大型运载火箭重量特性快速测量技术研究

In order to further adapt to the task requirements for rapid testing and high-density launches,the LM-5 series of rocket boosters have adopted an automated acquisition and measurement process for key parameters such as the weight and centroid of the launch vehicle.A fully automatic rapid measurement technology for the weight characteristics of the rocket,consisting of a measurement system,a control system,an execution system,and a data processing system,has been developed and incorporated.This does not just achieve the adjustment of the overall assembly attitude of the rocket body and the measurement of the center of mass,but also greatly reduces the workload in the traditional measurement operations such as for assembly erection and rail transfer.Thus improving the general convenience,while greatly improving the reliability and measurement accuracy of product installation,which further promotes the popularization of an intelligent measurement technology application.

长征五号B助推器及其技术特点

The LM-5B launch vehicle is a new-generation large launch vehicle specially developed for the construction of China’s space station under its manned space program,and it has the largest launching capacity to low Earth orbit in China.The LM-5B booster is the largest booster ever built in China,which can produce 90%of the total thrust at liftoff,which laid a solid foundation for the successful development of the LM-5B launch vehicle.The booster team has overcome many technical challenges and gained rich experience in developing large cryogenic launch vehicles.

Dynamic Modeling and Analysis of 5‑PSS/UPU Parallel Mechanism with Elastically Active Branched Chains

To study the characteristics of the 5-prismatic–spherical–spherical(PSS)/universal–prismatic–universal(UPU)parallel mechanism with elastically active branched chains,the dynamics modeling and solutions of the parallel mechanism were investigated.First,the active branched chains and screw sliders were considered as spatial beam elements and plane beam element models,respectively,and the dynamic equations of each element model were derived using the Lagrange method.Second,the equations of the 5-PSS/UPU parallel mechanism were obtained according to the kinematic coupling relationship between the active branched chains and moving platform.Finally,based on the parallel mechanism dynamic equations,the natural frequency distribution of the 5-PSS/UPU parallel mechanism in the working space and elastic displacement of the moving platform were obtained.The results show that the natural frequency of the 5-PSS/UPU parallel mechanism under a given motion situation is greater than its operating frequency.The maximum position error is -0.096 mm in direction Y,and the maximum orientation error is -0.29°around the X-axis.The study provides important information for analyzing the dynamic performance,dynamic optimization design,and dynamic control of the 5-PSS/UPU parallel mechanism with elastically active branched chains.

Metallographic structure,mechanical properties,and process parameter optimization of 5A06 joints formed by ultrasonic-assisted refill friction stir spot welding

Novel hybrid refill friction stir spot welding （RFSSW） assisted with ultrasonic oscillation was introduced to 5A06 aluminum alloy joints. The metallographic structure and mechanical properties of 5A06 aluminum alloy RFSSW joints formed without ultrasonic assistance and with lateral and longitudinal ultrasonic assistance were compared, and the ultrasonic-assisted RFSSW process parameters were opti- mized. The results show that compared with lateral ultrasonic oscillation, longitudinal ultrasonic oscillation strengthens the horizontal bond- ing ligament in the joint and has a stronger effect on the joint＇s shear strength. By contrast, lateral ultrasonic oscillation strengthens the ver- tical bonding ligament and is more effective in increasing the joint＇s tensile strength. The maximum shear strength of ultrasonic-assisted RFSSW 5A06 aluminum alloy joints is as high as 8761 N, and the maximum tensile strength is 3679 N when the joints are formed at a tool rotating speed of 2000 r/rain, a welding time of 3.5 s, a penetration depth of 0.2 mm, and an axial pressure of 11 kN.

Research on Two-Step Hydro-Bulge Forming of Ellipsoidal Shell with Larger Axis Length Ratio

The two-step hydro-bulge forming technique was proposed to manufacture the ellipsoidal shell with the length ratio of the long axis to the short axis larger than 1.4. A central tube was introduced into the first step of the hydro-bulge forming process to constrain the over growth of the short axis during bulging,and then the central tube was replaced with two polar plates in the second step of the hydro-bulge forming process to manufacture an integral ellipsoidal shell. It is shown that the central tube restricts the growth of the short axis and simultaneously reduces the shrunk tendency of the long axis. The wrinkling occurs due to the latitudinal compressive stress at the equator at the early stage of hydro-bulge forming. However,with the increase of internal pressure,the compressive stress areas gradually decrease and finally the tensile latitudinal stress occupies approximately the whole shell,thus the wrinkles are eliminated. A sound ellipsoidal shell with the axis length ratio of 1.8 is obtained after two-step hydro bulging.

Effect of Cu element on morphology of TiB2 particles in TiB2/Al-Cu composites

In order to explore the influence of Cu element on the morphology evolution of the in-situ TiB2 particles, the10 wt.% TiB2 reinforced Al-5 wt.%Cu based composite was prepared by mixed salt casting. The morphology characterization and transformation of TiB2 reinforcements caused by Cu element were investigated by multi-scale microstructure characterization and statistics techniques. In the case of controlled casting, 5 wt.% Cu addition was found to transform the TiB2 particle morphology from hexagonal plate with sharp edges and corners to hexagonal or tetragonal prism with chamfered edges and corners with the distinguishing growth steps both on the top surface and the side surface. The TiB2 growth in Al-Cu matrix followed the rules: nano-scaled spherical nuclei-polyhedron grains-chamfered hexagonal particles-hexagonal plates-chamfered particles with obvious growth steps. The adsorption energy of Cu on different crystal surfaces of TiB2 was caculated to reveal the influence mechanism and the results indicated that Cu was preferentially adsorbed on the(10-11)TiB2 crystal planes, devoting to the small aspect ratio of TiB2.

Microstructure evolution and mechanical properties of the Sip/Zn- Al composite joints by ultrasonic-assisted soldering in air

Hypereutectic Al -27Si alloys were joined without flux by ultrasonic-assisted soldering at 420 ℃ in air using Zn -5Al the filler alloys, and Si particulate-reinforced Zn - Al based composites filler joints were obtained. The ultrasonic vibration introduced into soldering could influence the migration of Si particles and the microstructure of solidified Zn - Al based alloys. Both the distribution of Si particles and microstructure of the solidified Zn - Al based alloys affected the shear strength of joints. The shear strength increased with the ultrasonic vibration time. The highest average shear strength of joints reached to -68.5 MPa. Transcrystalline rupture mode was observed on the fracture surface.

Accuracy Analysis for 6-DOF PKM with Sobol Sequence Based Quasi Monte Carlo Method

To improve the precisions of pose error analysis for 6-dof parallel kinematic mechanism( PKM)during assembly quality control,a Sobol sequence based on Quasi Monte Carlo( QMC) method is introduced and implemented in pose accuracy analysis for the PKM in this paper. The Sobol sequence based on Quasi Monte Carlo with the regularity and uniformity of samples in high dimensions,can prevail traditional Monte Carlo method with up to 98. 59% and 98. 25% enhancement for computational precision of pose error statistics.Then a PKM tolerance design system integrating this method is developed and with it pose error distributions of the PKM within a prescribed workspace are finally obtained and analyzed.

Experimental Study of Machinability in Millgrinding of SiCp/Al Composites

An attempt was made to investigate the machinability of Si Cp/Al composites based on the experimental study using mill-grinding processing method. The experiments were carried out on a high-speed CNC machining center using integrated abrasive cutting tool. The effects of combined machining parameters, e g, cutting speed（vs）, feed rate（vf）, and depth of cut（ap）, with the same change of material removal rate（MRR） on the mill-grinding force and surface roughness（Ra） were investigated. The formation mechanism of typical machined surface defects was analyzed by SEM. The experimental results reveal that with the same change of material removal rate, lower mill-grinding force values can be gained by increasing depth of cut and feed rate simultaneously at higher cutting speed. With the same change of MRR value, lower surface roughness values can be gained by increasing the feed rate at higher cutting speed, rather than just increasing the depth of cut, or increasing the feed rate and depth of cut simultaneously. The machined surface of Si Cp/Al composites reveals typical defects which can influence surface integrity.

Forward-Kinematics-Based Approaches for Pose Accuracy of Docking Mechanism with Joint Clearance

Joint clearance,as an important stochastic factor,can significantly deteriorate positioning and repeatability accuracies and lower assembly quality of a 6-DOF docking mechanism.Considering pose accuracy with traditional error model that possesses inherent imprecision,both probabilistic and deterministic approaches based on forward kinematics are presented to analyze comprehensive pose error(CPE)in simulation.Results indicate an identical trend emerges for each CPE with both approaches,and both CPEs perform opposite variations as the moving platform upgrades.The findings provide theoretical reference for refinement of assembly quality evaluation of this mechanism.

Mechanical properties of welded joints in vertical-up variable polarity plasma arc welding of 2219 aluminum alloy

The mechanical properties of the 2219 aluminum alloy welded joints by vertical-up variant polarity plasma arc welding (VPPAW) with keyhole were analyzed. The tensile strength of welded joints can reach 55% of that of base metal. The microstructure of weld joints was studied to explain the mechanical properties of the weld. The results show that the intensity of weld center is less than that of HAZ, and the intensity of weld center is the worst. So an advanced welding procedures is presented to reduce the heat input and increase the welding speed. The results in this procedures show that the tensile strength of welded joints reaches more than 60% of that of the parent metal, and the specific elongation does not descend.

Vacuum current-carrying tribological behavior of MoS2-Ti films with different conductivities

Current-carrying sliding is widely applied in aerospace equipment,but it is limited by the poor lubricity of the present materials and the unclear tribological mechanism.This study demonstrated the potential of MoS_(2)-based materials with excellent lubricity as space sliding electrical contact materials by doping Ti to improve its conductivity.The tribological behavior of MoS_(2)-Ti films under current-carrying sliding in vacuum was studied by establishing a simulation evaluating device.Moreover,the noncurrent-carrying sliding and static current-carrying experiments in vacuum were carried out for comparison to understand the tribological mechanism.In addition to mechanical wear,the current-induced arc erosion and thermal effect take important roles in accelerating the wear.Arc erosion is caused by the accumulation of electric charge,which is related to the conductivity of the film.While the current-thermal effect softens the film,causing strong adhesive wear,and good conductivity and the large contact area are beneficial for minimizing the thermal effect.So the moderate hardness and good conductivity of MoS_(2)-Ti film contribute to its excellent current-carrying tribological behavior in vacuum,showing a significant advantage compared with the traditional ones.

Experimental Investigations of Axial Force Monitoring and Control for Friction Stir Welding Process

Friction stir welding( FSW) is a solid-state welding process that utilizes a rotating tool to induce gross material plastic deformation and join two parts together. A large number of studies have indicated that axial force control can be used to achieve good welding quality. However,in the welding process,due to workpiece's geometry error,improper clamping and other process variations,the axial force can vary significantly and produce welding defects.The control of force in the process of FSW is investigated. At first,the development and evaluation of a closed-loop control system is described,which is equipped with a custom real-time wireless force dynamometer for FSW. Then,an axial force controller is designed based on nonlinear force controllers for FSW. Experimental validations are carried out on an FSW platform. The experimental results demonstrate that the controller maintains the constant axial force and shows desirable dynamic behavior, even when the disturbance is encountered during the welding process.

Workshop Oriented Tolerance Synthesis for Spatial PKM

To promote the pose accuracy performance of a spatial parallel kinematic Mechanism( PKM) in service,a workshop oriented tolerance synthesis method based on design of experiment( DOE) is proposed,which involves two consecutive stages. In the first stage of DOE,the tolerance factor sensitivities are obtained according to initial tolerance settings with the consideration of the current manufacturing capacity,and the second stage of DOE makes use of them to produce multiple tolerance allocations which can adapt to current manufacturing capacity. A tolerance synthesis procedure is developed and integrated in tolerance design system for PKM. Comparing the results with peer method,the validity and practicability of this method is verified.

Process and Equipment of Double-Sided Sheet Hydroforming for Large-Sized Al-Alloy Tailored Shell

In the industrial field,tailored blank forming with aluminum alloy(Al-alloy)has developed fast to meet the demands for large size integrated components with curved surfaces of high precision and with uniform mechanical properties.Traditional forming methods for tailored blank components faced challenges with uneven deformation behaviors and coexistence of rupture and wrinkling defects occuring during the forming process.In this paper,a new manufacturing procedure is proposed with advanced welding and forming technologies for forming integrated shell components.Friction stir welding with post-weld heat treatment was employed to prepare the tailor welded blank and improve its formability prior to forming.A double-sided pressure sheet hydroforming process was introduced to fabricate the Al-alloy tailored blank into a curved surface shell.Finite element modeling was established to analyze the effect of the weld line position and loading paths of stress distributions during the double-sided sheet hydroforming(DSHF)process.A large double-action CNC sheet hydroforming press with tonnage of 150 MN and high pressure liquid volume of 5 m~3 was developed in China.As an application case of the proposed process and equipment,a full-scale tank dome with a diameter of 3 m was successfully hydroformed with a large size Al-alloy tailored blank.It was shown that the DSHF process has the advantages in controlling rupture and wrinkling defects with an Al-alloy tailored blank,and the novel manufacturing procedure enables the production of integrated thin-walled component more competitively than traditional methods.

A Study of Low-Density Heat-Resistant Coating for New-Generation Launch Vehicle Fairings

In this paper,the properties of different low-density heat-resistant coating prescriptions were compared,and a heat-resistant coating with a density of 0.65 g/cm^(3),a tensile strength of 2.04 MPa,and a thermal conductivity of 0.126 W/(m·K)was obtained.The thermal performance of the coating was characterized by an oxygen-acetylene ablation test,a hot radiation test using a quartz lamp and in an arc-heated wind tunnel test.The results indicated that the low-density heat-resistant coating prescription has advantages of high temperature resistance,erosion resistance,ablative resistance and excellent heat resistance,which can satisfy the heat resistance requirements of new-generation launch vehicle fairings.The successful application of this heat-resistant coating technology resolved the problems of low efficiency and poor adhesive performance of the traditional hand-pasted cork process,and realized the rapid spray application of the thermal protection layer,effectively improved the manufacturing efficiency and production quality of the heat-resistant layer of new-generation launch vehicle fairings.

Magnetron sputtering NbSe_(2)film as lubricant for space current-carrying sliding contact

This study demonstrates that magnetron-sputtered NbSe_(2)film can be used as a lubricant for space current-carrying sliding contact,which accommodates both metal-like conductivity and MoS_(2)-like lubricity.Deposition at low pressure and low energy is performed to avoid the generation of the interference phase of NbSe_(3).The composition,microstructure,and properties of the NbSe_(2)films are further tailored by controlling the sputtering current.At an appropriate current,the film changed from amorphous to crystalline,maintained a dense structure,and exhibited excellent comprehensive properties.Compared to the currently available electrical contact lubricating materials,the NbSe_(2)film exhibits a significant advantage under the combined vacuum and current-carrying conditions.The friction coefficient decreases from 0.25 to 0.02,the wear life increases more than seven times,and the electric noise reduces approximately 50%.

A review of the end-effector of large space manipulator with capabilities of misalignment tolerance and soft capture

The space manipulator which has advantages of high dexterity and universality, is used to the space capturing usually. According to the different types of mechanical interfaces of targets, the on orbit capturing operation includes capturing of cooperative target and capturing of uncooperative target. The performances of the famous large space manipulators named space shuttle remote manipulator system(SRMS), the space station remote manipulator system(SSRMS) and the Europe robotic arm(ERA) are reviewed and studied respectively. Moreover, the space manipulators being developed by China for space station is also surveyed. Based on the performance analysis of the large space manipulators and end-effectors, which are adapted to the construction and daily maintenance for the large space structure such as the space station, the basic requirements of large misalignment tolerance capability, soft capturing capability and hard docking capability for the end-effector of large space manipulator are proposed in this paper. According to these requirements, the capture mechanism and methods that can enable the end-effector to have the capability of misalignment tolerance and soft capturing are presented. The development trend and key technologies of the large space manipulators and the end-effectors are also reviewed.

Intermetallic Compounds in the Banded Structure and Their Effect on Mechanical Properties of Al/Mg Dissimilar Friction Stir Welding Joints

Dissimilar friction stir welding（FSW） between aluminum and magnesium alloy was performed, using various tool rotational speed（TRS） at a ？xed travel speed, with tool offset to aluminum to investigate the formation of intermetallic compounds（IMCs） in the banded structure（BS） zone and their effect on mechanical properties. Large quantities of IMCs, in the form of alternating bands of particles or lamellae, were found in the BS zone, where drastic material intermixing occurred during FSW. The BS microstructural characters in terms of the morphology of the bands and the quantity and distribution of IMC particles varied with TRS. All welds exhibited brittle fracture mode with their fracture paths propagating mainly in/along the IMCs in the BS. It is shown that these BS microstructural characters have significant effect on the mechanical properties of the joints. Suggestions on tailoring the BS microstructure were proposed for improving the strength of the BS zone and the final mechanical properties of the Al/Mg FSW joints.

Advances and challenges on springback control for creep age forming of aluminum alloy

Creep age forming(CAF)is an advanced forming technology that combines creep deformation and age hardening processes.When compared with the conventional forming technologies including roll bending and shot-peen forming,CAF has many advantages of low residual stress,excellent dimensional stability,good service performance and short production cycle.It is an optimal technique for precise manufacturing for shape and properties of large-scale complicated thinwalled components of light-weight and high strength aluminum alloys in the aviation and aerospace industries.Nevertheless,CAF has an inevitable disadvantage that a large amount of springback occurs after unloading,which brings a challenge on the accurate shape forming and property tailoring of components.Therefore,how to achieve accurate prediction and control of springback has always been a bottleneck hindering the development of CAF to more industrial applications.After the factors of affecting springback and measures of reducing springback are summarized from the internal and external aspects,constitutive models for predicting springback and springback compensation methods for CAF of aluminum alloy panel components are reviewed.Then,a review of research progresses on tool design for CAF is presented.Finally,in view of the key issue that it is difficult to predict and control the shape and properties of components during CAF,the technical challenges are discussed and future development trends of CAF are prospected.