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The purpose of this study is analysis of deformation and vibrations of turbine blades produced by high electrolyte pressure during electrochemical machining.

An experimental setup was designed, experiments were conducted and the obtained results were compared with the finite element results. The deformations were measured according to various flow rates of electrolyte. In finite element calculations, the pressure distribution created by the electrolyte on the blade surface was obtained in the ANSYS® (A finite element analysis software) Fluent software and transferred to the static structural where the deformation analysis was carried out. Three different parameters were examined, namely blade thickness, blade material and electrolyte pressure on blade disk caused by mass flow rate. The deformation results were compared with the gap distances between cathode and anode.

Large deformations were obtained at the free end of the blade and the most curved part of it. The appropriate pressure values for the electrolyte to be used in the production of blisk blades were proposed numerically. It has been determined that high pressure applications are not suitable for gap distance lower than 0.5 mm.

When the literature is examined, it is required that the high speed flow of the electrolyte is desired in order to remove the parts that are separated from the anode from the machining area during electrochemical machining. However, the electrolyte flowing at high speeds causes high pressure in the blisk blades, excessive deformation and vibration of the machined part, and as a result, contact of the anode with the cathode. This study provides important findings for smooth electro chemical machining at high electrolyte flows.

The purpose of this review is to comprehensively consider the material properties and processing of additive titanium alloy and provide a new perspective for the robotic grinding and polishing of additive titanium alloy blades to ensure the surface integrity and machining accuracy of the blades.

At present, robot grinding and polishing are mainstream processing methods in blade automatic processing. This review systematically summarizes the processing characteristics and processing methods of additive manufacturing (AM) titanium alloy blades. On the one hand, the unique manufacturing process and thermal effect of AM have created the unique processing characteristics of additive titanium alloy blades. On the other hand, the robot grinding and polishing process needs to incorporate the material removal model into the traditional processing flow according to the processing characteristics of the additive titanium alloy.

Robot belt grinding can solve the processing problem of additive titanium alloy blades. The complex surface of the blade generates a robot grinding trajectory through trajectory planning. The trajectory planning of the robot profoundly affects the machining accuracy and surface quality of the blade. Subsequent research is needed to solve the problems of high machining accuracy of blade profiles, complex surface material removal models and uneven distribution of blade machining allowance. In the process parameters of the robot, the grinding parameters, trajectory planning and error compensation affect the surface quality of the blade through the material removal method, grinding force and grinding temperature. The machining accuracy of the blade surface is affected by robot vibration and stiffness.

This review systematically summarizes the processing characteristics and processing methods of aviation titanium alloy blades manufactured by AM. Combined with the material properties of additive titanium alloy, it provides a new idea for robot grinding and polishing of aviation titanium alloy blades manufactured by AM.

The geometric parameters of the compressor blade have a noteworthy influence on compressor stability, which should be meticulously designed. However, machining inaccuracies cause the blade geometric parameters to deviate from the ideal design, and the geometric deviation exhibits high randomness. Therefore, the purpose of this study is to quantify the uncertainty and analyze the sensitivity of the impact of blade geometric deviation on compressor stability.

In this work, the influence of blade geometric deviation is analyzed based on a subsonic compressor rotor stage, and three-dimensional numerical simulations are used to compute samples with different geometric features. A method of combining Halton sequence and non-intrusive polynomial chaos is adopted to carry out uncertainty quantitative analysis. Sobol’ index and Spearman correlation coefficient are used to analysis the sensitivity and correlation between compressor stability and blade geometric deviation, respectively.

The results show that the compressor stability is most sensitive to the tip clearance deviation, whereas deviations in the leading edge radius, trailing edge radius and chord length have minimal impact on the compressor stability. And, the effects of various blade geometric deviations on the compressor stability are basically independent and linearly superimposed.

This work provided a new approach for uncertainty quantification in compressor stability analysis. The conclusions obtained in this work provide some reference value for the manufacturing and maintenance of rotor blades.

This study aims to find the characteristics of supercritical airfoil in helicopter rotor blades for hovering phase using numerical analysis and the validation using experimental results.

Using numerical analysis in the forward phase of the helicopter, supercritical airfoil is compared with the conventional airfoil for the aerodynamic performance. The multiple reference frame method is used to produce the results for rotational analysis. A grid independence test was carried out, and validation was obtained using benchmark values from NASA data.

From the analysis results, a supercritical airfoil in hovering flight analysis proved that the NASA SC rotor produces 25% at 5°, 26% at 12° and 32% better thrust at 8° of collective pitch than the HH02 rotor. Helicopter performance parameters are also calculated based on momentum theory. Theoretical calculations prove that the NASA SC rotor is better than the HH02 rotor. The results of helicopter performance prove that the NASA SC rotor provides better aerodynamic efficiency than the HH02 rotor.

The novelty of the paper is it proved the aerodynamic performance of supercritical airfoil is performing better than the HH02 airfoil. The results are validated with the experimental values and theoretical calculations from the momentum theory.

The purpose of this study was to improve the overall equipment effectiveness (OEE) of the production process of the shredder operation of ABC company, an industrial waste management company which supplies pre-processed industrial waste as alternative fuel to a cement plant.

This case study investigated all possible availability and performance losses that caused the shredder system’s OEE and various problem-solving techniques, such as root cause analysis and Pareto analysis, were used to find the root cause of the reduced OEE.

After analysing this case study, three significant loss factors were identified from all the availability and performance losses, which caused the shredder system’s OEE losses. Practical solutions were found for the effect of those loss factors to improve the machine’s OEE and productivity.

This case study has been concentrated on only analysing of losses and improvement of OEE in the production process and not about cost analysis between loss and improvements.

This paper shows how to improve the OEE of a production process through various problem-solving techniques by identifying its losses and how to achieve the best solutions for those losses in a practical manner.

This paper establishes a quality model for automation assembly of range hood impeller based on generalized grey relational degree, it improves the debugging efficiency of the newly developed assembly workstation.

First, spot check the trial production impellers and obtain three indexes that reflect the assembly quality of the impellers. Then, analyze the parameters that affect the assembly quality of the impeller using grey relational analysis (GRA), establish a model for the assembly quality of the range hood impeller based on the generalized grey relational degree and identify the main parameters. After that, analyze the transmission structure of automation assembly workstation, identify the reasons that affect parameters and propose improvement plans. Finally, a trial production is conducted on the automation assembly workstation after adopting the improved plan to verify the quality model of impeller automation assembly.

The research shows that compared to manual assembly, the automation assembly quality of the impeller using GRA model has been improved, shortening the debugging cycle of the newly developed assembly workstation.

The newly developed automation equipment will have some problems in the trial production stage, which often rely on the experience of engineers for debugging. In this paper, the automation assembly quality model of range hood impeller based on GRA is established, which can not only ensure the quality of finished impeller but also shorten the debugging cycle of the equipment. In addition, GRA can be widely used in the commissioning of other automation equipment.

This study has developed a set of impeller automation assembly workstation. The debugging method in the trial production stage is beneficial to shorten the trial production time and improve the economic benefits.

The sandy environment is one of the typical environments in which helicopters operate. Air-sand two-phase flow in sandy environments may be an important factor affecting flight safety. Taking a typical example, this paper aims to investigate the aerodynamic and rotor trim characteristics of the UH-60 helicopter in sandy environments.

A computational study is conducted to simulate the air-sand flow over airfoils based on the Euler–Lagrange framework. The simulation uses the S-A turbulence model and the two-way momentum coupling methodology. Additionally, the trim characteristics of the UH-60 rotor are calculated based on the isolated rotor trim algorithm.

The simulation results show that air-sand flow significantly affects the aerodynamic characteristics of the SC1095 airfoil and the SC1094R8 airfoil. The presence of sand particles leads to a decrease in lift and an increase in drag. The calculation results of the UH-60 helicopter rotor indicate that the thrust decreases and the torque increases in the sandy environment. To maintain a steady forward flight in sandy environments, it is necessary to increase the collective pitch and the longitudinal cyclic pitch.

In this paper, the aerodynamic characteristics of airfoils and the trim characteristics in the air-sand flow of the UH-60 helicopter are discussed, which might be a new view to analyse the impact of sandy environments on helicopter safety and manoeuvring.

Thermal protection of a flange is critical for preventing tower icing and collapse of wind turbines (WTs) in extremely cold weather. This study aims to develop a novel thermal protection system for the WTs flanges using an electrical heat-tracing element.

A three-dimensional model and the Poly-Hexacore mesh structure are used, and the fluid-solid coupling method was validated and then deployed to analyze the heat transfer and convection process. Intra-volumetric heat sources are applied to represent the heat generated by the heating element, and the dynamic boundary conditions are considered. The steady temperature and temperature uniformity of the flange are the assessment criteria for the thermal protection performance of the heating element.

Enlarging the heating area and increasing the heating power improved the flange's temperature and temperature uniformity. A heating power of 4.9 kW was suitable for engineering applications with the lowest temperature nonuniformity. Compared with continuous heating, the increased temperature nonuniformity was buffered, and the electrical power consumption was reduced by half using pulse heating. Pulse heating time intervals of 1, 3 and 4 h were determined for the spring, autumn and winter, respectively.

The originality of this study is to propose a novel electrical heat-tracing thermal protection system for the WTs flanges. The effect of different arrangements, heating powers and heating strategies was studied, by which the theoretical basis is provided for a stable and long-term utilization of the WT flange.

The research focused on analysing a unique type of heat exchanger that uses swirling air flow over heated tubes. This heat exchanger includes a round baffle plate with holes and opposite-oriented trapezoidal air deflectors attached at different angles. The deflectors are spaced at various distances, and the tubes are arranged in a circular pattern while maintaining a constant heat flux.

This setup is housed inside a circular duct with airflow in the longitudinal direction. The study examined the impact of different inclination angles and pitch ratios on the performance of the heat exchanger within a specific range of Reynolds numbers.

The findings revealed that the angle of inclination significantly affected the flow velocity, with higher angles resulting in increased velocity. The heat transfer performance was best at lower inclination angles and pitch ratios. Flow resistance decreased with increasing angle of inclination and pitch ratio.

The average thermal enhancement factor decreased with higher inclination angles, with the maximum value observed as 0.94 at a pitch ratio of 1 at an angle of 30°.

Unconventional machining processes, particularly ultrasonic vibration cutting (UVC), can overcome such technical bottlenecks. However, the precise mechanism through which UVC affects the in-service functional performance of advanced aerospace materials remains obscure. This limits their industrial application and requires a deeper understanding.

The surface integrity and in-service functional performance of advanced aerospace materials are important guarantees for safety and stability in the aerospace industry. For advanced aerospace materials, which are difficult-to-machine, conventional machining processes cannot meet the requirements of high in-service functional performance owing to rapid tool wear, low processing efficiency and high cutting forces and temperatures in the cutting area during machining.

To address this literature gap, this study is focused on the quantitative evaluation of the in-service functional performance (fatigue performance, wear resistance and corrosion resistance) of advanced aerospace materials. First, the characteristics and usage background of advanced aerospace materials are elaborated in detail. Second, the improved effect of UVC on in-service functional performance is summarized. We have also explored the unique advantages of UVC during the processing of advanced aerospace materials. Finally, in response to some of the limitations of UVC, future development directions are proposed, including improvements in ultrasound systems, upgrades in ultrasound processing objects and theoretical breakthroughs in in-service functional performance.

This study provides insights into the optimization of machining processes to improve the in-service functional performance of advanced aviation materials, particularly the use of UVC and its unique process advantages.