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Mechanical behavior and semiempirical force model of aerospace aluminum alloy milling using nano biological

《机械工程前沿（英文）》 2023年 第18卷 第1期 doi: 10.1007/s11465-022-0720-4

摘要： Aerospace aluminum alloy is the most used structural material for rockets, aircraft, spacecraft, and space stations. The deterioration of surface integrity of dry machining and the insufficient heat transfer capacity of minimal quantity lubrication have become the bottleneck of lubrication and heat dissipation of aerospace aluminum alloy. However, the excellent thermal conductivity and tribological properties of nanofluids are expected to fill this gap. The traditional milling force models are mainly based on empirical models and finite element simulations, which are insufficient to guide industrial manufacturing. In this study, the milling force of the integral end milling cutter is deduced by force analysis of the milling cutter element and numerical simulation. The instantaneous milling force model of the integral end milling cutter is established under the condition of dry and nanofluid minimal quantity lubrication (NMQL) based on the dual mechanism of the shear effect on the rake face of the milling cutter and the plow cutting effect on the flank surface. A single factor experiment is designed to introduce NMQL and the milling feed factor into the instantaneous milling force coefficient. The average absolute errors in the prediction of milling forces for the NMQL are 13.3%, 2.3%, and 7.6% in the x-, y-, and z-direction, respectively. Compared with the milling forces obtained by dry milling, those by NMQL decrease by 21.4%, 17.7%, and 18.5% in the x-, y-, and z-direction, respectively.

关键词： milling     force     nanofluid minimum quantity lubrication     aerospace aluminum alloy     nano biological lubricant    

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Comparative assessment of force, temperature, and wheel wear in sustainable grinding aerospace alloy

《机械工程前沿（英文）》 2023年 第18卷 第1期 doi: 10.1007/s11465-022-0719-x

摘要： The substitution of biolubricant for mineral cutting fluids in aerospace material grinding is an inevitable development direction, under the requirements of the worldwide carbon emission strategy. However, serious tool wear and workpiece damage in difficult-to-machine material grinding challenges the availability of using biolubricants via minimum quantity lubrication. The primary cause for this condition is the unknown and complex influencing mechanisms of the biolubricant physicochemical properties on grindability. In this review, a comparative assessment of grindability is performed using titanium alloy, nickel-based alloy, and high-strength steel. Firstly, this work considers the physicochemical properties as the main factors, and the antifriction and heat dissipation behaviours of biolubricant in a high temperature and pressure interface are comprehensively analysed. Secondly, the comparative assessment of force, temperature, wheel wear and workpiece surface for titanium alloy, nickel-based alloy, and high-strength steel confirms that biolubricant is a potential replacement of traditional cutting fluids because of its improved lubrication and cooling performance. High-viscosity biolubricant and nano-enhancers with high thermal conductivity are recommended for titanium alloy to solve the burn puzzle of the workpiece. Biolubricant with high viscosity and high fatty acid saturation characteristics should be used to overcome the bottleneck of wheel wear and nickel-based alloy surface burn. The nano-enhancers with high hardness and spherical characteristics are better choices. Furthermore, a different option is available for high-strength steel grinding, which needs low-viscosity biolubricant to address the debris breaking difficulty and wheel clogging. Finally, the current challenges and potential methods are proposed to promote the application of biolubricant.

关键词： grinding     aerospace     difficult-to-machine material     biolubricant     physicochemical property     grindability    

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Numerical analysis of aluminum alloy reticulated shells with gusset joints under fire conditions

《结构与土木工程前沿（英文）》 2023年 第17卷 第3期   页码 448-466 doi: 10.1007/s11709-022-0910-5

摘要： In this study, a numerical analysis was conducted on aluminum alloy reticulated shells (AARSs) with gusset joints under fire conditions. First, a thermal-structural coupled analysis model of AARSs considering joint semi-rigidity was proposed and validated against room-temperature and fire tests. The proposed model can also be adopted to analyze the fire response of other reticulated structures with semi-rigid joints. Second, a parametric analysis was conducted based on the numerical model to explore the buckling behavior of K6 AARS with gusset joints under fire conditions. The results indicated that the span, height-to-span ratio, height of the supporting structure, and fire power influence the reduction factor of the buckling capacity of AARSs under fire conditions. In contrast, the reduction factor is independent of the number of element divisions, number of rings, span-to-thickness ratio, and support condition. Subsequently, practical design formulae for predicting the reduction factor of the buckling capacity of K6 AARSs were derived based on numerical analysis results and machine learning techniques to provide a rapid evaluation method. Finally, further numerical analyses were conducted to propose practical design suggestions, including the conditions of ignoring the ultimate bearing capacity analysis of K6 AARS and ignoring the radiative heat flux.

关键词： aluminum alloy reticulated shell     gusset joint     numerical analysis     fire resistance    

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铝合金材料发展现状、趋势及展望

管仁国,娄花芬,黄晖,梁霄鹏,肖翔,李慧中,李芳,王建军,运新兵,曾黎滨

《中国工程科学》 2020年 第22卷 第5期   页码 68-75 doi: 10.15302/J-SSCAE-2020.05.013

摘要：

本文综合分析了铝合金材料在航空航天、交通运输等领域的应用现状，论述了我国铝合金材料的产业规模和技术水平。针对我国在一些关键铝合金材料方面存在的短板，以及在高性能铝合金开发、加工工艺与智能控制等原创技术方面的不足，系统梳理了目前我国在铝合金材料方面存在的主要问题。针对汽车、船舶、空天等领域的发展态势，分析了铝合金材料的市场需求。针对我国铝合金材料的产业现状，提出以下发展对策和建议：加强研发体系建设，完善发展环境；优化结构，促进提质增效和协同发展；加强配套政策支持；推进人才队伍建设；推广智能制造和“互联网+”；加强国际合作，尤其是“一带一路”国际合作。解决铝合金材料卡脖子问题，并为铝合金材料向高端化、绿色化方向发展提供重要参考。

关键词： 铝合金材料，汽车工业，船舶工业，空天领域    

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Experiment on aluminum alloy members under axial compression

Xiaonong GUO,Shuiping LIANG,Zuyan SHEN

《结构与土木工程前沿（英文）》 2015年 第9卷 第1期   页码 48-64 doi: 10.1007/s11709-014-0271-9

摘要： To improve the design methods of Chinese aluminum alloy members, experiment of 63 profiled aluminum alloy members, made of Chinese aluminum alloy 6061-T6, under axial compression is conducted in this paper. Valuable experimental data are obtained. At the same time, in order to obtain the relevant data, a large number of other experimental data from published papers and technical reports are collected and sorted out. 167 valid experimental data points are obtained finally. Furthermore, for the purpose of creating column curves, the aluminum alloy members under the axial compression, used in experiments, are analyzed by means of FEM. Based on the numerical results, 2 column curves are created by means of the numerical fitting method. The column curves are compared with the calculated data according to the experimental results for verification, and also are verified with the curves in design codes of several relevant countries. The numerical results show that the column curves obtained in this paper are valid and reliable.

关键词： aluminum alloy     column curve     compression members     overall stability coefficient    

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Parameter prediction in laser bending of aluminum alloy sheet

WANG Xuyue, XU Weixing, CHEN Hua, WANG Jinsong

《机械工程前沿（英文）》 2008年 第3卷 第3期   页码 293-298 doi: 10.1007/s11465-008-0046-x

摘要： Based on the basic platform of BP neural networks, a BP network model is established to predict the bending angle in the laser bending process of an aluminum alloy sheet (1–2 mm in thickness) and to optimize laser bending parameters for bending control. The sample experimental data is used to train the BP network. The nonlinear regularities of sample data are fitted through the trained BP network; the predicted results include laser bending angles and parameters. Experimental results indicate that the prediction allowance is controlled less than 5%–8% and can provide a theoretical and experimental basis for industry purpose.

关键词： control     industry purpose     nonlinear     network     aluminum    

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Flexural-torsional buckling behavior of aluminum alloy beams

Xiaonong GUO,Zhe XIONG,Zuyan SHEN

《结构与土木工程前沿（英文）》 2015年 第9卷 第2期   页码 163-175 doi: 10.1007/s11709-014-0272-8

摘要： This paper presents an investigation on the flexural-torsional buckling behavior of aluminum alloy beams (AAB). First, based on the tests of 14 aluminum alloy beams under concentrated loads, the failure pattern, load-deformation curves, bearing capacity and flexural-torsional buckling factor are studied. It is found that all the beam specimens collapsed in the flexural-torsional buckling with excessive deformation pattern. Moreover, the span, loading location and slenderness ratio influence the flexural-torsional buckling capacity of beams significantly. Secondly, besides the experiments, a finite element method (FEM) analysis on the flexural-torsional buckling behavior of AAB is also conducted. The main parameters in the FEM analysis are initial imperfection, material property, cross-section and loading scheme. According to the analytical results, it is indicated that the FEM is reasonable to capture mechanical behavior of AAB. Finally, on the basis of the experimental and analytical results, theoretical formulae to estimate the flexural-torsional buckling capacity of AAB are proposed, which could improve the application of present codes for AAB.

关键词： flexural-torsional buckling     aluminum alloy beams (AAB)     finite element method (FEM)     theoretical formula    

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Towards Cr(VI)-free anodization of aluminum alloys for aerospace adhesive bonding applications: A review

Shoshan T. Abrahami, John M. M. de Kok, Herman Terryn, Johannes M. C. Mol

《化学科学与工程前沿（英文）》 2017年 第11卷 第3期   页码 465-482 doi: 10.1007/s11705-017-1641-3

摘要： For more than six decades, chromic acid anodizing (CAA) has been the central process in the surface pre-treatment of aluminum for adhesively bonded aircraft structures. Unfortunately, this electrolyte contains hexavalent chromium (Cr(VI)), a compound known for its toxicity and carcinogenic properties. To comply with the new strict international regulations, the Cr(VI)-era will soon have to come to an end. Anodizing aluminum in acid electrolytes produces a self-ordered porous oxide layer. Although different acids can be used to create this type of structure, the excellent adhesion and corrosion resistance that is currently achieved by the complete Cr(VI)-based process is not easily matched. This paper provides a critical overview and appraisal of proposed alternatives to CAA, including combinations of multiple anodizing steps, pre- and post anodizing treatments. The work is presented in terms of the modifications to the oxide properties, such as morphological features (e.g., pore size, barrier layer thickness) and surface chemistry, in order to evaluate the link between fundamental principles of adhesion and bond performance.

关键词： aluminum     Cr(VI)-free     surface pre-treatments     anodizing     adhesive bonding    

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Finite element modeling of counter-roller spinning for large-sized aluminum alloy cylindrical parts

Dawei ZHANG, Fan LI, Shuaipeng LI, Shengdun ZHAO

《机械工程前沿（英文）》 2019年 第14卷 第3期   页码 351-357 doi: 10.1007/s11465-019-0528-z

摘要： Counter-roller spinning (CRS), where the mandrel is replaced by rollers, is an effective means of manufacturing large-sized, thin-walled, cylindrical parts with more than 2500 mm diameter. CRS is very complex because of multi-axis rotation, multi-local loading along the circumference, and radial-axial compound deformation. Analytical or experimental methods cannot fully understand CRS. Meanwhile, numerical simulation is an adequate approach to investigate CRS with comprehensive understanding and a low cost. Thus, a finite element (FE) model of CRS was developed with the FORGE code via meshing technology, material modeling, determining the friction condition, and so on. The local fine mesh moving with the roller is one of highlights of the model. The developed 3D-FE model was validated through a CRS experiment by using a tubular blank with a 720 mm outer diameter. The developed 3D-FE model of CRS can provide a basis for parameter optimization, process control, die design, and so on. The data on force and energy predicted by the 3D-FE model can offer reasonable suggestions for determining the main mechanical parameters of CRS machines and selecting the motors. With the predicted data, an all-electric servo-drive system/machine with distributed power was designed in this work for CRS with four pairs of rollers to manufacture a large-sized, thin-walled, cylindrical part with 6000 mm diameter.

关键词： large-sized cylindrical part     counter-roller spinning     aluminum alloy     finite element method     distributed power    

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Study on shear resistance of aluminum alloy I-section members

DONG Zhen, ZHANG Qilin

《结构与土木工程前沿（英文）》 2008年 第2卷 第1期   页码 79-86 doi: 10.1007/s11709-008-0007-9

摘要： The design method for the shear resistance of aluminum alloy I-section members is presented, taking into consideration of the post-buckling strength of webs and the restraint effect of flanges, and the practical design formulas are proposed. The deflection of aluminum alloy I-section members under concentrated load is simulated by using the finite element method, and several design theories are discussed. The relation of shear resistance to the maximum web displacement reflects that the web of aluminum alloy I-section member is under fewer shears buckling force, while the whole member has higher shear resistance. However, the traditional design method is not able to give the real shear resistance of aluminum alloy I-section members. The proposed design formulas for the shear resistance of aluminum alloy I-section members is used to calculate accurately the post-buckling resistance of webs and the shear resistance contribution of flanges. The results are in a great agreement with the test data of Hamoodi M J, Burt C A, Evans H R and the results from Eurocode9 formulas.

关键词： formulas     displacement     deflection     relation     I-section member    

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Experimental investigation and design of aluminum columns with longitudinal welds

Yun WU, Qilin ZHANG

《结构与土木工程前沿（英文）》 2011年 第5卷 第3期   页码 366-373 doi: 10.1007/s11709-011-0101-2

摘要： This paper presents an experimental investigation of longitudinally welded aluminum alloy I-section columns subjected to pure axial compression. The specimens were fabricated using 6061-T6 heat-treated aluminum alloy. The test program included 20 column tests which were separated into 2 test series of different types of welding sections. Each test series contained 10 columns. All the specimens were welded using the Tungsten Inert Gas welding method. The length of the specimens ranged from 442 to 2433 mm in order to obtain a column curve for each test series. The observed failure mode for the column tests includes mainly flexural buckling around the minor axis and the major axis by applying support except for one column (ZP1217-1) which buckled in the local zone and some columns which failed in the weld. The test strengths were compared with the design strengths predicted by the European Code and China Code for aluminum structures. The purpose of this paper is to present the tests results of two typically longitudinally welded I-section columns, and to check the accuracy of the design rules in the current specifications.

关键词： aluminum alloy     longitudinal weld     heat-affected zone (HAZ)     reduced strength zone (RSZ)     buckling     column     experimental study    

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Effect of electrolyte concentration on the tribological performance of MAO coatings on aluminum alloys

Chao Wang, Jun Chen, Jihua He, Jing Jiang, Qinyong Zhang

《化学科学与工程前沿（英文）》 2020年 第14卷 第6期   页码 1065-1071 doi: 10.1007/s11705-019-1909-x

摘要： Micro-arc oxidation (MAO) is an efficient approach to improve the hardness, wear resistance, and other properties of aluminum alloys. In order to investigate the effect of the electrolyte concentration on the properties of MAO coatings for LY12 alloy, the voltage variation during the MAO process was recorded. The surface morphologies and phase compositions of the coatings produced with different electrolytes were investigated using scanning electron microscopy and X-ray diffraction, respectively. The roughness and thickness of the coatings were measured using a pocket roughness meter and an eddy-current thickness meter, respectively. The tribological performances of the coatings were investigated against GCr15 bearing steel on a ball-on-disc wear tester in open air. The results showed that with an increase in the Na SiO content, the working voltage of the MAO process decreased, the roughness and thickness of the coatings increased significantly, and the relative content of the -Al O phase decreased. With an increase in the KOH content, the working voltage decreased slightly, the roughness and thickness of the coatings increased slightly, and the α- and -Al O phase contents remained unchanged. The friction coefficient and wear rate of the coatings increased with an increase in the Na SiO and KOH concentrations. A decrease in the porosity and roughness and an increase in the α-Al O content of the coatings reduced their wear mass loss.

关键词： aluminum alloy     micro-arc oxidation     coating     electrolyte concentration     tribological performance    

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Precision forging technology for aluminum alloy

Lei DENG, Xinyun WANG, Junsong JIN, Juchen XIA

《机械工程前沿（英文）》 2018年 第13卷 第1期   页码 25-36 doi: 10.1007/s11465-018-0477-y

摘要：

Aluminum alloy is a preferred metal material for lightweight part manufacturing in aerospace, automobile, and weapon industries due to its good physical properties, such as low density, high specific strength, and good corrosion resistance. However, during forging processes, underfilling, folding, broken streamline, crack, coarse grain, and other macro- or microdefects are easily generated because of the deformation characteristics of aluminum alloys, including narrow forgeable temperature region, fast heat dissipation to dies, strong adhesion, high strain rate sensitivity, and large flow resistance. Thus, it is seriously restricted for the forged part to obtain precision shape and enhanced property. In this paper, progresses in precision forging technologies of aluminum alloy parts were reviewed. Several advanced precision forging technologies have been developed, including closed die forging, isothermal die forging, local loading forging, metal flow forging with relief cavity, auxiliary force or vibration loading, casting-forging hybrid forming, and stamping-forging hybrid forming. High-precision aluminum alloy parts can be realized by controlling the forging processes and parameters or combining precision forging technologies with other forming technologies. The development of these technologies is beneficial to promote the application of aluminum alloys in manufacturing of lightweight parts.

关键词： precision forging     aluminum alloy     closed die forging     flow control forging     hybrid-forming technology    

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Characterization of the tensile properties of friction stir welded aluminum alloy joints based on axial

Biranchi PANDA,A. GARG,Zhang JIAN,Akbar HEIDARZADEH,Liang GAO

《机械工程前沿（英文）》 2016年 第11卷 第3期   页码 289-298 doi: 10.1007/s11465-016-0393-y

摘要：

Friction stir welding (FSW) process has gained attention in recent years because of its advantages over the conventional fusion welding process. These advantages include the absence of heat formation in the affected zone and the absence of large distortion, porosity, oxidation, and cracking. Experimental investigations are necessary to understand the physical behavior that causes the high tensile strength of welded joints of different metals and alloys. Existing literature indicates that tensile properties exhibit strong dependence on the rotational speed, traverse speed, and axial force of the tool that was used. Therefore, this study introduces the experimental procedure for measuring tensile properties, namely, ultimate tensile strength (UTS) and tensile elongation of the welded AA 7020 Al alloy. Experimental findings suggest that a welded part with high UTS can be achieved at a lower heat input compared with the high heat input condition. A numerical approach based on genetic programming is employed to produce the functional relationships between tensile properties and the three inputs (rotational speed, traverse speed, and axial force) of the FSW process. The formulated models were validated based on the experimental data, using the statistical metrics. The effect of the three inputs on the tensile properties was investigated using 2D and 3D analyses. A high UTS was achieved, including a rotational speed of 1050 r/min and traverse speed of 95 mm/min. The results also indicate that 8 kN axial force should be set prior to the FSW process.

关键词： tensile properties     ultimate tensile strength     tensile elongation     friction stir welding     tool rotational speed     genetic programming     welding speed    

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Shape optimization of aluminium alloy spherical reticulated shells considering nonlinearities

Wei LIU; Lishu XU; Shaojun ZHU; Lijuan LI; Feng LIU; Zhe XIONG

《结构与土木工程前沿（英文）》 2022年 第16卷 第12期   页码 1565-1580 doi: 10.1007/s11709-022-0867-4

摘要： This study proposes a shape optimization method for K6 aluminum alloy spherical reticulated shells with gusset joints, considering geometric, material, and joint stiffness nonlinearities. The optimization procedure adopts a genetic algorithm in which the elastoplastic non-linear buckling load is selected as the objective function to be maximized. By confinement of the adjustment range of the controlling points, optimization results have enabled a path toward achieving a larger elastoplastic non-linear buckling load without changing the macroscopic shape of the structure. A numerical example is provided to demonstrate the effectiveness of the proposed method. In addition, the variation in structural performance during optimization is illustrated. Through parametric analysis, practical design tables containing the parameters of the optimized shape are obtained for aluminum alloy spherical shells with common geometric parameters. To explore the effect of material nonlinearity, the optimal shapes obtained based on considering and not considering material non-linear objective functions, the elastoplastic and elastic non-linear buckling loads, are compared.

关键词： shape optimization     aluminum alloy     spherical reticulated shell     non-linear buckling     material nonlinearity     genetic algorithm    

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标题 作者 时间 类型 操作

Mechanical behavior and semiempirical force model of aerospace aluminum alloy milling using nano biological

期刊论文

Comparative assessment of force, temperature, and wheel wear in sustainable grinding aerospace alloy

期刊论文

Numerical analysis of aluminum alloy reticulated shells with gusset joints under fire conditions

期刊论文

铝合金材料发展现状、趋势及展望

管仁国,娄花芬,黄晖,梁霄鹏,肖翔,李慧中,李芳,王建军,运新兵,曾黎滨

期刊论文

Experiment on aluminum alloy members under axial compression

Xiaonong GUO,Shuiping LIANG,Zuyan SHEN

期刊论文

Parameter prediction in laser bending of aluminum alloy sheet

WANG Xuyue, XU Weixing, CHEN Hua, WANG Jinsong

期刊论文

Flexural-torsional buckling behavior of aluminum alloy beams

Xiaonong GUO,Zhe XIONG,Zuyan SHEN

期刊论文

Towards Cr(VI)-free anodization of aluminum alloys for aerospace adhesive bonding applications: A review

Shoshan T. Abrahami, John M. M. de Kok, Herman Terryn, Johannes M. C. Mol

期刊论文

Finite element modeling of counter-roller spinning for large-sized aluminum alloy cylindrical parts

Dawei ZHANG, Fan LI, Shuaipeng LI, Shengdun ZHAO

期刊论文

Study on shear resistance of aluminum alloy I-section members

DONG Zhen, ZHANG Qilin

期刊论文

Experimental investigation and design of aluminum columns with longitudinal welds

Yun WU, Qilin ZHANG

期刊论文

Effect of electrolyte concentration on the tribological performance of MAO coatings on aluminum alloys

Chao Wang, Jun Chen, Jihua He, Jing Jiang, Qinyong Zhang

期刊论文

Precision forging technology for aluminum alloy

Lei DENG, Xinyun WANG, Junsong JIN, Juchen XIA

期刊论文

Characterization of the tensile properties of friction stir welded aluminum alloy joints based on axial

Biranchi PANDA,A. GARG,Zhang JIAN,Akbar HEIDARZADEH,Liang GAO

期刊论文

Shape optimization of aluminium alloy spherical reticulated shells considering nonlinearities

Wei LIU; Lishu XU; Shaojun ZHU; Lijuan LI; Feng LIU; Zhe XIONG

期刊论文