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A new multi-DOF envelope forming process for fabricating spiral bevel gears with back taper tooth

Chinese Journal of Aeronautics 2025年第1期38卷 568-585页

作者： Xinghui HAN Yanhui WANG Lin HUA Wuhao ZHUANG Fangyan ZHENG Wei FENG Hubei Key Laboratory of Advanced Technology for Automotive Components Wuhan University of TechnologyWuhan 430070China Hubei Longzhong Laboratory Xiangyang 441000China

Spiral bevel gears are critical transmission components,and are widely used in the aerospace *** paper proposes a new multi-DOF envelope forming process for fabricating spiral bevel ***,the multi-DOF envelope forming principle of spiral bevel gears is ***,the design methods for the envelope tool geometry and movement are proposed based on the envelope geometry and movement ***,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 ***,a new method for separating the envelope tool and the formed spiral bevel gear with back taper tooth is proposed to avoid their ***,experiments on multi-DOF envelope forming of this typical spiral bevel gear are conducted using new heavy load multi-DOF envelope forming *** 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.

关键词： Multi-DOF envelope forming Spiral bevel gear Back taper tooth Metal flow Process design

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Strengthening and toughening mechanisms of martensite-bainite microstructure in 2 GPa ultra-high strength steel during hot stamping

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Science China Technological Sciences 2025年第5期68卷 19-33页

作者： Yanli SONG Ye LI Jue LU Lin HUA Yanfeng GU Yikuan YANG Hubei Key Laboratory of Advanced Technology for Automotive Components Wuhan University of Technology State Key Laboratory of Advanced Technology for Materials Synthesis and Processing Wuhan University of Technology

In response to the growing demand for energy efficiency, safety, and lightweight designs in new energy vehicles, this study addresses the challenge of balancing strength and toughness in ultra-high strength steel(UHSS) components produced by hot stamping. An innovative hot stamping process based on a martensite-bainite(M-B) complex-phase microstructure was proposed to enhance the strength and toughness of UHSS. The microstructural evolution of the M-B complexphase during the hot stamping process was investigated using commercial B1800HS steel. With a microstructure consisting of 87.4.% martensite, 8.7% lower bainite, and 3.9% film-like retained austenite by volume fraction, the steel achieved a tensile strength of 1944 MPa, total elongation of 9.66%, and impact energy of 25.8 J. Compared with conventional hot stamping, the strength of the material showed only a slight improvement, whereas elongation and impact energy were enhanced by approximately 53% and 32%, respectively. A quantitative relationship among process parameters, resulting microstructure, and mechanical properties was established. Optimization between strength and toughness was observed when the low bainite volume fraction ranged from 5.06% to 8.73%. The toughening mechanisms are attributed to the refinement of martensite lath bundles(width of 202 nm) facilitated by bainite formation, the increase in high-angle grain boundaries, and the presence of nanoscale retained austenite(width of 80 nm) between the laths. Additionally, the refinement of grains and the formation of nanoscale(Nb, Ti)C precipitates(diameter of 17 nm) further contributed to the overall strength. The developed M-B complexphase process, which involves medium-temperature slow cooling followed by rapid low-temperature quenching, provides an optimal combination of strength and toughness for a wide range of applications.

关键词： ultra-high strength steel hot stamping strengthening and toughening mechanisms martensite-bainite complex-phase microstructure

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Catalytic Performance of Carbon Smoke over Ag-LSCF Composite Catalysts

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Journal of Wuhan University of technology(Materials Science) 2025年第1期40卷 30-34页

作者： GUO Guanlun HAN Ming LU Shaomin YU Jing JU Hongling 无 Hubei Key Laboratory of Advanced Technology for Automotive Components&Hubei Collaborative Innovation Center for Automotive Components Technology Wuhan University of TechnologyWuhan 430070China College of Mechanical and Transportation Southwest Forestry UniversityKunming 650000China

To improve the catalytic performance of La_(0.6)Sr_(0.4)Co_(0.2)Fe_(0.8)O_(3)(LSCF)towards carbon soot,we utilized the impregnation method to incorporate Ag into the prepared LSCF *** conducted a series of characterization tests and evaluated the soot catalytic activity of the composite catalyst by comparing it with the LaCoO_(3) group,LaFeO_(3) group,and catalyst-free *** results indicate that the Ag-LSCF composite catalyst exhibits the highest soot catalytic activity,with the characteristic temperature values of 376.3,431.1,and 473.9℃at 10%,50%,and 90%carbon soot conversion,*** values are 24.8,20.2,and 23.1℃lower than those of the LSCF *** also shows that LSCF can improve the catalytic activity of soot after compounding with Ag,and reflects the necessity of using catalysts in soot combustion *** characterization and BET test show that Ag-LSCF has more abundant surface-adsorbed oxygen species,larger specific surface area and pore volume than LSCF,which also proves that Ag-LSCF has higher soot catalytic activity.

关键词： metallic composites carbon smoke oxidation perovskite catalyst soot

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Bending Characteristics of Folded Multi-celled Tubes with Square and Circular Section Geometries

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Acta Mechanica Solida Sinica 2025年第1期38卷 125-141页

作者： Rui Liang Fengxiang Xu Zhen Zou Xiaoqiang Niu Xuebang Tang Tingpeng Li School of Automobile Engineering Guilin University of Aerospace TechnologyGuilin541004China Hubei Key Laboratory of Advanced Technology of Automotive Components Wuhan University of TechnologyWuhan430070China Hubei Collaborative Innovation Center for Automotive Components Technology Wuhan University of TechnologyWuhan430070China Academic Affairs Office Guilin University of Aerospace TechnologyGuilin541004China

This research investigates the bending response of folded multi-celled tubes(FMTs)fabricated by folded metal sheets.A three-point bending test for FMTs with circular and square sections is designed and *** base numerical models are correlated with physical experiments and a static crashworthiness analysis of six FMT configurations to assess their energy absorption *** influences of thickness,sectional shape,and load direction on the bending response are *** indicate that increasing the thickness of the tube and radian of the inner tube enhances the crashworthiness performance of FMT,yielding a 20.50%increase in mean crushing force,a 55.53%increase in specific energy absorption,and an 18.05%decrease in peak crushing force compared to traditional multi-celled tubes(TMTs).A theoretical analysis of the specific energy absorption indicates that FMTs outperform TMTs,particularly when the peak crushing force is *** study highlights the innovative and practical potential of FMTs to improve the crashworthiness of thin-walled structures.

关键词： Bending Folded Multi-celled tube Energy absorption Numerical

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Residual stress optimization in laser melting deposited TC4 titanium alloy using in-situ electromagnetic field

Residual stress optimization in laser melting deposited TC4 ...

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Chinese Materials Conference 2024, CMC 2024

作者： Li, Weihao Fu, Tao Zhou, Jian Wang, Haoxing Wen, Yan Xie, Lenchun Hubei Key Laboratory of Advanced Technology for Automotive Components Wuhan University of Technology Wuhan430070 China Hubei Collaborative Innovation Center for Automotive Components Technology Wuhan430070 China

This study explores the optimization of residual stress in TC4 titanium alloy fabricated using laser melting deposition (LMD) through the application of in-situ electromagnetic fields. The electromagnetic field was found to significantly enhance the uniformity of residual stress both on the surface and along the depth direction of alloy. Specifically, a electromagnetic field strength of 35 mT induced the most uniform surface stress distribution, while 56 mT provided the most consistent stress profile along the depth. These results are attributed to the electromagnetic field-induced stirring within the molten pool, which promotes grain refinement and leads to a more uniform distribution of residual stresses. Microstructure analysis further reveals that the electromagnetic field refines the grain structure, promoting the formation of equiaxed grains instead of large columnar crystals typically observed in the absence of electromagnetic field. The findings highlight the potential of electromagnetic field-assisted LMD in optimizing the mechanical properties and stability of additively manufactured titanium alloy, offering valuable insights for improving the reliability and performance of advanced titanium alloys. © 2025 Institute of Physics Publishing. All rights reserved.

关键词： Titanium alloys

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Effect of the electromagnetic field on the microstructure of TC4 titanium alloy during laser melting deposition

Effect of the electromagnetic field on the microstructure of...

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Chinese Materials Conference 2024, CMC 2024

作者： Fu, Tao Xie, Lechun Li, Weihao Wen, Yan Wu, Yongjian Sun, Hongxin Hubei Key Laboratory of Advanced Technology for Automotive Components Wuhan University of Technology Wuhan430070 China Hubei Collaborative Innovation Center for Automotive Components Technology Wuhan430070 China

This paper characterized and analyzed the microstructure of TC4 (Ti6Al-4V) titanium alloy manufactured by laser melting deposition (LMD) under the electromagnetic field. The results showed that the initial LMD-TC4 specimen contains many coarse columnar crystals, and there were aM phases with high aspect ratios, which constitute a dense mesh basket structure and Widmannstatten structure. After electromagnetic treatment, the equiaxial trend of columnar crystals became more and more obvious, and the needle-like a phases are precipitated in the ß phase, the size of the a phases became significantly smaller, and the arrangement mode between grains also changed to the parallel and staggered arrangement. The Electron Backscatter Diffraction (EBSD) results showed that the grain orientation became uniform, the dislocation density decreased, and the average grain size of the sample after electromagnetic treatment was also reduced, indicating that electromagnetic treatment can play a role in grain refinement. © 2025 Institute of Physics Publishing. All rights reserved.

关键词： Titanium alloys

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Kinematics Analysis and Optimization of Stepping Rotary Three-Dimensional Braiding Machine 4th

Kinematics Analysis and Optimization of Stepping Rotary Thre...

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4th International Conference on Mechanical Design and Simulation, MDS 2024

作者： Ji, Cheng Chen, Yizhe Wang, Hui Hubei Key Laboratory of Advanced Technology for Automotive Components Wuhan University of Technology Wuhan430070 China Hubei Longzhong Laboratory Hubei Xiangyang441000 China School of Automotive Engineering Wuhan University of Technology Wuhan430070 China

ISBN: (纸本)9789819778867

Due to its excellent performance, three-dimensional composites are an ideal choice for components in the aerospace and automotive fields. However, the need for smooth operation and productivity of current braiding equipment limits the further application of braided composites. A virtual prototype model of a 3D braiding machine is built for a stepping rotary braiding machine. The kinematic simulation is carried out using ADAMS software to analyze the operational performance of the braiding machine. Through orthogonal experimental design, the effects of different factors such as spindle fit, the gap, yarn tension, and spindle material on the operation of the braiding machine were quantified, and the optimal combination of spindle design parameters was determined based on the experimental results. The Optimization result shows that the optimized spindle operation of the braiding machine has improved by 73% compared with that before the optimization, thus improving the reliability and efficiency of the braided component forming. © The Author(s) 2025.

关键词： Composite material manufacturing Kinematics of machinery Mechanical design Three-dimensional braiding machine

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Innovative warm rolling plus electromagnetic shock treatment for high-quality M50 bearing ring manufacturing

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Journal of Materials Science 2025年第18期60卷 7710-7731页

作者： Zhai, Jiajun Yin, Fei Yi, Yuxuan Song, Chao Hubei Longzhong Laboratory Xiangyang China Hubei Key Laboratory of Advanced Technology for Automotive Components Wuhan University of Technology Wuhan China School of Automotive Engineering Wuhan University of Technology Wuhan China

M50 bearing steel is a high-carbon alloy extensively utilized in the aerospace industry due to its exceptional mechanical properties at elevated temperatures. Its production typically involves cold ring rolling (CRR) at room temperature and hot ring rolling (HRR) at high temperatures. The CRR process offers high precision but is susceptible to microcrack formation, while HRR can effectively eliminate defects but may induce coarse grain structures, reducing material performance. To address these issues, this study proposes a novel warm ring rolling (WRR) process, which integrates the benefits of both CRR and HRR. The aim is to optimize the forming rate while improving the plasticity limit and microstructural integrity of the material. Additionally, the study investigates the hot deformation behavior of M50 bearing steel under various deformation conditions and derives strain-compensated constitutive equations to predict its deformation, failure, and fatigue characteristics during the warm forming process. Temperature-dependent compression tests, along with electromagnetic shock treatment (EST) experiments, were also conducted. Results indicate that increasing the compression temperature reduces void formation, while EST significantly mitigates voids and promotes the dissolution and fragmentation of carbides. Furthermore, under the influence of EST, the average grain size of the WRR specimen notably decreases. The study concludes that the optimal processing temperature for EST–WRR technology is 400 ℃, with a current density of 140 A/mm2. This research provides a theoretical foundation for the future processing and performance optimization of M50 bearing steel and validates the efficacy of EST in the WRR process.

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Microstructure and mechanical properties of ZK61 magnesium alloy thin-walled cylindrical component processed by two-step forging

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Journal of Magnesium and Alloys 2025年

作者： Chai, Fang Feng, Jianqiang Han, Xinghui Zhuang, Wuhao Chen, Yizhe Hu, Zhili Hu, Xuan Zheng, Fangyan Hua, Lin Hubei Key Laboratory of Advanced Technology for Automotive Components Wuhan University of Technology Wuhan430070 China Hubei Longzhong Laboratory Xiangyang441000 China

Magnesium alloy thin-walled cylindrical components with the advantages of high specific stiffness and strength present broad prospect for the lightweight of aerospace components. However, poor formability resulting from the hexagonal close-packed crystal structure in magnesium alloy puts forwards a great challenge for thin-walled cylindrical components fabrication, especially for extreme structure with the thickness-changing web and the high thin-wall. In this research, an ZK61 magnesium alloy thin-walled cylindrical component was successfully fabricated by two-step forging, i.e., the pre-forging and final-forging is mainly used for wed and thin-wall formation, respectively. Microstructure and mechanical properties at the core, middle and margin of the web and the thin-wall of the pre-forged and final-forged components are studied in detail. Due to the large strain-effectiveness and metal flow along the radial direction (RD), the grains of the web are all elongated along RD for the pre-forged component, where an increasingly elongated trend is found from the core to the margin of the wed. A relatively low recrystallized degree occurs during pre-forging, and the web at different positions are all with prismatic and pyramid textures. During final-forging, the microstructures of the web and the thin-wall are almost equiaxed due to the remarkable occurrence of dynamic recrystallization. Similarity, except for few basal texture of the thin-wall, only prismatic and pyramid textures are found for the final-forged component. Compared with the initial billet, an obviously improved mechanical isotropy is achieved during pre-forging, which is well-maintained during final-forging. © 2025

关键词： Magnesium alloys

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Research on Laser Ultrasonic Detection Method of Residual Stress Based on Line Source Excitation & Dual-Point Receiving 7

Research on Laser Ultrasonic Detection Method of Residual St...

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7th International Symposium on Laser Ultrasonics and advanced Sensing, LU 2024

作者： Yan, Wenlong Wang, Xiaokai Dai, Shutong Chen, Hongyu Huang, Andi Han, Zhixiong Gui, Linlin Hubei Key Laboratory of Advanced Technology for Automotive Components Wuhan University of Technology Wuhan430070 China Hubei Collaborative Innovation Center for Automotive Components Technology Wuhan430070 China School of Automotive Engineering Wuhan University of Technology Wuhan430070 China Wuhan Zhongke Innovation Technology Co. Ltd. Wuhan430070 China

Metal components inevitably generate residual stress during the manufacturing process, which has a significant impact on the performance and safety of the components. This article proposes a high-precision residual stress laser ultrasonic detection method based on line source excitation & dual-point receiving. Finite element simulation models of point source and line source laser excitation ultrasonic surface waves are established, and the propagation and energy attenuation laws of surface waves under these two excitation modes are analyzed. A residual stress detection model based on line source excitation & dual-point receiving is derived, and a residual stress detection system is constructed. Taking 6061 aluminum alloy sheet as the object, the detection model was calibrated through standard tensile tests, and multiple sets of tensile tests were conducted to verify the reliability of the model. The error between the calculated value of the stress detection model and the theoretical value of the tensile test was within ± 11.57MPa. A U-shaped test block was designed to obtain the different stress distribution conditions, and residual stress detection experiments were conducted using the proposed method. The detection results accurately reflected the stress gradient distribution state of the U-shaped test block along the top center downwards, and had good consistency with the finite element simulation results. This provides a method for high-precision non-destructive testing of residual stress in metal parts. © 2025 Institute of Physics Publishing. All rights reserved.

关键词： Tensile testing

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