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2021 Vol. 64, No. 18
Published: 2021-09-15
FEATURE
FORUM
C0NTENTS
COVER STORY
APPROACHING SCIENCE
SPECIAL TOPIC
 
       FEATURE
14 Research on Chatter Detection and Particle Damping of Elastic Shaft Face Grinding
SUN Hao,ZHANG Bing,TANG Qi,WANG Shancheng,DONG Chao,YAO Bin
DOI: 10.16080/j.issn1671-833x.2021.18.014
The flange of elastic transmission shaft is connected with the shaft by diaphragm, serious chatter will occur in precision grinding of flange end face, resulting in low grinding efficiency and poor quality control. Therefore, a laser displacement sensor is used to measure the vibration displacement data of elastic transmission shaft end face in grinding process. According to the time domain and frequency domain characteristics of end face vibration, a particle damper is designed and the optimization of structural parameters is carried out. Firstly, according to the workpiece structure and grinding process, the installation form and external dimensions of the damper are determined. Then, the performances of different internal parameters are compared by discrete element simulation, and the optimal particle filling scheme is determined. Finally, the vibration suppression effect of the designed particle damper is verified by the experiment of electromagnetic vibration exciter.
2021 Vol. 64 (18): 14-20 [Abstract] ( 148 ) HTMLNew PDF (3242 KB)  ( 392 )
       COVER STORY
22 Progress of Data-Driven Aero-Engine Materials Design
YUAN Ruihao, LIAO Weijie, TANG Bin, FAN Jiangkun, WANG Jun, KOU Hongchao, LI Jinshan
DOI: 10.16080/j.issn1671-833x.2021.18.022
The data-driven materials design paradigm has been largely applied in the research of materials science, to shorten the process from materials discovery to applications. As the key and hot pot in the research of data-driven materials design, machine learning can extract the pattern or law behind the data, of which the active-learning based strategy has been successfully employed to guide the exploitation of materials. Firstly, this paper introduces the main idea and elements of the active learning loop, as well as the methods/algorithms used in each step. Then the paper reviews the applications and effect of machine learning in the field of aero-engine materials including superalloys, titanium-based alloys, composites and thermal barrier coating. Considering the extreme service environment of aero-engine materials, the review is concluded by discussing the possible challenges and solutions.
2021 Vol. 64 (18): 22-30 [Abstract] ( 280 ) HTMLNew PDF (5506 KB)  ( 882 )
       FORUM
34 Research on Technologies and Equipment of Electro Machining Film Cooling Holes
TONG Hao, LI Yong, LI Baoquan
DOI: 10.16080/j.issn1671-833x.2021.18.034
As for machining film cooling holes in the turbine blades at the hot end of aero-engines, the research status in nearly a decade is reported about the electro discharge machining (EDM) of film cooling holes. The emphasis is focused on our innovation ideas and research progress in the electro machining processes and equipment technologies for solving machining problems of the film cooling holes with composite materials (high temperature alloy substrate and ceramic thermal barrier coating), composite structure (circular hole section and diffusion structure section), and low/no damage surfaces. Key methods and core technologies were researched and developed including a functional spindle head, a pulse power supply with high energy density, a servo control method of machining gap, a combined flushing system, and a method of drilling-penetration detection. The feasibility of three processes was verified including the hybrid process of EDM and ECM (electrochemical machining) for drilling the holes without recasting layers, the block divided EDM process for machining diffuser shaped structures, and the spark assisted chemical engraving (SACE) process for machining the thermal barrier coating of zirconia ceramic. The six-axis NC EDM equipment for machining film cooling holes was developed, which realized the automated machining process of straight holes and inclined holes with the drilling efficiency >20mm/min, dimensional accuracy better than ±20μm, and the controllable average thickness of recasting layer <10μm.
2021 Vol. 64 (18): 34-45 [Abstract] ( 177 ) HTMLNew PDF (24696 KB)  ( 220 )
46 Review on Advanced Film Cooling Hole Shapes
WANG Haitao, ZHANG Wenwu, GUO Chunhai
DOI: 10.16080/j.issn1671-833x.2021.18.046
The film cooling technologies can significantly improve the high temperature resistance of turbine blades. This paper focuses on film cooling technology, compares hole shapes at home and abroad, introduces the mechanism of the interaction between the main stream and the secondary flow, analyzes the influence of the cooling gas distribution on the film quality, and summarizes the effect of film cooling technology on aero-engine performance. A detailed discussion is carried out from the interactive flow field, hole shapes, hole accessory structure (tabs, slopes) and hole arrangements. There are four main routes for improving the cooling efficiency: (1) Reducing the strength of the kidney vortex; (2) Producing a pair of anti-kidney vortices; (3) Using groove structure; (4) Changing the outlet pressure distribution. Through the discussion and analysis of the hole shapes and accessory structures, it could provide guiding ideas for the optimal design of film cooling holes.
2021 Vol. 64 (18): 46-52/61 [Abstract] ( 211 ) HTMLNew PDF (2085 KB)  ( 817 )
53 Process of Turbine Blade Film Cooling Holes by Nanosecond and Femtosecond Laser Pulses
JIANG Qilin, CAO Kaiqiang, CHEN Long, FENG Chaopeng, JIA Tianqing, SUN Zhenrong
DOI: 10.16080/j.issn1671-833x.2021.18.053
To meet the demand of strict process of turbine blade film cooling holes in aero-engine, a method was proposed and a system was set up based on nanosecond laser and femtosecond laser pulses. A 3D scanner was used to compensate errors of coordinates accurately in process of film cooling holes. Combining high-efficiency feature of 532nm nanosecond laser with high-precision feature of 400nm femtosecond laser, eighty-one film cooling holes were processed in each of stainless-steel turbine blades. Deviations of the diameter are kept within 10μm and the position errors are no more than 50μm. Profiles of film cooling holes are in good condition and no resolidified layer or microcracks are found under the detection of industrial computer tomography and high magnification microscope. High-quality film cooling holes are processed with no interference.
2021 Vol. 64 (18): 53-61 [Abstract] ( 160 ) HTMLNew PDF (9999 KB)  ( 106 )
62 Experimental Study on Surface Quality of Engine Turbine Blade by Magnetic Needle Magnetic Abrasive Technology
ZHU Huining, MA Xiaogang, CHENG Haidong, CHEN Yan, HAN Bing
DOI: 10.16080/j.issn1671-833x.2021.18.062
The surface quality of turbine blade in aviation gas turbine engine directly affects the overall performance of the engine. In view of the low geometric accuracy and unstable quality in the surface treatment of turbine blade at home and abroad, the magnetic abrasive technology with magnetic needle is introduced, and different types of magnetic needle, rotating speed of magnetic pole and grinding time are taken as variable factors. The surface roughness and residual stress of the blade are taken as the indexes, and the law between the change factors and the index parameters is analyzed through experiments. The results show that the residual stress on the surface of turbine blade changes from original tensile stress to compressive stress, and the compressive stress increases with the increase of magnetic needle length and magnetic pole speed. The surface roughness of turbine blade and the burr height around the gas film hole are improved obviously by magnetic needle grinding. The research results can provide a reference for improving the surface quality of turbine blade by magnetic needle grinding process.
2021 Vol. 64 (18): 62-68 [Abstract] ( 121 ) HTMLNew PDF (5939 KB)  ( 367 )
       APPROACHING SCIENCE
70 Mechanics Supports Design and Manufacture of Advanced Composite Materials, Boosts Development of Lightweight Aerospace Structures
2021 Vol. 64 (18): 70-71 [Abstract] ( 108 ) HTMLNew PDF (818 KB)  ( 111 )
       SPECIAL TOPIC
72 Multi-Objective Optimization of Slot Milling Process Parameters Based on Scallop Height Control
XU Weihong,SONG Weiwei,CHEN Lunwang,HUANG Tao,ZHANG Xiaoming
DOI: 10.16080/j.issn1671-833x.2021.18.072

In this paper, the deep groove plunge milling process of nickel-based super-alloys was researched. Taking material removal rate and residual height as the optimization goals, a process parameter optimization model under the constraints of cutting force and stability was proposed. The weight of each target was difficult to quantify and adjust  when the objective function was established by the weighting method. Aiming at the problem, the ratio weighting method was used to establish the objective function to ensure the balance of the optimization direction. The genetic algorithm was used to solve the optimization model example, and the performance indicators of the optimization results and empirical results were compared. The results show that when the constraints are met, the optimized process parameters can not only significantly increase the material  removal  rate, but also control the  residual height, so as to achieve high-efficiency and  high-quality processing.
2021 Vol. 64 (18): 72-78/87 [Abstract] ( 142 ) HTMLNew PDF (5287 KB)  ( 490 )
79 Precisely Overlapping Toolpath Generation Method for Machining Blade Root Transitional Surface of Blisk Based on Reconstructed Surface
ZHU Yu, LI Shijun, WANG Wenli
DOI: 10.16080/j.issn1671-833x.2021.18.079
This paper presented a method to compute toolpaths for machining the transitional surface, which can gradually change from the boundary of the machined surface to the boundary of the fillet corner. The toolpaths generated by  our method can precisely overlap the boundary of the region that has been machined. This method analyzed the toolpaths, which had been used, to find a group of points. These points were employed to  represent the machined surface. Then a  boundary extraction algorithm was employed to reconstruct a NURBS curve to represent the boundary of the point set. A group of curves were generated between the boundary of machined surface and the boundary of the fillet corner. Then those  curves were applied to reconstruct the blade root transitional surface. And the surface was employed to generate relevant toolpaths. This method was applied to machining the blade root transitional surface of a blisk. The machining result indicated that the blade root transitional surface smoothly connected the upper region of the blade and the corresponding fillet corner after machining.
2021 Vol. 64 (18): 79-87 [Abstract] ( 100 ) HTMLNew PDF (15891 KB)  ( 99 )
88 Experimental and Computational Studies of Isothermal Sections of Ni–Al–Ru Ternary System at 1273K and 1473K
MAO Xinru,WU Xueting,LU Xiaogang
DOI: 10.16080/j.issn1671-833x.2021.18.088
Computational thermodynamics (CALPHAD) method makes use of various experimental data and firstprinciples calculations to optimize model parameters and then establish thermodynamic databases, which is the key point of researching quantitative relations among composition, process, microstructure and material properties for multi–component and multi-phase materials. In the present work, the experimental and computational studies of the Ni–Al–Ru ternary system adopt the CALPHAD method and phase equilibrium experiment to clarify the new approach of Materials Genome Initiative (MGI). The core idea of MGI is the deep integration of computation–experiment–database, which is also the feature of CALPHAD method. The isothermal sections of the Ni–Al–Ru ternary system at 1273K and 1473K were constructed experimentally by examining equilibrated alloys and diffusion couples, through which the phase equilibria were determined by Energy Dispersive Spectroscopy (EDS) and Electron Probe Micro-Analysis (EPMA). Based on the measured phase equilibria and first–principles calculation data, the model parameters formulating the Gibbs energies of various phases of the binary/ternary systems of Ni–Al–Ru were assessed by the CALPHAD method with the Thermo-Calc software. A set of self-consistent thermodynamic parameters of the Ni–Al–Ru system has been obtained successfully and can be extended to multi-component thermodynamic databases for superalloys.
2021 Vol. 64 (18): 88-97 [Abstract] ( 125 ) HTMLNew PDF (4798 KB)  ( 646 )
98 Study on Ultra-High Temperature Thermal Barrier Coatings Based on Material Genome Engineering
LIANG Yingxue,YU Wei,ZHOU Yunxuan,GAN Mengdi,WEI Yan,ZHANG Jiankang,CHEN Yongtai,YE Bo,CHONG Xiaoyu,FENG Jing
DOI: 10.16080/j.issn1671-833x.2021.18.098
Material genome engineering is a revolutionary cutting-edge technology in the field of materials, which greatly shortens the process of materials from design to application, improves research efficiency and reduces cost, and becomes a new mode of material research and development. This paper mainly introduces the materials genome engineering technology in the development of ultra-high temperature thermal barrier coating system, including ceramic insulation of ultra-high temperature rare earth tantalate and bonding layer of Pt–Ir based superalloys. At the same time, it is prospected the application of material genome engineering in the research and development of ultra-high temperature thermal barrier coatings.
2021 Vol. 64 (18): 98-112 [Abstract] ( 165 ) HTMLNew PDF (41748 KB)  ( 278 )
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· 'Aeronautical Manufacturing technology ' is included in EI database
· China Science Citation Database (CSCD)
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· 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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