2007 Vol.20(2)
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2007, 21(2).
Abstract:
A modern design method, in which traditional design formulas are conjoined with numerical simulation and optimization, is successfully used to design the out-size extrusion frame precisely so that the press cost can be saved. A new technology used for decompressing by a multi-steps dynamical mode is put forward, which makes it possible to decompress the large flow-volume high-pressure oil in the main cylinders. In addition, a method for realizing the fixed mandrel process by hydraulic support is proposed and its control equation is established. Pre-tightening frame tests are carried out by over-operating pressure on 100 MN aluminium extrusion press with oil-driven double action, which is developed based on the above key techniques and is the largest press so far in the world, and the results show that the frame structure designed is reasonable and reliable, and the modern design method used is an useful tool for designing large and out-size heavy plastic forming machinery. The results of decompressing curve in main cylinder and noise inspection indicate that multi-steps dynamical mode for decompressing the large flow-volume high pressure oil is valid and reliable. Meanwhile, the fixed mandrel process is well realized based on the control equation. These key techniques have been used in the development of 125 MN aluminium extrusion press with oil-driven double action.
A modern design method, in which traditional design formulas are conjoined with numerical simulation and optimization, is successfully used to design the out-size extrusion frame precisely so that the press cost can be saved. A new technology used for decompressing by a multi-steps dynamical mode is put forward, which makes it possible to decompress the large flow-volume high-pressure oil in the main cylinders. In addition, a method for realizing the fixed mandrel process by hydraulic support is proposed and its control equation is established. Pre-tightening frame tests are carried out by over-operating pressure on 100 MN aluminium extrusion press with oil-driven double action, which is developed based on the above key techniques and is the largest press so far in the world, and the results show that the frame structure designed is reasonable and reliable, and the modern design method used is an useful tool for designing large and out-size heavy plastic forming machinery. The results of decompressing curve in main cylinder and noise inspection indicate that multi-steps dynamical mode for decompressing the large flow-volume high pressure oil is valid and reliable. Meanwhile, the fixed mandrel process is well realized based on the control equation. These key techniques have been used in the development of 125 MN aluminium extrusion press with oil-driven double action.
2007, 21(2).
Abstract:
A simulative analysis coupled with experiment on behaviors of a soil bed cut by a model bulldozer blade is carried out using the finite element/distinct element method(FE/DEM) facility built in the ELFEN package. Before simulation, the soil specimens are examined through uniaxial tensile/compression, triaxial compression and direct shear tests to obtain model characteristics and relevant parameters, then soil cutting experiments are carried out via a mini-soil bin system with a soil bed of 60/120 mm in width and 10 mm in depth cut by a 1/9 scale model bulldozer blade moving with the velocity of 10 mm/s. The soil constitutive model includes the tensile elastic model for tensile breakage and the compressive elastoplastic relationship with Mohr-Coulomb criterion. The cutting length in simulation is set as 1/4 of that in the experiment divided into 1 869 triangular elements. The comparison between the simulated results and experimental ones shows that the used model is capable of analyzing soil dynamic behaviors qualitatively, and the predicted fracturing profiles in general conform to the experiment. Hence the feasibility for analyzing soil fracturing behaviors in tillage or other similar processes is validated.
A simulative analysis coupled with experiment on behaviors of a soil bed cut by a model bulldozer blade is carried out using the finite element/distinct element method(FE/DEM) facility built in the ELFEN package. Before simulation, the soil specimens are examined through uniaxial tensile/compression, triaxial compression and direct shear tests to obtain model characteristics and relevant parameters, then soil cutting experiments are carried out via a mini-soil bin system with a soil bed of 60/120 mm in width and 10 mm in depth cut by a 1/9 scale model bulldozer blade moving with the velocity of 10 mm/s. The soil constitutive model includes the tensile elastic model for tensile breakage and the compressive elastoplastic relationship with Mohr-Coulomb criterion. The cutting length in simulation is set as 1/4 of that in the experiment divided into 1 869 triangular elements. The comparison between the simulated results and experimental ones shows that the used model is capable of analyzing soil dynamic behaviors qualitatively, and the predicted fracturing profiles in general conform to the experiment. Hence the feasibility for analyzing soil fracturing behaviors in tillage or other similar processes is validated.
2007, 21(2).
Abstract:
The pressure loss of cross-flow perforated muffler has been computed with the procedure of physical modeling, simulation and data processing. Three-dimensional computational fluid dynamics (CFD) has been used to investigate the relations of porosities, flow velocity and diameter of the holes with the pressure loss. Accordingly, some preliminary results have been obtained that pressure loss increases with porosity descent as nearly a hyperbolic trend, rising flow velocity of the input makes the pressure loss increasing with parabola trend, diameter of holes affects little about pressure loss of the muffler. Otherwise, the holes on the perforated pipes make the air flow gently and meanly, which decreases the air impact to the wall and pipes in the muffler. A practical perforated muffler is used to illustrate the available of this method for pressure loss computation, and the comparison shows that the computation results with the method of CFD has reference value for muffler design.
The pressure loss of cross-flow perforated muffler has been computed with the procedure of physical modeling, simulation and data processing. Three-dimensional computational fluid dynamics (CFD) has been used to investigate the relations of porosities, flow velocity and diameter of the holes with the pressure loss. Accordingly, some preliminary results have been obtained that pressure loss increases with porosity descent as nearly a hyperbolic trend, rising flow velocity of the input makes the pressure loss increasing with parabola trend, diameter of holes affects little about pressure loss of the muffler. Otherwise, the holes on the perforated pipes make the air flow gently and meanly, which decreases the air impact to the wall and pipes in the muffler. A practical perforated muffler is used to illustrate the available of this method for pressure loss computation, and the comparison shows that the computation results with the method of CFD has reference value for muffler design.
2007, 21(2).
Abstract:
To deal with over-shooting and gouging in high speed machining, a novel approach for velocity smooth link is proposed. Considering discrete tool path, cubic spline curve fitting is used to find dangerous points, and according to spatial geometric properties of tool path and the kinematics theory, maximum optimal velocities at dangerous points are obtained. Based on method of velocity control characteristics stored in control system, a fast algorithm for velocity smooth link is analyzed and formulated. On-line implementation results show that the proposed approach makes velocity changing more smoothly compared with traditional velocity control methods and improves producti-vity greatly
To deal with over-shooting and gouging in high speed machining, a novel approach for velocity smooth link is proposed. Considering discrete tool path, cubic spline curve fitting is used to find dangerous points, and according to spatial geometric properties of tool path and the kinematics theory, maximum optimal velocities at dangerous points are obtained. Based on method of velocity control characteristics stored in control system, a fast algorithm for velocity smooth link is analyzed and formulated. On-line implementation results show that the proposed approach makes velocity changing more smoothly compared with traditional velocity control methods and improves producti-vity greatly
2007, 21(2).
Abstract:
Under the hypothesis of the rigid-plastic material, specific efforts are placed on the deve- lopments of the key simulation techniques of the meshless Galerkin method because of the complexity of the deformation process as well as the generality and atomization of the simulation procedures for non-steady state large deformation plastic processes, therefore, an adaptive rigid meshless Galerkin method is developed. The influence domain control method is used in the least square approximation by dynamic evaluation of the magnitude of the influence domain and the effective control of the amount and the positions of the points in the least square approximation in order to improve approxi-mation precision. The amount of the Gauss integration points in the discrete domain is maintained in a considerable magnitude in order to ensure the integration precision in the discrete domain. The length of the frictional boundary of the plastic deformation process may be getting longer when its deforma-tion is getting severe. Thus, the densities of the boundary points of some places get lower. The adap-tive boundary points setting method is employed to improve the approximation precision of the boundary points and enhance the constraint of the boundary condition by adaptive control of boun- dary point density. Some typical extrusion processes are analyzed, detail simulation results such as the deformation field, velocity field, effective strain field, effective strain rate field, the volume loss curve and load-stroke curve are obtained. The effectiveness of the method developed is demonstrated and the precision of the meshless simulation is proved by overall comparison with the results obtained by using the commercial software deform.
Under the hypothesis of the rigid-plastic material, specific efforts are placed on the deve- lopments of the key simulation techniques of the meshless Galerkin method because of the complexity of the deformation process as well as the generality and atomization of the simulation procedures for non-steady state large deformation plastic processes, therefore, an adaptive rigid meshless Galerkin method is developed. The influence domain control method is used in the least square approximation by dynamic evaluation of the magnitude of the influence domain and the effective control of the amount and the positions of the points in the least square approximation in order to improve approxi-mation precision. The amount of the Gauss integration points in the discrete domain is maintained in a considerable magnitude in order to ensure the integration precision in the discrete domain. The length of the frictional boundary of the plastic deformation process may be getting longer when its deforma-tion is getting severe. Thus, the densities of the boundary points of some places get lower. The adap-tive boundary points setting method is employed to improve the approximation precision of the boundary points and enhance the constraint of the boundary condition by adaptive control of boun- dary point density. Some typical extrusion processes are analyzed, detail simulation results such as the deformation field, velocity field, effective strain field, effective strain rate field, the volume loss curve and load-stroke curve are obtained. The effectiveness of the method developed is demonstrated and the precision of the meshless simulation is proved by overall comparison with the results obtained by using the commercial software deform.
2007, 21(2).
Abstract:
In the steady operation condition, the experiments and the numerical simulations are used to investigate the tip leakage flow fields in three low pressure axial flow fans with three kinds of circumferential skewed rotors, including the radial rotor, the forward-skewed rotor and the back-ward-skewed rotor. The three-dimensional viscous flow fields of the fans are computed. In the ex-periments, the two-dimensional plane particle image velocimetry (PIV) system is used to measure the flow fields in the tip region of three different pitchwise positions of each fan. The results show that the computational results agree well with the experimental data in the flow field of the tip region of each fan. The tip leakage vortex core segments based on method of the eigenmode analysis can dis-play clearly some characteristics of the tip leakage vortex, such as the origination position of tip leak-age vortex, the development of vortex strength, and so on. Compared with the radial rotor, the other two skewed rotors can increase the stability of the tip leakage vortex and the increment in the for-ward-skewed rotor is more than that in the backward-skewed one. Among the tip leakage vortices of the three rotors, the velocity of the vortex in the forward-skewed rotor is the highest in the circumfer-ential direction and the lowest in the axial direction.
In the steady operation condition, the experiments and the numerical simulations are used to investigate the tip leakage flow fields in three low pressure axial flow fans with three kinds of circumferential skewed rotors, including the radial rotor, the forward-skewed rotor and the back-ward-skewed rotor. The three-dimensional viscous flow fields of the fans are computed. In the ex-periments, the two-dimensional plane particle image velocimetry (PIV) system is used to measure the flow fields in the tip region of three different pitchwise positions of each fan. The results show that the computational results agree well with the experimental data in the flow field of the tip region of each fan. The tip leakage vortex core segments based on method of the eigenmode analysis can dis-play clearly some characteristics of the tip leakage vortex, such as the origination position of tip leak-age vortex, the development of vortex strength, and so on. Compared with the radial rotor, the other two skewed rotors can increase the stability of the tip leakage vortex and the increment in the for-ward-skewed rotor is more than that in the backward-skewed one. Among the tip leakage vortices of the three rotors, the velocity of the vortex in the forward-skewed rotor is the highest in the circumfer-ential direction and the lowest in the axial direction.
2007, 21(2).
Abstract:
Three-dimensional flow field of turbine in torque converter is simulated by numerical calculation in order to improve the performance of torque converter. Calculation model of a torque converter is presented based on the mixing-plane technology. In the calculation of flow field, the 3D N-S equations are separated by finite-volume method and solved by semi-implicit method for pressure-linked equations(SIMPLE). Based on flow field calculation, the flow field of turbine is simulated. The velocity and pressure in the flow field of turbine are analyzed. The external performance of the torque converter is also calculated. Results of flow simulation show that there are secondary flow, off flow and velocity gradient in turbine passage. The validity of numerical simulation is verified by comparing the results of numerical simulation with experiment data.
Three-dimensional flow field of turbine in torque converter is simulated by numerical calculation in order to improve the performance of torque converter. Calculation model of a torque converter is presented based on the mixing-plane technology. In the calculation of flow field, the 3D N-S equations are separated by finite-volume method and solved by semi-implicit method for pressure-linked equations(SIMPLE). Based on flow field calculation, the flow field of turbine is simulated. The velocity and pressure in the flow field of turbine are analyzed. The external performance of the torque converter is also calculated. Results of flow simulation show that there are secondary flow, off flow and velocity gradient in turbine passage. The validity of numerical simulation is verified by comparing the results of numerical simulation with experiment data.
2007, 21(2).
Abstract:
Adaptive layered Cartesian cut cell method is presented to solve the difficulty of the unstructured hexahedral anisotropic Cartesian grids generation from the complex CAD model. Vertex merging algorithm based on relaxed AVL tree is investigated to construct topological structure for stereo lithography (STL) files, and a topology-based self-adaptive layered slicing algorithm with special features control strategy is brought forward. With the help of convex hull, a new points-in-polygon method is employed to improve the Cartesian cut cell method. By integrating the self-adaptive layered slicing algorithm and the improved Cartesian cut cell method, the adaptive layered Cartesian cut cell method gains the volume data of the complex CAD model in STL file and generates the unstructured hexahedral anisotropic Cartesian grids.
Adaptive layered Cartesian cut cell method is presented to solve the difficulty of the unstructured hexahedral anisotropic Cartesian grids generation from the complex CAD model. Vertex merging algorithm based on relaxed AVL tree is investigated to construct topological structure for stereo lithography (STL) files, and a topology-based self-adaptive layered slicing algorithm with special features control strategy is brought forward. With the help of convex hull, a new points-in-polygon method is employed to improve the Cartesian cut cell method. By integrating the self-adaptive layered slicing algorithm and the improved Cartesian cut cell method, the adaptive layered Cartesian cut cell method gains the volume data of the complex CAD model in STL file and generates the unstructured hexahedral anisotropic Cartesian grids.
2007, 21(2).
Abstract:
According to the results of experiments and theoretical analysis, a phenomenon called “capture effect” is put forward, which could be used to describe the particles dynamic behavior of electrorheological (ER) suspensions. Then a “structure-force” mathematical model is established to explain this effect based on electrostatic energy density equation. The analysis results show that the dynamic coupling process of ER suspensions under an external electric filed is the function not only of the electric intensity, but also of the dielectric properties and the structure form.
According to the results of experiments and theoretical analysis, a phenomenon called “capture effect” is put forward, which could be used to describe the particles dynamic behavior of electrorheological (ER) suspensions. Then a “structure-force” mathematical model is established to explain this effect based on electrostatic energy density equation. The analysis results show that the dynamic coupling process of ER suspensions under an external electric filed is the function not only of the electric intensity, but also of the dielectric properties and the structure form.
2007, 21(2).
Abstract:
A newly found phenomenon of carved driving wheels of a rear-wheel-drive tractor used in an airport is discussed. The circum of every driving wheel is damaged at three regions, which distribute regularly and uniformly. Everyday, the tractor tows a trailer which are times heavier than the tractor, and moves on the same road in the airport. The phenomenon is explained by the torsional self-excited vibration system of the powertrain. The simplified torsional vibration system is discribed by a 2-order ordinary differential equation, which has a limit circle. Experiments and numerical simulations show the followings: Because of the heavy trailer, the slip ratio of the tractor’s driving wheels is very large. Therefore, there is severe torsional self-excited vibration in the tractor’s drivetrain, and the self-excited vibration results in severe and regular fluctuations of the rear wheel’s velocity. The severe fluctuations in velocity fastens the damage of the driving wheels. At the same time, the time interval in which an arbitrary point in the circum of the driving wheel contacts with the road twice is two times more than the period of the torsional self-excited vibration, and this times explained the existence of three damaged regions. At last, it points out that the phenomenon can be avoided when the torsional damping is large enough.
A newly found phenomenon of carved driving wheels of a rear-wheel-drive tractor used in an airport is discussed. The circum of every driving wheel is damaged at three regions, which distribute regularly and uniformly. Everyday, the tractor tows a trailer which are times heavier than the tractor, and moves on the same road in the airport. The phenomenon is explained by the torsional self-excited vibration system of the powertrain. The simplified torsional vibration system is discribed by a 2-order ordinary differential equation, which has a limit circle. Experiments and numerical simulations show the followings: Because of the heavy trailer, the slip ratio of the tractor’s driving wheels is very large. Therefore, there is severe torsional self-excited vibration in the tractor’s drivetrain, and the self-excited vibration results in severe and regular fluctuations of the rear wheel’s velocity. The severe fluctuations in velocity fastens the damage of the driving wheels. At the same time, the time interval in which an arbitrary point in the circum of the driving wheel contacts with the road twice is two times more than the period of the torsional self-excited vibration, and this times explained the existence of three damaged regions. At last, it points out that the phenomenon can be avoided when the torsional damping is large enough.
2007, 21(2).
Abstract:
In order to cool computer chip efficiently with the least noise, a single phase water-cooling radiator for computer chip driven by piezoelectric pump with two parallel-connection chambers is developed. The structure and work principle of this radiator is described. Material, processing method and design principles of whole radiator are also explained. Finite element analysis (FEA) software, ANSYS, is used to simulate the heat distribution in the radiator. Testing equipments for water-cooling radiator are also listed. By experimental tests, influences of flowrate inside the cooling system and fan on chip cooling are explicated. This water-cooling radiator is proved more efficient than current air-cooling radiator with comparison experiments. During cooling the heater which simulates the working of computer chip with different power, the water-cooling radiator needs shorter time to reach lower steady temperatures than current air-cooling radiator.
In order to cool computer chip efficiently with the least noise, a single phase water-cooling radiator for computer chip driven by piezoelectric pump with two parallel-connection chambers is developed. The structure and work principle of this radiator is described. Material, processing method and design principles of whole radiator are also explained. Finite element analysis (FEA) software, ANSYS, is used to simulate the heat distribution in the radiator. Testing equipments for water-cooling radiator are also listed. By experimental tests, influences of flowrate inside the cooling system and fan on chip cooling are explicated. This water-cooling radiator is proved more efficient than current air-cooling radiator with comparison experiments. During cooling the heater which simulates the working of computer chip with different power, the water-cooling radiator needs shorter time to reach lower steady temperatures than current air-cooling radiator.
2007, 21(2).
Abstract:
Aiming at the characteristics of modularity and reconfigurable in open architecture computer numerical control (CNC) system, the open architecture CNC system, Harbin Institute of Technology computer numerical control (HITCNC), is researched and manufactured based on the interface standards. The system’s external interfaces are coincident with the corresponding international stan-dards, and the internal interfaces follow the open modular architecture controller (OMAC) agreement. In the research and manufacturing process, object-oriented technology is used to ensure the openness of the HITCNC, and static programming is applied in the CNC system according to the idea of modu-larization disassembly. The HITCNC also actualizes real-time and unreal-time modules adopting real-time dynamical linked library (RTDLL) and component object model (COM). Finite state ma-chine (FSM) is adopted to do dynamically modeling of HITCNC. The complete separation between the software and the hardware is achieved in the HITCNC by applying the SoftSERCANS technique. The application of the above key techniques decreases the programming workload greatly, and uses software programs replacing hardware functions, which offers plenty technique ensures for the open-ness of HITCNC. Finally, based on the HITCNC, a three-dimensional milling system is established. On the system, series experiments are done to validate the expandability and interchangeability of HITCNC. The results of the experiments show that the established open architecture CNC system HITCNC is correct and feasible, and has good openness.
Aiming at the characteristics of modularity and reconfigurable in open architecture computer numerical control (CNC) system, the open architecture CNC system, Harbin Institute of Technology computer numerical control (HITCNC), is researched and manufactured based on the interface standards. The system’s external interfaces are coincident with the corresponding international stan-dards, and the internal interfaces follow the open modular architecture controller (OMAC) agreement. In the research and manufacturing process, object-oriented technology is used to ensure the openness of the HITCNC, and static programming is applied in the CNC system according to the idea of modu-larization disassembly. The HITCNC also actualizes real-time and unreal-time modules adopting real-time dynamical linked library (RTDLL) and component object model (COM). Finite state ma-chine (FSM) is adopted to do dynamically modeling of HITCNC. The complete separation between the software and the hardware is achieved in the HITCNC by applying the SoftSERCANS technique. The application of the above key techniques decreases the programming workload greatly, and uses software programs replacing hardware functions, which offers plenty technique ensures for the open-ness of HITCNC. Finally, based on the HITCNC, a three-dimensional milling system is established. On the system, series experiments are done to validate the expandability and interchangeability of HITCNC. The results of the experiments show that the established open architecture CNC system HITCNC is correct and feasible, and has good openness.
2007, 21(2).
Abstract:
The system mathematical model of flexible 3D measuring system is built by theoretical analysis, and the theoretical formula for measuring space point coordinate is also derived. Frog-jumping based coordinate transform method is put forward in order to solve measuring problem for large size parts. The frog-jumping method is discussed, and the coordinate transform mathematical model is method of the space point coordinate compared to original value, and an advanced method is provided. Form the space point coordinate transform formula can derive the calculation measuring method for measuring large size parts.
The system mathematical model of flexible 3D measuring system is built by theoretical analysis, and the theoretical formula for measuring space point coordinate is also derived. Frog-jumping based coordinate transform method is put forward in order to solve measuring problem for large size parts. The frog-jumping method is discussed, and the coordinate transform mathematical model is method of the space point coordinate compared to original value, and an advanced method is provided. Form the space point coordinate transform formula can derive the calculation measuring method for measuring large size parts.
2007, 21(2).
Abstract:
A high fidelity dynamic model of a high-energy hydraulically-actuated shock test machine for heavy weight devices is presented to satisfy the newly-built shock resistance standard and simulate the actual underwater explosion environments in laboratory as well as increase the testing capability of shock test machine. In order to produce the required negative shock pulse in the given time duration, four hydraulic actuators are utilized. The model is then used to formulate an advanced feedforward controller for the system to produce the required negative waveform and to address the motion synchronization of the four cylinders. The model provides a safe and easily controllable way to per-form a “virtual testing” before starting potentially destructive tests on specimen and to predict per-formance of the system. Simulation results have demonstrated the effectiveness of the controller.
A high fidelity dynamic model of a high-energy hydraulically-actuated shock test machine for heavy weight devices is presented to satisfy the newly-built shock resistance standard and simulate the actual underwater explosion environments in laboratory as well as increase the testing capability of shock test machine. In order to produce the required negative shock pulse in the given time duration, four hydraulic actuators are utilized. The model is then used to formulate an advanced feedforward controller for the system to produce the required negative waveform and to address the motion synchronization of the four cylinders. The model provides a safe and easily controllable way to per-form a “virtual testing” before starting potentially destructive tests on specimen and to predict per-formance of the system. Simulation results have demonstrated the effectiveness of the controller.
2007, 21(2).
Abstract:
A newly developed pure rolling fatigue test rig with three contact points is used to test the rolling contact fatigue properties of silicon nitride ceramic balls. Ball surfaces are examined after failure with optical microscopy and scanning electron microscopy. The failure cause, fatigue phenomenon and mechanics are analyzed. The research shows that subsurface cracks play a dominant role in the formation of spalling failure. These cracks originated from volume defects of the material and propagate, to form elliptical fatigue spalls under the action of principal tensile stresses. The principal tensile stress increases with increasing contact load, causing spall formation and reduction of rolling contact life. The greater the principal tensile stress is, the more severe the peeling of near surface is. Under the same condition, the closer volume defects are to the surface, the more likely failure occurs, the shorter the rolling contact life is.
A newly developed pure rolling fatigue test rig with three contact points is used to test the rolling contact fatigue properties of silicon nitride ceramic balls. Ball surfaces are examined after failure with optical microscopy and scanning electron microscopy. The failure cause, fatigue phenomenon and mechanics are analyzed. The research shows that subsurface cracks play a dominant role in the formation of spalling failure. These cracks originated from volume defects of the material and propagate, to form elliptical fatigue spalls under the action of principal tensile stresses. The principal tensile stress increases with increasing contact load, causing spall formation and reduction of rolling contact life. The greater the principal tensile stress is, the more severe the peeling of near surface is. Under the same condition, the closer volume defects are to the surface, the more likely failure occurs, the shorter the rolling contact life is.
2007, 21(2).
Abstract:
A contour-parallel offset (CPO) tool-path linking algorithm is derived without tool- retractions and with the largest practicability. The concept of “tool-path loop tree” (TPL-tree) providing the information on the parent/child relationships among the tool-path loops (TPLs) is presented. The direction, tool-path loop, leaf/branch, layer number, and the corresponding points of the TPL-tree are introduced. By defining TPL as a vector, and by traveling throughout the tree, a CPO tool-path without tool-retractions can be derived.
A contour-parallel offset (CPO) tool-path linking algorithm is derived without tool- retractions and with the largest practicability. The concept of “tool-path loop tree” (TPL-tree) providing the information on the parent/child relationships among the tool-path loops (TPLs) is presented. The direction, tool-path loop, leaf/branch, layer number, and the corresponding points of the TPL-tree are introduced. By defining TPL as a vector, and by traveling throughout the tree, a CPO tool-path without tool-retractions can be derived.
2007, 21(2).
Abstract:
Morlet wavelet is suitable to extract the impulse components of mechanical fault signals. And thus its continuous wavelet transform (CWT) has been successfully used in the field of fault diagnosis. The principle of scale selection in CWT is discussed. Based on genetic algorithm, an optimization strategy for the waveform parameters of the mother wavelet is proposed with wavelet entropy as the optimization target. Based on the optimized waveform parameters, the wavelet scalogram is used to analyze the simulated acoustic emission (AE) signal and real AE signal of rolling bearing. The results indicate that the proposed method is useful and efficient to improve the quality of CWT.
Morlet wavelet is suitable to extract the impulse components of mechanical fault signals. And thus its continuous wavelet transform (CWT) has been successfully used in the field of fault diagnosis. The principle of scale selection in CWT is discussed. Based on genetic algorithm, an optimization strategy for the waveform parameters of the mother wavelet is proposed with wavelet entropy as the optimization target. Based on the optimized waveform parameters, the wavelet scalogram is used to analyze the simulated acoustic emission (AE) signal and real AE signal of rolling bearing. The results indicate that the proposed method is useful and efficient to improve the quality of CWT.
2007, 21(2).
Abstract:
40Cr steel is laser quenched by the NEL-2500A rapidly axial flow CO2 laser. Then the martensite induced by laser quenched is shocked by Nd:YAG laser again. Through comparing and analyzing the appearance and size of martensite, the dislocation density in microstructure between the treated zones by laser quenched and by laser quenched plus laser shock, the following results are shown: The sec-ond martensite obtained by laser compound treatment is more finer compared with those obtained by laser quenched; In the hardened zones obtained by compound treatment, a lot of slender second twin crystal martensites are induced; A lot of more high density dislocation tangles and cellular dislocations are generated. From the transmission electron microscope (TEM) micrograph after compound treatment, there are not only long lath and short nubbly martensites arranged in cross direction, but also massive nubbly and small short nubbly martensites arranged in longitudinal direc-tion. Some martensites look like the broken blocks of quenched martensites. These new martensites are inserted transversely in the quenched martensites with large tangle. And they make quenched martensites break into pieces. Compared with the quenched martensites, the size of fresh martensites are smaller, about 0.3~0.5 μm.
40Cr steel is laser quenched by the NEL-2500A rapidly axial flow CO2 laser. Then the martensite induced by laser quenched is shocked by Nd:YAG laser again. Through comparing and analyzing the appearance and size of martensite, the dislocation density in microstructure between the treated zones by laser quenched and by laser quenched plus laser shock, the following results are shown: The sec-ond martensite obtained by laser compound treatment is more finer compared with those obtained by laser quenched; In the hardened zones obtained by compound treatment, a lot of slender second twin crystal martensites are induced; A lot of more high density dislocation tangles and cellular dislocations are generated. From the transmission electron microscope (TEM) micrograph after compound treatment, there are not only long lath and short nubbly martensites arranged in cross direction, but also massive nubbly and small short nubbly martensites arranged in longitudinal direc-tion. Some martensites look like the broken blocks of quenched martensites. These new martensites are inserted transversely in the quenched martensites with large tangle. And they make quenched martensites break into pieces. Compared with the quenched martensites, the size of fresh martensites are smaller, about 0.3~0.5 μm.
2007, 21(2).
Abstract:
The ring expansion procedures over various forming velocities are calculated with ANSYS software in order to show the effect of forming velocity on ductility of rate insensitive materials. Ring expansion procedures are simplified to one-dimensional tension by constraining the radial deformation, with element birth and death method, fracture problem of circular ring are considered. The calculated results show that for insensitive materials of 1060 aluminum and 3A21 aluminum alloy, fracture strain increases corresponding to the increase of forming velocity. This trend agrees well with experimental results, and indicates inertia is the key factor to affect ductility; With element birth and death methods, fracture problems can be solved effectively. Experimental studies on formability of tubular workpieces are also conducted, experimental results show that the formability of 1060 aluminum and 3A21 aluminum alloy under electromagnetic forming is higher than that under quasistatic forming, according to the characteristics of electromagnetic forming, the forming limit diagrams of the two materials tube are also built respectively, this is very important to promote the development of electromagnetic forming and guide the engineering practices.
The ring expansion procedures over various forming velocities are calculated with ANSYS software in order to show the effect of forming velocity on ductility of rate insensitive materials. Ring expansion procedures are simplified to one-dimensional tension by constraining the radial deformation, with element birth and death method, fracture problem of circular ring are considered. The calculated results show that for insensitive materials of 1060 aluminum and 3A21 aluminum alloy, fracture strain increases corresponding to the increase of forming velocity. This trend agrees well with experimental results, and indicates inertia is the key factor to affect ductility; With element birth and death methods, fracture problems can be solved effectively. Experimental studies on formability of tubular workpieces are also conducted, experimental results show that the formability of 1060 aluminum and 3A21 aluminum alloy under electromagnetic forming is higher than that under quasistatic forming, according to the characteristics of electromagnetic forming, the forming limit diagrams of the two materials tube are also built respectively, this is very important to promote the development of electromagnetic forming and guide the engineering practices.
2007, 21(2).
Abstract:
In order to overcome the system non-linearity and uncertainty inherent in magnetic bearing systems, a GA(genetic algorithm)-based PID neural network controller is designed and trained to emulate the operation of a complete system (magnetic bearing, controller, and power amplifiers). The feasibility of using a neural network to control nonlinear magnetic bearing systems with unknown dynamics is demonstrated. The key concept of the control scheme is to use GA to evaluate the candidate solutions (chromosomes), increase the generalization ability of PID neural network and avoid suffering from the local minima problem in network learning due to the use of gradient descent learning method. The simulation results show that the proposed architecture provides well robust performance and better reinforcement learning capability in controlling magnetic bearing systems.
In order to overcome the system non-linearity and uncertainty inherent in magnetic bearing systems, a GA(genetic algorithm)-based PID neural network controller is designed and trained to emulate the operation of a complete system (magnetic bearing, controller, and power amplifiers). The feasibility of using a neural network to control nonlinear magnetic bearing systems with unknown dynamics is demonstrated. The key concept of the control scheme is to use GA to evaluate the candidate solutions (chromosomes), increase the generalization ability of PID neural network and avoid suffering from the local minima problem in network learning due to the use of gradient descent learning method. The simulation results show that the proposed architecture provides well robust performance and better reinforcement learning capability in controlling magnetic bearing systems.
2007, 21(2).
Abstract:
Zero placement method in the frequency domain is utilized to design robust multi-hump EI optimal arbitrary time-delay filter (OATF) by placing two or more filter zeros near the system poles. A total insensitive OATF can be also achieved if the problem of insensitivity to damping errors is considered. This design strategy is easier to derive and implement. Applications in the anti-swing control of overhead cranes verify the fine performance of this strategy. A better suppression of the load vibrations is obtained using the proposed new OATF, which is more robust to the variation of the cable length.
Zero placement method in the frequency domain is utilized to design robust multi-hump EI optimal arbitrary time-delay filter (OATF) by placing two or more filter zeros near the system poles. A total insensitive OATF can be also achieved if the problem of insensitivity to damping errors is considered. This design strategy is easier to derive and implement. Applications in the anti-swing control of overhead cranes verify the fine performance of this strategy. A better suppression of the load vibrations is obtained using the proposed new OATF, which is more robust to the variation of the cable length.
2007, 21(2).
Abstract:
A rectangular bimorph will vibrate in bending mode under alternating current (AC) electric field. If two opposite tips along longitudinal direction are both clamped, the maximum magnitude of bending displacement occurs on the short center line. Using bimorph type vibrators forementioned as actuators, an invention of simple traveling machine based on stick-slip principle is presented. The machine can not only move along both x and y direction within horizontal working plane, further-more, excellent bearing ability and agile response as well as stable step are also proved. In addition, the machine can work on stepping mode and scanning mode at the same time, hence the contradiction between long stroke and high precise positioning is solved. Therefore, it meets the needs of mi-cro/nanometer precise positioning under long stroke and is desired to be used as carrying stage for micro-assembling system and locomotive mechanism for miniature robot system.
A rectangular bimorph will vibrate in bending mode under alternating current (AC) electric field. If two opposite tips along longitudinal direction are both clamped, the maximum magnitude of bending displacement occurs on the short center line. Using bimorph type vibrators forementioned as actuators, an invention of simple traveling machine based on stick-slip principle is presented. The machine can not only move along both x and y direction within horizontal working plane, further-more, excellent bearing ability and agile response as well as stable step are also proved. In addition, the machine can work on stepping mode and scanning mode at the same time, hence the contradiction between long stroke and high precise positioning is solved. Therefore, it meets the needs of mi-cro/nanometer precise positioning under long stroke and is desired to be used as carrying stage for micro-assembling system and locomotive mechanism for miniature robot system.
2007, 21(2).
Abstract:
Robotic unmanned blimps own an enormous potential for applications in low-speed and low-altitude exploration, surveillance, and monitoring, as well as telecommunication relay platforms. To make lighter-than-air platform a robotic blimp with significant levels of autonomy, the decoupled longitude and latitude dynamic model is developed, and the hardware and software of the flight control system are designed and detailed. Flight control and navigation strategy and algorithms for waypoint flight problem are discussed. A result of flight experiment is also presented, which validates that the flight control system is applicable and initial machine intelligence of robotic blimp is achieved.
Robotic unmanned blimps own an enormous potential for applications in low-speed and low-altitude exploration, surveillance, and monitoring, as well as telecommunication relay platforms. To make lighter-than-air platform a robotic blimp with significant levels of autonomy, the decoupled longitude and latitude dynamic model is developed, and the hardware and software of the flight control system are designed and detailed. Flight control and navigation strategy and algorithms for waypoint flight problem are discussed. A result of flight experiment is also presented, which validates that the flight control system is applicable and initial machine intelligence of robotic blimp is achieved.
2007, 21(2).
Abstract:
The compressive behaviour of paper honeycombs is studied by means of an experimental analysis. Experiment results show how geometry aspects of hexagonal paper honeycombs, e.g. the height of paper honeycomb, the thickness and length of honeycomb cell-wall, the drawing ratio of hexagonal honeycomb, affect the compressive properties of the paper honeycombs. It is in good agreement with the theory model. The constraint factor K of the critical buckling stress is mainly determined by the length of honeycomb cell-wall. It can be described as K=1.54 for B type paper honeycombs and K=3.32 for D type paper honeycombs. The plateau stress is the power exponent function of the thickness to length ratio of honeycomb cell-wall, and the experiment results show that the constant is 13.2 and the power exponent is 1.77. The research results can be used to characterize and improve efficiently the compressive properties of paper honeycombs.
The compressive behaviour of paper honeycombs is studied by means of an experimental analysis. Experiment results show how geometry aspects of hexagonal paper honeycombs, e.g. the height of paper honeycomb, the thickness and length of honeycomb cell-wall, the drawing ratio of hexagonal honeycomb, affect the compressive properties of the paper honeycombs. It is in good agreement with the theory model. The constraint factor K of the critical buckling stress is mainly determined by the length of honeycomb cell-wall. It can be described as K=1.54 for B type paper honeycombs and K=3.32 for D type paper honeycombs. The plateau stress is the power exponent function of the thickness to length ratio of honeycomb cell-wall, and the experiment results show that the constant is 13.2 and the power exponent is 1.77. The research results can be used to characterize and improve efficiently the compressive properties of paper honeycombs.
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