CN102867097B - Method for designing photo-cure quickly formed wind tunnel model in consideration of influence of static elastic deformation - Google Patents

Method for designing photo-cure quickly formed wind tunnel model in consideration of influence of static elastic deformation Download PDF

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CN102867097B
CN102867097B CN201210361976.2A CN201210361976A CN102867097B CN 102867097 B CN102867097 B CN 102867097B CN 201210361976 A CN201210361976 A CN 201210361976A CN 102867097 B CN102867097 B CN 102867097B
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rapid shaping
photocureable rapid
wind tunnel
fluid
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CN102867097A (en
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杨党国
张征宇
王超
孙岩
梁锦敏
张诣
李耀华
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High Speed Aerodynamics Research Institute of China Aerodynamics Research and Development Center
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Abstract

The invention discloses a method for designing a photo-cure quickly formed wind tunnel model in consideration of influence of static elastic deformation. Mapping relation between structural deformation of the model and aerodynamic force is predicted by an aerodynamic/structure coupling analysis method in order to overcome shortcomings of low rigidity, easiness in deformation and the like of thin positions (such as wing tips, wing edges and control plane edges) of the photo-cure quickly formed wind tunnel model, and the aerodynamic shape of the model after the model deforms in a wind tunnel test is consistent with the shape of a cruise required to be researched by searching for a coupling optimization design for the aerodynamic shape of the model by a response surface method, so that corresponding aerodynamic force characteristics of the model are obtained, and accuracy and feasibility of the method are tested by verifying results of practical wind tunnel tests by a typical high-aspect-ratio aircraft model.

Description

Take into account the photocureable rapid shaping wind tunnel model method for designing of static elasticity deformation effect
Technical field
The invention belongs to experimental aerodynamics technical field, particularly a kind of photocureable rapid shaping wind tunnel model method for designing of taking into account static elasticity deformation effect.
Background technology
Wind tunnel model is the object of wind tunnel test, is the prerequisite that obtains accurate test figure.
Traditional take high-speed wind tunnel modelling that metal is material and the process-cycle is long, cost is high, complex appearance model forming is difficult, has seriously restricted wind tunnel test progress, affect model and develops node.The high-speed wind tunnel model of metal material, because relying on numerical control cutting processing, causes being difficult to control the mass distribution and counterweight ratio of wind tunnel model on the one hand; Cause on the other hand that the manufacturing cycle is long, cost is high, with wing, is processed as example, after digital control processing, easily cause machining stress, can cause wing distortion, therefore conventionally need arrange repeatedly heat treatment step, eliminate forming residual stress, thereby increased model manufacturing cycle and cost.
The high-speed wind tunnel model lead time accounts for 70% of the aerodynamic configuration of aircraft design cycle at present, has become and has promoted aircraft conceptual design speed and the topmost bottleneck of model Development Schedule.
For better future aircraft design requirement, the quickening model development process of adapting to, the design of high-speed wind tunnel model and job operation are badly in need of improving at present, to complete design, processing and the correction of the flank shape of wind tunnel model and promote design level in Flight Vehicle Design process, complete faster and better wind tunnel test, obtain accurate test figure.
Introduction To Stereolithography can by the three-dimensional CAD model of any complexity discrete be that one group of parallel cut is cumulative, this has been avoided the geometrical interference and the unrelieved stress phenomenon that in cut, occur, therefore has following advantage:
(1) shape face machining precision and the surface quality of wind tunnel model are high, and the utmost point is suitable for manufacturing the aircraft wind tunnel model with complicated surface;
(2) be convenient to control quality and the Stiffness Distribution of wind tunnel model;
(3) proportion of photosensitive resin is far below metal material, therefore be convenient to make the high-speed wind tunnel model of lightweight.
Given this, the many wind tunnel experimental researches mechanism of present generally carries out model in wind tunnel method for designing and the applied research based on photocuring rapid technology, to solve a development difficult problem for large scale high-speed wind tunnel model, for accelerating model development process and model in wind tunnel correction of the flank shape etc., provide technical support.At rapid prototyping model forming technical elements, US and European maintains the leading position always, U.S. NASA Marshall flight research center has verified that photocureable rapid shaping model carries out the feasibility of high-speed wind tunnel test, result show " the model expense done of steel or aluminum is 15000 dollars, three first quarter moons consuming time; and the production costs of the lightweight wind tunnel model of photocureable rapid shaping between 3000 to 3500 dollars, 2-3 consuming time week, and quality is down to original 3/4 ".
Europe Air Passenger confirms " geometric shape of the wind tunnel model based on Introduction To Stereolithography is more accurate, makes it in the improvement of wing end, lift improved to 3% " in the results of wind tunnel of Britain's cloth reason Manfred Stohl.Also there is own unique mould processing technology in Russia central fluid mechanics study institute (TsAGI), the 2009 Nian Yecong U.S. have introduced model rapid forming equipment, tentative confirmation " rapid shaping technique can produce parts and the model that single fighter plane wind tunnel model parts and composite manufacturing go out combination with high precision ".The advance of Introduction To Stereolithography is mainly reflected in the aspects such as CAD/CAM modelling and machining software, mould, material and process technology, especially can realize the rapid shaping (as the moulding in several days of X-33 model) of wind tunnel model, and according to circumstances also can be to model correction of the flank shape real-time in wind tunnel test process, thereby make wind tunnel test CFDization.Like this, both greatly reduce the cost of mould processing, shorten again the model lead time.
Therefore, carry out photocureable rapid shaping wind tunnel model method for designing and high-speed wind tunnel applied research, development photocureable rapid shaping wind tunnel model method for designing, exploration high-speed wind tunnel application feasibility, not only to solving photocureable rapid shaping wind tunnel model design challenges, shorten the mould processing cycle, cut down finished cost significant, and to improving wind tunnel test efficiency, shorten the model lead time and have larger benefit.
But regrettably, the relevant report of the domestic development of the high-speed wind tunnel model at photocureable rapid shaping and wind tunnel test seldom.In recent years, preliminary pilot study has been carried out in photocureable rapid shaping high-speed wind tunnel modelling theory, method and application aspect in China's aerodynamic investigation and centre of development, obtain challenging progress, found some technological difficulties that need to further investigate and key issues.
In the research process in early stage, based on photosensitive resin proportion, much smaller than the advantage of metal material, processed photosensitive resin rapid shaping AGARD-B wind tunnel model, model quality reduces greatly, and changed model-support system natural frequency, the low peak frequency of avoiding the pneumatic pulsation of transonic wind tunnel test section has realized vibration damping; In model, metallic framework adopts configuration simple in structure, standard, and profile adopts the photosensitive resin configuration of photocureable rapid shaping.
The AGARD-B wind tunnel model demonstration test result of photocureable rapid shaping shows:
(1) photocureable rapid shaping high-speed wind tunnel model composite structural design method basic feasible solution, and obtain china national practical new-type patent (patent No. ZL200720082763.0);
(2) shorten the mould processing cycle approximately 69.5%;
(3) reduce mould processing cost approximately 70.3%;
(4) improve model first natural frequency approximately 73.2%;
(5) alleviate model weight approximately 38.9%.
Above-mentioned information slip Benq can be applied to high-speed wind tunnel test in the lightweight high-speed wind tunnel model of Introduction To Stereolithography, but photosensitive resin profile ratio of rigidity metal material model is low, yielding under high aerodynamic loading, pneumostatic bounce effect is more obvious, photocureable rapid shaping high-speed wind tunnel model aerodynamic test result is had to impact, there are differences with metal pattern, therefore current photocureable rapid shaping wind tunnel model both domestic and external is also only for initial stage aerodynamic configuration type selecting and member profile type Selection Test, can't meet at present to a certain extent aircraft model wind tunnel model development demand completely, be difficult to form engineering practical value.
For this reason, technician is actively developing photocureable rapid shaping wind tunnel model design theory, method and the applied research of taking into account static elasticity deformation effect both at home and abroad, to photocureable rapid shaping wind tunnel model is generalized to meticulousr pneumatic type Selection Test.
Summary of the invention
In order to overcome the above-mentioned shortcoming of prior art, the invention provides a kind of photocureable rapid shaping wind tunnel model method for designing of taking into account static elasticity deformation effect, for photocureable rapid shaping wind tunnel model thin location (as wing tip, wing edge, rudder face edges etc.) rigidity is low, the defect such as yielding, adopt the mapping relations between pneumatic/structure coupling analysis method forecast model malformation and aerodynamic force, by response surface method search model coupling optimal design aerodynamic configuration, make the profile of cruising that in wind tunnel test, the aerodynamic configuration after model deformation is studied with needs consistent, thereby obtain the corresponding aerodynamic characteristics of model, and utilize typical high aspect ratio dummy vehicle checking example results of wind tunnel to verify correctness and the feasibility of the method.
The technical solution adopted for the present invention to solve the technical problems is: a kind of photocureable rapid shaping wind tunnel model method for designing of taking into account static elasticity deformation effect, comprises the steps:
Step 1, set up CFD/CSD Coupled Numerical computation model and the grid of photocureable rapid shaping wind tunnel model:
(1) set up the three-dimensional structure geometric parameter database of describing photocureable rapid shaping model structure profile, obtain the three-dimensional structure schematic diagram of photocureable rapid shaping model;
(2) photocureable rapid shaping model surface is carried out to discretize, the non-structure triangular mesh of partitioning model object plane, then partitioning model inner structure zoning grid, complete the generation of model structure analysis grid model;
(3) photocureable rapid shaping model surface is carried out to discretize, partitioning model surface structure quadrilateral mesh, according to model object plane grid, extrapolate at numerical evaluation area of space again, divide fluid zoning and analyze grid, complete the generation of model object plane, fluid zoning, Nei Ji space, boundary layer grid model;
The pneumostatic dynamic elasticity distortion of the photocureable rapid shaping model elastic construction under step 2, employing CFD/CSD Coupled Numerical software prediction study condition:
(1), according to the different requirements of structure and fluid calculation, borderline region and the condition of photocureable rapid shaping model structure and fluid calculation is set;
(2) the three dimensions node of all subject coupled interfaces is projected on two-dimensional parameter space plane, carry out aerodynamic loading and the transmission of displacement structure data;
(3) carrying out photocureable rapid shaping MODEL C FD/CSD Coupled Numerical calculates;
(4) adopt dual-time Push Technology, in real physical time iterative process, call fluid calculation software and obtain photocureable rapid shaping model object plane aerodynamic force load, by coupling data transmission method, aerodynamic loading parameter is transmitted to structure analysis grid cell, carry out structural stress, deformation analysis, complete a time step fluid and structure Coupling and calculate; Along this time step fluid and structure analysis, enter into next time step and carry out iterative computation;
(5) when the model deformation after fluid calculation and Structure Calculation process iteration and changes in aerodynamic forces meet the constraint condition of setting, illustrate that the CFD/CSD coupling calculating based on fluid and structure meets the condition of convergence, fluid and structure coupling analysis process finish, and obtain the construction profile under photocureable rapid shaping model cruising condition;
The optimizing pneumatic profile of step 3, the pneumostatic dynamic elasticity deformation effect based on response surface method search photocureable rapid shaping model:
(1), according to the numerical grid model parameterization software of fairing Free Transform, set up and optimize the variable shape Optimal Parameters model of computation complexity;
(2) utilize photocureable rapid shaping model based on response surface method pneumatic/structure Coupling Optimization Software, to photocureable rapid shaping model pneumatic/disturbance in structure Coupling optimal design feasible zone carries out parametric modeling, by the operation of fairing Free Transform, obtains designing the optimal structural design in feasible zone;
Step 4, set up the composite structure form of photocureable rapid shaping model wind tunnel test model, complete design and the processing of model;
Step 5, photocureable rapid shaping model aerodynamic characteristic wind-tunnel demonstration test.
Described to photocureable rapid shaping model pneumatic/method that parametric modeling is carried out in disturbance in structure Coupling optimal design feasible zone is: photocureable rapid shaping model original shape is carried out to pneumatic/structure Coupling and calculates, obtain model convergence profile, obtain the response of node configuration load and malformation, be designated as , as initial value, bring Optimized Program into, obtain node configuration along different coordinate direction coefficient of indentations , design parameter is optimized , formula is as follows: , , ;
The photocureable rapid shaping model of utilization based on response surface method be pneumatic/and structure Coupling Optimization Software obtains the optimum profile of model structure.
Compared with prior art, good effect of the present invention is: for photocureable rapid shaping lightweight wind tunnel model under aerodynamic loading effect, model thin location easily deforms, thereby cause model test aerodynamic configuration and the profile of cruising to have the key issue of larger difference, propose to adopt pneumatic/structure Coupling Optimization Design to set up the photocureable rapid shaping wind tunnel model method for designing of taking into account pneumostatic dynamic elasticity deformation effect, by the optimizing of response surface method, process, obtain desirable model aerodynamic configuration, to meet high-speed wind tunnel test demand.
Embodiment
A photocureable rapid shaping wind tunnel model method for designing of taking into account static elasticity deformation effect, comprises the steps:
Step 1, set up CFD/CSD Coupled Numerical computation model and the grid of photocureable rapid shaping wind tunnel model:
(1) set up the three-dimensional structure geometric parameter database of describing photocureable rapid shaping model structure profile, obtain photocureable rapid shaping model three-dimensional structure schematic diagram;
(2) photocureable rapid shaping model surface is carried out to discretize, the non-structure triangular mesh of partitioning model object plane, then partitioning model inner structure zoning grid, complete the generation of model structure analysis grid model;
(3) photocureable rapid shaping model surface is carried out to discretize, partitioning model surface structure quadrilateral mesh, according to model object plane grid, extrapolate at numerical evaluation area of space again, divide fluid zoning and analyze grid, complete the generation of model object plane, fluid zoning, Nei Ji space, boundary layer grid model.
The pneumostatic dynamic elasticity distortion of the photocureable rapid shaping model elastic construction under step 2, employing CFD/CSD Coupled Numerical software prediction study condition:
(1), according to the different requirements of structure and fluid calculation, borderline region and the condition of photocureable rapid shaping model structure and fluid calculation is set;
(2) first carry out photocureable rapid shaping model object plane structure and the relationship analysis of fluid analysis mesh fitting, solve calculating parameter and a data transmission difficult problem between Structure Calculation software and fluid calculation software.The three dimensions node of all subject coupled interfaces is projected on two-dimensional parameter space plane, carry out aerodynamic loading and the transmission of displacement structure data;
(3) carrying out photocureable rapid shaping MODEL C FD/CSD Coupled Numerical calculates, utilize on synchronization model object plane grid the topological relation between CFD and CSD grid cell constant, and consider that coupled interface is improved quality, the conservation condition of momentum, energy, the Local Fairing means of communication of setting up stress-strain field/flow field coupling physical amount (comprising displacement, velocity and acceleration) that universality is higher, have solved the inconsistent and fluid of CFD fluid surface grids and CSD works surface grids and the exchanges data problem between structured grid model.
(4) adopt dual-time Push Technology, in real physical time iterative process, call fluid calculation software and obtain photocureable rapid shaping model object plane aerodynamic force load, by coupling data transmission method, aerodynamic loading parameter is transmitted to structure analysis grid cell, carry out structural stress/strain, deformation analysis, complete a time step fluid and structure Coupling and calculate; Along this time step fluid and structure analysis, enter into next time step and carry out iterative computation.
(5) when the model deformation after fluid calculation and Structure Calculation process iteration and changes in aerodynamic forces meet certain constraint condition, think that the CFD/CSD coupling calculating based on fluid and structure meets the condition of convergence, fluid and structure coupling analysis process finish, and just can obtain the construction profile under photocureable rapid shaping model cruising condition.
The optimizing pneumatic profile of step 3, the pneumostatic dynamic elasticity deformation effect based on response surface method search photocureable rapid shaping model:
(1) for existing response surface method, be applied to photocureable rapid shaping model optimization some shortcomings in when design (as the span of design variable can have a strong impact on the adaptive faculty of response surface model, larger design space will increase the prediction error of response surface, make to estimate that flow performance is inaccurate, the increase meeting assessing the cost with design variable number of response surface method increases fast), according to the numerical grid model parameterization software of fairing Free Transform, set up and optimize the variable shape Optimal Parameters model of computation complexity;
(2) utilize photocureable rapid shaping model based on response surface method pneumatic/structure Coupling Optimization Software, to photocureable rapid shaping model pneumatic/disturbance in structure Coupling optimal design feasible zone carries out parametric modeling, by the operation of fairing Free Transform, obtains designing the optimal structural design in feasible zone.
Concrete grammar is: photocureable rapid shaping model original shape is carried out to pneumatic/structure Coupling and calculate acquisition model convergence profile, grasp the response of node configuration load and malformation, be designated as , as initial value, bring Optimized Program into, obtain node configuration along different coordinate direction coefficient of indentations , design parameter is optimized , formula is as follows:
,?
Photocureable rapid shaping model based on response surface method is pneumatic/and structure Coupling Optimization Software obtains the optimum profile of model structure.
Step 4, set up the composite structure form of photocureable rapid shaping model wind tunnel test model, complete design and the processing of model:
(1) according to model structure profile, complete the design of model structure complex form, be mainly the aerodynamic configuration structure of photosensitive resin material and the design of model interior metal skeleton structure of descriptive model aerodynamic configuration;
(2) complete the assembling form design between model interior metal skeleton structure and photosensitive resin aerodynamic configuration Standard and model interior metal skeleton structure and force balance;
(3) the general design shape of interior metal skeleton structure is comparatively regular, be conducive on the one hand easy to process, save process time, be conducive on the other hand carry out structure analysis, and the analysis data to regular shape are comparatively reliable, therefore adopt traditional machining mode to manufacture, such as common car, milling, brill, line cutting etc.;
(4) mode shape parts adopt light-curing quick moulding method processing, and its processing model precision is high, and surface quality is good, can manufacture complex-shaped, meticulous part, and efficiency is high; Material selection high speed liquid photosensitive resin, can make there is high strength, the part of the function such as high temperature resistant, waterproof; In addition, the layout of model and put, manufacturing accuracy that forming direction directly affects profile.Therefore in first being processed, according to the accuracy requirement of model different parts, 3 d structure model is arranged and is put, adds and support and cut layer and process, then apply light-curing rapid forming equipment and complete processing;
(5) complete after model interior metal skeleton structure and the processing of photosensitive resin aerodynamic configuration structure, inspection model contoured surface formed precision and quality, complete the assembling of model material object and the check of mould processing quality.
Step 5, photocureable rapid shaping model aerodynamic characteristic wind-tunnel demonstration test:
(1) adopt structure analysis software to complete photocureable rapid shaping mold strength, rigidity check, in simulation laboratory, complete and adopt ground load mode to complete mold strength and rigidity check;
(2) formulate photocureable rapid shaping model wind tunnel test conceptual design, comprise wind tunnel test condition and project, Data Processing Method, experiment error analysis etc.;
(3) complete wind-tunnel demonstration test, analytical test result, compares to relevant list of references and all-metal model test findings, feasibility and the correctness of checking Optimization Design.

Claims (1)

1. a photocureable rapid shaping wind tunnel model method for designing of taking into account static elasticity deformation effect, is characterized in that: comprise the steps:
Step 1, set up CFD/CSD Coupled Numerical computation model and the grid of photocureable rapid shaping wind tunnel model:
(1) set up the three-dimensional structure geometric parameter database of describing photocureable rapid shaping model structure profile, obtain the three-dimensional structure schematic diagram of photocureable rapid shaping model;
(2) photocureable rapid shaping model surface is carried out to discretize, the non-structure triangular mesh of partitioning model object plane, then partitioning model inner structure zoning grid, complete the generation of model structure analysis grid model;
(3) photocureable rapid shaping model surface is carried out to discretize, partitioning model surface structure quadrilateral mesh, according to model object plane grid, extrapolate at numerical evaluation area of space again, divide fluid zoning and analyze grid, complete the generation of model object plane, fluid zoning, Nei Ji space, boundary layer grid model;
The pneumostatic dynamic elasticity distortion of the photocureable rapid shaping model elastic construction under step 2, employing CFD/CSD Coupled Numerical software prediction study condition:
(1), according to the different requirements of structure and fluid calculation, borderline region and the condition of photocureable rapid shaping model structure and fluid calculation is set;
(2) the three dimensions node of all subject coupled interfaces is projected on two-dimensional parameter space plane, carry out aerodynamic loading and the transmission of displacement structure data;
(3) carrying out photocureable rapid shaping MODEL C FD/CSD Coupled Numerical calculates;
(4) adopt dual-time Push Technology, in real physical time iterative process, call fluid calculation software and obtain photocureable rapid shaping model object plane aerodynamic force load, by coupling data transmission method, aerodynamic loading parameter is transmitted to structure analysis grid cell, carry out structural stress, deformation analysis, complete a time step fluid and structure Coupling and calculate; Along this time step fluid and structure analysis, enter into next time step and carry out iterative computation;
(5) when the model deformation after fluid calculation and Structure Calculation process iteration and changes in aerodynamic forces meet the constraint condition of setting, illustrate that the CFD/CSD coupling calculating based on fluid and structure meets the condition of convergence, fluid and structure coupling analysis process finish, and obtain the construction profile under photocureable rapid shaping model cruising condition;
The optimizing pneumatic profile of step 3, the pneumostatic dynamic elasticity deformation effect based on response surface method search photocureable rapid shaping model:
(1), according to the numerical grid model parameterization software of fairing Free Transform, set up and optimize the variable shape Optimal Parameters model of computation complexity;
(2) utilize photocureable rapid shaping model based on response surface method pneumatic/structure Coupling Optimization Software, to photocureable rapid shaping model pneumatic/disturbance in structure Coupling optimal design feasible zone carries out parametric modeling, by the operation of fairing Free Transform, obtains designing the optimal structural design in feasible zone; Described to photocureable rapid shaping model pneumatic/method that parametric modeling is carried out in disturbance in structure Coupling optimal design feasible zone is: photocureable rapid shaping model original shape is carried out to pneumatic/structure Coupling and calculates, obtain model convergence profile, obtain the response of node configuration load and malformation, be designated as Δ x, Δ y, Δ z, as initial value, bring Optimized Program into, obtain node configuration along different coordinate direction coefficient of indentation k x, k y, k z, the design parameter Δ x' that is optimized, Δ y', Δ z', formula is as follows:
Δx'=k xΔx,Δy'=k yΔy,Δz'=k zΔz;
The photocureable rapid shaping model of utilization based on response surface method be pneumatic/and structure Coupling Optimization Software obtains the optimum profile of model structure;
Step 4, set up the composite structure form of photocureable rapid shaping model wind tunnel test model, complete design and the processing of model;
Step 5, photocureable rapid shaping model aerodynamic characteristic wind-tunnel demonstration test.
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