase and liquid phase simultaneously.XFEM is becoming more and more popular with the need of solving the discontinuous problem happening in engineering field.The implementation method of XFEM is proposed on Abaqus code by using UEL(user element) with the flowchart.The key is to modify the element stiffness in the proposed method by using UEL on the platform of Abaqus code.In contrast to XFEM used in the simulation of solidification,the geometrical and physical properties of elements were modified at the same time in our method that is beneficial to getting smooth interface transition and precise analysis results.The analysis is simplified significantly with XFEM.
文摘Recent development and recognition methods of raster to vector conversion for engineering drawings are presented. The advantages and disadvantages of all existing models are analyzed. Some research challenges and future directions are discussed.
基金National Natural Science Foundation of China (50805119) Aeronautical Science Foundation in China (2010ZE53049) Fund of National Engineering and Research Center for Commercial Aircraft Manufacturing (SAMC11 -JS-07-200)
基金supported by National Science and Technology Major Project of the Ministry of Science and Technology of China (No. 2013ZX04001081)
文摘As a key assembly in the 5-axis CNC machine tools, positioning precision of the A-axis directly affects the machining accuracy and surface quality of the parts. First of all, mechanical structure and control system of the A-axis are designed. Then, considering the influence of nonlinear friction, backlash, unmodeled dynamics, uncertain cutting force and other external disturbance on the control precision of the A-axis, an adaptive sliding mode control(ASMC) based on extended state observer(ESO) is proposed. ESO is employed to estimate the state variables of the unknown system and an adaptive law is adopted to compensate for the input dead-zone caused by friction,backlash and other nonlinear characteristics. Finally, stability of the closed-loop system is guaranteed by the Lyapunov theory. Positioning experiments illustrate the perfect estimation of ESO and the stronger anti-interference and robustness of ASMC, which can improve the control precision of the A-axis by about 40 times. Processing experiments show that the ASMC can reduce the waviness,average error and roughness of the processed surface by 35.63%, 31.31% and 30.35%, respectively.
基金supported by National Natural Science Foundation of China (Nos. 11432011, 11620101002)National key research and development program of China (No. 2017YFB1102800)Key Research and Development Program of Shaanxi, China (No. S2017-ZDYF-ZDXM-GY-0035)
文摘The purpose of this paper is to present an extended topology optimization method for the stiffeners layout design of aircraft assembled structures. Multi-fastener joint loads and manufacturing constraints are considered simultaneously. On one hand, the joint loads are calculated and constrained within a limited value to avoid the failure of fasteners. On the other hand, the manufacturing constraints of the material distribution in the machining directions of stiffeners are implemented by an improved piecewise interpolation based on a beveled cut-surface. It is proven that the objective function is strictly continuous and differentiable with respect to the piecewise interpolation. The effects of the extended method with two different constraints are highlighted by typical numerical examples. Compared with the standard topology optimization, the final designs have clearly shown the layout of stiffeners and the joint loads have been perfectly constrained to a satisfying level.
基金Project(50972121) supported by the National Natural Science Foundation of China
文摘A damage prediction method based on FE simulation was proposed to predict the occurrence of hot shortness cracks and surface cracks in liquid-solid extrusion process.This method integrated the critical temperature criterion and Cockcroft & Latham ductile damage model, which were used to predict the initiation of hot shortness cracks and surface cracks of products, respectively.A coupling simulation of deformation with heat transfer as well as ductile damage was carried out to investigate the effect of extrusion temperature and extrusion speed on the damage behavior of Csf/AZ91D composites.It is concluded that the semisolid zone moves gradually toward deformation zone with the punch descending.The amplitude of the temperature rise at the exit of die from the initial billet temperature increases with the increase of extrusion speed during steady-state extrusion at a given punch displacement.In order to prevent the surface temperature of products beyond the incipient melting temperature of composites, the critical extrusion speed is decreased with the increase of extrusion temperature, otherwise the hot shortness cracks will occur.The maximum damage values increase with increasing extrusion speed or extrusion temperature.Theoretical results obtained by the DeformTM-2D simulation agree well with the experiments.
基金the National Natural Science Foundation of China(No.51790512)the 111 Project(No.B17037)the National Key Laboratory Foundation,Industry-Academia-Research Collaboration Project of Aero Engine Corporation of China(No.HFZL2018CXY011-1)and MIIT。
文摘To investigate the influence of real leading-edge manufacturing error on aerodynamic performance of high subsonic compressor blades,a family of leading-edge manufacturing error data were obtained from measured compressor cascades.Considering the limited samples,the leadingedge angle and leading-edge radius distribution forms were evaluated by Shapiro-Wilk test and quantile–quantile plot.Their statistical characteristics provided can be introduced to later related researches.The parameterization design method B-spline and Bezier are adopted to create geometry models with manufacturing error based on leading-edge angle and leading-edge radius.The influence of real manufacturing error is quantified and analyzed by self-developed non-intrusive polynomial chaos and Sobol’indices.The mechanism of leading-edge manufacturing error on aerodynamic performance is discussed.The results show that the total pressure loss coefficient is sensitive to the leading-edge manufacturing error compared with the static pressure ratio,especially at high incidence.Specifically,manufacturing error of the leading edge will influence the local flow acceleration and subsequently cause fluctuation of the downstream flow.The aerodynamic performance is sensitive to the manufacturing error of leading-edge radius at the design and negative incidences,while it is sensitive to the manufacturing error of leading-edge angle under the operation conditions with high incidences.
基金National Natural Science Foundation of China (70931004)
文摘For aircraft manufacturing industries, the analyses and prediction of part machining error during machining process are very important to control and improve part machining quality. In order to effectively control machining error, the method of integrating multivariate statistical process control (MSPC) and stream of variations (SoV) is proposed. Firstly, machining error is modeled by multi-operation approaches for part machining process. SoV is adopted to establish the mathematic model of the relationship between the error of upstream operations and the error of downstream operations. Here error sources not only include the influence of upstream operations but also include many of other error sources. The standard model and the predicted model about SoV are built respectively by whether the operation is done or not to satisfy different requests during part machining process. Secondly, the method of one-step ahead forecast error (OSFE) is used to eliminate autocorrelativity of the sample data from the SoV model, and the T2 control chart in MSPC is built to realize machining error detection according to the data characteristics of the above error model, which can judge whether the operation is out of control or not. If it is, then feedback is sent to the operations. The error model is modified by adjusting the operation out of control, and continually it is used to monitor operations. Finally, a machining instance containing two operations demonstrates the effectiveness of the machining error control method presented in this paper.