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2020 Vol. 63, No. 11
Published: 2020-06-01
FEATURE
FORUM
RESEARCH
C0NTENTS
COVER STORY
APPROACHING SCIENCE
FEATURE
14
Experimental Research on PCD Tool Turning SiCp/Al Composites
PEN Hongmin，LIU Xin，NI Na，CHEN Zhitao，LIU Fei，YUE Caixu
DOI: 10.16080/j.issn1671-833x.2020.11.014
Silicon carbide aluminum matrix composite, which has excellent thermal conductivity, high specific strength and specific stiffness, will be widely applied in the field of aerospace. However, the reinforced phase in this composite results in poor machined surface quality and severe tool wear. Therefore, the influence of SiCp/Al materials with different particle contents (nanometer-level 5% and micron-level 25%) and cutting parameters (cutting speed, cutting depth and feed rate) on tool wear and machined surface quality were analyzed through experiments. The tool wear mechanism was also analyzed. The experimental results showed that PCD tool wear was more serious and the machined surface quality was worse when turning 25% SiCp/Al composite with micron-level particles. With the increases of feed rate and cutting depth, the machined surface roughness increased, and the rake face was seriously worn. With the increase of cutting speed, the surface roughness of the workpiece decreased, and the wear of rake face increased. Under the cutting parameters used in this research, the tool abrasive wear and blade breakage were the main wear mechanisms for PCD inserts, and built-up edge (BUE) will be generated on rake face of the cutting tool. The experimental results provide a theoretical basis for optimizing the turning process of SiCp/Al composite with PCD tools.
2020 Vol. 63 (11): 14-19 [
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197
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COVER STORY
20
Research Progress on Double Laser-Beam Bilateral Synchronous Welding of T-Joints for Light Alloy
ZHAN Xiaohong，ZHAO Yanqiu， CHEN Shuai，KANG Yue
DOI: 10.16080/j.issn1671-833x.2020.11.020
Double laser-beam bilateral synchronous welding (DLBSW) of T-joints for light alloy is an advancing technology with promising applications and potential development. It is significant for the aerospace panel structures in the lightweight and efficient manufacturing. However, there are still many unresolved details in DLBSW technology of T-joint for light alloy owing to the material properties of light alloy and the particularity of DLBSW technology. In this paper, the welding metallurgy characteristics and stability of DLBSW process for light alloy T-joints are analyzed. The formation mechanism and suppression measures for welding defects in DLBSW T-joint are emphatically researched. The mechanical properties and fracture mechanism of the T-joint are investigated. Besides, the significance of the numerical simulation study on DLBSW of T-joints for light alloy is discussed.
2020 Vol. 63 (11): 20-31 [
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309
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FORUM
34
Numerical Simulation of Temperature Field During Refill Friction Stir Spot Welding
CHAI Peng,ZUO Yingying,CHEN Kepeng,QI Bojin,JI Shude
DOI: 10.16080/j.issn1671-833x.2020.11.034
According to the joining mechanism of refill friction stir spot welding, reasonable temperature field is the basis of obtaining joints with high quality. Based on the characteristics of refill friction stir spot welding process, a finite element model was established by the finite element analysis software MSC. Marc. The rightness of this model was verified by the temperature measurement experiments, and then the temperature field of 7075-T6 aluminum alloy during welding was investigated by numerical simulation. The results show that at the pre-heating stage, the peak temperature increases rapidly and then slowly with the increase of friction time, and the value reaches a stable one at about 8s. At the welding stage, the peak temperature is located at the center of bottom surface of the sleeve, and the maximum value is obtained when the sleeve is retracted for 1s. Increasing the rotating speed of stirring tool can increase the peak temperature during welding.
2020 Vol. 63 (11): 34-40 [
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165
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41
Numerical Analysis of Stationary Shoulder Friction Stir Welding Process for Aluminum Alloy Thick-Plate
Numerical Analysis of Stationary Shoulder Friction Stir Welding Process for Aluminum Alloy Thick-Plate[J]. journal1, 2020,63(11): 41-49')" href="#">
TANG Wenshen，YANG Xinqi,ZHAO Huihui,GUO Lijie
DOI: 10.16080/j.issn1671-833x.2020.11.041
A thermo-mechanically coupled numerical model was developed to analyze the processes of stationary shoulder friction stir welded (SSFSW) AA6061–T6 aluminum alloy plate with a thickness of 12mm based on the Deform-3D software. The effects of welding parameters on the temperature distribution, welding thermal cycling and bearing status of the tool in the welded joint were investigated. It was found that the 50% increase in rotational speed will cause the peak temperature of the nugget to increase more than 21.6%, and the 50% increase in welding speed will cause the high-temperature residence time and cooling time to decrease more than 50% and 60%, respectively. For given rotating speed in the range of 1000r/min to 1500r/min and welding speed in the range of 100mm/min to 150mm/min, the axial force of SSFSW is in the range of 28.2kN to 24.3kN and the forward resistance is in the range of 17.4kN to15.3kN; The maximum torque of tool pin is in the range of 27.3N·m to 25N·m. The 50% increase in rotating speed will reduce 13.8% axial force, the 50% increase in welding speed will increase 13.7% forward resistance. These numerical results mentioned above provide the important theoretical basis for the tool design and welding parameters optimum of SSFSW for aluminum alloy thick-plate.
2020 Vol. 63 (11): 41-49 [
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150
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50
Effect of TLP Process Parameters on Liquefaction of DD407 Base Metal
TAN Fei,WU Yanying,NIU Wentao，ZHANG Chengcong,CHEN Yuhua,HUANG Yongde
DOI: 10.16080/j.issn1671-833x.2020.11.050
In order to make full use of the advantages of TLP and solid state diffusion welding for combination of these two processes, it was necessary to study the liquefaction law of base metal at the joint interface. DD407 nickelbased single crystal superalloy was joined by intermediate layer alloy of BNi9 with 3.5% B. The variations of width of joint and liquefied base metal as process parameters were investigated. Results were as follow: With the increase of welding temperature and the holding time, the width of the liquefaction zone increased. When welding with interlayer in thickness of 150μm at temperature of 1100℃ and holding time of 5min, the width of liquefied base metal reached 65.8μm. The effect of the thickness of interlayer on the liquefaction of the base metal was relatively higher due to the increase of B contents. The liquefying procedure of base metal was summarized as follow: interacted region of base metal were liquefied by diffusion of melting point depressing element of B, which resulted in the increase of the liquefied area width. But the content decrease of B element in the interlayer gave rise of isothermal solidification, which ceased the further liquefaction, thus the action of surface cleaning was affected in some content.
2020 Vol. 63 (11): 50-55 [
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129
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56
Effects of Process Parameters on Microstructure and Performance of Joints for Laser Spot Welding of Thrust Foil Bearings
WANG Luting,LUO Xinyang,WANG Shanlin,CHEN Yuhua,HUANG Yongde
DOI: 10.16080/j.issn1671-833x.2020.11.056
The thrust foil bearing is an important support element in the aviation gyroscope. In order to improve the wear resistance and corrosion resistance of the supporting surface, Teflon coating is usually coated on the supporting surface, while the addition of this coating brings uncertainty to the subsequent manufacturing process. In this paper, the effects of laser spot welding process parameters on the microstructure and performance of thrust foil bearing joints were studied. The analysis methods such as optical microscope, scanning electron microscope, electronic precision tensile tester and ultrasonic testing were used to analyze the weld surface forming, joint microstructure and mechanical properties. The results showed that the surface diameter of joint increased with the increase of pulse power, while the tensile shear force increased first and then decreased with the increase of heat input. The optimized process parameters of laser spot welding manufacture: pulse power percentage 22%, pulse width 5.0ms, tensile shear force 63.0N; Ultrasonic immersion testing can accurately measure the size of the lap interface, but the tensile shear force was not fully proportional to the size of the interface. The tensile shear force of the joint was mainly related to the fracture modes of the joint.
2020 Vol. 63 (11): 56-61 [
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126
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APPROACHING SCIENCE
62
Research and Explore Modern Surface Technologies for High-End Equipment Manufacturing
2020 Vol. 63 (11): 62-63 [
Abstract
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118
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RESEARCH
64
Multi-Axis Additive Manufacturing Process Planning Method Based on Centroid Axis
WANG Bingjie, HAO Xiaozhong, XU Ke, JIANG Sen
DOI: 10.16080/j.issn1671-833x.2020.11.064
Additive and subtractive hybrid manufacturing is one of the key technologies for aerospace manufacturing at present. Owing to the rotational degrees of freedom provided by five-axis machining center, the build direction can be continuously changed during additive manufacturing (AM) process, which can theoretically eradicate support structure. However, the introduction of multi-axis motion capacity increases the solution space, which poses great challenge for finding the solution of the process. In view of the above problem, a multi-axis AM process planning method based on centroid axis was proposed. On the basis of the definition of the centroid axis, the extraction method of centroid axis with “columnar” feature was studied, and sliced perpendicular to the centroid axis direction. Accordingly, the volume decomposition constraint was constructed. The slice position that dissatisfies the constraint was searched from the bottom to the top, where the part model was decomposed, and the direction of the centroid axis was used as the new build direction. The search was continued until the decomposition was completed. Finally, the part models are designed, and the feasibility of the method is verified through experiments, and support-free additive manufacturing of parts is realized.
2020 Vol. 63 (11): 64-75 [
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140
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69
Accuracy Control of Pulse Current Assisted Hot Pressing Forming for Titanium Alloy Sheet Metal Parts
XUE Jie, LI Baoyong, QIN Zhonghuan, LIU Yuping, WANG Zhanqi, FAN Jiangling
DOI: 10.16080/j.issn1671-833x.2020.11.069
A pulse current assisted hot pressing forming is designed to solve the problem of low accuracy of cold forming and high cost of heat forming machine. In this paper, the influence of pulse current assisted hot pressing process on defects, dimensional accuracy and mechanical property of TC1 titanium alloy U-shaped parts was studied. The results show that the pulse current heating can improve the forming efficiency. When the pulse current density is 9.2A /mm2 and the closing speed is 15mm/s, the heat loss in the forming process is compensated, the titanium alloy sheet metal parts are kept in a good forming temperature range and the forming limit is increased. During the forming process, with the rise of forming pressure, holding time and mould preheating temperature, the dimensional accuracy of the parts is gradually improved. When the shape pressure is 10t, holding time is 10s and the mould is not preheated, the dimensional accuracy of the parts reaches ±0.2mm. The grain size of the part after pulse current assisted hot pressing is smaller than that of the hot forming machine, and the mechanical property is better.
2020 Vol. 63 (11): 69-75 [
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154
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76
Design and Application of Portable Precision Finishing Milling Machine
ZHAO Anan,ZHANG Cheng,BA Xiaofu
DOI: 10.16080/j.issn1671-833x.2020.11.076
In order to meet the requirements of finishing a large number of small mounting surfaces in aircraft assembly manufacturing, a technical scheme of finishing with portable milling machine is proposed. Through the analysis of the precision machining object and the portable machining process, carry out force analysis, dynamics modeling and detailed design of the portable precision milling machine, and carry out the application and comparative analysis. The results show: for the batch manufacturing of small mounting surface of aircraft, in terms of processing efficiency, the portable finishing milling machine improves about 3 times compared with the fixed milling machine, and in terms of processing accuracy, the portable finishing milling machine improves about 5 times compared with the hand grinder.
2020 Vol. 63 (11): 76-82 [
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149
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Machining Deformation Control Method of Structural Parts by Multi-Process Fusion Based on Natural Evolution Strategy
LIU Xingyan, LIU Changqing
DOI: 10.16080/j.issn1671-833x.2020.11.083
The pre-deformation of the blank and the machining position of the workpiece have an important influence on the final machining deformation of the workpiece. Pre-deformation of the blank and optimization of the machining position are an effective way to control the deformation of the workpiece. Due to the difficulty in solving the parameters of multi-process variable optimization, it is difficult to achieve precise control of the deformation of the workpiece only for single process optimization. Aiming at the above problems, this paper proposes a multi-process fusion structure processing deformation control method based on natural evolution strategy. Considering the influence of blank pre-deformation and machining position on workpiece variables, a finite element simulation model is established, and the optimal parameters are searched by PEPG (Parameter-exploring policy gradients) optimization algorithm to realize the control of machining deformation. Finally, a typical aircraft structural member is taken as an example to verify in the simulation environment. The results show that the method can significantly control the workpiece deformation.
2020 Vol. 63 (11): 83-93 [
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138
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Ultra-Precision Grinder Embedded Monitoring System Based on LabVIEW
SU Shibo, BI Guo, PENG Yunfeng, ZENG Xinlong, GAO Kai
DOI: 10.16080/j.issn1671-833x.2020.11.088
Based on the monitoring requirements of ultra-precision grinding machine tools, an embedded monitoring system for super-precision grinding machine condition monitoring and data acquisition was developed based on NI-sbRIO hardware platform. Real-time data of temperature, vibration and acoustic emission were performed using FPGA. Collect and use real-time processor to analyze and process the data to realize real-time condition monitoring and data storage of the machine tool. The hardware data acquisition card is replaced by FPGA programming, which is low in cost and flexible. Experiments show that the system is capable of monitoring tasks for ultra-precision grinding machines.
2020 Vol. 63 (11): 88-93 [
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154
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Research on Strength and Failure Analysis of Fiber Reinforced Resin Matrix Composites
GAO Jiajia, CHU Longsheng, MA Tianyang, GAO Peng
DOI: 10.16080/j.issn1671-833x.2020.11.094
Experimental methods and finite element are used to study the failure mechanism of mechanical joints and adhesive-bolt hybrid joints. The load-displacement curve is analyzed by tensile-shear test, and the microstructure of the section is analyzed combining the stress distribution of the finite element simulation results. The results show that the perforated carbon fiber tow of the bolted joint structure is deformed by the bolt pressing force, which is passed to the resin matrix, so the fiber is subjected to buckle deformation, and the resin matrix is squeezed into a cluster by a short bundle of fibers that are uniformly distributed. Therefore the formed weak structure is due to uneven structure. Adhesive-bolt hybrid joints exhibits tensile fracture failure, the carbon fiber tow at the fracture is pulled out from the epoxy resin matrix under tensile-shearing and damages the fracture, and the direction of the tow is disorderly arranged. The resin matrix attached to the fiber changes to be agglomerated, and the joint structure fractures after reaching the ultimate load. And the adhesive between the sheets has a retarding effect on the destruction of the fibers after the redistribution of the load. Factors such as material strength, bolt strength, adhesive strength and bolt width to diameter ratio will be factors that affect the failure of the joint structure.
2020 Vol. 63 (11): 94-101 [
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156
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Notices
·
'Aeronautical Manufacturing technology ' is included in EI database
·
China Science Citation Database (CSCD)
·
Chinese S&T Journal Citation Reports (CJCR)
·
World Journal Clout Index (WJCI) Report of Scientific and Technological Periodicals
·
Supported in China Science and Technology Journal Excellence Action Plan
·
Aeronautical Manufacturing Technology ranked No. 3 in Chinese S&T Journal Citation Reports (CJCR)
·
High Quality Sci-tech Journal Classification Catalogue in Aerospace Field （2023）
·
A Guide to the Core Journals of China (hosted by Peking University Library)
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