Design-and-Technological Solutions for Rational Blanks Selection of the Aviation-and-Rocket Engineering Critical Parts Based on Digital Twins Creation


Аuthors

Mironova L. I.*, Dmitriev O. N.**, Koval N. A.***, Kolesnik S. A.****

Moscow Aviation Institute (National Research University), 4, Volokolamskoe shosse, Moscow, А-80, GSP-3, 125993, Russia

*e-mail: mironova_lub@mail.ru
**e-mail: olegdmitriev@yandex.ru
***e-mail: niki-kov@yandex.ru
****e-mail: sergey@oviont.com

Abstract

The article adduces the gist of rational design-and-technological decisions making in matters of blank type and material selection for the parts of aviation and rocket engineering. In this regard, the top-priority and responsibility of the designer at the stage of the aviation structures designing, which ultimate goal consists in obtaining the high-quality product with the required performance characteristics and specified service life. Focusing on the advantages of the cast blanks application in aircraft building, particularly on the castings from the aluminum alloys, some problems of foundry, which directly linked with both selecting and assigning of the blank type and casting alloy grade, are adduced. The article provides a brief analysis of casting production features and presents characteristics of both traditional and promising aluminum casting alloys. The multifactor nature of the interrelationships in the casting preparation stage complicates selection of the blank key parameters. It is noted that implementation of new technologies for production process digital prototyping based on the digital twins creation is a prospective tooling. The article provides the examples of the software products applied for the casting processes computer modeling of in the design practice. Functional capabilities of the “PoligonSoft” domestic software product, which allow simulating complex processes of the liquid metal filling and crystallization, heat exchange in the casting mould, as well as predicting casting defects of shrinkable and other character, are adduced. The article presents the results of modeling typical aviation engineering parts manufactured by casting with the metal moulds from various grades of aluminum alloys. It is noted that the virtual prototypes testing with the  computer systems for production processes modeling  allows detecting the most critical zones from the viewpoint of ensuring specified qualitative and quantitative characteristics of the product being developed. The developer gets the software tools and extensive opportunities for refining the design configuration and technical requirements, as well as managing the production process cycle. Thus, a unified information environment is being formed, in which the design and technological plans of specialists with a wide range of competencies are being realized through the digital maintenance of the twins at the stages of the product life cycle “development – design – manufacturing”.

Keywords:

design and technological decisions making, digital prototyping, of blank type selection, virtual prototypes, technological try-out of manufacturing processes, reducing labor intensity

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