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Modelling and analysis of metal flowing behaviors in constraining ring rolling of tapered ring with thin wall and three high ribs

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Chinese Journal of Aeronautics 2023年第6期36卷 476-492页

作者： Lin HUA Duanyang TIAN Xinghui HAN Wuhao ZHUANG Hubei Key Laboratory of Advanced Technology for Automotive Components Wuhan University of TechnologyWuhan 430070China Hubei Longzhong Laboratory Xiangyang 441000China School of Automotive Engineering Wuhan University of TechnologyWuhan 430070China

Tapered ring with thin wall and three high ribs(TRTWTHR),showing complicated geometry(wall thickness is less than 4 mm and rib height exceeds 20 mm),is extensively utilized to fabricate the critical structural parts of aerospace equipment such as spacecraft cabin,rocket body and fuel tank because of light weight and high carrying *** to fabricate TRTWTHR with high performance is a critical problem that aerospace area needs to *** this work,constraining ring rolling(CRR)technique is first adopted to form *** metal streamlines(UMS)and uncoordinated growth of three ribs easily occur in CRR of TRTWTHR,which makes the forming quality of TRTWTHR difficult to be *** with this difficulty,an analytical model that can predict UMS and the height of three ribs in CRR of TRTWTHR is established so as to guide the process design of ***,the reliability of the established analytical model and the feasibility of CRR of TRTWTHR are confirmed by FE simulation and ***,using the established analytical model,the window of UMS occurring relevant to the tapered angle of TRTWTHR and the location of the rib of middle end is ***,three uncoordinated growth modes among three ribs are found when the width of three ribs is identical and UMS do not occur,and the mechanisms of three uncoordinated growth modes are revealed.

关键词： Analytical model Constraining ring rolling Growth of three ribs Metal streamlines Tapered ring with thin wall and three high ribs

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An innovative constraining ring rolling process for manufacturing conical rings with thin sterna and high ribs

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Chinese Journal of Aeronautics 2022年第8期35卷 324-339页

作者： Duanyang TIAN Xinghui HAN Lin HUA Xuan HU Hubei Key Laboratory of Advanced Technology for Automotive Components Wuhan University of TechnologyWuhan 430070 China School of Automotive Engineering Wuhan University of TechnologyWuhan 430070China

Conical rings with thin sterna and high ribs(CRTSHR)are key bearing-load parts of aerospace equipment,which are required to be manufactured with high performance and *** ring rolling is the most preferred method for manufacturing high-performance ring parts,but it can hardly achieve the forming of CRTSHR due to the extreme geometry of *** solve this difficulty,an innovative constraining ring rolling process(CRR)is proposed in this paper to manufacture *** evaluate the proposed CRR and reveal its deformation behaviors,a thermomechanical coupled FE model for CRR of CRTSHR is ***,the experiment for CRR of CRTSHR is performed on a modified ring rolling machine,which proves that CRR of CRTSHR is feasible and the established FE model is *** on the reliable FE model,the metal flow mode in deformed CRTSHR is analyzed,and the deformation characteristics such as the stress state,strain distribution and the evolution of power parameters in CRR of CRTSHR are ***,the influences of key parameters such as the friction factor between ring and molds,the diameter of idle roll and the feed velocity of idle roll on CRR of CRTSHR are investigated by FE simulation.

关键词： Conical rings with thin sterna and high ribs Deformation characteristics FE simulation Metal flow Ring rolling

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Research on Measurement Method of Muffler Performance under High Temperature and High-Speed Airflow Conditions

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Journal of Beijing Institute of technology 2020年第2期29卷 241-250页

作者： Liping Xie Chihua Lu Zhien Liu Yawei Zhu Hubei Key Laboratory of Advanced Technology of Automotive Components Wuhan University of TechnologyWuhan 430070China Hubei Collaborative Innovation Center for Automotive Components Technology Wuhan 430070China

Ignoring the influence of flow velocity and flow temperature on muffling performance,performance tests were conducted without airflow in the development phase of the muffler which accounts to the difficulty of obtaining a perfect match between the actual noise reduction effect and the design *** on the two-load test theory,a set of high-temperature and high-speed airflow simulation measurement devices for the muffler has been *** order to avoid the impact of high-temperature and high-speed airflow on the sensor,a high temperature resistant sensor holder has been designed for the test *** sound pressure has been measured in the pipe by using the lead-out *** addition,a variable impedance load is placed at the end of the test tube to realize the switch between two different impedance loads by the wave handle of the variable impedance load.A sound source correction method is proposed to decrease the random fluctuation of the spectral characteristics of the output noise signal,which is caused by the acoustic impedance variation at the connection between the transition pipeline and the combined sound source ***,an acoustic software has been used to calculate the transmission loss of the muffler in the presence of high temperature *** comparing the experimental measurements and the simulation results,the small difference shows that:the bench not only can effectively simulate high-temperature and flow velocity environment of the engine but also accurately test the transmission loss of the muffler.

关键词： muffler lead-out measurement variable load source correction transmission loss

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Failure Mechanisms and Structural Optimization of Shredder Hammer for Metal Scraps

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Chinese Journal of Mechanical Engineering 2016年第4期29卷 792-801页

作者： ZHOU Xianyan HU Zhili TAO Yijun QIN Xunpeng HUA Lin Hubei Key Laboratory of Advanced Technology for Automotive Components Wuhan University of Technology Wuhan 430070 China Hubei Lidi Machine Tool Company Limited Yichang 443000 China

Recycling retired cars can relieve the environmental pollution and resource waste ***,a few publications can be found on the failure mechanisms and optimization method of recycling equipment,***,the failure mechanisms and structural optimization of shredder hammers for retired cars are studied aiming improving shredding efficiency and reducing *** types of shredder hammer are studied theoretically,and it is found that wear failure and fatigue failure are the two main failure types of shredder *** shredding process of metal scraps is analyzed by finite element method,and it can be divided into four stages based on the stress states：initial stage,collision stage,grinding stage and separation *** is proved that the shredding efficiency can be improved by increasing cutouts on the hammer ***,it is determined that the hammer with two cutouts is the optimal structure for metal scraps,which can improve the shredding efficiency by 20% and lengthen the hammer life by 15%.This study provides scientific basis for the industry application and theoretical foundation for further research.

关键词： Metal scraps recycling impacts grinding structural optimization

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Analysis and prediction of surface roughness for robotic belt grinding of complex blade considering coexistence of elastic deformation and varying curvature

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Science China(Technological Sciences) 2021年第5期64卷 957-970页

作者： XU XiaoHu YE SongTao YANG ZeYuan YAN SiJie ZHU DaHu DING Han State Key Laboratory of Digital Manufacturing Equipment and Technology Huazhong University of Science and TechnologyWuhan 430074China Hubei Key Laboratory of Advanced Technology for Automotive Components Wuhan University of TechnologyWuhan 430070China Hubei Collaborative Innovation Center for Automotive Components Technology Wuhan University of TechnologyWuhan 430070China

Precision prediction of machined surface roughness is challenging facing the robotic belt grinding of complex blade,since this process is accompanied by significant elastic *** resulting poor prediction accuracy,to a great extent,is attributed to the existing prediction model which less considers the *** this paper,an improved scallop height model is developed to predict and assess the machined surface roughness by taking into account the elastic deformation and the varying curvature of blade,then robotic belt grinding experiments are carried out to evaluate the proposed model from the perspective of surface *** factors that influence the scallop height are analyzed,and the suitable empirical equation of surface roughness is proposed to assess and predict the surface quality from the aspect of blade concave and convex surface by adopting the constant scallop height machining.

关键词： robotic belt grinding scallop height elastic deformation surface roughness prediction

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Anti-wear properties evaluation of frictional sliding interfaces in automobile engines lubricated by copper/graphene nanolubricants

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Friction 2020年第5期8卷 905-916页

作者： Mohamed Kamal Ahmed ALI Xianjun HOU Mohamed AAABDELKAREEM Hubei Key Laboratory of Advanced Technology for Automotive Components Wuhan University of TechnologyWuhan 430070China Automotive and Tractors Engineering Department Faculty of EngineeringMinia UniversityEl-Minia 61111Egypt Hubei Collaborative Innovation Center for Automotive Components Technology Wuhan 430070China

Owing to the significance of improving fuel economy, reducing emissions, and extending the durability of engine components, this study focused on the tribological performance of nano-additives. In this study, copper (Cu) and graphene (Gr) nanomaterials were dispersed in a fully formulated engine oil (5W-30) with different concentrations. The tribological trials were investigated under various speeds and loads, utilizing a reciprocating tribometer to mimic the ring/liner interfaces in the engine. The frictional surface morphologies were com-prehensively analyzed using electron probe X-ray microanalysis (EPMA), field emission scanning electron microscopy (FESEM), energy dispersive spectrometer (EDS), and three dimensional (3D) surface profilometry to explore the mechanisms responsible for improving the tribological performance of the frictional sliding parts in the engine. The tribological test results illustrated that lubrication by nano-additives reduced the wear rate (WR) and friction coefficient (COF) by 25%–30% and 26.5%–32.6%, respectively, as compared with 5W-30. The results showed that this is a promising approach for increasing the durability and lifespan of frictional sliding components and fuel economy in automobile engines.

关键词： engine tribology nanomaterial nanolubricant friction wear tribofilm

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Subsurface crack propagation under rolling contact fatigue in bearing ring

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Science China(Technological Sciences) 2013年第10期56卷 2422-2432页

作者： DENG Song HAN XingHui QIN XunPeng HUANG Song School of Automotive Engineering Hubei Key Laboratory of Advanced Technology of Automotive Parts Wuhan University of Technology

The influences of subsurface cracks,distributing along the axial direction,on the rolling contact fatigue(RCF)faliure in a bearing ring are investigated.A realistic three-dimensional model of the bearing ring containing three subsurface cracks is used to evaluate the fatigue crack propagation based on stress intensity factor(SIF)***,the distributions of the subsurface cracks along the axial direction are varied to study their effects on *** results provide valuable guidelines for enhanced understanding of RCF in bearings.

关键词： bearing ring subsurface cracks rolling contact fatigue stress intensity factors

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Finite element analysis of contact fatigue and bending fatigue of a theoretical assembling straight bevel gear pair

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Journal of Central South University 2013年第2期20卷 279-292页

作者：邓松华林韩星会黄松 School of Automotive Engineering Hubei Key Laboratory of Advanced Technology of Automotive PartsWuhan University of Technology

The aim of this work is to propose a 3D FE model of a theoretical assembling straight bevel gear pair to analyze the contact fatigue on the tooth surface and the bending fatigue in the tooth root. Based on the cumulative fatigue criterion and the stress-life equation, the key meshing states of the gear pair were investigated for the contact fatigue and the bending fatigue. Then, the reliability of the proposed model was proved by comparing the calculation result with the simulation result. Further study was performed to analyze the variation of the contact fatigue stress and the bending fatigue stress under different loads. Furthermore, the roles of the driving pinion and the driven gear pair were evaluated in the fatigue life of the straight bevel gear pair and the main fatigue failure mode was determined for the significant gear. The results show that the fatigue failure of the driving pinion is the main fatigue failure for the straight bevel gear pair and the bending fatigue failure is the main fatigue failure for the driving pinion.

关键词： straight bevel gear finite element method contact fatigue bending fatigue

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Modelling and simulation of contact force in cold rotary forging

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Journal of Central South University 2014年第1期21卷 35-42页

作者：秦训鹏 School of Automotive Engineering Hubei Key Laboratory of Advanced Technology of Automotive PartsWuhan University of Technology

Cold rotary forging is an advanced and complex metal forming technology with continuous local plastic *** the contact force between the dies and the workpiece has a great significance to improve the life of the dies in cold rotary *** purpose of this work is to reveal the contact force responses in cold rotary forging through the modelling and *** this purpose,a 3D elastic-plastic dynamic explicit FE model of cold rotary forging is developed using the FE code ABAQUS/*** the modelling and simulation,the distribution and evolution of the contact force in cold rotary forging is investigated in *** experiment has been conducted and the validity of the 3D FE model of cold rotary forging has been *** results show that: 1) The contact force distribution is complex and exhibits an obvious non-uniform characteristic in the radial and circumferential directions; 2) The maximum contact force between the upper die and the workpiece is much larger than that between the lower die and the workpiece; 3) The contact force evolution history is periodic and every period experiences three different stages; 4) The total normal contact force is much larger than the total shear contact force at any given time.

关键词： cold rotary forging metal forming simulation contact force die life

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Simplified Method of Simulating Double-Layer Micro-Perforated Panel Structure

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automotive Innovation 2018年第4期1卷 374-380页

作者： Wan Chen Chihua Lu Zhien Liu Songze Du Hubei Key Laboratory of Advanced Technology for Automotive Components Wuhan University of TechnologyWuhan 430070China Hubei Collaborative Innovation Center for Automotive Components Technology Wuhan University of TechnologyWuhan 430070China

The micro-perforated panel(MPP)structure has been widely used in various noise control applications,and thus its acoustic performance prediction has been receiving increasing *** acoustic performance of simple MPP structures,such as a MPPsound absorber,has been predicted using an analytical calculation ***,this is not a suitable approach toward predicting the acoustic performance of complicated MPP structures,owing to the structural complexity of these ***,the many perforations of submillimeter scale diameter render the MPP structures very difficult to analyze using numerical ***,this study focused on two different simplified MPP simulation methods:the transfer admittance method and the equivalent fluid method,and their application on double-layer MPP *** on the two simplified MPP simulation methods,the transmission loss value of the double-layer MPP mufflers with two sets of different structural parameters was calculated,*** predicted results were compared with the impedance tube *** results revealed that the two simplified MPP simulation methods could effectively predict the acoustic performance of doublelayer MPP ***,the prediction based on the transfer admittance method can outperform the two simplified simulation methods.

关键词： Double-layer MPP structure Acoustic simulation Transfer admittance Porous material Experimental test

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