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Computational efficiency is always the major concern in aircraft design. The purpose of this research is to investigate an efficient jig-shape optimization design method. A new jig-shape optimization method is presented in the current study and its application on the high aspect ratio wing is discussed.

First, the effects of bending and torsion on aerodynamic distribution were discussed. The effect of bending deformation was equivalent to the change of attack angle through a new equivalent method. The equivalent attack angle showed a linear dependence on the quadratic function of bending. Then, a new jig-shape optimization method taking integrated structural deformation into account was proposed. The method was realized by four substeps: object decomposition, optimization design, inversion and evaluation.

After the new jig-shape optimization design, both aerodynamic distribution and structural configuration have satisfactory results. Meanwhile, the method takes both bending and torsion deformation into account.

The new jig-shape optimization method can be well used for the high aspect ratio wing.

The new method is an innovation based on the traditional single parameter design method. It is suitable for engineering application.

Reinforced S-shape bellows are novel metal bellows with high pressure resistance. Displacement compensation ability is a key index in the design of metal bellows. Axial-tension-compression deformation and bending deformation are two typical displacement compensation forms. Thus, analysis of axial and bending stiffness is important in structure design.

In this study, theory analytics of axial tension and compression stiffness of reinforced S-shaped bellows structure is derived, and the load-displacement relationship during axial deformation is obtained by correcting the geometric parameters of waveform during axial tension and compression deformations. On the basis of them, the relationships of bending stiffness with axial tensile and compression stiffness under the action of bending loading are constructed, and thus, the theory analytics of bending stiffness is realized for S-shaped bellows.

This theory analytics is verified by comparing the results of theory analytics with those of numerical simulation for a few typical examples. An investigation on the axial and bending non-linear mechanical behaviors of multi-layer-reinforced S-shaped bellows was also carried out by numerical simulation and experiment, and the experimental results verified the reliability of the analysis method.

It is found that non-linearity behavior occurs greatly during the first loading course of reinforced S-shaped bellows, and the structure is strain-strengthened due to plastic deformation; however, stable stiffness characteristic is exhibited during the succeeding cyclic-loading course.

The fracture mechanism of S-07 steel was investigated by observing the fracture surface of the specimens with scanning electron microscope (SEM). Furthermore, the overall elastic–plastic behaviors and the stress state evolution during the loading procedure of all specimens were simulated by FE analysis to obtain the local strain at crack nucleated location and the average triaxiality of each type of specimen.

Three types of tests under various stress states were performed to study the ductile fracture characteristics of S-07 high strength steel in quasi-static condition.

Under tensile and torsion loading conditions, S-07 steel exhibits two distinctive rupture mechanisms: the growth and internal necking of voids governs the rupture mechanism in tension dominated loading mode, while the change of void shape and internal shearing in the ligaments between voids dominants for shear conditions.

The failure criterion for S-07 steel considering the influence of the triaxial stress state was established.

Regeneratively cooled thrust chamber is a key component of reusable liquid rocket engines. Subjected to cyclic thermal-mechanical loadings, its failure can seriously affect the service life of engines. QCr0.8 copper alloy is widely used in thrust chamber walls due to its excellent thermal conductivity, and its mechanical and fatigue properties are essential for the evaluation of thrust chamber life. This paper contributes to the understanding of the damage mechanism and material selection of regeneratively cooled thrust chambers for reusable liquid rocket engines.

In this paper, tensile and low-cycle fatigue (LCF) tests were conducted for QCr0.8 alloy, and a Chaboche combined hardening model was established to describe the elastic-plastic behavior of QCr0.8 at different temperatures and strain levels. In addition, an LCF life prediction model was established based on the Manson–Coffin formula. The reliability and accuracy of models were then verified by simulations in ABAQUS. Finally, the service life was evaluated for a regenerative cooling thrust chamber, under the condition of cyclic startup and shutdown.

In this paper, a Chaboche combined hardening model was established to describe the elastoplastic behavior of QCr0.8 alloy at different temperatures and strain levels through LCF experiments. The parameters of the fitted Chaboche model were simulated in ABAQUS, and the simulation results were compared with the experimental results. The results show that the model has high reliability and accuracy in characterizing the viscoplastic behavior of QCr0.8 alloy.

(1)The parameters of a Chaboche combined hardening constitutive model and LCF life equation were optimized by tensile and strain-controlled fatigue tests of QCr0.8 copper alloy. (2) Based on the Manson–Coffin formula, the reliability and accuracy of constitutive model were then verified by simulations in ABAQUS. (3)Thermal-mechanical analysis was carried out for regeneratively cooled thrust chamber wall of a reusable liquid rocket engine, and the service life considering LCF, creep and ratcheting damage was analyzed.