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Chinese Journal of aeronautics 2024年第3期37卷 404-416页

作者： Huibin SUN Meng LIU Yingzhi ZHANG Chenle WEI key laboratory of high performance manufacturing for aero engine Ministry of Industry and Information TechnologyNorthwestern Polytechnical UniversityXi’an 710072China AECC South Industry Company Limited Zhuzhou 412002China

Due to the excellent self-centering and load-carrying capability,curvic couplings have been widely used in advanced aero-engine ***,curvic tooth surface errors lead to poor assembly *** physical-master-gauge-based indirect tooth surface error measurement and circumferential assembly angle optimization methods have the disadvantages of high cost and weak *** unknown tooth surface fitting mechanism is a big barrier to assembly precision prediction and ***,this work puts forward a data-driven assembly simulation and optimization approach for aero-engine rotors connected by curvic *** origin of curvic tooth surface error is deeply *** 5-axis sweep scan method,a large amount of high-precision curvic tooth surface data are acquired *** on geometric models of parts,the fitting mechanism of curvic couplings is uncovered for assembly precision simulation and prediction.A circumferential assembly angle optimization model is developed to decrease axial and radial assembly *** results show that the assembly precision can be predicted accurately and improved *** uncovering the essential principle of the assembly precision formation and proposing circumferential assembly angle optimization model,this work is meaningful for assembly quality,efficiency and economy improvement of multistage aero-engine rotors connected by curvic couplings.

关键词： Curvic couplings Tooth surface error Assembly precision Axial and radial runouts Circumferential assembly angle

Geometric error measuring,modeling,and compensation for CNC machine tools:A review

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Chinese Journal of aeronautics 2024年第2期37卷 163-198页

作者： Zhao ZHANG Feng JIANG Ming LUO Baohai WU Dinghua ZHANG Kai TANG engineering Research Center of Advanced manufacturing Technology for aero engine(Northwestern Polytechnical University) Ministry of EducationXi’an 710072China key laboratory of high performance manufacturing for aero engine(Northwestern Polytechnical University) Ministry of Industry and Information TechnologyXi’an 710072China Department of Mechanical and aerospace engineering Hong Kong University of Science and TechnologyHong KongChina

Geometric error,mainly due to imperfect geometry and dimensions of machine components,is one of the major error sources of machine *** that geometric error has significant effects on the machining quality of manufactured parts,it has been a popular topic for academic and industrial research for many years.A great deal of research work has been carried out since the 1970s for solving the problem and improving the machining *** have studied how to measure,detect,model,identify,reduce,and compensate the geometric *** paper presents a thorough review of the latest research activities and gives an overview of the state of the art in understanding changes in machine tool performance due to geometric *** advances in measuring the geometrical errors of machine tools are summarized,and different kinds of error identification methods of translational axes and rotation axes are illustrated ***,volumetric geometric error modeling,tracing,and compensation techniques for five-axis machine tools are emphatically ***,research challenges in order to improve the volumetric accuracy of machine tools are also highlighted.

关键词： Error compensation Error identification Error measurement Error modeling Geometric error Machine tools

Study on a probabilistic algorithm for the forming and 3D characterization of special-shaped surfaces under profile grinding

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Advances in manufacturing 2024年第2期12卷 288-299页

作者： Zhao-Qing Zhang Kai-Ning Shi Yao-Yao Shi Yi-Hui Song Zhe He Ya-Song Pu School of Mechanical engineering Northwestern Polytechnical UniversityXi’an710072People’s Republic of China key laboratory of high performance manufacturing for aero engine(Northwestern Polytechnical University) Ministry of Industry and Information TechnologyXi’an710072People’s Republic of China engineering Research Center of Advanced manufacturing Technology for aero engine(Northwestern Polytechnical University) Ministry of EducationXi’an710072People’s Republic of China

Profile grinding is the most crucial method for the ultra-precision machining of special-shaped ***,profile grinding produces a unique machining profile,and many random factors in the machining process lead to complex surface *** this study,the structural and probabilistic characteristics of the profile grinding of a special-shaped surface were analyzed,and a probabilistic algorithm for the forming and 3D characterization of special-shaped surfaces under profile grinding was *** forming process of a GH738 blade tenon tooth surface was considered as an example to demonstrate the *** comparison results showed that the simulation results had similar surface characteristics to the measurement results,and the relative error range of the 3D roughness parameter was 0.21%–19.76%,indicating an accurate prediction and characterization of the complex special-shaped surface under the action of multiple factors.

关键词： Special-shaped surface Profile grinding Surface morphology 3D characterization

Insights into thermodynamic performance of a hypersonic precooled air-breathing engine with a complicated multi-branch closed cycle

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Chinese Journal of aeronautics 2024年第8期37卷 106-123页

作者： Yifan WANG Zhengping ZOU Pengcheng DU Lichao YAO Huoxing LIU Yusen XU Research Institute of aero-engine Beihang UniversityBeijing 102206China National key laboratory of Science and Technology on aero-engine and aero-Thermodynamics Beihang UniversityBeijing 102206China

An advanced precooled airbreathing engine with a closed Brayton cycle is a promising solution for high-speed propulsion,of which the Synergetic Air Breathing Rocket engine(SABRE)is a representative *** performance of the latest SABRE-4 cycle was analyzed in this ***,a relatively complete engine performance model that considers the characteristics of turbomachinery and heat exchangers was ***,Sobol’global sensitivity analysis of key performance parameters was carried out to identify the most influential design *** specific impulses under different target specific thrusts were obtained by particle swarm optimization,of which the thermodynamic parameters corresponding to a specific thrust of 1.12 kN·s·kg^(-1)and a specific impulse of 3163 s were chosen as the design *** different control laws were analyzed in contrast,and the charge control method had the strongest ability of thrust regulation as well as maintaining a favorable specific impulse ***,working characteristics under the charge control and over a typical flight envelope were calculated,in which the average value of the maximum specific impulse was as high as 5315 *** study would help to deepen the understanding of SABRE-4 thermodynamic characteristics and other precooled airbreathing engine cycles with similar layouts.

关键词： Hypersonic Precooled airbreathing engine Thermodynamic cycle Control law Working characteristics

Core shift limitation in investment casting process of hollow turbine blade

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Chinese Journal of aeronautics 2024年第8期37卷 513-526页

作者： Kang CUI Lin JING Ruisong JIANG Longnv YU Xiao GAO Automation and Software engineering Shanxi UniversityTaiyuan 030006China key laboratory of high performance manufacturing for aero engine Ministry of Industry and Information TechnologySchool of Mechanical EngineeringNorthwestern Polytechnical UniversityXi’an 710072China School of Mechanical engineering Sichuan UniversityChengdu 610065China

The deviation in wall thickness caused by core shift during the investment casting process significantly impacts the strength and service life of hollow turbine *** address this issue,a core shift limitation method is developed in this ***,a shift model is established based on computational fluid dynamics and motion simulation to predict the movement of the ceramic core in investment casting ***,utilizing this model,an optimization method for fixturing layout inside the refractory ceramic shell is devised for the ceramic *** casting experiment demonstrates that by utilizing the optimized fixture layout,not only can core shift during the investment casting pouring process be effectively controlled,but also the maximum wall thickness error of the blade can be reduced by 42.02%.In addition,the core shift prediction is also validated,with a prediction error of less than 26.9%.

关键词： Hollow turbine blade Wall thickness Ceramic core Shift prediction Fixturing layout optimization

Nonlinear uncertainty impact of geometric variations on aerodynamic performance of low-pressure turbine blades with ultra-high loading under extreme operational conditions

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Chinese Journal of aeronautics 2024年第5期37卷 281-300页

作者： Xiaojing WANG Zhengping ZOU Chao FU Pengcheng DU School of Energy and Power engineering Beihang UniversityBeijing 100191China National key laboratory of Science and Technology on aero-engine aero-Thermodynamics Beihang UniversityBeijing 100191China Research Institute of aero-engine Beihang UniversityBeijing 100191China

Uncertainty impact of random geometric variations on the aerodynamic performance of low-pressure turbine blades is considerable,which is further amplified by the current ultra-high-lift design trend for weight ***,this uncertainty impact on ultra-highly loaded blades under extreme operational conditions near the margins with potential large-scale open separation is focused on in this *** is demonstrated that this impact is significant,unfavourable,and nonlinear,which is clearly severer under extreme *** addition to the overall attenuation and notable scattering of specific performance,the operational margins with open separation are also notably scattered with great risk of significant *** scattering and nonlinearity are dominated by the variations in leading-edge *** thinning of leading edge triggers local transition,enhancing downstream friction and reducing resistance to open separation,which is further exacerbated by operational ***,the opposite thickening yields less benefit,implying *** unfavourable impact highlights the need for robust aerodynamic design,where both a safer operational condition and a more robust blade are indispensable,i.e.,a compromise among performance,weight,and *** the necessary limitation of loading levels,a mid-loaded design is recommended to reduce adverse pressure gradients in both the leading edge and rear region of the suction side,which helps to decrease the susceptibility of the transition and open separation to random *** improvements can also be achieved by appropriately thickening the leading edge.

关键词： Ultra-highly loaded turbine blade Geometric variations Uncertainty analysis Operational margins Robust aerodynamic design Nonlinearity

Experimental and computational investigation on flow characteristics of rotating cavities with high inlet pre-swirl axial throughflow

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Chinese Journal of aeronautics 2024年第4期37卷 276-293页

作者： Sipeng WANG Xiang LUO Linji GUO Zeyu WU Yang BAI Zongchao LI Lichun MA School of Energy and Power engineering Beihang UniversityBeijing 100191China Research Institude of aero-Enigine Beihang UniversityBeijing 100191China National key laboratory of Science and Technology on aero-engine aero-Thermodynamics Beihang UniversityBeijing 100191China Shenyang aeroengine Research Institute Aero Engine Corporation of ChinaShenyang 110015China

As an integral part of the internal air system of aero-engines,the axial throughflow of the cooling air can interact with the cavity flow between the rotating compressor disks,forming a threedimensional,unsteady,and unstable flow *** flow characteristics in an engine-like rotating multi-stage cavity with throughflow were investigated using particle image velocimetry,flow visualization technology and three-dimensional unsteady Reynolds-Averaged Navier-Stokes (RANS)*** focus of current research was to understand the distribution of the mean swirl ratio and its variation with a wide range of non-dimensional parameters in the co-rotating cavity with high inlet pre-swirl axial *** maximum axial Reynolds number and rotational Reynolds numbers could reach 4.41×10^(4)and 1.24×10^(6),*** velocity measurement results indicate that the mean swirl ratio is greater than 1 and decreases with an increase in the radial *** flow structure is dominated by the Rossby number,and two different flow patterns (flow penetration and flow stratification) are identified and confirmed by flow visualization *** the absence of buoyancy,the flow penetration caused by the precession of the throughflow makes it easier for the throughflow to reach a high radius *** consistency of results between measurements and numerical calculations is *** study provides a theoretical basis and data support for toroidal vortex breakdown,which is of practical significance for the design of high-pressure compressor cavities.

关键词： Compressor Axial throughflow Rotating cavity flow Particle image velocimetry Unsteady RANS Flow pattern

Ammonia storage and slip under steady and transient state in close-coupled SCR

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Journal of Environmental Sciences 2024年第4期138卷 470-481页

作者： Shiyu Liu Zhaohuan Zhang Zexian Guo Boyuan Wang Buyu Wang Xiao Ma Shijin Shuai State key laboratory of Automotive Safety and Energy Tsinghua UniversityBeijing 100084China Institute for aero engine Tsinghua UniversityBeijing 100084China

The close-coupled selective catalytic reduction(cc-SCR)catalyst is an effective technology to reduce tailpipe NOx emission during cold *** paper investigated the optimal ammonia storage under steady and transient state in the *** study showed that a trade-off between NOx conversion efficiency and ammonia slip is observed on the pareto solutions under steady state,and the optimal ammonia storage is calculated with ammonia slip less than 10μL/L based on the ChinaⅥemission *** rapid temperature increase will lead to severe ammonia slip in the transient test cycle.A simplified 0-D calculation method on ammonia slip under transient state is proposed based on kinetic model of ammonia adsorption and *** addition,the effect of ammonia storage,catalyst temperature and temperature increasing rate on ammonia slip are *** optimal ammonia storage is calculated with maximum ammonia slip less than 100μL/L according to the oxidation efficiency of ammonia slip catalyst(ASC)downstream *** was found that the optimal ammonia storage under transient state is much lower than that under steady state in cc-SCR at lower temperature,and a phase diagram is established to analyze the influence of temperature and temperature increasing rate on optimal ammonia storage.

关键词： Close-coupled SCR Ammonia storage and slip Steady and transient state Generic algorithm

Efflcient machining of a complex blisk channel using a disc cutter

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Chinese Journal of aeronautics 2024年第1期37卷 414-437页

作者： Xiangyu LI Zhaoyu LI Dong HE Junxue REN Qian FENG Kai TANG Department of Mechanical and aerospace engineering Hong Kong University of Science and TechnologyHong Kong 999077China key laboratory of high performance manufacturing for aero engine(Northwestern Polytechnical University) Ministry of Industry and Information TechnologyXi’an 710072China Xi’an Sanhang Power Technology Co. LtdXi’an 710000China HKUST Shenzhen-Hong Kong Collaborative Innovation Research Institute FutianShenzhen 518057China HKUST Shenzhen Research Institute Shenzhen 518057China

For rough machining of a complex narrow cavity,e.g.,a complex blisk channel on an aero-engine,the typically used cutting tools are the slender cylindrical cutter and conical ***,as neither of the two is particularly suited for rough machining,wherein the main purpose is to remove a large volume as quickly as possible,the machining efficiency is low,especially when the part materials are of hard-to-cut types(e.g.,Titanium-alloy)for which it often takes days to rough machine a ***,disc machining provides a new and efficient roughing solution,since a disc cutter with a large radius enables a much larger cutting speed and thus a larger material removal ***,due to the large radius of the disc cutter,its potential collision with narrow and twisted channels becomes a serious *** this paper,we propose a novel twophase approach for efficiently machining a complex narrow cavity workpiece using a disc-shaped cutter,i.e.,3+2-axis disc-slotting of the channel by multiple layers(rough machining)+five-axis disc-milling of the freeform channel side surfaces(semi-finish machining).Both simulation and physical cutting experiments are conducted to assess the effectiveness and advantages of the proposed *** experimental results show that,with respect to a same cusp-height threshold on the channel side surfaces,the total machining time of the tested part by the proposed method is about only 36%of that by the conventional approach of plunging-milling(for roughing)plus milling by a slender cylindrical cutter(for semi-finishing).

关键词： Blisk channel CNC machining Disc cutter Roughing efficiency Tool path planning

Improving fatigue properties of normal direction ultrasonic vibration assisted face grinding Inconel 718 by regulating machined surface integrity

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International Journal of Extreme manufacturing 2024年第3期6卷 458-475页

作者： Nianwei Xu Renke Kang Bi Zhang Yuan Zhang Chenxu Wang Yan Bao Zhigang Dong State key laboratory of high-performance Precision manufacturing Dalian University of TechnologyDalian 116024People’s Republic of China Department of Mechanical and Energy engineering Southern University of Science and TechnologyShenzhen 518055People’s Republic of China

Fatigue properties are crucial for critical aero-engine components in extreme serviceenvironments,which are significantly affected by surface integrity(SI)indexes(especially surface topography,residual stressσ_(res),and microhardness)after machining ***-direction ultrasonic vibration-assisted face grinding(ND-UVAFG)has advantages in improving the machinability of Inconel 718,but there is a competitive relationship between higher compressiveσ_(res)and higher surface roughness R_(a)in affecting fatigue *** lack of a quantitative relationship between multiple SI indexes and fatigue strength makes theindeterminacy of a regulatory strategy for improving fatigue *** this work,a model of fatigue strength(σ_f)_(sur)considering multiple SI indexes was ***,high-cycle fatigue tests were carried out on Inconel 718 samples with different SI characteristics,and the influence of ND-UVAFG process parameters on SI was *** on SI indexes data,the(σ_f)_(sur)distribution in the grinding surface layer for ND-UVAFG Inconel 718 samples was determined using the developed model,and then the fatigue crack initiation(FCI)sites were *** predicted FCI sites corresponded well with the experimental results,therebyverifying this model.A strategy for improving the fatigue life was proposed in this work,which was to transfer the fatigue source from the machined surface to the bulk material by controlling the SI ***,a critical condition of SI indexes that FCI sites appeared on the surface or in bulk material was given by fitting the predicted *** to the critical condition,an SI field where FCI sites appeared in the bulk material could be *** this field,thefatigue life of Inconel 718 samples could be improved by approximately 140%.

关键词： surface integrity fatigue strength Inconel 718 ultrasonic assisted grinding