2006 Vol.19(2)
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2006, 20(2).
Abstract:
The identification of the inter-electrode gap size in the high frequency group pulse micro-electrochemical machining (HGPECM) is mainly discussed. The auto-regressive(AR) model of group pulse current flowing across the cathode and the anode are created under different situations with different processing parameters and inter-electrode gap size. The AR model based on the current signals indicates that the order of the AR model is obviously different relating to the different processing conditions and the inter-electrode gap size; Moreover, it is different about the stability of the dynamic system, I.e. the white noise response of the Green’s function of the dynamic system is diverse. In addition, power spectrum method is used in the analysis of the dynamic time series about the current signals with different inter-electrode gap size, the results show that there exists a strongest power spectrum peak, characteristic power spectrum(CPS), to the current signals related to the different inter-electrode gap size in the range of 0~5 kHz. Therefore, the CPS of current signals can implement the identification of the inter-electrode gap.
The identification of the inter-electrode gap size in the high frequency group pulse micro-electrochemical machining (HGPECM) is mainly discussed. The auto-regressive(AR) model of group pulse current flowing across the cathode and the anode are created under different situations with different processing parameters and inter-electrode gap size. The AR model based on the current signals indicates that the order of the AR model is obviously different relating to the different processing conditions and the inter-electrode gap size; Moreover, it is different about the stability of the dynamic system, I.e. the white noise response of the Green’s function of the dynamic system is diverse. In addition, power spectrum method is used in the analysis of the dynamic time series about the current signals with different inter-electrode gap size, the results show that there exists a strongest power spectrum peak, characteristic power spectrum(CPS), to the current signals related to the different inter-electrode gap size in the range of 0~5 kHz. Therefore, the CPS of current signals can implement the identification of the inter-electrode gap.
2006, 20(2).
Abstract:
LF6 aluminum alloy plates with 4.5 mm thickness are welded in this experiment. Welding is carried out by using the CO2 laser-MIG paraxial hybrid welding in flat position. The experimental results indicate that the inherent droplet transfer cycle time of conventional MIG arc is changed due to the interaction between CO2 laser beam and MIG arc in the short-circuiting mode of laser-MIG hybrid welding. Because of the preheating action of CO2 laser to electrode and base material, the droplet transfer frequency of MIG arc is increased in the hybrid welding process. When laser power is increased to a certain degree, the droplet transfer frequency is decreased due to the effect of laser-induced keyhole. Furthermore, through analyzing the MIG welding current and arc voltage waveforms and the characteristics of droplet transfer in the hybrid welding process, the effect of laser energy and the action point between laser beam and arc on the frequency of droplet transfer and weld appearance is investigated in details.
LF6 aluminum alloy plates with 4.5 mm thickness are welded in this experiment. Welding is carried out by using the CO2 laser-MIG paraxial hybrid welding in flat position. The experimental results indicate that the inherent droplet transfer cycle time of conventional MIG arc is changed due to the interaction between CO2 laser beam and MIG arc in the short-circuiting mode of laser-MIG hybrid welding. Because of the preheating action of CO2 laser to electrode and base material, the droplet transfer frequency of MIG arc is increased in the hybrid welding process. When laser power is increased to a certain degree, the droplet transfer frequency is decreased due to the effect of laser-induced keyhole. Furthermore, through analyzing the MIG welding current and arc voltage waveforms and the characteristics of droplet transfer in the hybrid welding process, the effect of laser energy and the action point between laser beam and arc on the frequency of droplet transfer and weld appearance is investigated in details.
2006, 20(2).
Abstract:
Based on the standpoint to take for the crack size also to be a damage variable like the damage variable, by means of the two-directions coordinate system, several new calculation equations on the small crack growth rate are suggested for describing the elastic-plastic behavior of some metallic materials. And the estimation formulas of life are also suggested relative to varied small crack size at each loading history, which is unsymmetric cyclic loading. In the calculation method, as a loaded stress-strain parameter to adopt the ratio with plastic strain range to elastic strain range, and as the material constants using the typical material parameters in damage calculation expression, a new concept of the compositive material constant, which has functional relation with the typical material constants, average stress, average strain, critical loading time is given out. In addition, the fatigue damage of a part of car is put up to calculate as an example, its calculation results are accordant with the Landgraf’s equation, and calculation precision is more rigorous, so could avoid unnecessary fatigue tests and will be of practical significance on saving times, manpower and capitals, as well as the convenience for engineering applications.
Based on the standpoint to take for the crack size also to be a damage variable like the damage variable, by means of the two-directions coordinate system, several new calculation equations on the small crack growth rate are suggested for describing the elastic-plastic behavior of some metallic materials. And the estimation formulas of life are also suggested relative to varied small crack size at each loading history, which is unsymmetric cyclic loading. In the calculation method, as a loaded stress-strain parameter to adopt the ratio with plastic strain range to elastic strain range, and as the material constants using the typical material parameters in damage calculation expression, a new concept of the compositive material constant, which has functional relation with the typical material constants, average stress, average strain, critical loading time is given out. In addition, the fatigue damage of a part of car is put up to calculate as an example, its calculation results are accordant with the Landgraf’s equation, and calculation precision is more rigorous, so could avoid unnecessary fatigue tests and will be of practical significance on saving times, manpower and capitals, as well as the convenience for engineering applications.
2006, 20(2).
Abstract:
Six kinds of micro bridge-beam specimens with different sizes are fabricated using photolithography technology for bending test. Beam specimens with trapezoidal section could be representatives of those with rectangle and square section, which are usually applied in MEMS. Nano indentation method used in bending test can be applied to both elastic and plastic materials. Also, some me-chanical properties parameters such as the modulus of elasticity, hardness and the bending strength are obtained. The average modulus of elasticity of SCS is 170.295 0±2.485 0 Gpa, showing no size effects, but the bending strength ranges from 3.24 Gpa to 10.15 Gpa, displaying strong size effects, and the average hardness is 9.496 7±1.753 3 Gpa, in which no obvious size effects are observed.
Six kinds of micro bridge-beam specimens with different sizes are fabricated using photolithography technology for bending test. Beam specimens with trapezoidal section could be representatives of those with rectangle and square section, which are usually applied in MEMS. Nano indentation method used in bending test can be applied to both elastic and plastic materials. Also, some me-chanical properties parameters such as the modulus of elasticity, hardness and the bending strength are obtained. The average modulus of elasticity of SCS is 170.295 0±2.485 0 Gpa, showing no size effects, but the bending strength ranges from 3.24 Gpa to 10.15 Gpa, displaying strong size effects, and the average hardness is 9.496 7±1.753 3 Gpa, in which no obvious size effects are observed.
2006, 20(2).
Abstract:
Performance analysis and kinematic design of the 3-PUU pure translational parallel mechanism with vertical guide-ways are investigated. Two novel performance indices, the critical slider stroke and the main section area of workspace, are defined; The expressions of two other indices, I.e. the global dexterity and global force transfer ratio are revised based on the main section of workspace. Using these indices, performance changes versus the varieties of dimensional parameters of mechanism are investigated in detail and the graphic descriptions of change tendencies of the performance indices are illustrated. By means of these obtained graphic descriptions, kinematic parameters for the 3-PUU pure translational parallel mechanism with better characteristics can be directly acquired.
Performance analysis and kinematic design of the 3-PUU pure translational parallel mechanism with vertical guide-ways are investigated. Two novel performance indices, the critical slider stroke and the main section area of workspace, are defined; The expressions of two other indices, I.e. the global dexterity and global force transfer ratio are revised based on the main section of workspace. Using these indices, performance changes versus the varieties of dimensional parameters of mechanism are investigated in detail and the graphic descriptions of change tendencies of the performance indices are illustrated. By means of these obtained graphic descriptions, kinematic parameters for the 3-PUU pure translational parallel mechanism with better characteristics can be directly acquired.
2006, 20(2).
Abstract:
A valid image-processing algorithm of weld pool surface reconstruction according to an input image of weld pool based on shape from shading (SFS) in computer vision is presented. The weld pool surface information is related to the backside weld width, which is crucial to the quality of weld joint. The image of weld pool is recorded with an optical sensing method. Firstly, the reflectance map model, which specifies the imaging process, is estimated. Then, the algorithm of weld pool surface reconstruction based on SFS is implemented by iteration scheme and speeded by hierarchical structure. The results indicate the accuracy and effectiveness of the approach.
A valid image-processing algorithm of weld pool surface reconstruction according to an input image of weld pool based on shape from shading (SFS) in computer vision is presented. The weld pool surface information is related to the backside weld width, which is crucial to the quality of weld joint. The image of weld pool is recorded with an optical sensing method. Firstly, the reflectance map model, which specifies the imaging process, is estimated. Then, the algorithm of weld pool surface reconstruction based on SFS is implemented by iteration scheme and speeded by hierarchical structure. The results indicate the accuracy and effectiveness of the approach.
2006, 20(2).
Abstract:
The concepts, principles and usages of principal component analysis (PCA) and independent component analysis (ICA) are interpreted. Then the algorithm and methodology of ICA-based blind source separation (BSS), in which the pre-whitened based on PCA for observed signals is used, are researched. Aiming at the mixture signals, whose frequency components are overlapped by each other, a simulation of BSS to separate this type of mixture signals by using theory and approach of BSS has been done. The result shows that the BSS has some advantages what the traditional methodology of frequency analysis has not.
The concepts, principles and usages of principal component analysis (PCA) and independent component analysis (ICA) are interpreted. Then the algorithm and methodology of ICA-based blind source separation (BSS), in which the pre-whitened based on PCA for observed signals is used, are researched. Aiming at the mixture signals, whose frequency components are overlapped by each other, a simulation of BSS to separate this type of mixture signals by using theory and approach of BSS has been done. The result shows that the BSS has some advantages what the traditional methodology of frequency analysis has not.
2006, 20(2).
Abstract:
An algorithm of auto-searching weld line for welding mobile robot is presented. Auto-searching weld line is that the robot can automatically recognize a weld groove according to the characteristics of the weld groove before welding, and then adjust itself posture to the desired status preparing for welding, namely, it is a process that the robot autonomously aligns itself to the center of welding seam. Firstly, the configuration of welding mobile robot with the function of auto-searching weld line is introduced, then the algorithm and implementation of auto-searching weld line are presented on the basis of kinematics model of the robot, at last trajectory planning among auto-searching weld line is investigated in detail. The experiment result shows that the developed welding mobile robot can successfully implement the task of auto-searching weld line before welding, tracking error precision can be controlled to approximate ± 1.5 mm, and satisfy the requirement of practical welding project.
An algorithm of auto-searching weld line for welding mobile robot is presented. Auto-searching weld line is that the robot can automatically recognize a weld groove according to the characteristics of the weld groove before welding, and then adjust itself posture to the desired status preparing for welding, namely, it is a process that the robot autonomously aligns itself to the center of welding seam. Firstly, the configuration of welding mobile robot with the function of auto-searching weld line is introduced, then the algorithm and implementation of auto-searching weld line are presented on the basis of kinematics model of the robot, at last trajectory planning among auto-searching weld line is investigated in detail. The experiment result shows that the developed welding mobile robot can successfully implement the task of auto-searching weld line before welding, tracking error precision can be controlled to approximate ± 1.5 mm, and satisfy the requirement of practical welding project.
2006, 20(2).
Abstract:
In order to increase the efficiency in the machining of the sculptured surfaces, the contact principle of differential geometry is applied to the 5-axis NC machining; The best contact condition between tool and the surfaces is researched. Through analysis the contact degree of the intersection line of the cutter and the surfaces is known. In comparison to previous studies, the theory is more restricted and accurate by going beyond the second-order parameters into the third-order, suiting both the primary surfaces of analytical geometry and the computer-generated surfaces of the computation geometry. It has definite procedure of calculation, and the equations are easy to solve. The thought process is very clear: First, suppose that there is a surface of third-order, the coefficients of which are arbitrary; Then find out the best posture of the circle in order that the circle and the surface will most closely contact with each other at the origin position; Finally, develop the surface into a third-order surface at every point of machining and employ the results mentioned above to find the best cutter posture at every point of machining. As a result, the equations are easy to solve, and the concept is clear.
In order to increase the efficiency in the machining of the sculptured surfaces, the contact principle of differential geometry is applied to the 5-axis NC machining; The best contact condition between tool and the surfaces is researched. Through analysis the contact degree of the intersection line of the cutter and the surfaces is known. In comparison to previous studies, the theory is more restricted and accurate by going beyond the second-order parameters into the third-order, suiting both the primary surfaces of analytical geometry and the computer-generated surfaces of the computation geometry. It has definite procedure of calculation, and the equations are easy to solve. The thought process is very clear: First, suppose that there is a surface of third-order, the coefficients of which are arbitrary; Then find out the best posture of the circle in order that the circle and the surface will most closely contact with each other at the origin position; Finally, develop the surface into a third-order surface at every point of machining and employ the results mentioned above to find the best cutter posture at every point of machining. As a result, the equations are easy to solve, and the concept is clear.
2006, 20(2).
Abstract:
Difference of offset spinning with conventional symmetric spinning is analyzed. A 3D FEM model for offset tube neck-spinning is established and the spinning process is simulated by means of ANSYS software. Dynamic boundary and contact problems in simulation are solved. Transient stress distribution of contact area, transient strain distribution of nodes in typical section and strain distribu-tion of the workpiece at last are attained, the place and the cause of crack are analyzed. Strain variation curves with time of offset spinning and conventional spinning are compared. It shows the mechanism difference between offset spinning and conventional spinning. In addition, simulation results show how strain distribution of typical section, thickness of some typical nodes, axial extension in left section and force of three rollers change with time. According to the study of the variation curve, material flow law along radial, tangential and axial direction is attained and the whole spinning process is studied. The simulation results discover that offset distance is the key to manufacture offset non-symmetric tube, and process parameters change with spinning angle. Experiment data really reflect different process parameters’ influence on conventional symmetric and offset spinning force. Experiments accord well with simulation.
Difference of offset spinning with conventional symmetric spinning is analyzed. A 3D FEM model for offset tube neck-spinning is established and the spinning process is simulated by means of ANSYS software. Dynamic boundary and contact problems in simulation are solved. Transient stress distribution of contact area, transient strain distribution of nodes in typical section and strain distribu-tion of the workpiece at last are attained, the place and the cause of crack are analyzed. Strain variation curves with time of offset spinning and conventional spinning are compared. It shows the mechanism difference between offset spinning and conventional spinning. In addition, simulation results show how strain distribution of typical section, thickness of some typical nodes, axial extension in left section and force of three rollers change with time. According to the study of the variation curve, material flow law along radial, tangential and axial direction is attained and the whole spinning process is studied. The simulation results discover that offset distance is the key to manufacture offset non-symmetric tube, and process parameters change with spinning angle. Experiment data really reflect different process parameters’ influence on conventional symmetric and offset spinning force. Experiments accord well with simulation.
2006, 20(2).
Abstract:
An asymmetric damping force generation algorithm is originally proposed to yield the asymmetric force-velocity characteristics for the symmetric magneto-rheological (MR) dampers. The command current is formulated in an asymmetric manner to excite the symmetric MR dampers by employing the “on-off” control law in response to the direction of velocity, and a smooth modulation function is developed without phase shift to suppress strong transients in the damping forces caused by the current-switching discontinuity. The effectiveness of the proposed algorithm is evaluated by analyzing the dynamic responses of a quarter-vehicle suspension system with a symmetric MR-damper by modulating the command current into the asymmetric manner. The simulation results show that the proposed algorithm could achieve a better compromise between the conflicting requirements of the asymmetric damping force ratio and the force-velocity curve smoothness, and the asymmetric damping MR-suspension design can ideally improve the road holding and ride performances of vehicle motion. The proposed algorithm can be generally incorporated with a controller synthesis to realize an intelligent vehicle suspension design with the symmetric MR dampers.
An asymmetric damping force generation algorithm is originally proposed to yield the asymmetric force-velocity characteristics for the symmetric magneto-rheological (MR) dampers. The command current is formulated in an asymmetric manner to excite the symmetric MR dampers by employing the “on-off” control law in response to the direction of velocity, and a smooth modulation function is developed without phase shift to suppress strong transients in the damping forces caused by the current-switching discontinuity. The effectiveness of the proposed algorithm is evaluated by analyzing the dynamic responses of a quarter-vehicle suspension system with a symmetric MR-damper by modulating the command current into the asymmetric manner. The simulation results show that the proposed algorithm could achieve a better compromise between the conflicting requirements of the asymmetric damping force ratio and the force-velocity curve smoothness, and the asymmetric damping MR-suspension design can ideally improve the road holding and ride performances of vehicle motion. The proposed algorithm can be generally incorporated with a controller synthesis to realize an intelligent vehicle suspension design with the symmetric MR dampers.
2006, 20(2).
Abstract:
The forming mechanism of hole flanging on a thick-wall heavy cylinder forging is simulated by DEFORM3D. The cylinder is 4 390 mm in diameter and 390 mm in thickness. The results show that the compound deformation with bending and expanding happens in the process of hole flanging. The diameter of pre-hole of the workpiece is one of the key parameters in the process of hole flanging. The optimal diameter is obtained for reverse-conical hole of average diameter 40 mm by simulation of hole flanging process on 5 pre-holes with different diameters and 3 pre-holes with different shapes. The results can provide the scientific base for engineering application of the process.
The forming mechanism of hole flanging on a thick-wall heavy cylinder forging is simulated by DEFORM3D. The cylinder is 4 390 mm in diameter and 390 mm in thickness. The results show that the compound deformation with bending and expanding happens in the process of hole flanging. The diameter of pre-hole of the workpiece is one of the key parameters in the process of hole flanging. The optimal diameter is obtained for reverse-conical hole of average diameter 40 mm by simulation of hole flanging process on 5 pre-holes with different diameters and 3 pre-holes with different shapes. The results can provide the scientific base for engineering application of the process.
2006, 20(2).
Abstract:
S-N curve and fatigue parameters of 48MnV are obtained using small sample tests and staircase or up and down method, which paves the way for predicting fatigue life of crankshaft made of 48MnV. The fatigue life of the crankshaft of a six-cylinder engine is calculated using different damage models such as S-N method, normal strain approach, Smoth-Watson-Topper (SWT)- Bannantine approach, shear strain approach, and Fatemi-Socie method based on dynamic simulation and finite element analysis (FEA) of crankshaft. The results indicate that the traditional calculation is conservative and the residual fatigue life of crankshaft is sufficient to maintain next life cycle if the crankshaft is remanufactured after its end of life.
S-N curve and fatigue parameters of 48MnV are obtained using small sample tests and staircase or up and down method, which paves the way for predicting fatigue life of crankshaft made of 48MnV. The fatigue life of the crankshaft of a six-cylinder engine is calculated using different damage models such as S-N method, normal strain approach, Smoth-Watson-Topper (SWT)- Bannantine approach, shear strain approach, and Fatemi-Socie method based on dynamic simulation and finite element analysis (FEA) of crankshaft. The results indicate that the traditional calculation is conservative and the residual fatigue life of crankshaft is sufficient to maintain next life cycle if the crankshaft is remanufactured after its end of life.
2006, 20(2).
Abstract:
A coupled electrical-thermal-mechanical analysis is conducted for electrical/laser heating assisted blanking. Two novel localized-heating methods, electrical heating and laser-heating, recently proposed for small-part blanking, are investigated with FE simulations. Results show that electrical heating would result in an advantageous distribution of temperature in a 316 stainless steel work-material. A desired temperature distribution may also be achievable for a copper work-material, if laser beam is used. Both electrical heating and laser-heating enable to reduce the blanking force and increase the aspect ratio achievable by blanking. The simulation also demonstrates that both electrical heating and laser-heating can result in desired temperature-distributions at sufficiently high heating-rates, ease of implementation and application. Comparatively, electrical heating could generate more favorable temperature distribution for small-part blanking.
A coupled electrical-thermal-mechanical analysis is conducted for electrical/laser heating assisted blanking. Two novel localized-heating methods, electrical heating and laser-heating, recently proposed for small-part blanking, are investigated with FE simulations. Results show that electrical heating would result in an advantageous distribution of temperature in a 316 stainless steel work-material. A desired temperature distribution may also be achievable for a copper work-material, if laser beam is used. Both electrical heating and laser-heating enable to reduce the blanking force and increase the aspect ratio achievable by blanking. The simulation also demonstrates that both electrical heating and laser-heating can result in desired temperature-distributions at sufficiently high heating-rates, ease of implementation and application. Comparatively, electrical heating could generate more favorable temperature distribution for small-part blanking.
2006, 20(2).
Abstract:
The study of multipoint blank holder force(BHF) control is carried out for hydroforming a complicated shape motorcycle fuel tank. By finite element method (FEM) simulation, the configuration of multipoint blank holder cylinders and the setting of local BHF are optimized, and the influences of the multipoint BHF on the hydromechanical deep drawing and conventional hydroforming processes are studied. The desired fluid pressure and whole BHF are predicted for hydromechanical deep drawing process. Finally, simulation results are testified by forming experiment, and they are in agreement very well.
The study of multipoint blank holder force(BHF) control is carried out for hydroforming a complicated shape motorcycle fuel tank. By finite element method (FEM) simulation, the configuration of multipoint blank holder cylinders and the setting of local BHF are optimized, and the influences of the multipoint BHF on the hydromechanical deep drawing and conventional hydroforming processes are studied. The desired fluid pressure and whole BHF are predicted for hydromechanical deep drawing process. Finally, simulation results are testified by forming experiment, and they are in agreement very well.
2006, 20(2).
Abstract:
In order to improve machining accuracy and efficiency, a software-controlled system of ultra-precision machining for axisymmetric aspheric mirror, using techniques of error compensation, remote transmission and modularization, is designed based on industrial PC, Windows 2000 work platform and Visual Basic 6.0. By experiments, this system realizes functions of ultra-precision machining, machining error compensation, remote data transmission and automatic data transformation among first machining, compensation machining and accuracy measurement. The actual application shows that error compensation improves machining accuracy, remote transmission improves machining efficiency while modularization avoids repeated work and improves design efficiency. Therefore, the system has met ultra-precision machining need for aspheric mirror.
In order to improve machining accuracy and efficiency, a software-controlled system of ultra-precision machining for axisymmetric aspheric mirror, using techniques of error compensation, remote transmission and modularization, is designed based on industrial PC, Windows 2000 work platform and Visual Basic 6.0. By experiments, this system realizes functions of ultra-precision machining, machining error compensation, remote data transmission and automatic data transformation among first machining, compensation machining and accuracy measurement. The actual application shows that error compensation improves machining accuracy, remote transmission improves machining efficiency while modularization avoids repeated work and improves design efficiency. Therefore, the system has met ultra-precision machining need for aspheric mirror.
2006, 20(2).
Abstract:
In order to decrease the anisotropy of mechanical properties, the rigid-plastic mechanical model for the forging method with horizontal V-shaped anvil is presented. The forging method, through the change of anvils shape, is able to control fibrous tissue direction, to improve the anisotropy of mechanical properties of axial forgings, to realize uniform forging. Therefore, the forging method can overcome the defect that conventional forging methods produce. The mechanism of the forging method with horizontal V-shaped anvil and the process of metal deformation are analyzed. The agreement of theoretical analysis with experimental study verifies the fact that the forging method with horizontal V-shaped anvil can control effectively the mechanical properties of axial forgings.
In order to decrease the anisotropy of mechanical properties, the rigid-plastic mechanical model for the forging method with horizontal V-shaped anvil is presented. The forging method, through the change of anvils shape, is able to control fibrous tissue direction, to improve the anisotropy of mechanical properties of axial forgings, to realize uniform forging. Therefore, the forging method can overcome the defect that conventional forging methods produce. The mechanism of the forging method with horizontal V-shaped anvil and the process of metal deformation are analyzed. The agreement of theoretical analysis with experimental study verifies the fact that the forging method with horizontal V-shaped anvil can control effectively the mechanical properties of axial forgings.
2006, 20(2).
Abstract:
Fabrication of microchannels on polymethylmethacrylate (PMMA) substrates using novel microfabrication methods is demonstrated. The image of microchannels is transferred from a silicon master possessing the inverse image of the microchannel to a PMMA plate by using hot embossing methods. The silicon master is electrostatically bonded to a Pyrex 7740 glass wafer, which improves the device yield from about 20 devices to hundreds of devices per master. Effects of embossing temperature, pressure and time on the accuracy of replication are systematically studied using the orthogonal factorial design. According to the suggested experimental model, the time for the whole embossing procedure is shorten from about 20 min to 6 min, and the accuracy of replication is 99.3%. The reproducibility of the hot embossing method is evaluated using 10 channels on different microfluidic devices, with variations of 1.4 % in depth and 1.8% in width.
Fabrication of microchannels on polymethylmethacrylate (PMMA) substrates using novel microfabrication methods is demonstrated. The image of microchannels is transferred from a silicon master possessing the inverse image of the microchannel to a PMMA plate by using hot embossing methods. The silicon master is electrostatically bonded to a Pyrex 7740 glass wafer, which improves the device yield from about 20 devices to hundreds of devices per master. Effects of embossing temperature, pressure and time on the accuracy of replication are systematically studied using the orthogonal factorial design. According to the suggested experimental model, the time for the whole embossing procedure is shorten from about 20 min to 6 min, and the accuracy of replication is 99.3%. The reproducibility of the hot embossing method is evaluated using 10 channels on different microfluidic devices, with variations of 1.4 % in depth and 1.8% in width.
2006, 20(2).
Abstract:
A new method of collision-free path plan integrated in virtual processing is developed to improve the efficiency of laser surface hardening on dies. The path plan is based on the premise of no collision and the optimization object is the shortest path. The optimization model of collision-free path is built from traveling salesman problem (TSP). Collision-free path between two machining points is calculated in configuration space (C-Space). Ant colony optimization (ACO) algorithm is applied to TSP of all the machining points to find the shortest path, which is simulated in virtual environment set up by IGRIP software. Virtual machining time, no-collision report, etc, are put out after the simulation. An example on autobody die is processed in the virtual platform, the simulation results display that ACO has perfect optimization effect, and the method of virtual processing with integration of collision-free optimal path is practical.
A new method of collision-free path plan integrated in virtual processing is developed to improve the efficiency of laser surface hardening on dies. The path plan is based on the premise of no collision and the optimization object is the shortest path. The optimization model of collision-free path is built from traveling salesman problem (TSP). Collision-free path between two machining points is calculated in configuration space (C-Space). Ant colony optimization (ACO) algorithm is applied to TSP of all the machining points to find the shortest path, which is simulated in virtual environment set up by IGRIP software. Virtual machining time, no-collision report, etc, are put out after the simulation. An example on autobody die is processed in the virtual platform, the simulation results display that ACO has perfect optimization effect, and the method of virtual processing with integration of collision-free optimal path is practical.
2006, 20(2).
Abstract:
A new vehicle steering control algorithm is presented. Unlike the traditional methods do, the algorithm uses a sigmoid function to describe the principle of the human driver’s steering strategy. Based on this function, a human simulating vehicle steering model, human-simulating steering control(HS) algorithm is designed. In order to improve the adaptability to different environments, a parameter adaptive adjustment algorithm is presented. This algorithm can online modify the value of the key parameters of the HS real time. HS controller is used on a vehicle equipped with computer vision system and computer controlled steering actuator system, the result from the automatic vehicle steering experiment shows that the HS algorithm gives good performance at different speed, even at the maximum speed of 172 km/h.
A new vehicle steering control algorithm is presented. Unlike the traditional methods do, the algorithm uses a sigmoid function to describe the principle of the human driver’s steering strategy. Based on this function, a human simulating vehicle steering model, human-simulating steering control(HS) algorithm is designed. In order to improve the adaptability to different environments, a parameter adaptive adjustment algorithm is presented. This algorithm can online modify the value of the key parameters of the HS real time. HS controller is used on a vehicle equipped with computer vision system and computer controlled steering actuator system, the result from the automatic vehicle steering experiment shows that the HS algorithm gives good performance at different speed, even at the maximum speed of 172 km/h.
2006, 20(2).
Abstract:
In the diagnosis of rotor crack based on wavelet analysis, it is a painful task to find out an adaptive mother wavelet as many of them can be chosen and the analytic results of different mother wavelets are yet not the same. For this limitation of wavelet analysis, a novel diagnostic approach of rotor crack based on multi-scale singular-spectrum analysis (MS-SSA) is proposed. Firstly, a Jeffcott model of a cracked rotor is developed and the forth-order Runge-Kutta method is used to solve the motion equations of this rotor to obtain its time response (signals). Secondly, a comparatively simple approach of MS-SSA is presented and the empirical orthogonal functions of different orders in various scales are regarded as analyzing functions. At last, the signals of the cracked rotor and an uncracked rotor are analyzed using the proposed approach of MS-SSA, and the simulative results are compared. The results show that, the data-adaptive analyzing functions can capture many features of signals and the rotor crack can be identified and diagnosed effectively by comparing the analytic results of signals of the cracked rotor with those of the uncracked rotor using the analyzing functions of different orders.
In the diagnosis of rotor crack based on wavelet analysis, it is a painful task to find out an adaptive mother wavelet as many of them can be chosen and the analytic results of different mother wavelets are yet not the same. For this limitation of wavelet analysis, a novel diagnostic approach of rotor crack based on multi-scale singular-spectrum analysis (MS-SSA) is proposed. Firstly, a Jeffcott model of a cracked rotor is developed and the forth-order Runge-Kutta method is used to solve the motion equations of this rotor to obtain its time response (signals). Secondly, a comparatively simple approach of MS-SSA is presented and the empirical orthogonal functions of different orders in various scales are regarded as analyzing functions. At last, the signals of the cracked rotor and an uncracked rotor are analyzed using the proposed approach of MS-SSA, and the simulative results are compared. The results show that, the data-adaptive analyzing functions can capture many features of signals and the rotor crack can be identified and diagnosed effectively by comparing the analytic results of signals of the cracked rotor with those of the uncracked rotor using the analyzing functions of different orders.
2006, 20(2).
Abstract:
Iterations in optimization and numerical simulation for the sheet metal forming process may lead to extensive computation. In addition, uncertainties in materials or processing parameters may have great influence on the design quality. A six sigma optimization method is proposed, by combining the dual response surface method (DRSM) and six sigma philosophy, to save computation cost and improve reliability and robustness of parts. Using this method, statistical technology, including the design of experiment and analysis of variance, approximate model and six sigma philosophy are integrated together to achieve improved quality. Two sheet metal forming processes are provided as examples to illustrate the proposed method.
Iterations in optimization and numerical simulation for the sheet metal forming process may lead to extensive computation. In addition, uncertainties in materials or processing parameters may have great influence on the design quality. A six sigma optimization method is proposed, by combining the dual response surface method (DRSM) and six sigma philosophy, to save computation cost and improve reliability and robustness of parts. Using this method, statistical technology, including the design of experiment and analysis of variance, approximate model and six sigma philosophy are integrated together to achieve improved quality. Two sheet metal forming processes are provided as examples to illustrate the proposed method.
2006, 20(2).
Abstract:
An experiment is conducted to investigate the effects of lubricant10#, which contains extreme pressure additives T304 and T305, on the rolling contact fatigue (RCF) life of the contact pairs of a Si3N4 ceramic ball and a steel rod. The experimental investigation is carried out using a ball-rod RCF test rig. The results show that the extreme pressure additives increase the anti-contact-fatigue performance of ceramic balls; When the content of the additives varies from 1% to 5%, the increasing gradient of the RCF life curve decreases; And the oil sample with 1% T305 additive corresponds to the maximal gradient of the RCF life curve, with the RCF life being increased by about 10.77 times. The fatigue surface of the ceramic ball is analyzed with scanning electron microscope (SEM) and X-ray electron dispersion analysis(EDAX), and the physical model of extreme pressure additives’ increasing the RCF life of the ceramic ball is proposed. It is found that the extreme pressure additives form a corrosive film and a transfer film on the surface of the ceramic ball, which decrease the surface tangential stress, and to increase the surface energy is the most effective means for increasing the RCF life.
An experiment is conducted to investigate the effects of lubricant10#, which contains extreme pressure additives T304 and T305, on the rolling contact fatigue (RCF) life of the contact pairs of a Si3N4 ceramic ball and a steel rod. The experimental investigation is carried out using a ball-rod RCF test rig. The results show that the extreme pressure additives increase the anti-contact-fatigue performance of ceramic balls; When the content of the additives varies from 1% to 5%, the increasing gradient of the RCF life curve decreases; And the oil sample with 1% T305 additive corresponds to the maximal gradient of the RCF life curve, with the RCF life being increased by about 10.77 times. The fatigue surface of the ceramic ball is analyzed with scanning electron microscope (SEM) and X-ray electron dispersion analysis(EDAX), and the physical model of extreme pressure additives’ increasing the RCF life of the ceramic ball is proposed. It is found that the extreme pressure additives form a corrosive film and a transfer film on the surface of the ceramic ball, which decrease the surface tangential stress, and to increase the surface energy is the most effective means for increasing the RCF life.
2006, 20(2).
Abstract:
A new precision piezoelectric actuator is proposed to improve its drive capabilities. The actuator is based on the piezoelectric technology. It adopts the principle of bionics and works with a new method of stator initiative anchoring/loosen and a distortion structure of double-side thin flexible hinge. It solves the problem of anchoring/loosen, frequency, journey, resolution and velocity. The experiment shows that the new linear piezoelectric actuator works with high frequency (100 Hz), high speed (502 μm/s), large travel (>10 mm), high resolution (0.05 μm) and high load (100 N). This kind of new piezoelectric actuator will be applied for large travel and high resolution driving device, optics engineering, precision positioning and some micromanipulation field.
A new precision piezoelectric actuator is proposed to improve its drive capabilities. The actuator is based on the piezoelectric technology. It adopts the principle of bionics and works with a new method of stator initiative anchoring/loosen and a distortion structure of double-side thin flexible hinge. It solves the problem of anchoring/loosen, frequency, journey, resolution and velocity. The experiment shows that the new linear piezoelectric actuator works with high frequency (100 Hz), high speed (502 μm/s), large travel (>10 mm), high resolution (0.05 μm) and high load (100 N). This kind of new piezoelectric actuator will be applied for large travel and high resolution driving device, optics engineering, precision positioning and some micromanipulation field.
2006, 20(2).
Abstract:
A novel three-module robot has been introduced. It can change its configuration to adapt to the uneven terrain and to improve its tipover stability. This three-module tracked robot has three kinds of symmetry configuration. They are line type, triangle type, and row type. After the factors and the countermeasures of mobile robot’s tipover problem are analyzed, stability pyramid and tipover stability index are proposed to globally determinate the mobile robot’s static stability and dynamic stability. The shape shifting robot is tested by this technique under the combined disturbance of pitch, roll and yaw in simulation. The simulation result shows that this technique is effective for the analysis of mobile robot’s tipover stability, especially for the reconfigurable or shape shifting modular robot. Experiments on three symmetry configurations are made under unstructured environments. The environment experiment shows the same result as that of the simulation that the triangle type configuration has the best stability. Both simulation and experiment provide a valid reference for the reconfigurable robot’s potential application.
A novel three-module robot has been introduced. It can change its configuration to adapt to the uneven terrain and to improve its tipover stability. This three-module tracked robot has three kinds of symmetry configuration. They are line type, triangle type, and row type. After the factors and the countermeasures of mobile robot’s tipover problem are analyzed, stability pyramid and tipover stability index are proposed to globally determinate the mobile robot’s static stability and dynamic stability. The shape shifting robot is tested by this technique under the combined disturbance of pitch, roll and yaw in simulation. The simulation result shows that this technique is effective for the analysis of mobile robot’s tipover stability, especially for the reconfigurable or shape shifting modular robot. Experiments on three symmetry configurations are made under unstructured environments. The environment experiment shows the same result as that of the simulation that the triangle type configuration has the best stability. Both simulation and experiment provide a valid reference for the reconfigurable robot’s potential application.
2006, 20(2).
Abstract:
The load distribution of multi-row bearings of large strip rolling mill is fully analyzed by 3D contact boundary element method (BEM). It is found out that bearings are frequently worn out due to serious uneven load on the multi-row rollers. The constraint mechanism of the previous rolling system is found to be unreasonable by theoretical analysis on heavy machinery structure. A mechanism of self-aligning even load for workroll bearing of 2 050 mm hot rolling mill of Baoshan I&S Co. is developed. This device is manufactured with particular regard to the structure of 2 050 mm hot rolling mill mentioned above. Hence, uneven load on multi-row bearings is greatly relieved and their lives are remarkably prolonged. Meanwhile, theoretical analysis and on-spot tests prove the rationality and validity of the device.
The load distribution of multi-row bearings of large strip rolling mill is fully analyzed by 3D contact boundary element method (BEM). It is found out that bearings are frequently worn out due to serious uneven load on the multi-row rollers. The constraint mechanism of the previous rolling system is found to be unreasonable by theoretical analysis on heavy machinery structure. A mechanism of self-aligning even load for workroll bearing of 2 050 mm hot rolling mill of Baoshan I&S Co. is developed. This device is manufactured with particular regard to the structure of 2 050 mm hot rolling mill mentioned above. Hence, uneven load on multi-row bearings is greatly relieved and their lives are remarkably prolonged. Meanwhile, theoretical analysis and on-spot tests prove the rationality and validity of the device.
2006, 20(2).
Abstract:
A comprehensive hot wire investigation of the flow around a circular cylinder is carried out in an 18" ´ 18" wind tunnel to look into the dominant frequencies at the stagnation, separation and separated shear layers in the transition Reynolds number range. The majority of the experiments are carried out at Reynolds number of 4.5 ´104, with additional transition frequency tests at Reynolds numbers of 2.9 ´ 104, 3.3 ´ 104 and 9.7 ´ 104 respectively. The results are analysed in terms of power spectral density. While the frequency associated with stagnation is found to be essentially due to vortex shedding, frequency doubling of vortex shedding is also evident in the separated shear layers. Two peaks associated with transition frequencies are detected and their possible implications are presented.
A comprehensive hot wire investigation of the flow around a circular cylinder is carried out in an 18" ´ 18" wind tunnel to look into the dominant frequencies at the stagnation, separation and separated shear layers in the transition Reynolds number range. The majority of the experiments are carried out at Reynolds number of 4.5 ´104, with additional transition frequency tests at Reynolds numbers of 2.9 ´ 104, 3.3 ´ 104 and 9.7 ´ 104 respectively. The results are analysed in terms of power spectral density. While the frequency associated with stagnation is found to be essentially due to vortex shedding, frequency doubling of vortex shedding is also evident in the separated shear layers. Two peaks associated with transition frequencies are detected and their possible implications are presented.
2006, 20(2).
Abstract:
Constituting the reasonable control models of the wrinkle limit blank holder forces is the sticking point of the processes of the deep drawing with variable blank-holder forces, especially in the square-box forming. To begin with, a mode of segmenting flange of the square-box into eight zones is put forward according to the fact that the uniformity of flange deforming can be improved by controlling segment blank-holders. Considering the integral influence of shear stress, a new concept, strain relaxation factor is defined. Hereby, the law of distribution of stress and stain in the deforming flange of square-box is achieved. Then based on these mechanical analysis models and the energy principle, the wrinkling flexivity functions of the straight flange and the circle flange are given, and the corresponding formulae of wrinkling limit blank-holder force in these two situations are also educed. In these processes, ply-anisotropy, strain hardening, thickness and friction are considered. In the end, a calculating example is designed to validate the rationality of the formulae of wrinkling limit blank-holder force, at the same time, the influences of the ply-anisotropy exponent and the strain hardening exponent on the wrinkle limit blank holder forces are also analyzed
Constituting the reasonable control models of the wrinkle limit blank holder forces is the sticking point of the processes of the deep drawing with variable blank-holder forces, especially in the square-box forming. To begin with, a mode of segmenting flange of the square-box into eight zones is put forward according to the fact that the uniformity of flange deforming can be improved by controlling segment blank-holders. Considering the integral influence of shear stress, a new concept, strain relaxation factor is defined. Hereby, the law of distribution of stress and stain in the deforming flange of square-box is achieved. Then based on these mechanical analysis models and the energy principle, the wrinkling flexivity functions of the straight flange and the circle flange are given, and the corresponding formulae of wrinkling limit blank-holder force in these two situations are also educed. In these processes, ply-anisotropy, strain hardening, thickness and friction are considered. In the end, a calculating example is designed to validate the rationality of the formulae of wrinkling limit blank-holder force, at the same time, the influences of the ply-anisotropy exponent and the strain hardening exponent on the wrinkle limit blank holder forces are also analyzed
2006, 20(2).
Abstract:
The mission and function requirements of lunar rover are analyzed, based on virtual prototype technology, the mobility evaluation theory and method for wheeled space rover are proposed, which provide a new way to study the innovative design of lunar rover. Based on the above theoretical system, an innovative lunar rover suspension system, which adopts a two-crank-slider mechanism, is proposed, and its dynamics model is created. Adopting virtual prototype technology, the ground adaptability, over-obstacle ability and driving placidity of the rover are evaluated in the virtual proto-type software ADAMS. The analysis results show that the rover provides a high degree of mobility.
The mission and function requirements of lunar rover are analyzed, based on virtual prototype technology, the mobility evaluation theory and method for wheeled space rover are proposed, which provide a new way to study the innovative design of lunar rover. Based on the above theoretical system, an innovative lunar rover suspension system, which adopts a two-crank-slider mechanism, is proposed, and its dynamics model is created. Adopting virtual prototype technology, the ground adaptability, over-obstacle ability and driving placidity of the rover are evaluated in the virtual proto-type software ADAMS. The analysis results show that the rover provides a high degree of mobility.
2006, 20(2).
Abstract:
To study the tribological properties of the piston ring-cylinder liner in liquid-solid lubrication, the experiment is carried out on a modified piston ring-cylinder liner tester. Two kinds of liquid-solid lubricants are used, one with ultra-dispersed diamond (UDD) nano-particles suspending in pure lubri-cant, the other with micro-sized MoS2 particles. The particle concentrations are 0%, 0.02% and 0.1% by weight. The experimental temperature is 30 ℃ and 75 ℃ respectively. The results show that with the presence of ultra-dispersed diamond particles, the load when scuffing failure occurs is increased. For the lubricant contains MoS2 particles, the scuffing load is decreased. The liquid-solid lubricant also affects the thermal behavior of piston ring-cylinder liner. The surface bulk temperatures of cylinder liner specimen are measured. It has been seen that liquid-solid lubricant used in this research tends to improve the thermal properties generally and the measured friction forces also decreases with the presence of UDD nano-particles. The surface bulk temperature when scuffing occurs is also measured. The results show that the size effect and environment temperature have obvious influence on scuffing load and scuffing temperature. With some new findings, this work is an important complement to the existing research on particle effect on lubrication, because the existing results only show one aspect of this problem.
To study the tribological properties of the piston ring-cylinder liner in liquid-solid lubrication, the experiment is carried out on a modified piston ring-cylinder liner tester. Two kinds of liquid-solid lubricants are used, one with ultra-dispersed diamond (UDD) nano-particles suspending in pure lubri-cant, the other with micro-sized MoS2 particles. The particle concentrations are 0%, 0.02% and 0.1% by weight. The experimental temperature is 30 ℃ and 75 ℃ respectively. The results show that with the presence of ultra-dispersed diamond particles, the load when scuffing failure occurs is increased. For the lubricant contains MoS2 particles, the scuffing load is decreased. The liquid-solid lubricant also affects the thermal behavior of piston ring-cylinder liner. The surface bulk temperatures of cylinder liner specimen are measured. It has been seen that liquid-solid lubricant used in this research tends to improve the thermal properties generally and the measured friction forces also decreases with the presence of UDD nano-particles. The surface bulk temperature when scuffing occurs is also measured. The results show that the size effect and environment temperature have obvious influence on scuffing load and scuffing temperature. With some new findings, this work is an important complement to the existing research on particle effect on lubrication, because the existing results only show one aspect of this problem.
2006, 20(2).
Abstract:
In order to estimate the motion errors of 5-axis machine center, the double ball bar (DBB) method is adopted to realize the diagnosis procedure. The motion error sources of rotary axes in 5-axis machining center comprise of the alignment error of rotary axes and the angular error due to various factors, e.g. the inclination of rotary axes. From sensitive viewpoints, each motion error is possible to have a particular sensitive direction in which deviation of DBB error trace arises from only some specific error sources. The model of the DBB error trace is established according to the spatial geometry theory. Accordingly, the sensitive direction of each motion error source is made clear through numerical simulation, which is used as the reference patterns for rotational error estimation. The estimation method is proposed to easily estimate the motion error sources of rotary axes in quantitative manner. To verify the proposed DBB method for rotational error estimation, the experimental tests are carried out on a 5-axis machining center M-400 (MORISEIKI). The effect of the mismatch of the DBB is also studied to guarantee the estimation accuracy. From the experimental data, it is noted that the proposed estimation method for 5-axis machining center is feasible and effective.
In order to estimate the motion errors of 5-axis machine center, the double ball bar (DBB) method is adopted to realize the diagnosis procedure. The motion error sources of rotary axes in 5-axis machining center comprise of the alignment error of rotary axes and the angular error due to various factors, e.g. the inclination of rotary axes. From sensitive viewpoints, each motion error is possible to have a particular sensitive direction in which deviation of DBB error trace arises from only some specific error sources. The model of the DBB error trace is established according to the spatial geometry theory. Accordingly, the sensitive direction of each motion error source is made clear through numerical simulation, which is used as the reference patterns for rotational error estimation. The estimation method is proposed to easily estimate the motion error sources of rotary axes in quantitative manner. To verify the proposed DBB method for rotational error estimation, the experimental tests are carried out on a 5-axis machining center M-400 (MORISEIKI). The effect of the mismatch of the DBB is also studied to guarantee the estimation accuracy. From the experimental data, it is noted that the proposed estimation method for 5-axis machining center is feasible and effective.
2006, 20(2).
Abstract:
Based on Reynolds average Navier-Storkes equations of viscous incompressible fluid and k-e two equations turbulent model, the aerodynamic forces of high-speed magnetically-levitated (maglev) trains in transverse and longitudinal wind are investigated by finite volume method. Near 80 calculation cases for 2D transverse wind fields and 20 cases for 3D longitudinal wind fields are analyzed. The aerodynamic side force, yawing, drag, lift and pitching moment for different types of maglev trains and a wheel/rail train are compared under the different wind speeds. The types of maglev train models for 2D transverse wind analysis included electromagnetic suspension (EMS) type train, electrodynamic suspension (EDS) type train, EMS type train with shelter wind wall in one side or two sides of guideway and the walls, which are in different height or/and different distances from train body. The situation of maglev train running on viaduct is also analyzed. For 3D longitudinal wind field analysis, the model with different sizes of air clearances beneath maglev train is examined for the different speeds. Calculation result shows that: ① Different transverse effects are shown in different types of maglev trains. ② The shelter wind wall can fairly decrease the transverse effect on the maglev train. ③ When the shelter wall height is 2 m, there is minimum side force on the train. When the shelter wall height is 2.5 m, there is minimum yawing moment on the train. ④ When the distance between inside surfaces of the walls and center of guideway is 4.0 m, there is minimum transverse influence on the train. ⑤ The size of air clearance beneath train body has a small influence on aerodynamic drag of the train, but has a fairly large effect on aerodynamic lift and pitching moment of the train. ⑥ The calculating lift and pitching moment for maglev train models are minus values.
Based on Reynolds average Navier-Storkes equations of viscous incompressible fluid and k-e two equations turbulent model, the aerodynamic forces of high-speed magnetically-levitated (maglev) trains in transverse and longitudinal wind are investigated by finite volume method. Near 80 calculation cases for 2D transverse wind fields and 20 cases for 3D longitudinal wind fields are analyzed. The aerodynamic side force, yawing, drag, lift and pitching moment for different types of maglev trains and a wheel/rail train are compared under the different wind speeds. The types of maglev train models for 2D transverse wind analysis included electromagnetic suspension (EMS) type train, electrodynamic suspension (EDS) type train, EMS type train with shelter wind wall in one side or two sides of guideway and the walls, which are in different height or/and different distances from train body. The situation of maglev train running on viaduct is also analyzed. For 3D longitudinal wind field analysis, the model with different sizes of air clearances beneath maglev train is examined for the different speeds. Calculation result shows that: ① Different transverse effects are shown in different types of maglev trains. ② The shelter wind wall can fairly decrease the transverse effect on the maglev train. ③ When the shelter wall height is 2 m, there is minimum side force on the train. When the shelter wall height is 2.5 m, there is minimum yawing moment on the train. ④ When the distance between inside surfaces of the walls and center of guideway is 4.0 m, there is minimum transverse influence on the train. ⑤ The size of air clearance beneath train body has a small influence on aerodynamic drag of the train, but has a fairly large effect on aerodynamic lift and pitching moment of the train. ⑥ The calculating lift and pitching moment for maglev train models are minus values.
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