Search Results (67)

The operational reliability of aero-engines is critically dependent on the health of rolling element bearings, while incipient fault diagnosis remains particularly challenging under small-sample conditions. Although multiscale entropy methods are widely used for complexity analysis, conventional coarse-graining strategies suffer from severe information loss and unstable estimation when data are extremely limited. To address this, the primary objective of this study is to develop a robust diagnostic framework that ensures feature consistency and classification stability even with minimal training samples. Specifically, this paper proposes an integrated approach combining Refined Time-shifted Multiscale Rating Entropy (RTSMRaE) with an Animated Oat Optimization (AOO)-optimized Extreme Learning Machine (ELM). By introducing a refined time-shift operator and a dual-weight fusion mechanism, RTSMRaE effectively preserves transient impulsive features across multiple scales while suppressing stochastic fluctuations. Meanwhile, the AOO algorithm is employed to optimize the input weights and hidden biases of the ELM, alleviating performance instability caused by random initialization and improving generalization capability. Experimental validation on both laboratory-scale and real-world aviation bearing datasets demonstrates that the proposed RTSMRaE-AOO-ELM framework achieves a diagnostic accuracy of 99.47% with a standard deviation of ±0.48% using only five training samples per class. These results indicate that the proposed method offers superior diagnostic robustness and computational efficiency, providing a promising solution for intelligent condition monitoring in data-scarce industrial environments. Full article

This study provides a detailed technical and sustainability comparison of the conventional CNC machining and additive manufacturing routes for an aerospace bearing bracket. The work integrates material selection, process parameterization, build simulation, and environmental–economic assessment within a single framework. For the CNC route, machining of Al 7175-T7351 is characterized through process sequencing, tooling requirements, and waste generation. For the Laser Powder Bed Fusion (LPBF) route, two build strategies, single-part distortion-minimized and multi-part volume-optimized, are developed using Siemens NX for orientation optimization and Atlas3D for thermal and recoater collision simulations. The mechanical properties of Al 7175-T7351 and Scalmalloy^® are compared to justify material selection for aerospace applications. Both the experimental and simulation-derived process metrics are reported, including the build time, support mass, energy consumption, distortion tolerances, and buy-to-fly (B2F) ratio. CNC machining exhibited a B2F ratio of 1:7, with cradle-to-gate CO₂ emissions of ~11,000 g and an energy consumption exceeding 100 kWh per component. In contrast, both LPBF strategies achieved a B2F ratio of 1:1.2, reducing CO₂ emissions by over 90% and energy consumption by up to 63%. Build volume optimization further reduced the LPBF unit cost by over 50% relative to the CNC machining. Use-phase analysis in an aviation context indicated estimated lifetime fuel savings of 776,640 L and the avoidance of 2328 tons of CO₂ emissions. The study demonstrates how simulation-guided build preparation enables informed sustainability-driven decision-making for manufacturing route selection in aerospace applications. Full article

The traction behavior of lubricant films forms the foundation of dynamic modeling for aeroengine mainshaft ball bearings. Its accuracy directly determines the reliability of predicted dynamic responses and the available design safety margins. Existing traction models produce artificial friction in the zero slip region and exhibit strong sensitivity to ball size effects, which leads to significant deviations from experimental observations. These limitations make them unsuitable for high-fidelity analyses of aeroengine mainshaft bearings. In this study, a self-developed high-speed traction test rig was used to systematically measure the traction–slip responses of three aviation lubricants, including the newly developed 4102 (7 cSt) and the inservice 4050 (5 cSt) and 4010 (3 cSt). The tests covered a wide range of operating conditions, including maximum Hertzian pressures of 1.0 to 1.5 GPa, oil supply temperatures of 25 to 120 °C, entrainment speeds of 25 to 40 m/s, and slide–roll ratios (SRR) of 0 to 0.3. The evolution of lubricant traction characteristics was examined in detail. Based on the experimental data, a four-parameter and three-coefficient traction model was proposed. This model eliminates the non-physical traction outputs at zero slip observed in previous formulations. When embedded into the bearing dynamic simulations, the maximum deviation between the predicted friction torque and the measured values is only 3.79%. On the basis of typical operating conditions of aeroengine bearings, lubricant selection guidelines were established. Under combined high-speed, light-load, and high-temperature conditions, the high-viscosity lubricant 4102 is preferred because it suppresses cage sliding and enhances film stiffness. When the cage slip ratio is below 15% and lubrication is sufficient, the low-viscosity lubricant 4010 is recommended, followed by 4050, in order to reduce frictional heating. This study provides a theoretical basis for high-accuracy dynamic design and lubricant selection for aeroengine ball bearings. Full article

This paper proposes a comprehensive framework, Theory–Simulation–Experimental Verification, for the elasto-aerodynamic analysis of elastic foil gas bearings (EFGBs). In contrast to many studies that approximate the foil structure using simplified two-dimensional models, the present work adopts a macro-element beam theory model that incorporates the actual 3D geometry, nonlinear elasticity, and frictional contact effects, and couples it directly with the Reynolds equation. To improve accuracy and robustness, the macro-beam results are validated against a fully coupled fluid–structure interaction (FSI) model developed in COMSOL Multiphysics. Emphasis is placed on quantifying the influence of foil thickness, clearance, and eccentricity, where the pressure distribution, foil deflection, and load capacity are obtained through the coupled solver. The results reveal that increasing foil thickness from 0.1 mm to 0.2 mm elevates the peak gas film pressure from 1.36 × 10⁵ Pa to 1.97 × 10⁵ Pa while simultaneously reducing displacement and pressure fluctuations, thereby enhancing bearing stability. Smaller clearances are shown to increase load capacity but also induce stronger oscillatory flow behavior, indicating a stiffness–stability trade-off. Additionally, prototype experiments with a 0.05 mm clearance confirm practical lift-off at 4300–7000 rpm under 10–30 N external loads, with measured torques of 0.18–0.30 N·m. By combining computational efficiency, 3D fidelity, and experimental validation, the proposed framework provides quantitative guidance for the design and optimization of EFGBs used in high-speed turbomachinery, such as aviation and compact energy systems, including turbine-based air-cycle refrigeration units and small gas-turbine rotors for unmanned aerial vehicles. Full article

One of the limitations of additive manufacturing technology is the high surface roughness of finished products caused by the layered structure of the deposition and the effect of adhesion of unfused powder particles. This worsens the fatigue characteristics, wear resistance, and functional properties of the parts, which are especially important for critical applications in medicine, aviation, and mechanical engineering. The paper presents the results of a study on the possibility of using plasma electrolytic polishing for post-processing of products made of additively manufactured Ti6Al4V alloy to form a homogeneous surface with reduced roughness. The morphology, roughness, and tribotechnical characteristics of the surface after processing in a fluoride electrolyte were studied with varying voltage and polishing time. A 90% reduction in surface roughness is achieved by polishing at 300 V for 20 min. The results of tribological tests revealed that after the polishing of the oxidative wear mechanism is maintained, the temperature in the tribological contact zone decreases, and the load-bearing capacity of the surface increases (the Kragelsky–Kombalov criterion decreases). The greatest decrease in the friction coefficient by 2.1 times was observed with minimal surface roughness, when the largest average radius of rounding of the microprotrusions of the friction track microtopology is formed with a low value of the Kragelsky–Kombalov criterion. Full article

This study focuses on the problem of local instability of sandwich panels, which consist of two thin but relatively stiff facings and a thick but shear-deformable core. Such structures are commonly used in civil engineering and in the aerospace, aviation, and automotive industries. A case is presented in which one of the facings is deep-profiled. Due to typical mechanical or thermal interactions, this facing is subjected to compression. The thick core of the sandwich panel plays a stabilizing role. However, at a specific critical load, local stability is lost, representing a typical form of damage that occurs in sandwich panels. In the case of a deep-profiled facing, the geometry of the facing must also be taken into account, specifically the fact that the bends resulting from profiling constitute a significant limitation to its deformation. In this study, expressions are derived that enable the determination of the critical (wrinkling) stress, taking into account the geometry of the compressed facing bands and various boundary conditions defined along their edges. The energy approach is used to solve the problem. The presented solution to the problem of local instability is illustrated using examples. The obtained results indicate that the use of narrow bands is particularly effective while also allowing for determination of the maximum benefits resulting from deep profiling of the facings. This information is essential when considering changes to the geometry of industrially produced sandwich panels or when optimizing the load-bearing capacity of individual sandwich elements. Full article

This paper provides a comprehensive analysis of common manufacturing delamination defects in composite curved beams, as well as delamination issues arising from cutting processes in engineering practice. Curved beams, widely used as connecting components in the aviation industry, are susceptible to delamination under out-of-plane loads. This study employs three-dimensional finite element methods and progressive damage failure analysis to examine the impact of delamination damage on the load-bearing capacity of curved beam structures under four-point bending loads. The investigation focuses on three key factors: delamination size, the position of delamination along the thickness direction, and the in-plane position of delamination. The results indicate that for the orthotropic symmetric layup used in this study, the closer the initial delamination is to the midplane of the curved beam, the more significant the reduction in load-bearing capacity. Delamination in the lower part of the beam has a greater impact than in the upper part, and edge delamination poses a greater threat to the structure compared to center-width delamination. These findings can offer valuable technical support for engineering tolerance management. Full article

Porous media gas bearings utilize gas as a lubricating medium to achieve non-contact support technology. Compared with traditional liquid-lubricated bearings or rolling bearings, they are more efficient and environmentally friendly. With the uniform gas film pressure of gas bearings, the rotating shaft can achieve mechanical motion with low friction, high rotational speed, and long service life. They have significant potential in improving energy efficiency and reducing carbon emissions, enabling oil-free lubrication. By eliminating the friction losses of traditional oil-lubricated bearings, porous media gas bearings can reduce the energy consumption of industrial rotating machinery by 15–25%, directly reducing fossil energy consumption, which is of great significance for promoting carbon neutrality goals. They have excellent prospects for future applications in the civil and military aviation fields. Based on the three-dimensional flow characteristics of the bearing’s fluid domain, this paper considers the influences of the transient flow field in the variable fluid domain of the gas film and the radial pressure gradient of the gas film, establishes a theoretical model and a three-dimensional simulation model for porous media gas bearings, and studies the static–dynamic pressure coupling mechanism of porous media gas bearings. Furthermore, through the trial production of bearings and performance tests, the static characteristics are verified, and the steady-state characteristics are studied through simulation, providing a basis for the application of gas bearings made from porous media materials in the civil and military aviation fields. Full article

Lubrication failure has become a predominant failure mode in aviation roller bearings. Timely identification of lubrication degradation is critical for preventing premature bearing failure. This paper presents a fuzzy identification method of lubrication degradation stages by fusing multiple indicators. Firstly, four monitoring indicators, including the oil film thickness (OFT), wear surface roughness (WSR), contact resonance frequency (CRF), and amplitude of CRF (CRFA), are extracted through numerical simulations to characterize the lubrication degradation process. Then, a fuzzy evaluation method is proposed to identify the lubrication degradation stages by integrating these indicators. The results indicate that these four indicators can identify three typical stages of the lubrication degradation process—good lubrication, normal wear, and severe wear, with an accuracy rate exceeding 92%. Finally, lubrication degradation experiments are carried out on a sliding-rolling test rig to verify the method’s effectiveness. This work provides superior interpretability of the multifactorial coupled lubrication degradation process analysis. Full article

The 7075-T7451 aluminum alloy, widely used in aerospace, aviation, and automotive fields for critical load-bearing components due to its excellent mechanical properties, suffers from residual stresses induced by thermo-mechanical coupling during milling, which deteriorate workpiece performance. This study explores how key milling parameters—spindle speed *n_c*, feed per tooth *f_z*, cutting depth *a_p*, and cutting width *a_e*—affect surface residual stress and cutting force via orthogonal experiments and finite element analysis (FEA). Results show *a_e* is critical for X-direction residual stresses, while *f_z* dominates Y-direction ones. Cutting force increases with *f_z*, *a_p*, and *a_e* but decreases with higher *n_c*. Multivariate regression-based prediction models for residual stress and cutting force were established, which effectively characterize parameter–response relationships with maximum prediction errors of 18.69% (residual stress) and 12.27% (cutting force), showing good engineering applicability. The findings provide theoretical and experimental foundations for multi-parameter optimization in aluminum alloy milling and residual stress/cutting force control, with satisfactory practical effectiveness. Full article

The increasing demand for efficient aviation navigation system inspections has led to the use of Unmanned Aerial Vehicles (UAVs) as a flexible and cost-effective alternative to traditional manned aircraft. This study emphasizes the operational advantages of UAVs in transforming flight inspections, including Non-Directional Beacon (NDB) calibration. Following the successful performance evaluation of an NDB system in Banská Bystrica, Slovakia, using a manned aircraft, a UAV was deployed on the same flight path to validate its ability to replicate the procedure in terms of trajectory only, without performing any signal measurement. The UAV maintained accurate flight paths and continuous communication throughout the mission. A specialized rotatory system, operating at 868 MHz, enabled real-time tracking and ensured stable communication over long distances. The manned aircraft test revealed a maximum bearing deviation of 13.47° at 3.37 NM and a minimum received signal strength of −90 dBm, which approaches the ICAO threshold for en route navigation (±10°) but remains usable for diagnostic purposes. The UAV flight did not include signal capture but successfully completed the 40 NM profile with a circular error probable (CEP95) of 2.8 m and communication link uptime of 99.8%, confirming that the vehicle can meet procedural trajectory fidelity. These findings support the feasibility of UAV-based NDB inspections and provide the foundation for future test phases with onboard signal monitoring systems. Full article

Addressing the urgent need for lightweight and reusable energy-absorbing materials in aviation impact resistance, this study introduces an innovative multi-directional braided metamaterial design enabled by 4D printing technology. This approach overcomes the dual challenges of intricate manufacturing processes and the limited functionality inherent to traditional textile preforms. Six distinct braided structural units (types 1–6) were devised based on periodic trigonometric functions (Y = A sin(12πX)), and integrated with shape memory polylactic acid (SMP-PLA), thereby achieving a synergistic combination of topological architecture and adaptive response characteristics. Compression tests reveal that reducing strip density to 50–25% (as in types 1–3) markedly enhances energy absorption performance, achieving a maximum specific energy absorption of 3.3 J/g. Three-point bending tests further demonstrate that the yarn amplitude parameter A is inversely correlated with load-bearing capacity; for instance, the type 1 structure (A = 3) withstands a maximum load stress of 8 MPa, representing a 100% increase compared to the type 2 structure (A = 4.5). A multi-branch viscoelastic constitutive model elucidates the temperature-dependent stress relaxation behavior during the glass–rubber phase transition and clarifies the relaxation time conversion mechanism governed by the Williams–Landel–Ferry (WLF) and Arrhenius equations. Experimental results further confirm the shape memory effect, with the type 3 structure fully recovering its original shape within 3 s under thermal stimulation at 80 °C, thus addressing the non-reusability issue of conventional energy-absorbing structures. This work establishes a new paradigm for the design of impact-resistant aviation components, particularly in the context of anti-collision structures and reusable energy absorption systems for eVTOL aircraft. Future research should further investigate the regulation of multi-stimulus response behaviors and microstructural optimization to advance the engineering application of smart textile metamaterials in aviation protection systems. Full article

This paper addresses the vibration characteristics of angular contact ball bearings in aircraft engines under variable load conditions. Based on multibody dynamics theory, a dynamic model of the bearing was established. Vibration data under actual operating conditions were obtained using an experimental test platform. This study systematically investigated the influence of rotational speed, axial load, and radial load on the vibration acceleration level of the bearing outer ring. Through a comparison of simulation and experimental data (with an error rate below 10%), the reliability of the model was validated. The results indicate that the bearing vibration acceleration level exhibits a nonlinear increasing relationship with rotational speed. An increase in radial load significantly amplifies the amplitude of acceleration-level fluctuations, while appropriately increasing axial load can reduce bearing vibration intensity. Under variable load coupling conditions, the dynamic interaction between axial and radial forces results in complex nonlinear vibration responses, with a 2 s acceleration time achieving the optimal balance between vibration suppression and efficiency (steady-state average of 70.4 dB). Additionally, the morphological characteristics of the cage center-of-gravity trajectory (such as trajectory disorder and poor smoothness) are closely related to vibration characteristics, revealing the critical role of dynamic load changes in bearing stability. The research results provide a theoretical basis for optimizing the operating conditions, vibration control, and reliability design of aircraft engine bearings. Full article

The lubrication behavior and mechanical characteristics of the main bearing area of an aero-engine main shaft bearing determine the reliability and life of the main shaft bearing. In aero-engine main shaft bearings, the lubricant not only plays the role of lubrication but also affects the dynamic characteristics of the bearing; therefore, if the lubricant drag force is insufficient, it will lead to rolling body slipping. Slipping not only affects the reliability of the bearing operation but also will make the temperature of the contact area instantaneously increase, leading to the occurrence of gluing, scraping and other lubrication failure phenomena in the main bearing area. A lubricant under the shear conditions of traction characteristics is actually the external manifestation of rheological properties. Rheological properties are one of the elastic fluid power lubrication theories and are an important part of the study. Elasto-hydrodynamic lubrication theory of the oil film pressure, film thickness and temperature and solid domains interact to form a thermal–fluid–solid coupling relationship; this coupling relationship affects the main bearing area of the lubrication behavior and mechanical properties, thus affecting the lubrication state of the bearings and dynamic characteristics. With the continuous improvement of aero-engine performance requirements for main shaft bearings, it is of great significance to carry out a coupling study of the lubrication behavior and mechanical properties of the bearing contact zone under heavy load, high speed and high temperature conditions to improve the service performance, reliability and life of the bearings. Full article

This work focuses on the design and optimization of a morphing-compliant system developed within the project HERWINGT (Clean Aviation) and aimed at generating high lift during take-off and landing. The device was conceived to replace a conventional flap of a regional aircraft and work in synergy with a droop nose and a flow control system. The architecture is based on a compliant layout, specifically selected to obtain a final morphed shape of the trailing edge of the wing efficient for high-lift purposes and adequately smooth even in cruise clean configuration. At first, the requirements at aircraft level were critically examined and then elaborated to produce the specifications of the morphing device. A layout was then sketched, considering on its potential in approaching the target morphed shape and on its intrinsic criticalities. Starting from this scheme, a simplified FE model was introduced. The scope was to have an efficient predictive tool suited for optimization processes. After having identified the most relevant design parameters (skin thickness distribution, topology of the structure, and actuator interface parameters), the cost function, and the constraints of the problem (structural integrity and stability), a genetic optimization was implemented. Repeating the genetic process starting from different initial populations, some optimized configurations were identified. A trade-off was thus organized on different criteria, such as the lightness of the structure, the load-bearing capability, the force, and the stroke needed by the actuator. The best compromise was finally taken as baseline for the realization of an advanced FE model used to validate the numerical outcomes obtained during the optimization process and as starting point for the next steps planned in the project. The achieved design is characterized by an enhanced aerodynamic performance with the absence of steps and gaps and external track fairings, reduced weight of both the structure and the actuator, reduced maintenance costs due to a simple layout, and smaller take-off and landing distances owing to the high-lift capability and the intrinsic lightness. Full article