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2017 Vol. 60, No. 18
Published: 2017-09-15
FEATURE
FIGURE
NEW VIEWPOINT
RESEARCH
C0NTENTS
COVER STORY
C0NTENTS
6
C0NTENTS
2017 Vol. 60 (18): 6-10 [
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FEATURE
16
Development of Rapid Sheet Metal Process Planning System Based on Knowledge Engineering
LI Guangjun1, HUANG Qingyi1, LIU Hong1, WU Wei2, ZENG Yuansong2
DOI: 10.16080/j.issn1671-833x.2017.18.016
Actual rapid development needs of domestic and foreign modern civil aircraft are described. Referencing
experience of foreign aviation manufacturing enterprises and domestic aircraft sheet metal progress, overall methods and
ways of rapid sheet metal process design system are built, and taking knowledge engineering technology as the core, numerical
reasoning as means. Rapid sheet metal design process system is established by expert knowledge building and system
software development. Process analysis and design of sheet metal parts are realized in bulk and automatically; Process
analysis reports, manufacturing outline, NC code are automatically generated, which can greatly increase process design
efficiency of civil aircraft development and reduce labor.
2017 Vol. 60 (18): 16-19 [
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304
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FIGURE
20
Quality and Talent are the Eternal Theme of Aero-engine Development
2017 Vol. 60 (18): 20-21 [
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201
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COVER STORY
22
Application of Pulse Electric Current in the Field of Plastic Processing
WANG Guofeng, LI Xiao, LI Danfeng, ZHANG Kaifeng
DOI: 10.16080/j.issn1671-833x.2017.18.022
The introduction of electric current to materials will bring some obviously positive effects on mechanical
properties and microstructure. In the term of mechanical properties, the flow stress will decrease and the capacity for plasticity
will be improved. At the same time, microcrack blunt because of the influence of electric current. As for microstructure,
it accelerates recrystallization and refines grains, resulting in the change of texture. Materials heated directly by electric
current lead to low energy consumption and the efficiency of forming rises. Electric current is applied in many plastic
forming techniques, such as stamping, rolling and superplastic forming. Nowaday, the main purpose of forming is energy
conservation and high efficiency, and electric current drives sophisticated manufacturing greatly, especially in the field of
aeronautics and astronautics. It is proved that electric current is worth in the field of plastic processing by many attempts of
scholars.
2017 Vol. 60 (18): 22-28 [
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370
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FIGURE
32
Comparative Analysis of Rubber Fluid Forming Springback Compensation Technology
ZHANG Xin1, YU Changwang2, LI Xiaoqiang2
DOI: 10.16080/j.issn1671-833x.2017.18.032
Rubber fluid forming technology is one of the main methods for aviation sheet metal forming, while
the springback is the main defect that affects the manufacturing precision of sheet metal products. In order to improve the
manufacturing precision of the aviation manufacturing level, domestic researchers have carried out a lot of researches and
practices, but the effect of engineering application of various methods is not ideal. In this paper, springback prediction
method based on the numerical simulation and rapid springback compensation method based on geometric features of parts
are reviewed, the advantages and disadvantages of the two methods are compared and analysed. Combining with the aviation
enterprise engineering application and practical demand, the solution of combining the two methods is proposed.
2017 Vol. 60 (18): 32-35 [
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274
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36
Numerical Simulation and Experiment Study on Tube Spinning of GH625 Reducer Tube
LI Bo1, YUAN Qiwei1, JIN Kai2, WAN Bofang3, WANG Hui2, GUO Xunzhong1, TAO Jie1
DOI: 10.16080/j.issn1671-833x.2017.18.036
The elastic-plastic finite element model for the GH625 neck-spinning process was established by
ABAQUS/Explicit software. The distribution of the stress, strain and the variation of the cross section of tube spinning process
were analyzed. Furthermore, the effect of the spinning parameters on forming quality was obtained, such as axial feed
rate, roller nose radius and roller installation angle. The spinning process results showed that the cross-sections in different
zone of tube were generated different deformation. The results also reflected that the thickness increased with the increasing
of the axial feed rate and roller nose radius. The roller installation angle had little influence on the tube thickness. The ellipticity
became larger as the axial feed rate and roller nose radius increased. Located away from the free end, the ellipticity
increased as the roller installation angle decreased. The distribution of the ellipticity was uneven when the roller was near
the free end of the tube. Finally, the process parameters was selected based on the simulation: 0.25mm/r of axial feed rate,
2-4mm of roller nose radius, 90º of roller installation angle. The experiment was conducted and the accuracy quality tube
was manufactured by neck-spinning experiment.
2017 Vol. 60 (18): 36-42 [
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349
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43
Forming Technology Research of Complex Curved Surface Duct
XU Nian, NIE Ziyang
DOI: 10.16080/j.issn1671-833x.2017.18.043
Respectively from the three aspects,such as :the springback amount and size control, defect characteristics
and stamping mould repair, pre-press surface protection .Study of complex curved surface stamping control, puts forward a
method of complex curved surface stamping control . In addition, a correction method for improving the defects and sizes
of small diameter convex flange is presented. In this paper, the general rules of "forming control of complex curved surface
and small diameter flange sheet metal forming control" are analyzed, and the foundation for the forming research of the following
type parts is laid.
2017 Vol. 60 (18): 43-47 [
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279
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48
Research on Relationship Between Microstructure and Bending Properties of TB5 Sheet
SUN Yongna, LIU Changxu, WU Guoqing
DOI: 10.16080/j.issn1671-833x.2017.18.048
Due to excellent cold formability,TB5 titanium alloy sheet is apply to forming moderately complicated
spare parts of metal sheet for space flight and aviation, but it has such problems as poor setting, big spring-back after forming.
In the paper, the evolution rules of the deformation behavior, microstructures and formabilities in the bending deformation
were investigated for TB5 titanium alloy sheets.The results show that with the increasing of bending angles and
decreasing of the bend radius of the sheet, the spring-back angle is positive correlation with the grain size and horizontal
distanceand-vertical ratio of the grains. With the increasing of bending angles and decreasing of the bend radius of the
sheet, the hardness at the center of deformation is positive correlation with the grain size, negative correlation with horizontal-
vertical ratio of the grains at the center of deformation.
2017 Vol. 60 (18): 48-52 [
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311
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NEW VIEWPOINT
54
Development of Intelligent Manufacturing and Its Impact on Commercial Aircraft Engine Manufacturing
SU Qiaoling
DOI: 10.16080/j.issn1671-833x.2017.18.054
Nowadays the deployment of intelligent manufacturing policy is a global topic all over the world. Chinese
intelligent manufacturing policy is defined as “Made in China 2025”, in which the construction of smart factory for aircraft
engine manufacturing is one of the key tasks. This paper introduces the current situation of the foreign commercial aircraft
engine companies in intelligent manufacturing, and summaries the key issues of building a smart factory forcom-marcial
aircraft engine. The key issues include establishing the industrial standards, developing smart products or making changes
to the current products, formulating an intelligent production organization through digital and network tools.
2017 Vol. 60 (18): 54-61 [
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317
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RESEARCH
62
Effect of Femtosecond Laser Fluence on Recast Layer and Machining Time in Nickel-Based Superalloy
ZHANG Wei, ZHANG Xiaobing, CAI Min, JI Liang
DOI: 10.16080/j.issn1671-833x.2017.18.062
The effect of femtosecond laser fluence (0<Ф<44.2J/cm2) on recast layer and machining eff iciency were
investigated with the no-melting ablation threshold (Φth1) and melting ablation threshold (Φth2) in a single-crystal nickelbased
superalloy. For the laser fluence range (Φth1<Φ<Φth2), there are no indications of conventional laser-induced recast
layers in laser-machined area of nickel-base superalloy. For the laser fluence Φ>Φth2, recast layers appeared gradually and
increased with increasing laser fluence. The relationship between ablation depth for single pulse and laser fluence is established.
The larger ablation rate is associated with higher laser fluence.
2017 Vol. 60 (18): 62-65 [
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398
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66
Crack Growth Characteristic Analysis for a Typical Connection Structure of Titanium Alloy
XIAO Shan1, BI Jinying1, SUN Yanpeng1, LIU Shutian2, LIU Yang2
DOI: 10.16080/j.issn1671-833x.2017.18.066
The fatigue crack growth characteristics of the traditional lug and diffusion bonded lug with localized
non-welded area of TC4 titanium-alloy are studied, and the simulation techniques based on extended finite element method
(XFEM) under tension-tension cyclic loading are used, in order to reveal the inhibitory effect of non-welded area on crack
growth when the bolt hole is in the extrusion. The comparisons of the numerical results and the experimental results show
that the extended finite element method (XFEM) is an effective numerical method for the fatigue crack growth characteristics
analysis.
2017 Vol. 60 (18): 66-69 [
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212
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70
Stress Analysis and Structure Optimization of Main Landing Gear Frame Front Fork Based on Workbench
LI Jing, ZHANG Xianyu
DOI: 10.16080/j.issn1671-833x.2017.18.070
Based on main landing gear frame front fork root of a certain aircraft multiple occurrences of fatigue crack,
the front fork as main landing gear frame key-module, seriouly influence safety of the landing gear. Through stress analysis
of the structure using ANSYS Workbench simulation softwarely, weak positions of the frame front fork were obtained, and
its structure and comparative analysis were optimized by combination of topology optimization and goal driven optimization
method. Obtained weak parts were in conformity with the actual usage, structure is reasonable, stress obviously improved,
and weight decreased by 17.3% than before optimization.
2017 Vol. 60 (18): 70-73 [
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257
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74
Effect of Diffusion Bonding Defect on Mechanical Properties of Ti-6Al-4V Alloy
DOI: 10.16080/j.issn1671-833x.2017.18.074
The effect of diffusion bonding (DB) defect with φ 4mm and φ 2mm diameter on mechanical porperties of
Ti-6Al-4V alloy is investigated. The defect plane is parallel to the load axis, the strength and ductility of the material are
not affected because the area subjected to tensile load almost stayed the same. Ti-6Al-4V alloy with φ 4mm DB defect under
fully reversed fatigue load exhibited a large scatter of life, and the defect is not the unique crack initiation area. Samples
with surface crack initiation exhibited longer fatigue life; while almost all samples with defect-induced crack initiation exhibited
a much shorter fatigue life. Finite element analysis shows that the stress concentration is lower when the defect is in
center; The stress concentration is higher when the defect is on edge.
2017 Vol. 60 (18): 74-78 [
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275
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79
Research on Modularization, Standardization and Digital Rapid Design in Composite Molds
HAN Zhiren1,2, JIA Chen2, HE Wanfei3, SHI Zhanghu3, SUN Hao2
DOI: 10.16080/j.issn1671-833x.2017.18.079
Standardized agile design technology of composite material forming mold is one of key in aircraft digital
manufacturing. Based on the characteristics of composite mold pressing mold, this paper analyzed the structural characteristics
of the mold, design specification and parametric design in the feasibility. an algorithm for modularization and
parameter design of composite mold for composite material was proposed. According the algorithm, a function to achieve a
complete composite material curing mold design function in CATIA has been developed and performed in instantiated validation.
The function is an effective method for the design of composite material mold.
2017 Vol. 60 (18): 79-82 [
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295
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83
Process Design and Verfication of VARI Integrated Forming of Stiffened Panels
CONG Jingjie1, CHEN Zhiping1,2, HU Zhongmin1
DOI: 10.16080/j.issn1671-833x.2017.18.083
Based on the characteristics of composite stiffened panels, We develop its process design of VARI integrated
forming technology including the mold and the process steps, and then create some viable flow runner project to
simulate and analysis by PAM-RTM. According to the results, we chosen the project with reasonable injection mode and
flow run-ner to manufacture the stiffened panels by VARI process. the result of the nondestructive testing show that internal
defect barely exists in the component, which proved that the process design and the simulation is effective.
2017 Vol. 60 (18): 83-87 [
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254
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88
Finite Element Simulation on Porthole Die Extruding Process of 5005 Aluminum
CHEN Ling, DUAN Yafei, TAN Zimeng, ZENG Jianmin
DOI: 10.16080/j.issn1671-833x.2017.18.088
Using a mesh-reconstruction technology of welding-plane, the porthole die extrusion process of an hollow
profile was successfully simulated based on software DEFORM-3D. The metal flow behaviors, velocity distribution
regularities were revealed. Combining with the effective stress and strain on the profile, the distribution of grain size on the
profile and its causes were discussed. The result shows the stress and strain distribution of the extrusion profile has certain
corresponding relation with the grain size distribution, in other words, finer grain size at the corner area and inner part of
the hollow profile result from the concentration of the stress and strain during the extruding.
2017 Vol. 60 (18): 88-92 [
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259
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Study on Microstructrue and Mechanical Properties of Electron Beam Welded AF1410 Joints
TANG Daibin, LI Kai,MAO Zhiyong, WU Bing
Oscillated electron beam welding with cosmetic welding was applied to 5mm AF1410 steel. Microstructural
features and tensile failure fractures of joints were examined by means of OM, SEM and microhardness tester. Results
showed that the heat affected zone (HAZ) contains light etched zone and dark etched zone, which are composed of martensite
(M), M+ reverted austenite (Ar) respectively; the weld zone (WZ) is divided into 3 different zones, namely remelted
zone, normalized zone and tempered zone, and occupied by columnar grains, besides martensite exists in intragranular areas
and retained austenite (A) exists at intergranular areas. After post-weld heat treatment, microhardness and microstructure of
joint are nearly the same as base metal. The room tensile strength of joint reaches 98% of base metal and all cracks initiate
at HAZ and propagate through the whole WZ in60° direction.
2017 Vol. 60 (18): 93-96 [
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180
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97
Contrastive Analysis on Quality of Compression Riveting and Hammer Riveting of Slant Composites
LI Hui1, YI Chengjun1, WANG Qian1, LI Jing2, GAO Yan2, LI Zhenyu2
DOI: 10.16080/j.issn1671-833x.2017.18.097
The quality of two riveting methods of pressure riveting machine and manual riveting was evaluated by
experiment. The main contents of the evaluation include the appearance quality of the rivets, the appearance quality of the
composite rivets, the non destructive testing and the mechanical performance test. The results showed that the riveted rivet
is better than the appearance of the composite rivets and is less influenced by human factors. After the non destructive testing,
there is no delamination phenomenon in riveted riveted joints. In the mechanical performance test section, the compression
riveting strength is better than the hammer riveting strength. It can be seen that press riveting is more practical and
applicable.
2017 Vol. 60 (18): 97-99 [
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316
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100
Research on Construct Technology of MBD Model Ontology Knowledge Base oriented to Reuse
GU Li，LI Shu，WANG Zhe，GUO Yijing，ZHOU Pei
DOI: 10.16080/j.issn1671-833x.2017.18.100
There are many history MBD models in aviation enterprises, which have great reuse value. It is the key
problem to construct normalized model storage data structure in model reuse, we researched on the organizational form of
MBD model data, used ontology technology as knowledge expression form of model type division and attribute information,
designed ontology data structure including both geometry and non-geometry information. Based on this kind of data
form, We transform history model data into structural ontology knowledge base and verify technical feasibility by retrieval
of model key information, make preparation for magnanimity model data reuse.
2017 Vol. 60 (18): 100-105 [
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309
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Tensile Test and Numerical Simulation Analysis of Composite Laminates With Crack Damage
CHEN Juan1, WANG Xing2
DOI: 10.16080/j.issn1671-833x.2017.18.106
The crack damage forms on the tensile properties of carbon fiber composite laminated plates and the effect
of damage by tensile test of nondestructive, containing loss (the crack damage of different the length ) of carbon fibre
composite laminated plate have been studied. The tensile strength of carbon fiber composite laminates is 517.37MPa, and
the tensile properties of carbon fiber composite laminates are significantly reduced. Compared with the tensile properties
of non-destructive laminates, the tensile strength of laminates with a crack of 5mm was reduced by 26.3% and the tensile
strength of laminates with a crack of 15mm was reduced by 23.4%. Tensile numerical simulation analysis was carried out
on the carbon fibre composite laminated plates based on the three-dimensional progressive damage failure criterion subroutines,
including loss of laminated plates at damage initiation and extension stages. A good agreement was found between
the predicted results and the test data.
2017 Vol. 60 (18): 106-109 [
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214
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