科创中国

Most researches on the static performance of stiffened panel joined by friction stir welding(FSW) mainly focus on the compression stability rather than shear stability. To evaluate the potential of FSW as a replacement for traditional rivet fastening for stiffened panel assembly in aviation application, finite element method(FEM) is applied to compare compression and shear stability performances of FSW stiffened panels with stability performances of riveted stiffened panels. FEMs of 2024-T3 aluminum alloy FSW and riveted stiffened panels are developed and nonlinear static analysis method is applied to obtain buckling pattern, buckling load and load carrying capability of each panel model. The accuracy of each FEM of FSW stiffened panel is evaluated by stability experiment of FSW stiffened panel specimens with identical geometry and boundary condition and the accuracy of each FEM of riveted stiffened panel is evaluated by semi-empirical calculation formulas. It is found that FEMs without considering weld-induced initial imperfections notably overestimate the static strengths of FSW stiffened panels. FEM results show that, buckling patterns of both FSW and riveted compression stiffened panels represent local buckling of plate between stiffeners. The initial buckling waves of FSW stiffened panel emerge uniformly in each plate between stiffeners while those of riveted panel mainly emerge in the mid-plate. Buckling patterns of both FSW and riveted shear stiffened panels represent local buckling of plate close to the loading corner. FEM results indicate that, shear buckling of FSW stiffened panel is less sensitive to the initial imperfections than compression buckling. Load carrying capability of FSW stiffened panel is less sensitive to the initial imperfections than initial buckling. It can be concluded that buckling loads of FSW panels are a bit lower than those of riveted panels whereas carrying capabilities of FSW panels are almost equivalent to those of riveted panels with identical geometries. Finite element method for simulating static performances of FSW and riveted stiffened panels is proposed and evaluated and some beneficial conclusions are obtained, which offer useful references for analysis and application of FSW to replace rivet fastening in aviation stiffened panel assembly.

The major methods to investigate the airbags cushion system are experimental method,thermodynamic method and finite element method(FEM).Airbags cushion systems are very complicated and very difficult to be investigated thoroughly by such methods.For experimental method,it is nearly impossible to completely analyze and optimize the cushion characteristics of airbags of airborne vehicle because of charge issue,safety concern and time constraint.Thermodynamic method fails to take the non-linear effects of large airbag deformation and varied contact conditions into consideration.For finite element method,the FE model is usually complicated and the calculation takes tens of hours of CPU time.As a result,the optimization of the design based on a nonlinear model is very difficult by traditional iterative approach method.In this paper,a model based on FEM and control volume method is proposed to simulate landing cushion process of airborne vehicle with airbags cushion system in order to analyze and optimize the parameters in airbags cushion system.At first,the performance of airbags cushion system model is verified experimentally.In airdrop test,accelerometers are fixed in 4 test points distributed over engine mount,top,bottom and side armor plate of hull to obtain acceleration curves with time.The simulation results are obtained under the same conditions of the airdrop test and the simulation results agree very well with the experimental results,which indicate the established model is valid for further optimization.To optimize the parameters of airbags,equivalent response model based on Latin Hypercube DOE and radial basis function is employed instead of the complex finite element model.Then the optimal results based on equivalent response model are obtained using simulated annealing algorithm.After optimization,the maximal acceleration of airborne vehicle landing reduces 19.83%,while the energy absorption by airbags increases7.85%.The performance of the airbags cushion system thus is largely improved through optimization,which indicates the proposed method has the capability of solving the parameter optimization problem of airbags cushion system for airborne vehicle.

Thermal damage caused by frictional heat of rolling-sliding contact is one of the most important failure forms of wheel and rail.Many studies of wheel-rail frictional heating have been devoted to the temperature field,but few literatures focus on wheel-rail thermal stress caused by frictional heating.However,the wheel-rail creepage is one of important influencing factors of the thermal stress.In this paper,a thermo-mechanical coupling model of wheel-rail rolling-sliding contact is developed using thermo-elasto-plastic finite element method.The effect of the wheel-rail elastic creepage on the distribution of heat flux is investigated using the numerical model in which the temperature-dependent material properties are taken into consideration.The moving wheel-rail contact force and the frictional heating are used to simulate the wheel rolling on the rail.The effect of the creepage on the temperature rise,thermal strain,residual stress and residual strain under wheel-rail sliding-rolling contact are investigated.The investigation results show that the thermally affected zone exists mainly in a very thin layer of material near the rail contact surface during the rolling-sliding contact.Both the temperature and thermal strain of rail increase with increasing creepage.The residual stresses induced by the frictional heat in the surface layer of rail appear to be tensile.When the creepage is large,the frictional heat has a significant influence on the residual stresses and residual strains of rail.This paper develops a thermo-mechanical coupling model of wheel-rail rolling-sliding contact,and the obtained results can help to understand the mechanism of wheel/rail frictional thermal fatigue.

Forming limit curves(FLCs) are commonly used for evaluating the formability of sheet metals. However, it is difficult to obtain the FLCs with desirable accuracy by experiments due to that the friction effects are non-negligible under warm/hot stamping conditions. To investigate the experimental errors, experiments for obtaining the FLCs of the AA5754 are conducted at 250℃. Then, FE models are created and validated on the basis of experimental results. A number of FE simulations are carried out for FLC test-pieces and punches with different geometry configurations and varying friction coefficients between the test-piece and the punch. The errors for all the test conditions are predicted and analyzed. Particular attention of error analysis is paid to two special cases, namely, the biaxial FLC test and the uniaxial FLC test. The failure location and the variation of the error with respect to the friction coefficient are studied as well. The results obtained from the FLC tests and the above analyses show that, for the biaxial tension state, the friction coefficient should be controlled within 0.15 to avoid significant shifting of the necking location away from the center of the punch; for the uniaxial tension state, the friction coefficient should be controlled within 0.1 to guarantee the validity of the data collected from FLC tests. The conclusions summarized are beneficial for obtaining accurate FLCs under warm/hot stamping conditions.

Linear motors generate high heat and cause significant deformation in high speed direct feed drive mechanisms.It is relevant to estimate their deformation behavior to improve their application in precision machine tools.This paper describes a method to estimate its thermal deformation based on updated finite element(FE)model methods.Firstly,a FE model is established for a linear motor drive test rig that includes the correlation between temperature rise and its resulting deformation.The relationship between the input and output variables of the FE model is identified with a modified multivariate input/output least square support vector regression machine.Additionally,the temperature rise and displacements at some critical points on the mechanism are obtained experimentally by a system of thermocouples and an interferometer.The FE model is updated through intelligent comparison between the experimentally measured values and the results from the regression machine.The experiments for testing thermal behavior along with the updated FE model simulations is conducted on the test rig in reciprocating cycle drive conditions.The results show that the intelligently updated FE model can be implemented to analyze the temperature variation distribution of the mechanism and to estimate its thermal behavior.The accuracy of the thermal behavior estimation with the optimally updated method can be more than double that of the initial theoretical FE model.This paper provides a simulation method that is effective to estimate the thermal behavior of the direct feed drive mechanism with high accuracy.

In piezoceramic ultrasonic devices,the piezoceramic stacks may fail permanently or function improperly if their working temperatures overstep the Curie temperature of the piezoceramic material.While the end of the horn usually serves near the melting point of the molten metal and is enclosed in an airtight chamber,so that it is difficult to experimentally measure the temperature of the transducer and its variation with time,which bring heavy difficulty to the design of the ultrasonic molten metal treatment system.To find a way out,conjugate heat transfer analysis of an ultrasonic molten metal treatment system is performed with coupled fluid and heat transfer finite element method.In modeling of the system,the RNG model and the SIMPLE algorithm are adopted for turbulence and nonlinear coupling between the momentum equation and the energy equation.Forced air cooling as well as natural air cooling is analyzed to compare the difference of temperature evolution.Numerical results show that,after about 350 s of working time,temperatures in the surface of the ceramic stacks in forced air cooling drop about 7 K compared with that in natural cooling.At 240 s,The molten metal surface emits heat radiation with a maximum rate of about 19 036 W/m2,while the heat insulation disc absorbs heat radiation at a maximum rate of about 7922 W/m2,which indicates the effectiveness of heat insulation of the asbestos pad.Transient heat transfer film coefficient and its distribution,which are difficult to be measured experimentally are also obtained through numerical simulation.At 240 s,the heat transfer film coefficient in the surface of the transducer ranges from–17.86 to 20.17 W/(m2?K).Compared with the trial and error method based on the test,the proposed research provides a more effective way in the design and analysis of the temperature control of the molten metal treatment system.

Fiber reinforced polymer (FRP) composite materials having advantages such as higher strength to weight than conventional engineering materials, non-corrosiveness and modularization, which should help engineers to obtain more efficient and cost effective structural materials and systems. Currently, FRP composites are becoming more popular in civil engineering applications. The objectives of this research are to study performance and behavior of light weight multi-cellular FRP composite bridge decks (both module and system levels) under various loading conditions through finite element modeling, and to validate analytical response of FRP composite bridge decks with data from laboratory evaluations. The relative deflection, equivalent flexural rigidity, failure load (mode) and load distribution factors (LDF) based on FE results have been compared with experimental data and discussed in detail. The finite element results showing good correlations with experimental data are presented in this work.

The current development of precision plastic injection molding machines mainly focuses on how to save material and improve precision, but the two aims contradict each other. For a clamp unit, clamping precision improving depends on the design quality of the stationary platen. Compared with the parametric design of stationary platen, structural scheme design could obtain the optimization model with double objectives and multi-constraints. In this paper, a SE-160 precision plastic injection molding machine with 1600 kN clamping force is selected as the subject in the case study. During the motion of mold closing and opening, the stationary platen of SE-160 is subjected to a cyclic loading, which would cause the fatigue rupture of the tie bars in periodically long term operations. In order to reduce the deflection of the stationary platen, the FEA method is introduced to optimize the structure of the stationary platen. Firstly, an optimal topology model is established by variable density method. Then, structural topology optimizations of the stationary platen are done with the removable material from 50%, 60% to 70%. Secondly, the other two recommended optimization schemes are given and compared with the original structure. The result of performances comparison shows that the scheme II of the platen is the best one. By choosing the best alternative, the volume and the local maximal stress of the platen could be decreased, corresponding to cost-saving material and better mechanical properties. This paper proposes a structural optimization design scheme, which can save the material as well as improve the clamping precision of the precision plastic injection molding machine.

Iterative methods based on finite element simulation are effective approaches to design mold shape to compensate springback in sheet metal forming.However,convergence rate of iterative methods is difficult to improve greatly.To increase the springback compensate speed of designing age forming mold,process of calculating springback for a certain mold with finite element method is analyzed.Springback compensation is abstracted as finding a solution for a set of nonlinear functions and a springback compensation algorithm is presented on the basis of quasi Newton method.The accuracy of algorithm is verified by developing an ABAQUS secondary development program with MATLAB.Three rectangular integrated panels of dimensions 710 mm′750 mm integrated panels with intersected ribs of 10 mm are selected to perform case studies.The algorithm is used to compute mold contours for the panels with cylinder,sphere and saddle contours respectively and it takes 57%,22%and 33%iterations as compared to that of displacement adjustment(DA)method.At the end of iterations,maximum deviations on the three panels are 0.618 4 mm,0.624 1 mm and 0.342 0 mm that are smaller than the deviations determined by DA method(0.740 8 mm,0.740 8 mm and 0.713 7 mm respectively).In following experimental verification,mold contour for another integrated panel with 400 mm*380 mm size is designed by the algorithm.Then the panel is age formed in an autoclave and measured by a three dimensional digital measurement devise.Deviation between measuring results and the panel's design contour is less than 1 mm.Finally,the iterations with different mesh sizes(40 mm,35mm,30 mm,25 mm,20 mm)in finite element models are compared and found no considerable difference.Another possible compensation method,Broyden-Fletcher-Shanmo method,is also presented based on the solving nonlinear functions idea.The Broyden-Fletcher-Shanmo method is employed to compute mold contour for the second panel.It only takes 50%iterations compared to that of DA.The proposed method can serve a faster mold contour compensation method for sheet metal forming.

多年调节水库调节性能较高,其兴利库容对整个工程规模的确定至关重要.以贵州省麻江县上寨水库多年调节水库为例,通过对水库的径流系列进行分析,采用时历法和数理统计法对水库的兴利库容进行计算,对该水库的兴利库容计算结果进行了评价,并对多年调节水库兴利调节中采用的基础资料及计算方法进行了简要分析.