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Enhanced high-temperature mechanical properties of laser-arc hybrid additive manufacturing of Al-Zn-Mg-Cu alloy via microstructure control

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Journal of Materials Science & Technology 2024年第2期169卷 220-234页

作者： Dehua Liu Dongjiang Wu Yunsong Wang Zhuo Chen Changrong Ge Qingyu Zhao Fangyong Niu Guangyi Ma State Key laboratory of high-performance Precision manufacturing Dalian University of TechnologyDalian 116024China

Recently,rapid and cost-effective additive manufacturing solutions for lightweight aluminum alloys with excellent high-temperature mechanical properties have been increasingly in *** this study,we combined laser-arc hybrid additive manufacturing with solution and artificial aging treatments to achieve Al-Zn-Mg-Cu alloy with favorable high-temperature strength via microstructure *** pores became the major defect in the as-deposited and heat-treated *** continuous distribution of eutectics with hard-brittle characteristics at the grain boundaries was destructed following heat ***-densityηprecipitates were uniformly dispersed in the heat-treated Al-Zn-Mg-Cu alloy,whereas appeared coarsened and dissolved at 473 K,owing to the rapid diffusion of Zn and *** average 0.2%yield strength(318±16 MPa)and ultimate tensile strength(362±20 MPa)at 473 K af-ter heat treatment were enhanced by approximately 58%and 51%,respectively,compared to those of the as-deposited *** addition,theηprecipitates contributed to lattice distortions and strain fields,which prevented dislocation motion and increased slip deformation resistance at high *** as-deposited specimen exhibited intergranular fracture at 473 K,with cracks preferring to propagate along the aggregated ***,crack propagation proceeded in the sections with more pores in the heat-treated *** approach may provide a valid option for achieving alu-minum alloys with excellent high-temperature mechanical properties.

关键词： Laser-arc hybrid additive manufacturing Al-Zn-Mg-Cu alloy high-temperature strength Heat treatment,Microstructure evolution

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Optimizing circumferential assembly angle of rotor parts connected by curvic couplings based on acquired tooth surface error data

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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

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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

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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

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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

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Precise measurement of geometric and physical quantities in cutting tools inspection and condition monitoring: A review

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Chinese Journal of aeronautics 2024年第4期37卷 23-53页

作者： Wenqi WANG Wei LIU Yang ZHANG Yang LIU Peidong ZHANG Zhenyuan JIA State Key laboratory of high-performance Precision manufacturing Dalian University of TechnologyDalian 116024China

As one of the most important terminals in machining, cutting tools have been widely used for components manufacturing in aerospace and other industries. The quality of these components and processing efficiency are closely linked to the performance of cutting tools. Therefore, it is essential and critical to inspect the cutting tools and monitor the condition during the stage of manufacturing and machining. This review aims to discuss and summarize the key problems, methods,and techniques from the perspective of the tool geometric and the physical quantities measurement,including machine vision, physical sensors and data processing. It is worth mentioning that we focus on the topic of precision measurement methods and discuss universal solutions by identifying the common characteristics of the measured quantities. Eventually, the challenges and future trends for the development of in-depth research and practical applications are concluded. The research and application of precise measurement techniques for geometric and physical quantities will better promote the development of intelligent manufacturing.

关键词： Cutting tools Mechanical measurement Machine vision Physical sensors Tool condition monitoring

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Atomistic understanding of rough surface on the interfacial friction behavior during the chemical mechanical polishing process of diamond

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Friction 2024年第6期12卷 1119-1132页

作者： Song YUAN Xiaoguang GUO Hao WANG Renke KANG Shang GAO State Key laboratory of high-performance Precision manufacturing Dalian University of TechnologyDalian 116024China

The roughness of the contact surface exerts a vital role in *** is still a significant challenge to understand the microscopic contact of the rough surface at the atomic ***,the rough surface with a special root mean square(RMS)value is constructed by multivariate Weierstrass–Mandelbrot(W–M)function and the rubbing process during that the chemical mechanical polishing(CMP)process of diamond is mimicked utilizing the reactive force field molecular dynamics(ReaxFF MD)*** is found that the contact area A/A0 is positively related with the load,and the friction force F depends on the number of interfacial bridge *** the surface roughness will increase the friction force and friction *** model with low roughness and high lubrication has less friction force,and the presence of polishing liquid molecules can decrease the friction force and friction *** RMS value and the degree of damage show a functional relationship with the applied load and lubrication,i.e.,the RMS value decreases more under larger load and higher lubrication,and the diamond substrate occurs severer damage under larger load and lower *** work will generate fresh insight into the understanding of the microscopic contact of the rough surface at the atomic level.

关键词： diamond random roughness reactive force field molecular dynamics(ReaxFF MD) friction Weierstrass-Mandelbrot(W-M)function chemical mechanical polishing(CMP)

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Flexible head-following motion planning for scalable and bendable continuum robots

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Biomimetic Intelligence & Robotics 2024年第2期4卷 86-96页

作者： Te Li Guoqing Zhang Xinyuan Li Xu Li Haibo Liu Yongqing Wang State Key laboratory of high-performance Precision manufacturing School of Mechanical EngineeringDalian University of TechnologyDalian 116023China

Continuum robots,which are characterized by high length-to-diameter ratios and flexible structures,show great potential for various applications in confined and irregular *** to the combination of motion modes,the existence of multiple solutions,and the presence of complex obstacle constraints,motion planning for these robots is highly *** tackle the challenges of online and flexible operation for continuum robots,we propose a flexible head-following motion planning method that is suitable for scalable and bendable continuum ***,we establish a piecewise constant curvature(PCC)kinematic model for scalable and bendable continuum *** article proposes an adaptive auxiliary points model and a method for updating key nodes in head-following motion to enhance the precise tracking capability for paths with different ***,the article integrates the strategy for adjusting the posture of local joints of the robot into the head-following motion planning method,which is beneficial for achieving safe obstacle avoidance in local *** article concludes by presenting the results of multiple sets of motion simulation experiments and prototype *** study demonstrates that the algorithm presented in this paper effectively navigates and adjusts posture to avoid obstacles,meeting the real-time demands of online *** average time for a single-step solution is 4.41×10^(-5) s,and the average tracking accuracy forcircular paths is 7.8928mm.

关键词： Continuum robot Motion planning Scalable and bendable Head-following

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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

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A promising application of bulk metallic glasses in torque sensor

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Science China Technological Sciences 2024年第8期67卷 2505-2514页

作者： LU WenHao MA Jiang WANG Chao LIU YanHui Institute of Physics Chinese Academy of Sciences Shenzhen Key laboratory of high performance Nontraditional manufacturing College of Mechatronics and Control Engineering Shenzhen University

Torque sensors are essential components of robotic joints. In the past, structure optimization of force-sensing elements has been the common approach to improve the performance of the torque sensors. In this work, we demonstrate a torque sensor with bulk metallic glasses as a force-sensing element. Compared with the sensors made of stainless steel and aluminum alloy, the use of bulk metallic glass as a force-sensing element significantly improves sensor sensitivity, linearity, repeatability, hysteresis, and measuring range. Our work not only opens up a new avenue for the application of bulk metallic glasses, but also provides opportunities for enhancing the performance of force/torque sensors through materials optimization.

关键词： bulk metallic glasses amorphous alloys force sensors

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