Materials that are difficult to cut,such as titanium alloys,are widely used in large load-bearing integral components of aircraft,leading to great challenges for manufacturing.Electrochemical milling is a way for mach...Materials that are difficult to cut,such as titanium alloys,are widely used in large load-bearing integral components of aircraft,leading to great challenges for manufacturing.Electrochemical milling is a way for machining difficult-to-cut materials through Computer Numerical Control(CNC)trajectory motion.Using a tilted large cathode machining surface and the cut-in feed mode,an efficient and low-cost method is obtained for machining the large integral components.A novel crossed and inclined structure of the flow mode is designed to realize electrochemical milling with a large tilted cathode surface.Compared to the vertical flow mode with one inlet,the proposed flow mode has two inlets that independently supply electrolytes,and the inclined channels make the flow field more stable.Flow field simulations are performed for both the vertical and proposed flow modes.The results show that the proposed flow mode avoids the random diversion of electrolytes and the ultralow flow velocity at both ends of the nozzle area,improving the velocity,uniformity,and stability of the electrolytes.The inclination angle of the crossed and inclined flow field is optimized.Finally,limit feed rate experiments are conducted in two modes,and the limit feed rate is 70 mm/min in the proposed mode.A sector workpiece of a large circular surface with approximately 8.77 mm thickness is machined 9 times by the cut-in electrochemical milling,the material removal rate is 4872 mm^(3)/min,and the surface roughness is superior to 1.15μm.展开更多
Nowadays,there has been an increasing focus on integrated flight propulsion control and the inlet-exhaust design for the aero-propulsion system.Traditional component-level models are inadequate due to installed perfor...Nowadays,there has been an increasing focus on integrated flight propulsion control and the inlet-exhaust design for the aero-propulsion system.Traditional component-level models are inadequate due to installed performance deviations and mismatches between the real engine and the model,failing to meet the accuracy requirements of supersonic conditions.This paper establishes a quasi-one-dimensional model for the inlet-exhaust system and conducts experimental calibration.Additionally,a mechanism-data fusion adaptive modeling scheme using an Extreme Learning Machine based on the Salp Swarm Algorithm(SSA-ELM)is proposed.The study reveals the inlet model’s efficacy in reflecting installed performance,flow matching,and mitigating pressure distortion,while the nozzle model accurately predicts flow coefficients and thrust coefficients,and identifies various operational states.The model’s output closely aligns with typical experimental parameters.By combining offline optimization and online adaptive correction,the mechanismdata fusion adaptive model substantially reduces output errors during regular flights and varying levels of degradation,and effectively handles gradual degradation within a single flight cycle.Notably,the mechanism-data fusion adaptive model holistically addresses total pressure errors within the inlet-exhaust system and normal shock location correction.This approach significantly curbs performance deviations in supersonic conditions.For example,at Ma=2.0,the system error impressively drops from 34.17%to merely 6.54%,while errors for other flight conditions consistently stay below the 2.95%threshold.These findings underscore the clear superiority of the proposed method.展开更多
基金co-supported by National Natural Science Foundation of China(No.52075253)National Natural Science Foundation of China for Creative Research Groups(No.51921003).
文摘Materials that are difficult to cut,such as titanium alloys,are widely used in large load-bearing integral components of aircraft,leading to great challenges for manufacturing.Electrochemical milling is a way for machining difficult-to-cut materials through Computer Numerical Control(CNC)trajectory motion.Using a tilted large cathode machining surface and the cut-in feed mode,an efficient and low-cost method is obtained for machining the large integral components.A novel crossed and inclined structure of the flow mode is designed to realize electrochemical milling with a large tilted cathode surface.Compared to the vertical flow mode with one inlet,the proposed flow mode has two inlets that independently supply electrolytes,and the inclined channels make the flow field more stable.Flow field simulations are performed for both the vertical and proposed flow modes.The results show that the proposed flow mode avoids the random diversion of electrolytes and the ultralow flow velocity at both ends of the nozzle area,improving the velocity,uniformity,and stability of the electrolytes.The inclination angle of the crossed and inclined flow field is optimized.Finally,limit feed rate experiments are conducted in two modes,and the limit feed rate is 70 mm/min in the proposed mode.A sector workpiece of a large circular surface with approximately 8.77 mm thickness is machined 9 times by the cut-in electrochemical milling,the material removal rate is 4872 mm^(3)/min,and the surface roughness is superior to 1.15μm.
基金co-supported by the National Natural Science Foundation of China(Nos.61890921,61890924)the National Science and Technology Major Project,China(No.J2019-1-0019-0018).
文摘Nowadays,there has been an increasing focus on integrated flight propulsion control and the inlet-exhaust design for the aero-propulsion system.Traditional component-level models are inadequate due to installed performance deviations and mismatches between the real engine and the model,failing to meet the accuracy requirements of supersonic conditions.This paper establishes a quasi-one-dimensional model for the inlet-exhaust system and conducts experimental calibration.Additionally,a mechanism-data fusion adaptive modeling scheme using an Extreme Learning Machine based on the Salp Swarm Algorithm(SSA-ELM)is proposed.The study reveals the inlet model’s efficacy in reflecting installed performance,flow matching,and mitigating pressure distortion,while the nozzle model accurately predicts flow coefficients and thrust coefficients,and identifies various operational states.The model’s output closely aligns with typical experimental parameters.By combining offline optimization and online adaptive correction,the mechanismdata fusion adaptive model substantially reduces output errors during regular flights and varying levels of degradation,and effectively handles gradual degradation within a single flight cycle.Notably,the mechanism-data fusion adaptive model holistically addresses total pressure errors within the inlet-exhaust system and normal shock location correction.This approach significantly curbs performance deviations in supersonic conditions.For example,at Ma=2.0,the system error impressively drops from 34.17%to merely 6.54%,while errors for other flight conditions consistently stay below the 2.95%threshold.These findings underscore the clear superiority of the proposed method.
