Taking half-tube part with curvature as an example,the Impact Hydroforming(IHF)characteristics were studied by combining the actual forming experiment and numerical simulation.The IHF experiment showed that wrinkles a...Taking half-tube part with curvature as an example,the Impact Hydroforming(IHF)characteristics were studied by combining the actual forming experiment and numerical simulation.The IHF experiment showed that wrinkles appeared at the bottom of the part during single-step forming,but no wrinkles were observed during double-step forming.The thinning rate and deviation of the wall thickness of the part in each area were less than 20%and 2.7 mm,correspondingly,and the drawing depth of the part reached 45.8 mm.The effect of double-step forming was better than that of single-step forming,which was related to the IHF forming law.Besides,the characteristics of the IHF process were studied by numerical simulation.The results indicated that when double-step forming was utilized,there was almost no velocity field in the opposite direction of deformation after the bottom of the part contacted the die,and the existence of stress state at the bottom would restrain and eliminate the wrinkles.The inertia effect evolved with the driving pressure.Specially,the inertia effect can improve the flow of metal and reduce the deviation of the wall thickness of the part under double-step forming.展开更多
Developing precision forming of magnesium alloy micro-grooved heat pipes is of great significance for improving the lightweight level of aerospace thermal management systems.In this paper,the electrically-assisted ext...Developing precision forming of magnesium alloy micro-grooved heat pipes is of great significance for improving the lightweight level of aerospace thermal management systems.In this paper,the electrically-assisted extrusion of magnesium alloy heat pipes is explored,and the effects of extrusion and electrical parameters on the forming accuracy,microstructures,and mechanical properties are studied.Finite element simulation found that electrifying the extrusion ram and preheating the extrusion cylinder could effectively ensure the billet temperature,and an extrusion window(30-60 s)could be obtained.Reducing the extrusion velocity and increasing the current could both reduce the extrusion load.Within the range of the studied parameters,the micro-grooved heat pipes are relatively fully formed.It is found that increasing the extrusion velocity and electrical parameters would increase the grain size of the magnesium alloy.While the electrical parameter increases from 0 to 300 A,the grain size increases from~5.9 to~12.6μm,and the tensile strength and yield strength of the extruded profiles are also 20.7%and 16.8%lower than those without current.The tensile fracture surface shows that under the parameters of high extrusion velocity and high current,the fracture morphology changes from dimples and cleavage planes to large-area river patterns,and the fracture mode changes from the mixed ductile-brittle fracture to the brittle fracture.Under the extrusion parameters of 0.5 mm/s and 100 A,the extrusion load is reduced by 1.0-1.6 T,the cross-sectional filling rate is as high as 97.5%,and the size deviation of the micro-ribs(0.8 mm)is only±5μm.Simultaneously,under these parameters,the grain size does not significantly coarsen,and the strength and plasticity of the heat pipe increase slightly.This work provides theoretical and technical support for the development of precision forming technology of lightweight aerospace heat pipes.展开更多
The multi-pass intermittent local loading process,which features a more flexible processing path,can further enhance the second material distribution during local loading,improve the formability of components,and redu...The multi-pass intermittent local loading process,which features a more flexible processing path,can further enhance the second material distribution during local loading,improve the formability of components,and reduce forming loads.However,the absence of compatible forming equipment makes it difficult to control the constraint in the unloaded zones during the forming process.This difficulty complicates coordination and control of deformation,particularly for asymmetric rib-web components.Additionally,the current implementation involves multi-fire heating,a long process flow,and high energy consumption,which limits the popularization and application of the local loading process.In this study,a new multi-pass local loading hydraulic forming apparatus that can quickly and reliably switch between heavy-load deformation and low-load constraint for different local loading sub-dies was developed.A 10-tonne laboratory prototype was developed,and the forming characteristics during the forming process as well as the response characteristics of the hydraulic system during the multi-pass intermittent local loading of rib-web component were investigated using numerical simulations and physical experiments.Results indicated that,compared to a whole loading process with the same initial geometry of billet,the total forming load(i.e.,the sum of loaded and restrained loads)is reduced by more than 40%with the local loading process,and by nearly 50%with multi-pass local loading.The multi-pass local loading process allows for more effective control of material flow compared to single-pass local loading,leading to improved cavity filling and reduced flow line disturbance.For a large-scale,complex titanium alloy bulkhead,the cavity filling problem was addressed by optimizing the multi-pass local loading path with an unequal thickness billet.The dynamic performance of the multi-pass local loading hydraulic system was found to be robust,with stable pressure transitions during motion and load switching for the sub-die(s).The dynamic characteristic of the hydraulic cylinder when switching from non-moving/unloaded state to a moving/loading state are consistent whether a load is present or not.However,the dynamic characteristics differ when switching from a moving/loading state to non-moving/unloaded state,showing opposite behavior.The developed hydraulic drive mechanism provides a way for implementation of multi-pass local loading without auxiliary operation and extra heating.The results of the study provide a foundation for the industrial production of large-scale,complex components with reduced force requirement and low-energy consumption.展开更多
Based on the microstructure characterization,electrochemical impedance spectroscopy,potentiodynamic polarization,and immersion corrosion,this work comparatively analyzed the differences in the electrochemical corrosio...Based on the microstructure characterization,electrochemical impedance spectroscopy,potentiodynamic polarization,and immersion corrosion,this work comparatively analyzed the differences in the electrochemical corrosion morphology and post-foil formation surface morphology of laser beam welded(LBW)sample and spin-formed sample,and compared the corrosion resistance and Cu foil formation ability of two samples in H_(2)SO_(4)/NaCl solution and CuSO_(4) reducing electrolyte.Results show that in H_(2)SO_(4) and NaCl solutions,LBW sample and spin-formed sample exhibit excellent passivation ability and corrosion resistance.Both samples show uniform corrosion morphologies and similar corrosion resistance in the strong acidic solution containing Cl^(-).Meanwhile,the Cu foil formation ability of the welded joint is similar to that of the spin-formed sample,and both samples obtain intact Cu foils with high-quality surfaces and small differences in properties.展开更多
A new analytical model for geometric size and forming force prediction in incremental flanging(IF)is presented in this work.The complex deformation characteristics of IF are considered in the modeling process,which ca...A new analytical model for geometric size and forming force prediction in incremental flanging(IF)is presented in this work.The complex deformation characteristics of IF are considered in the modeling process,which can accurately describe the strain and stress states in IF.Based on strain analysis,the model can predict the material thickness distribution and neck height after IF.By considering contact area,strain characteristics,material thickness changes,and friction,the model can predict specific moments and corresponding values of maximum axial forming force and maximum horizontal forming force during IF.In addition,an IF experiment involving different tool diameters,flanging diameters,and opening hole diameters is conducted.On the basis of the experimental strain paths,the strain characteristics of different deformation zones are studied,and the stable strain ratio is quantitatively described through two dimensionless parameters:relative tool diameter and relative hole diameter.Then,the changing of material thickness and forming force in IF,and the variation of minimum material thickness,neck height,maximum axial forming force,and maximum horizontal forming force with flanging parameters are studied,and the reliability of the analytical model is verified in this process.Finally,the influence of the horizontal forming force on the tool design and the fluctuation of the forming force are explained.展开更多
The northwestern margin of Junggar Basin is the region with the richest oil sand resources in China.For better understanding the enrichment rules and deployment of exploration and development of regional oil sand,it i...The northwestern margin of Junggar Basin is the region with the richest oil sand resources in China.For better understanding the enrichment rules and deployment of exploration and development of regional oil sand,it is of great scientific significance to study the accumulation conditions of oil sand in different strata and mining areas of the Junggar Basin.Through a large number of field investigations,drilling verification and sampling tests,it is found that the oil sand in the region covers an area of 2000 km^(2),with shallow and thick reservoir,and predicted resource of 180 million tons.The oil sand resources are mainly distributed in four geological strata,namely the Middle Triassic Karamay Formation,Early Jurassic Badaowan Formation,Late Jurassic Qigu Formation,and Early Cretaceous Qingshuihe Formation.The reservoir is mainly composed of sandstone with high porosity and permeability,and the reservoir space is mainly intergranular pores with a medium average oil content.The oil sand deposit in the region is a typical destructive oil reservoir.The crude oil in the oil sand layer is degraded and thickened from the deep to the shallow,the content of saturated hydrocarbon decreased,and the content of aromatic hydrocarbon,non-hydrocarbon and asphaltene increased.The oil source comes from the deep Permian hydrocarbon-generating depression.Unconformities,faults and marginal fan delta-braided river depositional systems constitute effective migration and storage systems.Caprocks of the Upper Triassic Baijiantan Formation,Lower Jurassic Sangonghe Formation and Lower Cretaceous Hutubihe Formation were formed by three large scale lake transgressions.The Indosinian,Yanshan and Late Yanshan movements are the main driving forces for the migration of deep oil and gas to the shallow edge to form oil sand deposits.It is considered that the oil sand in the northwestern margin of Junggar Basin is of a slope complex migration type.展开更多
The carcass layer is the innermost structure of flexible marine risers and is responsible for resisting external pressure.It has an“S”section with a spiral interlocking feature.After the multi-pass roll forming of a...The carcass layer is the innermost structure of flexible marine risers and is responsible for resisting external pressure.It has an“S”section with a spiral interlocking feature.After the multi-pass roll forming of a flat steel strip,a carcass layer is formed by lock forming.During roll forming,the steel strip undergoes significant plastic deformation,and its local area accumulates residual stress owing to multiple loading and unloading cycles.These phenomena complicate the design and analysis of the carcass layer multi-pass roll forming(CLMRF)process and cause issues in the carcass layer during manufacturing,such as strip fracture and low forming quality.Thus,herein,CLMRF was investigated to clarify the stress distribution,and a parameter analysis was performed.First,the CLMRF process was designed on the basis of classical roll-forming design theory.Second,a finite element model was established,and CLMRF was simulated.Third,the distributions of the forming stress and residual stress of the strip during CLMRF were investigated.Finally,the influences of the strip thickness,roll gap,roll distance,and angular increment were investigated.The conclusions of this study can be used to provide technical guidance in the manufacturing of flexible risers.展开更多
Spiral bevel gears are critical transmission components,and are widely used in the aerospace field.This paper proposes a new multi-DOF envelope forming process for fabricating spiral bevel gears.Firstly,the multi-DOF ...Spiral bevel gears are critical transmission components,and are widely used in the aerospace field.This paper proposes a new multi-DOF envelope forming process for fabricating spiral bevel gears.Firstly,the multi-DOF envelope forming principle of spiral bevel gears is proposed.Secondly,the design methods for the envelope tool geometry and movement are proposed based on the envelope geometry and movement relationships.Thirdly,the metal flow and tooth filling laws are revealed through 3D FE simulation of the multi-DOF envelope forming process of a typical spiral bevel gear.Fourthly,a new method for separating the envelope tool and the formed spiral bevel gear with back taper tooth is proposed to avoid their interference.Finally,experiments on multi-DOF envelope forming of this typical spiral bevel gear are conducted using new heavy load multi-DOF envelope forming equipment.The simulation and experimental results show the feasibility of the proposed multi-DOF envelope forming process for fabricating spiral bevel gears with back taper tooth and the corresponding process design methods.展开更多
The influence of geometric configuration on the friction characteristics during incremental sheet forming of AA5052 was analyzed by integrating surface morphology and its characteristic parameters,along with plastic s...The influence of geometric configuration on the friction characteristics during incremental sheet forming of AA5052 was analyzed by integrating surface morphology and its characteristic parameters,along with plastic strain,contact pressure,and area.The interface promotes lubrication and support when wall angles were≤40°,a 0.5 mm-thin sheet was used,and a 10 mm-large tool radius was employed.This mainly results in micro-plowing and plastic extrusion flow,leading to lower friction coefficient.However,when wall angles exceed 40°,significant plastic strain roughening occurs,leading to inadequate lubrication on the newly formed surface.Increased sheet thickness and decreased tool radius elevate contact pressure.These actions trigger micro-cutting and adhesion,potentially leading to localized scuffing and dimple tears,and higher friction coefficient.The friction mechanisms remain unaffected by the part’s plane curve features.As the forming process progresses,abrasive wear intensifies,and surface morphology evolves unfavorably for lubrication and friction reduction.展开更多
This article examines the influence of annealing temperature on fracture toughness and forming limit curves of dissimilar aluminum/silver sheets.In the cold roll bonding process,after brushing and acid washing,the pre...This article examines the influence of annealing temperature on fracture toughness and forming limit curves of dissimilar aluminum/silver sheets.In the cold roll bonding process,after brushing and acid washing,the prepared surfaces are placed on top of each other and by rolling with reduction more than 50%,the bonding between layers is established.In this research,the roll bonding process was done at room temperature,without the use of lubricants and with a 70%thickness reduction.Then,the final thickness of the Ag/Al bilayer sheet reached 350μm by several stages of cold rolling.Before cold rolling,it should be noted that to decrease the hardness created due to plastic deformation,the roll-bonded samples were subjected to annealing heat treatment at 400℃for 90 min.Thus,the final samples were annealed at 200,300 and 400℃for 90 min and cooled in a furnace to examine the annealing temperature effects.The uniaxial tensile and microhardness tests measured mechanical properties.Also,to investigate the fracture mechanism,the fractography of the cross-section was examined by scanning electron microscope(SEM).To evaluate the formability of Ag/Al bilayer sheets,forming limit curves were obtained experimentally through the Nakazima test.The resistance of composites to failure due to cracking was also investigated by fracture toughness.The results showed that annealing increases the elongation and formability of the Ag/Al bilayer sheet while reduces the ultimate tensile strength and fracture toughness.However,the changing trend is not the same at different temperatures,and according to the results,the most significant effect is obtained at 300℃and aluminum layers.It was also determined that by increasing annealing temperature,the fracture mechanism from shear ductile with small and shallow dimples becomes ductile with deep cavities.展开更多
To overcome the shortage of complex equipment,large volume,and high energy consumption in space capsule manufacturing,a novel sliding pressure Joule heat fuse additive manufacturing technique with reduced volume and l...To overcome the shortage of complex equipment,large volume,and high energy consumption in space capsule manufacturing,a novel sliding pressure Joule heat fuse additive manufacturing technique with reduced volume and low energy consumption was proposed.But the unreasonable process parameters may lead to the inferior consistency of the forming quality of single-channel multilayer in Joule heat additive manufacturing process,and it is difficult to reach the condition for forming thinwalled parts.Orthogonal experiments were designed to fabricate single-channel multilayer samples with varying numbers of layers,and their forming quality was evaluated.The influence of printing current,forming speed,and contact pressure on the forming quality of the single-channel multilayer was analyzed.The optimal process parameters were obtained and the quality characterization of the experiment results was conducted.Results show that the printing current has the most significant influence on the forming quality of the single-channel multilayer.Under the optimal process parameters,the forming section is well fused and the surface is continuously smooth.The surface roughness of a single-channel 3-layer sample is 0.16μm,and the average Vickers hardness of cross section fusion zone is 317 HV,which lays a foundation for the subsequent use of Joule heat additive manufacturing technique to form thinwall parts.展开更多
Short process forming techniques for brazing and soldering materials can shorten the process,improve product quality,and increase production efficiency,which has received much attention from welding researchers.This r...Short process forming techniques for brazing and soldering materials can shorten the process,improve product quality,and increase production efficiency,which has received much attention from welding researchers.This review mainly summarized the research reports on short process forming techniques for brazing and soldering materials.Firstly,the traditional process and its shortcomings were presented.Secondly,the latest research of short process forming technologies,such as continuous casting technique,atomization powder technique,solder ball forming technique,and rapid solidification technique,was summarized,and the traditional forming performance of several brazing and soldering materials was introduced.Finally,the current restrictions and research trends of short process forming technique for brazing and solder materials were put forward,providing theoretical guidance and reference for related research and technique development in brazing and soldering field.展开更多
Four types of Mg-5Zn porous scaffolds with different pore geometries,including body-centered cubic(bcc),the rhombic dodecahedron(RD),gyroid(G),and primitive(P)types,were designed and fabricated using selective laser m...Four types of Mg-5Zn porous scaffolds with different pore geometries,including body-centered cubic(bcc),the rhombic dodecahedron(RD),gyroid(G),and primitive(P)types,were designed and fabricated using selective laser melting.Their forming quality,compression mechanical properties,and degradation behavior were investigated.Results indicate that the fabricated scaffolds exhibit good dimensional accuracy,and the surface chemical polishing treatment significantly improves the forming quality and reduces porosity error in porous scaffolds.Compared to the ones with rod structures(bcc,RD),the scaffolds with surface structures(G,P)have less powder particle adhesion.The G porous scaffold exhibits the best forming quality for the same design porosity.The predominant failure mode of scaffolds during compression is a 45°shear fracture.At a porosity of 75%,the compression property of all scaffolds meets the compressive property requirements of cancellous bone,while bcc and G structures show relatively better compression property.After immersion in Hank's solution for 168 h,the B-2-75% pore structure scaffold exhibits severe localized corrosion,with fractures in partial pillar connections.In contrast,the G-3-75% pore structure scaffold mainly undergoes uniform corrosion,maintaining structural integrity,and its corrosion rate and loss of compressive properties are less than those of the B-2-75%structure.After comparison,the G-pore structure scaffold is preferred.展开更多
An analytical model for contact area and contact stress considering the loading history in incremental sheet forming(ISF)was established.Then,by integrating with the directional characteristics of friction force and h...An analytical model for contact area and contact stress considering the loading history in incremental sheet forming(ISF)was established.Then,by integrating with the directional characteristics of friction force and horizontal force in the process,a friction test method reflecting the forming characteristics of ISF was proposed.Friction coefficients during the forming processes of parts with different wall angles were measured under various plane curves,process paths,and lubrication conditions.Furthermore,the accuracy of the analytical model,as well as the measured friction coefficients and their variation trends,was verified through comparative analysis with experimental results,simulation data,and outcomes from other existing models.The results indicate that the influence of the plane curve characteristics and process paths of parts on the friction condition is not significant.Under the lubrication conditions of L-HM46 oil,MoS_(2)grease,graphite powder,and dry friction,the friction coefficient shows a gradually increasing trend.Notably,when the wall angle is≤40°,the friction coefficient remains relatively constant;however,when the wall angle exceeds 40°,the friction coefficient increases progressively.展开更多
Dear Editor,This letter investigates the grid-forming control for power converters.Recently,grid-forming control based on matching of synchronous machines was suggested by using continuous measurements.In the present ...Dear Editor,This letter investigates the grid-forming control for power converters.Recently,grid-forming control based on matching of synchronous machines was suggested by using continuous measurements.In the present letter,we suggest a digital implementation using artificial delays where the controller employs the discrete-time measurements only.展开更多
To improve braking performance and achieve lightweight in transport equipment,it is necessary to implement overall plastic forming manufacturing of the brake pad baseboard(BPB),which is the core safety component of th...To improve braking performance and achieve lightweight in transport equipment,it is necessary to implement overall plastic forming manufacturing of the brake pad baseboard(BPB),which is the core safety component of the brake system.This study presents an innovative multi-DOF envelope forming(MDFEF)process to realize the plastic forming of BPB with thin skin and high reinforcing ribs.The MDFEF principle for BPB,and the design methods for the envelope mold are first presented.Through FE simulations,the behavior of metal flow,uneven growth pattern of reinforcing ribs,evolution of equivalent strain and evolution of forming force in MDFEF of BPB are investigated.To realize MDFEF,an innovative MDFEF equipment driven by parallel linkages is exploited.The force states of linkages in MDFEF are calculated,and the reasonable mold position is determined to reduce the maximum force on the linkages and improve the service performance of MDFEF equipment.The MDFEF experiments of BPB are conducted and qualified BPB is obtained,which demonstrates that the presented MDFEF process and equipment are applicable to manufacture BPB with thin skin and high reinforcing ribs.展开更多
Sheet metal spinning is an incremental forming process for producing axisymmetric thinwalled parts through continuous local deformation under the action of rollers.While studying the spinning process by finite element...Sheet metal spinning is an incremental forming process for producing axisymmetric thinwalled parts through continuous local deformation under the action of rollers.While studying the spinning process by finite element(FE)method,a critical bottleneck is the enormous simulation time.For beating off this challenge,a novel multi-mesh method is developed.The method can dynamically track the movement of rollers and adaptively refine the mesh.Thus,a locally refined quadrilateral computation mesh can be generated in the locally-deforming zone and reduce the unnecessary fine elements outside the locally-deforming zone.In the multi-mesh system,the fine elements and coarse elements are extracted from a storage mesh and a background mesh,respectively.Meanwhile,the hanging nodes in the locally refined mesh are removed by designing 4-refinement templates.Between computation mesh and storage mesh,a bi-cubic parametric surface fitting algorithm and accurate remapping methods are conducted to transmit geometric information and physical fields.The proposed method has been verified by two spinning processes.The results suggest that the method can save time by up to about 67%with satisfactory accuracy,especially for distributions of thickness and strain compared with the fully refined mesh.展开更多
Obtaining zero springback and good post-form performance simultaneously is an ultimate pursuit in metal sheet forming.The stress-relaxation ageing(SRA)behavior and mechanical properties of a commercial 2219 aluminum a...Obtaining zero springback and good post-form performance simultaneously is an ultimate pursuit in metal sheet forming.The stress-relaxation ageing(SRA)behavior and mechanical properties of a commercial 2219 aluminum alloy largely pre-deformed(LPD)by 80%have been systematically investigated.The stress relaxation ratio of the LPD alloy reaches approximately 94%regardless of the initial stress(50–350 MPa)after ageing for 12 h at 140°C.This relaxation ratio is about 2.9 and 1.8 times that in the T4 tempered alloy(27.6%under 50 MPa and 31.5%under 150 MPa)and T3 tempered alloy(37.6%under 50 MPa and 51.2%under 150 MPa),respectively.The microstructures,comprised of GP zones/θ'precipitates plus dislocation tangles,and tensile properties in the stress-relaxation-aged LPD alloys remain basically invariant with different initial stresses,as is vital importance for property consistency at different locations of the formed part.Under the same SRA condition,the LPD alloy has an increase of 150–230 MPa in yield strength relative to T3/T4 tempered alloy and obtains a uniform elongation of about 8%.A simple dislocation-based constitutive model accurately describing stress relaxation enhanced by the high dislocation density is established and embedded in the finite element package through a user subroutine.Simulations and experimental verifications show the LPD alloy sheet parts exhibit a nearly zero springback(<5%)after unloading in contrast to the springback larger than 65%in the T3/T4 alloy sheet parts under the same condition.Our findings demonstrate the high-dislocation-density-enhanced SRA response enables a high-performance springback-free age forming of Al alloy sheet.展开更多
基金financially supported by the National Key R&D Program of China(No.2024YFE0108800/T24KITG014)the National Natural Science Foundation of China(No:52475411)the International Partnership Program of Chinese Academy of Sciences(No.172GJHZ2022096FN)。
文摘Taking half-tube part with curvature as an example,the Impact Hydroforming(IHF)characteristics were studied by combining the actual forming experiment and numerical simulation.The IHF experiment showed that wrinkles appeared at the bottom of the part during single-step forming,but no wrinkles were observed during double-step forming.The thinning rate and deviation of the wall thickness of the part in each area were less than 20%and 2.7 mm,correspondingly,and the drawing depth of the part reached 45.8 mm.The effect of double-step forming was better than that of single-step forming,which was related to the IHF forming law.Besides,the characteristics of the IHF process were studied by numerical simulation.The results indicated that when double-step forming was utilized,there was almost no velocity field in the opposite direction of deformation after the bottom of the part contacted the die,and the existence of stress state at the bottom would restrain and eliminate the wrinkles.The inertia effect evolved with the driving pressure.Specially,the inertia effect can improve the flow of metal and reduce the deviation of the wall thickness of the part under double-step forming.
基金supported by the National Natural Science Foundation of China(Grant Nos.U24B2056,52505361)China Postdoctoral Science Foundation(Grant No.2025M774308)。
文摘Developing precision forming of magnesium alloy micro-grooved heat pipes is of great significance for improving the lightweight level of aerospace thermal management systems.In this paper,the electrically-assisted extrusion of magnesium alloy heat pipes is explored,and the effects of extrusion and electrical parameters on the forming accuracy,microstructures,and mechanical properties are studied.Finite element simulation found that electrifying the extrusion ram and preheating the extrusion cylinder could effectively ensure the billet temperature,and an extrusion window(30-60 s)could be obtained.Reducing the extrusion velocity and increasing the current could both reduce the extrusion load.Within the range of the studied parameters,the micro-grooved heat pipes are relatively fully formed.It is found that increasing the extrusion velocity and electrical parameters would increase the grain size of the magnesium alloy.While the electrical parameter increases from 0 to 300 A,the grain size increases from~5.9 to~12.6μm,and the tensile strength and yield strength of the extruded profiles are also 20.7%and 16.8%lower than those without current.The tensile fracture surface shows that under the parameters of high extrusion velocity and high current,the fracture morphology changes from dimples and cleavage planes to large-area river patterns,and the fracture mode changes from the mixed ductile-brittle fracture to the brittle fracture.Under the extrusion parameters of 0.5 mm/s and 100 A,the extrusion load is reduced by 1.0-1.6 T,the cross-sectional filling rate is as high as 97.5%,and the size deviation of the micro-ribs(0.8 mm)is only±5μm.Simultaneously,under these parameters,the grain size does not significantly coarsen,and the strength and plasticity of the heat pipe increase slightly.This work provides theoretical and technical support for the development of precision forming technology of lightweight aerospace heat pipes.
基金the supports of the National Natural Science Foundation of China(Grant No.52375378)。
文摘The multi-pass intermittent local loading process,which features a more flexible processing path,can further enhance the second material distribution during local loading,improve the formability of components,and reduce forming loads.However,the absence of compatible forming equipment makes it difficult to control the constraint in the unloaded zones during the forming process.This difficulty complicates coordination and control of deformation,particularly for asymmetric rib-web components.Additionally,the current implementation involves multi-fire heating,a long process flow,and high energy consumption,which limits the popularization and application of the local loading process.In this study,a new multi-pass local loading hydraulic forming apparatus that can quickly and reliably switch between heavy-load deformation and low-load constraint for different local loading sub-dies was developed.A 10-tonne laboratory prototype was developed,and the forming characteristics during the forming process as well as the response characteristics of the hydraulic system during the multi-pass intermittent local loading of rib-web component were investigated using numerical simulations and physical experiments.Results indicated that,compared to a whole loading process with the same initial geometry of billet,the total forming load(i.e.,the sum of loaded and restrained loads)is reduced by more than 40%with the local loading process,and by nearly 50%with multi-pass local loading.The multi-pass local loading process allows for more effective control of material flow compared to single-pass local loading,leading to improved cavity filling and reduced flow line disturbance.For a large-scale,complex titanium alloy bulkhead,the cavity filling problem was addressed by optimizing the multi-pass local loading path with an unequal thickness billet.The dynamic performance of the multi-pass local loading hydraulic system was found to be robust,with stable pressure transitions during motion and load switching for the sub-die(s).The dynamic characteristic of the hydraulic cylinder when switching from non-moving/unloaded state to a moving/loading state are consistent whether a load is present or not.However,the dynamic characteristics differ when switching from a moving/loading state to non-moving/unloaded state,showing opposite behavior.The developed hydraulic drive mechanism provides a way for implementation of multi-pass local loading without auxiliary operation and extra heating.The results of the study provide a foundation for the industrial production of large-scale,complex components with reduced force requirement and low-energy consumption.
基金Key Research and Development Program of Shaanxi Province(2022GY-410)Funding of Western Titanium Technologies Co.,Ltd(WX2210)。
文摘Based on the microstructure characterization,electrochemical impedance spectroscopy,potentiodynamic polarization,and immersion corrosion,this work comparatively analyzed the differences in the electrochemical corrosion morphology and post-foil formation surface morphology of laser beam welded(LBW)sample and spin-formed sample,and compared the corrosion resistance and Cu foil formation ability of two samples in H_(2)SO_(4)/NaCl solution and CuSO_(4) reducing electrolyte.Results show that in H_(2)SO_(4) and NaCl solutions,LBW sample and spin-formed sample exhibit excellent passivation ability and corrosion resistance.Both samples show uniform corrosion morphologies and similar corrosion resistance in the strong acidic solution containing Cl^(-).Meanwhile,the Cu foil formation ability of the welded joint is similar to that of the spin-formed sample,and both samples obtain intact Cu foils with high-quality surfaces and small differences in properties.
基金supported in part by financial support from the National Key R&D Program of China(No.2023YFB3407003)the National Natural Science Foundation of China(No.52375378).
文摘A new analytical model for geometric size and forming force prediction in incremental flanging(IF)is presented in this work.The complex deformation characteristics of IF are considered in the modeling process,which can accurately describe the strain and stress states in IF.Based on strain analysis,the model can predict the material thickness distribution and neck height after IF.By considering contact area,strain characteristics,material thickness changes,and friction,the model can predict specific moments and corresponding values of maximum axial forming force and maximum horizontal forming force during IF.In addition,an IF experiment involving different tool diameters,flanging diameters,and opening hole diameters is conducted.On the basis of the experimental strain paths,the strain characteristics of different deformation zones are studied,and the stable strain ratio is quantitatively described through two dimensionless parameters:relative tool diameter and relative hole diameter.Then,the changing of material thickness and forming force in IF,and the variation of minimum material thickness,neck height,maximum axial forming force,and maximum horizontal forming force with flanging parameters are studied,and the reliability of the analytical model is verified in this process.Finally,the influence of the horizontal forming force on the tool design and the fluctuation of the forming force are explained.
基金granted by the Xinjiang Geological Exploration Fund。
文摘The northwestern margin of Junggar Basin is the region with the richest oil sand resources in China.For better understanding the enrichment rules and deployment of exploration and development of regional oil sand,it is of great scientific significance to study the accumulation conditions of oil sand in different strata and mining areas of the Junggar Basin.Through a large number of field investigations,drilling verification and sampling tests,it is found that the oil sand in the region covers an area of 2000 km^(2),with shallow and thick reservoir,and predicted resource of 180 million tons.The oil sand resources are mainly distributed in four geological strata,namely the Middle Triassic Karamay Formation,Early Jurassic Badaowan Formation,Late Jurassic Qigu Formation,and Early Cretaceous Qingshuihe Formation.The reservoir is mainly composed of sandstone with high porosity and permeability,and the reservoir space is mainly intergranular pores with a medium average oil content.The oil sand deposit in the region is a typical destructive oil reservoir.The crude oil in the oil sand layer is degraded and thickened from the deep to the shallow,the content of saturated hydrocarbon decreased,and the content of aromatic hydrocarbon,non-hydrocarbon and asphaltene increased.The oil source comes from the deep Permian hydrocarbon-generating depression.Unconformities,faults and marginal fan delta-braided river depositional systems constitute effective migration and storage systems.Caprocks of the Upper Triassic Baijiantan Formation,Lower Jurassic Sangonghe Formation and Lower Cretaceous Hutubihe Formation were formed by three large scale lake transgressions.The Indosinian,Yanshan and Late Yanshan movements are the main driving forces for the migration of deep oil and gas to the shallow edge to form oil sand deposits.It is considered that the oil sand in the northwestern margin of Junggar Basin is of a slope complex migration type.
基金financially supported by the National Natural Science Foundation of China(Grant Nos.U1906233 and 52201312)Dalian High-Level Talent Innovation Program(Grant No.2021RD16)the Natural Science Foundation of Liaoning Province of China(Grant No.2023-BSBA-052).
文摘The carcass layer is the innermost structure of flexible marine risers and is responsible for resisting external pressure.It has an“S”section with a spiral interlocking feature.After the multi-pass roll forming of a flat steel strip,a carcass layer is formed by lock forming.During roll forming,the steel strip undergoes significant plastic deformation,and its local area accumulates residual stress owing to multiple loading and unloading cycles.These phenomena complicate the design and analysis of the carcass layer multi-pass roll forming(CLMRF)process and cause issues in the carcass layer during manufacturing,such as strip fracture and low forming quality.Thus,herein,CLMRF was investigated to clarify the stress distribution,and a parameter analysis was performed.First,the CLMRF process was designed on the basis of classical roll-forming design theory.Second,a finite element model was established,and CLMRF was simulated.Third,the distributions of the forming stress and residual stress of the strip during CLMRF were investigated.Finally,the influences of the strip thickness,roll gap,roll distance,and angular increment were investigated.The conclusions of this study can be used to provide technical guidance in the manufacturing of flexible risers.
基金the National Science and Technology Major Project of China(No.2019-VII0017e0158)the National Natural Science Foundation of China(No.U21A20131)+1 种基金the Industry-University Research Cooperation Project,China(No.HFZL2020CXY025)the National Key Laboratory of Science and Technology on Helicopter Transmission,China(No.HTL-O-21G05).
文摘Spiral bevel gears are critical transmission components,and are widely used in the aerospace field.This paper proposes a new multi-DOF envelope forming process for fabricating spiral bevel gears.Firstly,the multi-DOF envelope forming principle of spiral bevel gears is proposed.Secondly,the design methods for the envelope tool geometry and movement are proposed based on the envelope geometry and movement relationships.Thirdly,the metal flow and tooth filling laws are revealed through 3D FE simulation of the multi-DOF envelope forming process of a typical spiral bevel gear.Fourthly,a new method for separating the envelope tool and the formed spiral bevel gear with back taper tooth is proposed to avoid their interference.Finally,experiments on multi-DOF envelope forming of this typical spiral bevel gear are conducted using new heavy load multi-DOF envelope forming equipment.The simulation and experimental results show the feasibility of the proposed multi-DOF envelope forming process for fabricating spiral bevel gears with back taper tooth and the corresponding process design methods.
基金the support of the Key Research and Development Program of Shaanxi Province,China(No.2021GXLH-Z-049)。
文摘The influence of geometric configuration on the friction characteristics during incremental sheet forming of AA5052 was analyzed by integrating surface morphology and its characteristic parameters,along with plastic strain,contact pressure,and area.The interface promotes lubrication and support when wall angles were≤40°,a 0.5 mm-thin sheet was used,and a 10 mm-large tool radius was employed.This mainly results in micro-plowing and plastic extrusion flow,leading to lower friction coefficient.However,when wall angles exceed 40°,significant plastic strain roughening occurs,leading to inadequate lubrication on the newly formed surface.Increased sheet thickness and decreased tool radius elevate contact pressure.These actions trigger micro-cutting and adhesion,potentially leading to localized scuffing and dimple tears,and higher friction coefficient.The friction mechanisms remain unaffected by the part’s plane curve features.As the forming process progresses,abrasive wear intensifies,and surface morphology evolves unfavorably for lubrication and friction reduction.
基金Project(4013311)supported by the National Science Foundation of Iran(INSF)。
文摘This article examines the influence of annealing temperature on fracture toughness and forming limit curves of dissimilar aluminum/silver sheets.In the cold roll bonding process,after brushing and acid washing,the prepared surfaces are placed on top of each other and by rolling with reduction more than 50%,the bonding between layers is established.In this research,the roll bonding process was done at room temperature,without the use of lubricants and with a 70%thickness reduction.Then,the final thickness of the Ag/Al bilayer sheet reached 350μm by several stages of cold rolling.Before cold rolling,it should be noted that to decrease the hardness created due to plastic deformation,the roll-bonded samples were subjected to annealing heat treatment at 400℃for 90 min.Thus,the final samples were annealed at 200,300 and 400℃for 90 min and cooled in a furnace to examine the annealing temperature effects.The uniaxial tensile and microhardness tests measured mechanical properties.Also,to investigate the fracture mechanism,the fractography of the cross-section was examined by scanning electron microscope(SEM).To evaluate the formability of Ag/Al bilayer sheets,forming limit curves were obtained experimentally through the Nakazima test.The resistance of composites to failure due to cracking was also investigated by fracture toughness.The results showed that annealing increases the elongation and formability of the Ag/Al bilayer sheet while reduces the ultimate tensile strength and fracture toughness.However,the changing trend is not the same at different temperatures,and according to the results,the most significant effect is obtained at 300℃and aluminum layers.It was also determined that by increasing annealing temperature,the fracture mechanism from shear ductile with small and shallow dimples becomes ductile with deep cavities.
基金Shaanxi Province Qin Chuangyuan“Scientist+Engineer”Team Construction Project(2022KXJ-071)2022 Qin Chuangyuan Achievement Transformation Incubation Capacity Improvement Project(2022JH-ZHFHTS-0012)+1 种基金Shaanxi Province Key Research and Development Plan-“Two Chains”Integration Key Project-Qin Chuangyuan General Window Industrial Cluster Project(2023QCY-LL-02)Xixian New Area Science and Technology Plan(2022-YXYJ-003,2022-XXCY-010)。
文摘To overcome the shortage of complex equipment,large volume,and high energy consumption in space capsule manufacturing,a novel sliding pressure Joule heat fuse additive manufacturing technique with reduced volume and low energy consumption was proposed.But the unreasonable process parameters may lead to the inferior consistency of the forming quality of single-channel multilayer in Joule heat additive manufacturing process,and it is difficult to reach the condition for forming thinwalled parts.Orthogonal experiments were designed to fabricate single-channel multilayer samples with varying numbers of layers,and their forming quality was evaluated.The influence of printing current,forming speed,and contact pressure on the forming quality of the single-channel multilayer was analyzed.The optimal process parameters were obtained and the quality characterization of the experiment results was conducted.Results show that the printing current has the most significant influence on the forming quality of the single-channel multilayer.Under the optimal process parameters,the forming section is well fused and the surface is continuously smooth.The surface roughness of a single-channel 3-layer sample is 0.16μm,and the average Vickers hardness of cross section fusion zone is 317 HV,which lays a foundation for the subsequent use of Joule heat additive manufacturing technique to form thinwall parts.
基金National Key Research and Development Program(2021YFB3401101)。
文摘Short process forming techniques for brazing and soldering materials can shorten the process,improve product quality,and increase production efficiency,which has received much attention from welding researchers.This review mainly summarized the research reports on short process forming techniques for brazing and soldering materials.Firstly,the traditional process and its shortcomings were presented.Secondly,the latest research of short process forming technologies,such as continuous casting technique,atomization powder technique,solder ball forming technique,and rapid solidification technique,was summarized,and the traditional forming performance of several brazing and soldering materials was introduced.Finally,the current restrictions and research trends of short process forming technique for brazing and solder materials were put forward,providing theoretical guidance and reference for related research and technique development in brazing and soldering field.
基金Science and Technology Planning Project of Inner Mongolia Science and Technology Department(2022YFSH0021)Key Research and Development Program of Shaanxi Province(2024SF2-GJHX-14,2021SF-296)。
文摘Four types of Mg-5Zn porous scaffolds with different pore geometries,including body-centered cubic(bcc),the rhombic dodecahedron(RD),gyroid(G),and primitive(P)types,were designed and fabricated using selective laser melting.Their forming quality,compression mechanical properties,and degradation behavior were investigated.Results indicate that the fabricated scaffolds exhibit good dimensional accuracy,and the surface chemical polishing treatment significantly improves the forming quality and reduces porosity error in porous scaffolds.Compared to the ones with rod structures(bcc,RD),the scaffolds with surface structures(G,P)have less powder particle adhesion.The G porous scaffold exhibits the best forming quality for the same design porosity.The predominant failure mode of scaffolds during compression is a 45°shear fracture.At a porosity of 75%,the compression property of all scaffolds meets the compressive property requirements of cancellous bone,while bcc and G structures show relatively better compression property.After immersion in Hank's solution for 168 h,the B-2-75% pore structure scaffold exhibits severe localized corrosion,with fractures in partial pillar connections.In contrast,the G-3-75% pore structure scaffold mainly undergoes uniform corrosion,maintaining structural integrity,and its corrosion rate and loss of compressive properties are less than those of the B-2-75%structure.After comparison,the G-pore structure scaffold is preferred.
基金the National Key R&D Program of China(No.2023YFB3407003)the National Natural Science Foundation of China(No.52375378).
文摘An analytical model for contact area and contact stress considering the loading history in incremental sheet forming(ISF)was established.Then,by integrating with the directional characteristics of friction force and horizontal force in the process,a friction test method reflecting the forming characteristics of ISF was proposed.Friction coefficients during the forming processes of parts with different wall angles were measured under various plane curves,process paths,and lubrication conditions.Furthermore,the accuracy of the analytical model,as well as the measured friction coefficients and their variation trends,was verified through comparative analysis with experimental results,simulation data,and outcomes from other existing models.The results indicate that the influence of the plane curve characteristics and process paths of parts on the friction condition is not significant.Under the lubrication conditions of L-HM46 oil,MoS_(2)grease,graphite powder,and dry friction,the friction coefficient shows a gradually increasing trend.Notably,when the wall angle is≤40°,the friction coefficient remains relatively constant;however,when the wall angle exceeds 40°,the friction coefficient increases progressively.
基金supported by the National Natural Science Foundation of China(62403296,62303292,62173218).
文摘Dear Editor,This letter investigates the grid-forming control for power converters.Recently,grid-forming control based on matching of synchronous machines was suggested by using continuous measurements.In the present letter,we suggest a digital implementation using artificial delays where the controller employs the discrete-time measurements only.
基金Supported by National Natural Science Foundation of China(Grant No.U21A20131)Innovative Research Team Development Program of Ministry of Education of China(Grant No.IRT17R83)111 Project(Grant No.B17034)。
文摘To improve braking performance and achieve lightweight in transport equipment,it is necessary to implement overall plastic forming manufacturing of the brake pad baseboard(BPB),which is the core safety component of the brake system.This study presents an innovative multi-DOF envelope forming(MDFEF)process to realize the plastic forming of BPB with thin skin and high reinforcing ribs.The MDFEF principle for BPB,and the design methods for the envelope mold are first presented.Through FE simulations,the behavior of metal flow,uneven growth pattern of reinforcing ribs,evolution of equivalent strain and evolution of forming force in MDFEF of BPB are investigated.To realize MDFEF,an innovative MDFEF equipment driven by parallel linkages is exploited.The force states of linkages in MDFEF are calculated,and the reasonable mold position is determined to reduce the maximum force on the linkages and improve the service performance of MDFEF equipment.The MDFEF experiments of BPB are conducted and qualified BPB is obtained,which demonstrates that the presented MDFEF process and equipment are applicable to manufacture BPB with thin skin and high reinforcing ribs.
基金co-supported by the supports of Guangdong Basic and Applied Basic Research Foundation(No.2019B1515120047)the National Natural Science Foundation of China(No.52130507)。
文摘Sheet metal spinning is an incremental forming process for producing axisymmetric thinwalled parts through continuous local deformation under the action of rollers.While studying the spinning process by finite element(FE)method,a critical bottleneck is the enormous simulation time.For beating off this challenge,a novel multi-mesh method is developed.The method can dynamically track the movement of rollers and adaptively refine the mesh.Thus,a locally refined quadrilateral computation mesh can be generated in the locally-deforming zone and reduce the unnecessary fine elements outside the locally-deforming zone.In the multi-mesh system,the fine elements and coarse elements are extracted from a storage mesh and a background mesh,respectively.Meanwhile,the hanging nodes in the locally refined mesh are removed by designing 4-refinement templates.Between computation mesh and storage mesh,a bi-cubic parametric surface fitting algorithm and accurate remapping methods are conducted to transmit geometric information and physical fields.The proposed method has been verified by two spinning processes.The results suggest that the method can save time by up to about 67%with satisfactory accuracy,especially for distributions of thickness and strain compared with the fully refined mesh.
基金financially supported by the National Natural Science Foundation of China(Nos.52274404,52305441,and U22A20190)the Natural Science Foundation of Hunan province(Nos.2022JJ20065 and 2023JJ40739)+1 种基金the Science and Technology Innovation Program of Hunan Province(No.2022RC1001)the National Key R&D Program of China(No.2021YFB3400903).
文摘Obtaining zero springback and good post-form performance simultaneously is an ultimate pursuit in metal sheet forming.The stress-relaxation ageing(SRA)behavior and mechanical properties of a commercial 2219 aluminum alloy largely pre-deformed(LPD)by 80%have been systematically investigated.The stress relaxation ratio of the LPD alloy reaches approximately 94%regardless of the initial stress(50–350 MPa)after ageing for 12 h at 140°C.This relaxation ratio is about 2.9 and 1.8 times that in the T4 tempered alloy(27.6%under 50 MPa and 31.5%under 150 MPa)and T3 tempered alloy(37.6%under 50 MPa and 51.2%under 150 MPa),respectively.The microstructures,comprised of GP zones/θ'precipitates plus dislocation tangles,and tensile properties in the stress-relaxation-aged LPD alloys remain basically invariant with different initial stresses,as is vital importance for property consistency at different locations of the formed part.Under the same SRA condition,the LPD alloy has an increase of 150–230 MPa in yield strength relative to T3/T4 tempered alloy and obtains a uniform elongation of about 8%.A simple dislocation-based constitutive model accurately describing stress relaxation enhanced by the high dislocation density is established and embedded in the finite element package through a user subroutine.Simulations and experimental verifications show the LPD alloy sheet parts exhibit a nearly zero springback(<5%)after unloading in contrast to the springback larger than 65%in the T3/T4 alloy sheet parts under the same condition.Our findings demonstrate the high-dislocation-density-enhanced SRA response enables a high-performance springback-free age forming of Al alloy sheet.
