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2017 Vol. 60, No. 5
Published: 2017-03-01
FEATURE
FIGURE
FORUM
RESEARCH
C0NTENTS
COVER STORY
C0NTENTS
6
C0NTENTS
2017 Vol. 60 (5): 6-10 [
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FEATURE
16
Key Optimization Design Issues for Achieving Additively Manufactured Aircraft and Aerospace Structures
ZHU Jihong, HE Fei, ZHANG Weihong
DOI: 10.16080/j.issn1671-833x.2017.05.016
Concerning the severe demand of lightweight and high performance in aircraft and aerospace complicated
integrated structures design, this paper demonstrates the key issues and recent achievements in additively manufactured
structures design. Four aspects, i.e. integrated optimization modeling and performance analysis for multiple loading members
in additively manufactured structures, multidisciplinary performance and multi-functional design method for integrated
structures, performance description and scale effect of the cross-scale structures and microstructures, and the influence of
the additive manufacturing process and its manufacturing constraints are expounded here, to show how to achieve the best
match of the performance optimization and additive manufacturing with studies on both structural mechanics and processing
mechanics.
2017 Vol. 60 (5): 16-21 [
Abstract
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279
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FIGURE
22
Promoting Intelligent CNC Machining by Core Technology Research
2017 Vol. 60 (5): 22-23 [
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159
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COVER STORY
24
Brief Introduction on the Method and Progress of Nondestructive Testing for Ceramic Matrix Composites
MEI Hui, ZHANG Ding, XIA Junchao, YIN Liangxuan, YU Changkui, CHENG Laifei
DOI: 10.16080/j.issn1671-833x.2017.05.024
Ceramic matrix composites have been widely used in the field of aeronautics and astronautics because
of its excellent properties such as highlighted mechanical properties at high temperature, low density and good oxidation
resistance performance. Using nondestructive testing methods to make testing on ceramic matrix composites has significant
meanings in ensuring the quality of materials and improving the reliability of related products. In this paper the current state
and development of the nondestructive testing of the ceramic matrix composites are summarized. Principles of terahertz, Xray,
industrial CT, infrared thermal imaging, ultrasonic wave and acoustic emission for the ceramic matrix composites are
elucidated in detail, and their applications in ceramic matrix composites are introduced.
2017 Vol. 60 (5): 24-30 [
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374
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FORUM
34
Evaluation of Thick Diffusion Bonds by Using NLU Imaging Method
LIU Songping, LI Legang, LIU Feifei, SHI Junwei
DOI: 10.16080/j.issn1671-833x.2017.05.034
Diffusion bonding (DB), as a solid state welding, has been increasingly applied in aeronautical and space
industries. The defects induced in thick DB plate are much more difficult to be found out by conventional ultrasonic techniques
because of their characteristics of kiss-bonding, small-size and distribution and high ultrasonic attenuation. A new
ultrasonic imaging technique, which is based on non-linear ultrasonic (NLU) components of the received signals resulted
from diffusion bonding interface, is developed into nondestructive evaluation (NDE) of thick diffusion bonded plate. The
experimental results show the powerful ability to the NDE of thick plate diffusion bonds by using the NLU visual method.
The maximum thickness of diffusion bonding is up to 70mm.
2017 Vol. 60 (5): 34-37 [
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219
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38
Experimental Research on Ultrasonic Characteristics of TC18 Additive Manufacturing Titanium Alloy
YANG Pinghua, SHI Lijun, LIANG Jing, SHI Yiwei, KANG Lihong
DOI: 10.16080/j.issn1671-833x.2017.05.038
The experimental research was carried out on the ultrasonic characteristics of 3 kinds of TC18 titanium alloys,
which were manufactured by laser additive manufacturing, electron-beam additive manufacturing and forging, respectively.
The research reveals that, in contrast with forged titanium alloy, additive manufacturing titanium alloy has obvious
directivity, which is manifested in the difference in velocity, attenuation and ultrasonic sensitivity of different directions.
The results are of great value to the ultrasonic testing method research of additive manufacturing products.
2017 Vol. 60 (5): 38-42 [
Abstract
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259
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43
Ultrasonic Evaluation and Defect Discrimination of T-Shape R-Zone in Composite Structures
LIU Feifei, LIU Songping, FU Tianhang, LI Legang, BAI Jinpeng
DOI: 10.16080/j.issn1671-833x.2017.05.043
Currently, the nondestructive testing and evaluation (NDT & E) of R-zone in carbon fiber-reinforced
composite structures (CFRCS) has become a focus in the area. A high-resolution ultrasonic technique was employed for
the NDT & E of T-shape R-zone in CFRCS based on the reflected echo signals and their characterizations by studying the
interaction of incident short-pulse ultrasonic wave with T-shape R-zone. Series of ultrasonic testing and destructive testing
experiments were carried out. A water-film couple method was used between transducer and T-shape R-zone surface. The
incident direction and position of wave beam can be changed through the scanning of transducer and its aided mechanical
device for 100% NDT of T-shape R-zone. Series of experimental and practical results have shown that the ultrasonic tech-nique is very powerful in the NDT & E of T-shape R-zone in CFRCS. Defects and their exact positions in layup direction
can be effectively discriminated and quantitatively determined according to the time-resolved reflected echoes from T-shape
R-zone laminates and their time-domain characterization. The surface resolution and dead-zone of the ultrasonic method
can be reached to 0.13mm, i.e., the thickness of a single prepreg ply approximately. The series of destructive testing results
have excellently demonstrated the correction of ultrasonic results compared with the real defect induced during the manufacturing
of the CFRCS with T-shape R-zones.
2017 Vol. 60 (5): 43-48 [
Abstract
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283
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49
Ultrasonic Testing Study for Autoclave Cured Composite Material Porosity
GUO Zhiwen1, SHI Xiaochun1, SHEN Yang2, TAO Minggao1, ZHOU Songwei1
DOI: 10.16080/j.issn1671-833x.2017.05.049
AVIC General’s self-developed all-composite fuselage AG300 aircraft is a new kind of business jet based
on carbon fiber composite material, using the curing oven molding, which is high-efficiency than conventional autoclave
molding, but the porosity is bigger than that of the traditional process. The size and distribution of porosity directly affects
the mechanical properties of structure, particularly vital member with stress concentration, so the need is urgent for reliable
and accurate nondestructive evaluation of their porosity. We introduce a kind of preparation method for composite material
porosity block by spraying solvent, using the ultrasonic attenuation method and metallographic analysis to carry out the
calibration of the predecess or experical formula. We compare the porosities from calculated empirical formula and metallographic
analysis, and draw the fitting curve. The error is not more than 0.4%, which verifies application possibility of this
empirical formula in the engineering practice.
2017 Vol. 60 (5): 49-53 [
Abstract
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308
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54
Analysis of Effective Working Hours for Automatic Assembly Equipment of Aircraft
XIN Bo, LI Yuan, YU Jianfeng, ZHANG Jie
DOI: 10.16080/j.issn1671-833x.2017.05.054
To improve the accuracy of capacity analysis and prediction for automatic assembly equipment of aircraft,
a method of calculating the effective working hours of automatic assembly equipment based on the dynamic mixed Weibull
distribution model was proposed. According to the features of aircraft assembling, the dynamic mixed Weibull distribution
of availability with three parameters for automatic assembly equipment was established. Subsequently, effect of all subsystems
on the availability of whole equipment was analyzed. The dynamic weights of availability of subsystems were
calculated. Then, availability parameters of the dynamic mixed Weibull distribution were estimated in order to solve the
availability and the effective working hours of equipment. Finally, this method was tested on an automatic drilling & riveting
equipment from a wing panel assembly station, and the feasibility of proposed method was justified.
2017 Vol. 60 (5): 54-59 [
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263
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RESEARCH
60
Researching on the Surface Roughness and Defects of the TB6 Titanium Alloy During Milling
Researching on the Surface Roughness and Defects of the TB6 Titanium Alloy During Milling[J]. journal1, 2017,524(5): 60-66')" href="#">
YANG Houchuan, YANG Baosheng, DU Xiaowei, XIA Chengbao, CHEN Minghua
Surface roughness for TB6 titanium alloy impacts its performance significantly, The effect on surface roughness and defects was studied through face milling parameters, dry milling and tool wear experiment. The results show that surface roughness for TB6 titanium alloy is mostly sensitive to the variation of feed per tooth, the next is the milling width, then is the depth of milling and the last is the milling speed. The
VB
have a significant influence on surface roughness, especially when
VB
is greater than 0.2mm, the roughness values increases significantly as well as bringing on some scratches and grooves. Feed mark, smeared and uplift material defects are observed on all machined surface samples. A large number of deposited material or pitting corrosion adhere to the worked surface during dry milling as well as burr formation increasing. Burr formation decreases with the increasing of milling speeds, while increases with the
VB
increasing. Wherefore, TB6 titanium alloy is suitable for low milling speed with cooling lubrication during milling.
2017 Vol. 60 (5): 60-66 [
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182
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67
Investigation of the Creep Age Forming Mechanism and Springback Behavior of LY12
MA Zhenwu,TONG Guoquan,CHEN Feng, CUI Baojin
DOI: 10.16080/j.issn1671-833x.2017.05.067
Based on the goal of creep age forming of LY12, we have studied the evolution characteristics of the second
phase which was precipitated and analyzed the strengthening mechanism from the points of microscopic view. In the
article we modified the constitutive equation of creep and developed ABAQUS/CREEP, simulated the aging time, aging
temperature and prebending radius influencing on springback laws, establish unified springback simulation function. The
feasibility of this method can be proved by comparing the calculated value and experimental value.
2017 Vol. 60 (5): 67-71 [
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204
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FORUM
72
Machining Process Optimization Strategy of Integral Impeller Based On Non-Uniform Machining Allowance
Machining Process Optimization Strategy of Integral Impeller Based On Non-Uniform Machining Allowance
[J]. journal1, 2017,524(5): 72-76')" href="#">
WU Yan 1, LV Boxin 1, LV Shiqiang 2,ZHENG Gang1,ZHANG Jieren1
Large deformation and cutting vibration is an important problem in the process of manufacturing ultrathin blade of integral impeller, thus a non-uniform allowance process is used in this paper, which can reduce blade deformation and improve processing quality. Firstly, the influence of concentrated load both on the deformation of thin-walled structure and thickening structure wad analyzed. Then non-uniform allowance machining process of impeller blade was designed. Lastly, tool path was planned and processing experiment was done on the impeller. Results show that the process optimization strategy can effectively reduce milling vibration and milling deformation of ultra-thin blade, the max error optimization rate is 54.47% and the average error optimization rate is 52.57%, which is of significance to the actual production.
2017 Vol. 60 (5): 72-76 [
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166
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RESEARCH
77
Research on Measurement Technique of the Stepped Difference and Gap Between Aircraft Skins#br# Based on Linear Structural Light
XU Dashuai, DU Fuzhou
DOI: 10.16080/j.issn1671-833x.2017.05.077
Aiming at Dealing with the stepped difference and gap of aircraft assembling, this paper comes up with
an algorithm of the stepped difference and gap based on the structural light measuring theory from the size and position of
them. This paper completes the measurement of the stepped difference and gap of the aircraft skins with the linear structural
light vision sensor, and the pinpoint position of the measurement can be confirmed by using the indoor-GPS. As is confirmed
by experiments, the result of the algorithm is quite stable: the repeat precision of the stepped difference within 5mm
is not more than 0.04mm and the repeat precision of the gap is not more than 0.05mm.
2017 Vol. 60 (5): 77-81 [
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327
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82
Difference Analysis Between Laser Additive Manufacturing
and Conventional Forging and Casting
Difference Analysis Between Laser Additive Manufacturing
and Conventional Forging and Casting
[J]. journal1, 2017,524(5): 82-86')" href="#">
HAO Xiaoning
DOI: 10.16080/j.issn 1671-833x.2017.05.082
After collecting and sorting the domestic and foreign standards, we analyzed the differences between laser additive manufacturing (LAM) and the conventional forging and casting in forming technology, microstructure, defects and the causes, internal quality and mechanical properties. It revealed that compared with conventional forming and casting, the manufacturing cycle of LAM is shorter and the material utilization is higher; the porosity in the blank fabricated by LAM can reach class A1, which is lower than forging class AA. Compared with casting, porosity can reach class B. Yield strength of titanium alloy by LAM in transverse and horizontal are lower than forging and casting by 3.4%, and tensile strength that of forging and casting by 0.78% respectively.
2017 Vol. 60 (5): 82-86 [
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186
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87
Stability Study of the Unseparated Ultrasonic Composited Milling System
ZHAO Bo, ZHAO Binbin, ZHANG Yuemin
DOI: 10.16080/j.issn1671-833x.2017.05.087
In order to study the stability of the unseparated ultrasonic composited milling system, the kinetic characteristics
of ultrasonic composited milling are discussed, and the stability model of unseparated ultrasonic milling is established.
The semidiscrete method is used to study the stability of ultrasonic composite milling. The numerical analysis was
carried out by using MATLAB, and the stability lobe diagram of ultrasonic milling was obtained. Research shows that the
stability of ordinary milling system can be promoted by the unseparated ultrasonic milling system and the maximum cutting
depth is increased by about 13.8%.The experiment of ultrasonic composited milling was carried out by using titanium alloy
material. The correctness of the theoretical model and the stability lobe diagram was verified by the experiment.At the same
time, the feasibility of using semi discrete method to analyze the stability of ultrasonic composited milling system is verified.
2017 Vol. 60 (5): 87-91 [
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208
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92
Predi
c
tion on Pulse
P
roduction
L
ine
R
unning
S
tate Based on
Markov
F
orecast
M
odel
Predi
c
tion on Pulse
P
roduction
L
ine
R
unning
S
tate Based on
Markov
F
orecast
M
odel
[J]. journal1, 2017,524(5): 92-95')" href="#">
QIN Yaru,HOU Zhixia,LV Ruiqiang,LIU Yiping
The concept, characteristics of pulse production line is introduced, and the current application of pulse production line is reviewed. The factors influencing pulse production line and the necessity of state prediction are analyzed. Then, a method of state prediction based on Markov chain model is proposed. Based on Markov Chain forecast theory, the running states of pulse production line are classified. The state transition matrix is determined and the Markov forecast model is established. Last, the validity of the model is estimated.
2017 Vol. 60 (5): 92-95 [
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194
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96
Failure Analysis and Structure Optimization of Titanium Alloy Lug
LI Hui1, CHEN Peng1, YAO Zekun2, NING Yongquan2
DOI: 10.16080/j.issn1671-833x.2017.05.096
Titanium alloy is widely used in aviation, aerospace, marine and other fields for its high strength, good
corrosion resistance and high heat resistance. Lots of aircraft structures were manufactured by titanium alloys, such as the
pulley frame, hinge joint and the base structure, which relate to lug connection parts. In order to investigate the failure behavior
and optimize the geometric shape, the static-load tests were carried out on the titanium alloy lugs. The effect of lug
shape and loading method on the failure behavior has been studied, and K 0 and K con1 have been calculated. Meanwhile, typical
fracture mechanisms of the titanium alloy lugs were given in present research.
2017 Vol. 60 (5): 96-99 [
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245
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100
Tool Chain Construction of Civil Aircraft Design Based on MBSE Method
Tool Chain Construction of Civil Aircraft Design Based on MBSE Method[J]. journal1, 2017,524(5): 100-104')" href="#">
XU Zhou
As the complexity of system rising day by day, the idea of system engineering is used in civil aircraft design more and more, and the model based system engineering (MBSE) is the trend. This article described the concept and process of civil aircraft design based on MBSE method and three important standards which bring a lot of benefit to MBSE during its development. Then it listed a few familiar software tools which are wildly used in deferent stages of MBSE process. And it also proposed the tool chain architecture of MBSE which can provide a good reference for making MBSE practicable in civil aircraft design.
2017 Vol. 60 (5): 100-104 [
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168
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105
Study on the Morphology and Microstructure of TA15 Titanium Alloy EBW Welded Joint
KUANG Xiaocong1,2, PU Wende1, FU Pengfei2,WANG Xichang2, KE Liming1
DOI: 10.16080/j.issn1671-833x.2017.05.105
In this article, TA15 titanium alloy was welded by electron beam welding with different process parameters,
the morphology of welded joints were investigated by observing the morphology of the welded joints and measuring
the shape parameters, and the microstructure of the welding joint was analyzed. The results show that the weld penetration,
half of width and weld width increase when the electron current increases, and the weld shape changes from the nail shape
to the bell shape. The welding speed has little effect on the weld shape, the weld penetration, half of width and weld width
decreases with the increase of the welding speed, and the ratio of depth to width increases first and then decreases. The
increase of focusing current has a large effect on the weld penetration, but the half of width and weld width change little.
when the scanning amplitude increases, the weld penetration decreases, half of width increases. The heat affected zone (HAZ)
near the base metal was similar to the base metal, Which was mainly composed of the primary equiaxed α phase and transformed
β phase, and the acicular (α+β); The HAZ near the fusion line was consist of α phase and acicular (α+β), and appear
α´; the microstructure of fusion zone was α´, the columnar crystals grew perpendicularly to the weld center, and single or
multiple columns of equiaxed grain formed in the weld center.
2017 Vol. 60 (5): 105-109 [
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268
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