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An Exploration of Surface Integrity Remanufacturing for Aeroengine Components

Qiao Xiang,Yong He,Ting-hong Hou

《工程管理前沿（英文）》 2016年 第3卷 第2期   页码 107-114 doi: 10.15302/J-FEM-2016025

摘要： Surface integrity is the major factor impacting on the operation quality, service life and reliability of the aeroengine components. The surface integrity of aeroengine component is damaged by the failures such as crack, deformation, oxidation, corrosion, erosion, and microstructural degeneration. It adopts advanced remanufacturing technologies to restore or improve the surface integrity and regenerate these high value parts. This paper firstly puts forward the concept, namely surface integrity remanufacturing for aeroengine components, and its connotation. The key remanufacturing technologies have been developed to repair the components with surface damages. Ultimately, some application examples of surface integrity remanufacturing technologies as well as their effects in aeroengine maintenance are introduced. The discarded components have been reused and their service lives have been extended and their reliability has been increased by implementing surface integrity remanufacturing. It has realized “The Repaired Components Outpacing the New Ones”, material saving, energy saving, and emission reduction.

关键词： aeroengine component     surface integrity     remanufacturing     surface integrity remanufacturing    

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The Application and the Prospect of Remanufacturing Technologies in the Metallurgical Industry

Jie Xiong,Jian-cheng Fan,Jv Yuan

《工程管理前沿（英文）》 2016年 第3卷 第2期   页码 165-170 doi: 10.15302/J-FEM-2016023

摘要： Metallurgical equipment is subjected to severe working conditions and the components suffer from various types of physical damages such as abrasion, corrosion and crack. Advanced surface engineering technologies and resistant coatings on the damaged surface can improve surface properties, extend service lives, reduce maintenance costs and improve product quality in the metallurgical industry. This paper introduces remanufacturing technologies, including electroplating, overlaying welding, thermal spraying and laser surface cladding and their applications in the metallurgical industry, and analyzes the development tendency and prospect of remanufacturing technologies.

关键词： remanufacturing technology     electroplating     overlaying welding     thermal spraying     laser surface cladding    

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Experimental study of surface integrity and fatigue life in the face milling of Inconel 718

Xiangyu WANG, Chuanzhen HUANG, Bin ZOU, Guoliang LIU, Hongtao ZHU, Jun WANG

《机械工程前沿（英文）》 2018年 第13卷 第2期   页码 243-250 doi: 10.1007/s11465-018-0479-9

摘要：

The Inconel 718 alloy is widely used in the aerospace and power industries. The machining-induced surface integrity and fatigue life of this material are important factors for consideration due to high reliability and safety requirements. In this work, the milling of Inconel 718 was conducted at different cutting speeds and feed rates. Surface integrity and fatigue life were measured directly. The effects of cutting speed and feed rate on surface integrity and their further influences on fatigue life were analyzed. Within the chosen parameter range, the cutting speed barely affected the surface roughness, whereas the feed rate increased the surface roughness through the ideal residual height. The surface hardness increased as the cutting speed and feed rate increased. Tensile residual stress was observed on the machined surface, which showed improvement with the increasing feed rate. The cutting speed was not an influencing factor on fatigue life, but the feed rate affected fatigue life through the surface roughness. The high surface roughness resulting from the high feed rate could result in a high stress concentration factor and lead to a low fatigue life.

关键词： roughness     hardness     residual stress     microstructure     fatigue life    

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Fiber-reinforced composites in milling and grinding: machining bottlenecks and advanced strategies

《机械工程前沿（英文）》 2022年 第17卷 第2期 doi: 10.1007/s11465-022-0680-8

摘要： Fiber-reinforced composites have become the preferred material in the fields of aviation and aerospace because of their high-strength performance in unit weight. The composite components are manufactured by near net-shape and only require finishing operations to achieve final dimensional and assembly tolerances. Milling and grinding arise as the preferred choices because of their precision processing. Nevertheless, given their laminated, anisotropic, and heterogeneous nature, these materials are considered difficult-to-machine. As undesirable results and challenging breakthroughs, the surface damage and integrity of these materials is a research hotspot with important engineering significance. This review summarizes an up-to-date progress of the damage formation mechanisms and suppression strategies in milling and grinding for the fiber-reinforced composites reported in the literature. First, the formation mechanisms of milling damage, including delamination, burr, and tear, are analyzed. Second, the grinding mechanisms, covering material removal mechanism, thermal mechanical behavior, surface integrity, and damage, are discussed. Third, suppression strategies are reviewed systematically from the aspects of advanced cutting tools and technologies, including ultrasonic vibration-assisted machining, cryogenic cooling, minimum quantity lubrication (MQL), and tool optimization design. Ultrasonic vibration shows the greatest advantage of restraining machining force, which can be reduced by approximately 60% compared with conventional machining. Cryogenic cooling is the most effective method to reduce temperature with a maximum reduction of approximately 60%. MQL shows its advantages in terms of reducing friction coefficient, force, temperature, and tool wear. Finally, research gaps and future exploration directions are prospected, giving researchers opportunity to deepen specific aspects and explore new area for achieving high precision surface machining of fiber-reinforced composites.

关键词： milling     grinding     fiber-reinforced composites     damage formation mechanism     delamination     material removal mechanism     surface integrity     minimum quantity lubrication    

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高强度合金抗疲劳应用技术研究与发展

越振业

《中国工程科学》 2005年 第7卷 第3期   页码 90-94

摘要：

评述了超高强度钢、高强度A1合金和Ti合金表面完整性抗疲劳应用技术的研究和发展。高强度合金疲劳性能对应力集中敏感，不适当的加工工艺和切削热等造成的表面损伤和髙拉应力使其疲劳和应力腐蚀性能损失殆尽。先进的表面完整性加工尤其是表面改性可显著提高疲劳性能，如激光冲击使7475-T761拉-拉疲劳寿命提高约89%，7075-T6裂纹扩展速率降低到原来的1/1500;超声喷丸使超高强度钢低周疲劳强度提高约50%，Ti7A14Mo合金髙周疲劳强度提高约15%;表面超硬化可使Vasco X-2M齿轮钢接触疲劳寿命提高30～35倍等。

关键词： 高强度合金     表面完整性     激光冲击     表面超硬化    

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表面完整性研究的进展与展望

房丰洲, 顾春阳, 郝然, 游开元, 黄思雨

《工程（英文）》 2018年 第4卷 第6期   页码 754-758 doi: 10.1016/j.eng.2018.11.005

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Managing Coordination Complexity in the Remanufacturing of Aircraft Engines

Qing Yang,Lu Zheng

《工程管理前沿（英文）》 2016年 第3卷 第2期   页码 158-164 doi: 10.15302/J-FEM-2016022

摘要： The complexity of communication and coordination stemming from teams responsible for adjusting interdependent parameters of components is a fundamental feature in the aircraft engine remanufacturing engineering project. To manage coordination complexity, the features of the remanufacturing process of aircraft engine are analyzed and a systematic method is presented to measure and optimize the dependency between coupled components. Furthermore, quantitative models are built based on Design Structure Matrix (DSM) models to measure dependency strengths related to the parameter features of the components. Also, a two-stage DSM clustering criteria is used to reduce the complexity of an organization. An industrial example is provided to illustrate the proposed models. The results showed that the proposed approach can reduce total coordination complexity.

关键词： remanufacturing engineering project     aircraft engine     coordination complexity     organization optimization     design structure matrix (DSM)    

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Innovation on Remanufacturing Engineering Management —Striving for Sustainable Development

Qiao Xiang

《工程管理前沿（英文）》 2016年 第3卷 第2期   页码 101-101 doi: 10.15302/J-FEM-2016027

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Vibration characteristics and machining performance of a novel perforated ultrasonic vibration platform in the grinding of particulate-reinforced titanium matrix composites

《机械工程前沿（英文）》 2023年 第18卷 第1期 doi: 10.1007/s11465-022-0730-2

摘要： Ultrasonic vibration-assisted grinding (UVAG) is an advanced hybrid process for the precision machining of difficult-to-cut materials. The resonator is a critical part of the UVAG system. Its performance considerably influences the vibration amplitude and resonant frequency. In this work, a novel perforated ultrasonic vibration platform resonator was developed for UVAG. The holes were evenly arranged at the top and side surfaces of the vibration platform to improve the vibration characteristics. A modified apparent elasticity method (AEM) was proposed to reveal the influence of holes on the vibration mode. The performance of the vibration platform was evaluated by the vibration tests and UVAG experiments of particulate-reinforced titanium matrix composites. Results indicate that the reasonable distribution of holes helps improve the resonant frequency and vibration mode. The modified AEM, the finite element method, and the vibration tests show a high degree of consistency for developing the perforated ultrasonic vibration platform with a maximum frequency error of 3%. The employment of ultrasonic vibration reduces the grinding force by 36% at most, thereby decreasing the machined surface defects, such as voids, cracks, and burnout.

关键词： ultrasonic vibration-assisted grinding     perforated ultrasonic vibration platform     vibration characteristics     apparent elasticity method     grinding force     surface integrity    

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A novel approach for remanufacturing process planning considering uncertain and fuzzy information

《机械工程前沿（英文）》 2021年 第16卷 第3期   页码 546-558 doi: 10.1007/s11465-021-0639-1

摘要： Remanufacturing, as one of the optimal disposals of end-of-life products, can bring tremendous economic and ecological benefits. Remanufacturing process planning is facing an immense challenge due to uncertainties and fuzziness of recoverable products in damage conditions and remanufacturing quality requirements. Although researchers have studied the influence of uncertainties on remanufacturing process planning, very few of them comprehensively studied the interactions among damage conditions and quality requirements that involve uncertain, fuzzy information. Hence, this challenge in the context of uncertain, fuzzy information is undertaken in this paper, and a method for remanufacturing process planning is presented to maximize remanufacturing efficiency and minimize cost. In particular, the characteristics of uncertainties and fuzziness involved in the remanufacturing processes are explicitly analyzed. An optimization model is then developed to minimize remanufacturing time and cost. The solution is provided through an improved Takagi–Sugeno fuzzy neural network (T-S FNN) method. The effectiveness of the proposed approach is exemplified and elucidated by a case study. Results show that the training speed and accuracy of the improved T-S FNN method are 23.5% and 82.5% higher on average than those of the original method, respectively.

关键词： remanufacturing     uncertain and fuzzy information     process planning     T-S FNN    

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Remanufacturing in Industry 4.0

Ming-zhou Liu,Cong-hu Liu,Mao-gen Ge,Yuan Zhang,Qing-hua Zhu

《工程管理前沿（英文）》 2016年 第3卷 第2期   页码 144-146 doi: 10.15302/J-FEM-2016020

摘要： Using the theory of human blood circulation system, the authors explore the importance of remanufacturing in Industry 4.0. In this paper, they draw analogies between smart factory and human heart, between smart products and blood, and, between product function and nutrition and oxygen in the blood. Remanufacturing is analogous to the ingestion of oxygen and nutrition in lesser circulation or systemic circulation. Remanufacturing well supports recycling production, which is significant in realizing intelligent industry. Furthermore, this paper discusses the development direction of remanufacturing engineering in Industry 4.0 ages.

关键词： remanufacturing     Industry 4.0     sustainable development    

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Machinability of damage-tolerant titanium alloy in orthogonal turn-milling

Tao SUN, Lufang QIN, Junming HOU, Yucan FU

《机械工程前沿（英文）》 2020年 第15卷 第3期   页码 504-515 doi: 10.1007/s11465-020-0586-2

摘要： The damage-tolerant titanium alloy TC21 is used extensively in important parts of advanced aircraft because of its high strength and durability. However, cutting TC21 entails problems, such as high cutting temperature, high tool tip stress, rapid tool wear, and difficulty guaranteeing processing quality. Orthogonal turn-milling can be used to solve these problems. In this study, the machinability of TC21 in orthogonal turn-milling is investigated experimentally to optimize the cutting parameters of orthogonal turn-milling and improve the machining efficiency, tool life, and machining quality of TC21. The mechanism of the effect of turn-milling parameters on tool life is discussed, the relationship between each parameter and tool life is analyzed, and the failure process of a TiAlN-coated tool in turn-milling is explored. Experiments are conducted on the integrity of the machined surface (surface roughness, metallographic structure, and work hardening) by turn-milling, and how the parameters influence such integrity is analyzed. Then, reasonable cutting parameters for TC21 in orthogonal turn-milling are recommended. This study provides strong guidance for exploring the machinability of difficult-to-cut-materials in orthogonal turn-milling and improves the applicability of orthogonal turn-milling for such materials.

关键词： orthogonal turn-milling     damage-tolerant titanium alloy     tool life and failure     machined surface integrity     machinability    

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Local fracture properties and dissimilar weld integrity in nuclear power plants

Guozhen WANG, Haitao WANG, Fuzhen XUAN, Shantung TU, Changjun LIU

《机械工程前沿（英文）》 2013年 第8卷 第3期   页码 283-290 doi: 10.1007/s11465-013-0250-1

摘要：

In this paper, the local fracture properties in a Alloy52M dissimilar metal welded joint (DMWJ) between A508 ferritic steel and 316 L stainless steel in nuclear power plants were investigated by using the single-edge notched bend (SENB) specimens, and their use in integrity assessment of DMWJ structures was analyzed. The results show that the local fracture resistance in the DMWJ is determined by local fracture mechanism, and which is mainly related to the microstructures and local strength mismatches of materials at the crack locations. The initial cracks always grow towards the materials with lower strength, and the crack path deviation is mainly controlled by the local strength mismatch. If the local fracture properties could not be used for cracks in the heat affected zones (HAZs), interface and near interface zones, the use of the fracture properties ( -resistance curves) of base metals or weld metals following present codes will unavoidably produce non-conservative (unsafe) or excessive conservative assessment results. In most cases, the assessment results will be potentially unsafe. Therefore, it is recommended to obtain and use local mechanical and fracture properties in the integrity assessment of DMWJs.

关键词： local fracture properties     dissimilar metal welded joint     integrity assessment     strength mismatch     crack growth path    

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Emerging challenges to structural integrity technology for high-temperature applications

TU Shantung

《机械工程前沿（英文）》 2007年 第2卷 第4期   页码 375-387 doi: 10.1007/s11465-007-0066-y

摘要： Structural integrity technology has been widely used with great success for the design, manufacture and failure prevention of modern constructions such as chemical and petrochemical plants, power generation and energy conversion systems, as well as space and oceanic exploration. The modern needs of structural integrity technology are largely attributed to the increase of service temperature of the structures that results in the efficiency improvement in energy conversion and chemical processing technologies. Besides the needs arising from large-scale high-temperature plants, the high tech developments, such as micro chemo-mechanical systems and high-power electronics, provide new challenges to structural integrity technology. The present paper summarizes the recent technical progresses in large process plants and the aviation industry, micro chemo-mechanical systems, fuel cells, high-temperature electronics, and packaging and coating technologies. The state-of-the-art of structural integrity technology for high temperature applications is reviewed. Suggestions are provided for the improvement of current design and assessment methods.

关键词： manufacture     aviation industry     conversion     petrochemical     temperature    

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Damage mechanism and evaluation model of compressor impeller remanufacturing blanks: A review

Haiyang LU, Yanle LI, Fangyi LI, Xingyi ZHANG, Chuanwei ZHANG, Jiyu DU, Zhen LI, Xueju RAN, Jianfeng LI, Weiqiang WANG

《机械工程前沿（英文）》 2019年 第14卷 第4期   页码 402-411 doi: 10.1007/s11465-019-0548-8

摘要： The theoretical and technological achievements in the damage mechanism and evaluation model obtained through the national basic research program “Key Fundamental Scientific Problems on Mechanical Equipment Remanufacturing” are reviewed in this work. Large centrifugal compressor impeller blanks were used as the study object. The materials of the blanks were FV520B and KMN. The mechanism and evaluation model of ultra-high cycle fatigue, erosion wear, and corrosion damage were studied via theoretical calculation, finite element simulation, and experimentation. For ultra-high cycle fatigue damage, the characteristics of ultra-high cycle fatigue of the impeller material were clarified, and prediction models of ultra-high cycle fatigue strength were established. A residual life evaluation technique based on the “ - - ” (where was the nonlinear parameter, was the Vickers hardness, and was the fatigue life) double criterion method was proposed. For erosion wear, the flow field of gas-solid two-phase flow inside the impeller was simulated, and the erosion wear law was clarified. Two models for erosion rate and erosion depth calculation were established. For corrosion damage, the electrochemical and stress corrosion behaviors of the impeller material and welded joints in H S/CO environment were investigated. (critical stress intensity factor) and d /d (crack growth rate, where is the total crack length and is time) varied with H S concentration and temperature, and their variation laws were revealed. Through this research, the key scientific problems of the damage behavior and mechanism of remanufacturing objects in the multi-strength field and cross-scale were solved. The findings provide theoretical and evaluation model support for the analysis and evaluation of large centrifugal compressor impellers before remanufacturing.

关键词： remanufacturing     centrifugal compressor impeller     remanufacturing blank     damage mechanism     evaluation model    

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标题 作者 时间 类型 操作

An Exploration of Surface Integrity Remanufacturing for Aeroengine Components

Qiao Xiang,Yong He,Ting-hong Hou

期刊论文

The Application and the Prospect of Remanufacturing Technologies in the Metallurgical Industry

Jie Xiong,Jian-cheng Fan,Jv Yuan

期刊论文

Experimental study of surface integrity and fatigue life in the face milling of Inconel 718

Xiangyu WANG, Chuanzhen HUANG, Bin ZOU, Guoliang LIU, Hongtao ZHU, Jun WANG

期刊论文

Fiber-reinforced composites in milling and grinding: machining bottlenecks and advanced strategies

期刊论文

高强度合金抗疲劳应用技术研究与发展

越振业

期刊论文

表面完整性研究的进展与展望

房丰洲, 顾春阳, 郝然, 游开元, 黄思雨

期刊论文

Managing Coordination Complexity in the Remanufacturing of Aircraft Engines

Qing Yang,Lu Zheng

期刊论文

Innovation on Remanufacturing Engineering Management —Striving for Sustainable Development

Qiao Xiang

期刊论文

Vibration characteristics and machining performance of a novel perforated ultrasonic vibration platform in the grinding of particulate-reinforced titanium matrix composites

期刊论文

A novel approach for remanufacturing process planning considering uncertain and fuzzy information

期刊论文

Remanufacturing in Industry 4.0

Ming-zhou Liu,Cong-hu Liu,Mao-gen Ge,Yuan Zhang,Qing-hua Zhu

期刊论文

Machinability of damage-tolerant titanium alloy in orthogonal turn-milling

Tao SUN, Lufang QIN, Junming HOU, Yucan FU

期刊论文

Local fracture properties and dissimilar weld integrity in nuclear power plants

Guozhen WANG, Haitao WANG, Fuzhen XUAN, Shantung TU, Changjun LIU

期刊论文

Emerging challenges to structural integrity technology for high-temperature applications

TU Shantung

期刊论文

Damage mechanism and evaluation model of compressor impeller remanufacturing blanks: A review

Haiyang LU, Yanle LI, Fangyi LI, Xingyi ZHANG, Chuanwei ZHANG, Jiyu DU, Zhen LI, Xueju RAN, Jianfeng LI, Weiqiang WANG

期刊论文