2007 Vol.20(3)
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2007, 21(3).
Abstract:
An equivalent continuum method and a deformable discrete method to describe the mechanical behaviors of superconducting powder BSCCO (BiSrCaCuO) aggregate are studied syste- matically. The equivalent continuum model idealizes the aggregation of the powder as an equivalent continuum material. The powder aggregate yielding is caused by not only the deviatoric stress but also the hydrostatic stress and the modified Drucker-Prager/Cap model is adopted to describe the mechanical behaviors of BSCCO powder aggregate in continuum method. The deformable discrete model is known as a direct model, which considers the discrete nature of the powder particles. Its framework encompasses the local behaviors between the particles, such as particles contact, sliding and rolling. Based on commercial finite element software ABAQUS, the equivalent continuum model and the deformable discrete model are used to simulate the confined compression of superconducting powder BSCCO, and the numerical results show agreement with experimental results, which verify the correctness of these built models. Compared with the equivalent continuum model based on macroscopic statistics method, the deformable discrete model can present the microscopic information during processing and can describe the nature of mechanical behaviors of superconducting powder BSCCO. But from an industrial viewpoint, the equivalent continuum model has a definitive edge over the microscopic models in that the gross behavior of the powder mass can be modeled and simulated on an industrial scale.
An equivalent continuum method and a deformable discrete method to describe the mechanical behaviors of superconducting powder BSCCO (BiSrCaCuO) aggregate are studied syste- matically. The equivalent continuum model idealizes the aggregation of the powder as an equivalent continuum material. The powder aggregate yielding is caused by not only the deviatoric stress but also the hydrostatic stress and the modified Drucker-Prager/Cap model is adopted to describe the mechanical behaviors of BSCCO powder aggregate in continuum method. The deformable discrete model is known as a direct model, which considers the discrete nature of the powder particles. Its framework encompasses the local behaviors between the particles, such as particles contact, sliding and rolling. Based on commercial finite element software ABAQUS, the equivalent continuum model and the deformable discrete model are used to simulate the confined compression of superconducting powder BSCCO, and the numerical results show agreement with experimental results, which verify the correctness of these built models. Compared with the equivalent continuum model based on macroscopic statistics method, the deformable discrete model can present the microscopic information during processing and can describe the nature of mechanical behaviors of superconducting powder BSCCO. But from an industrial viewpoint, the equivalent continuum model has a definitive edge over the microscopic models in that the gross behavior of the powder mass can be modeled and simulated on an industrial scale.
2007, 21(3).
Abstract:
According to the suitable assumption, the deformation process of external spline cold rolling is analyzed. By the graphing method, the slip-line field of plastically deforming area in process of external spline cold rolling is set up. Different friction-conditions are used in different contact areas in order to realistically reflect the actual situation. The unit average pressure on contact surface of the rolling process is solved according to the stress filed theory of slip-line. And the formulae of the rolling-force and rolling-moment are established. The theoretical result is well consistent with the finite element analysis. A theoretical basis is provided for the precise forming process of spline cold rolling and the production of external splined shafts
According to the suitable assumption, the deformation process of external spline cold rolling is analyzed. By the graphing method, the slip-line field of plastically deforming area in process of external spline cold rolling is set up. Different friction-conditions are used in different contact areas in order to realistically reflect the actual situation. The unit average pressure on contact surface of the rolling process is solved according to the stress filed theory of slip-line. And the formulae of the rolling-force and rolling-moment are established. The theoretical result is well consistent with the finite element analysis. A theoretical basis is provided for the precise forming process of spline cold rolling and the production of external splined shafts
2007, 21(3).
Abstract:
A miniature wheel-track-legged mobile robot to carry out military and civilian missions in both indoor and outdoor environments is presented. Firstly, the mechanical design is discussed, which consists of four wheeled and four independently controlled tracked arms, embedded control system and teleop-eration. Then the locomotion modes of the mobile robot and motion analysis are analyzed. The mobile robot can move using wheeled, tracked and legged modes, and it has the characteristics of posture-recovering, high mobility, small size and light weight. Finally, the effectiveness of the deve- loped mobile robot is confirmed by experiments such as posture recovering when tipped over, climb-ing stairs and traversing the high step
A miniature wheel-track-legged mobile robot to carry out military and civilian missions in both indoor and outdoor environments is presented. Firstly, the mechanical design is discussed, which consists of four wheeled and four independently controlled tracked arms, embedded control system and teleop-eration. Then the locomotion modes of the mobile robot and motion analysis are analyzed. The mobile robot can move using wheeled, tracked and legged modes, and it has the characteristics of posture-recovering, high mobility, small size and light weight. Finally, the effectiveness of the deve- loped mobile robot is confirmed by experiments such as posture recovering when tipped over, climb-ing stairs and traversing the high step
2007, 21(3).
Abstract:
A new concept used for designing large-scale and high-precision NC slideway grinders which are called self-collimation slideway grinders is introduced to eliminate thermal deformation of them. Its principle is to make use of gravitational deformation of machine beds and their foundations automatically to compensate for thermal deformation caused by environmental temperature fluctuation and friction heat between machine tables and machine beds by decreasing longitudinal section stiffness of machine beds and foundations. By FEM analysis and application of more than 10 years, it shows that they have advantages of high precision and low cost, moreover, no constant temperature rooms are required. The linearity error of parts machined with them is less than 0.003 mm/m, and machining precision can almost keep constant for a long time.
A new concept used for designing large-scale and high-precision NC slideway grinders which are called self-collimation slideway grinders is introduced to eliminate thermal deformation of them. Its principle is to make use of gravitational deformation of machine beds and their foundations automatically to compensate for thermal deformation caused by environmental temperature fluctuation and friction heat between machine tables and machine beds by decreasing longitudinal section stiffness of machine beds and foundations. By FEM analysis and application of more than 10 years, it shows that they have advantages of high precision and low cost, moreover, no constant temperature rooms are required. The linearity error of parts machined with them is less than 0.003 mm/m, and machining precision can almost keep constant for a long time.
2007, 21(3).
Abstract:
A hybrid control strategy has been designed and developed for the electro-hydraulic position servo control system with generalized Pulse code modulation (GPCM), which is suitable for the area where the work condition is poor and a large flow rate is required. It is difficult to control the GPCM system because the system is discrete. With consideration of the stability and speediness of the GPCM position servo control system, a control strategy is developed through the theoretical and experimental analyses. The control strategy integrates the merits of Bang-Bang control, PID control and fuzzy control. With this hybrid control strategy, the electro hydraulic control system has good performances, and the servo control is carried out with GPCM through on-off valves.
A hybrid control strategy has been designed and developed for the electro-hydraulic position servo control system with generalized Pulse code modulation (GPCM), which is suitable for the area where the work condition is poor and a large flow rate is required. It is difficult to control the GPCM system because the system is discrete. With consideration of the stability and speediness of the GPCM position servo control system, a control strategy is developed through the theoretical and experimental analyses. The control strategy integrates the merits of Bang-Bang control, PID control and fuzzy control. With this hybrid control strategy, the electro hydraulic control system has good performances, and the servo control is carried out with GPCM through on-off valves.
2007, 21(3).
Abstract:
Product customization has been recognized as an effective means to implement mass customization (MC). A new theory and method for MC-oriented evolutionary design of configuration product is presented based on the study of developing law of evolutionary design in integrated environment, which focuses on the innovation and reuse properties of configuration product. The key technologies for general requirement modeling in quick response to customer requirement, multi-level stepwise configuration optimization driven by customer requirement and evolutionary deduction of product variable structure based on configuration association are thoroughly investigated. The successful application of the presented method in the development of real-life products demonstrates its utility, flexibility and robusticity.
Product customization has been recognized as an effective means to implement mass customization (MC). A new theory and method for MC-oriented evolutionary design of configuration product is presented based on the study of developing law of evolutionary design in integrated environment, which focuses on the innovation and reuse properties of configuration product. The key technologies for general requirement modeling in quick response to customer requirement, multi-level stepwise configuration optimization driven by customer requirement and evolutionary deduction of product variable structure based on configuration association are thoroughly investigated. The successful application of the presented method in the development of real-life products demonstrates its utility, flexibility and robusticity.
2007, 21(3).
Abstract:
Fluid-structure interaction (FSI) is essentially a dynamic phenomenon and always exists in fluid-filled pipe system. The four-equation model, which has been proved to be effective to describe and predict the phenomenon of FSI due to friction coupling and Poisson coupling being taken into account, is utilized to describe the FSI of fluid-filled pipe system. Terse compatibility equations are educed by the method of characteristics (MOC) to describe the fluid-filled pipe system. To shorten computing time needed to get the solutions under the condition of keeping accuracy requirement, two steps are adopted, firstly the time step t and divided number of the straight pipe are optimized, sec-ondly the mesh spacing z close to boundary is subdivided in several submeshes automatically ac-cording to the speed gradient of fluid. The mathematical model and arithmetic are validated by com-parisons between simulation solutions of two straight pipe systems and experiment known from lit-erature.
Fluid-structure interaction (FSI) is essentially a dynamic phenomenon and always exists in fluid-filled pipe system. The four-equation model, which has been proved to be effective to describe and predict the phenomenon of FSI due to friction coupling and Poisson coupling being taken into account, is utilized to describe the FSI of fluid-filled pipe system. Terse compatibility equations are educed by the method of characteristics (MOC) to describe the fluid-filled pipe system. To shorten computing time needed to get the solutions under the condition of keeping accuracy requirement, two steps are adopted, firstly the time step t and divided number of the straight pipe are optimized, sec-ondly the mesh spacing z close to boundary is subdivided in several submeshes automatically ac-cording to the speed gradient of fluid. The mathematical model and arithmetic are validated by com-parisons between simulation solutions of two straight pipe systems and experiment known from lit-erature.
2007, 21(3).
Abstract:
The nonlinear dynamics of the lateral micro-resonator including the air damping effect is researched. The air damping force is varied periodically during the resonator oscillating, and the air damp coefficient can not be fixed as a constant. Therefore the linear dynamic analysis which used the constant air damping coefficient can not describe the actual dynamic characteristics of the mi-cro-resonator. The nonlinear dynamic model including the air damping force is established. On the base of Navier-Stokes equation and nonlinear dynamical equation, a coupled fluid-solid numerical simulation method is developed and demonstrates that damping force is a vital factor in micro-comb structures. Compared with existing experimental result, the nonlinear numerical value has quite good agreement with it. The differences of the amplitudes (peak) between the experimental data and the results by the linear model and the nonlinear model are 74.5% and 6% respectively. Nonlinear nu-merical value is more exact than linear value and the method can be applied in other mi-cro-electro-mechanical systeme (MEMS) structures to simulate the dynamic performance.
The nonlinear dynamics of the lateral micro-resonator including the air damping effect is researched. The air damping force is varied periodically during the resonator oscillating, and the air damp coefficient can not be fixed as a constant. Therefore the linear dynamic analysis which used the constant air damping coefficient can not describe the actual dynamic characteristics of the mi-cro-resonator. The nonlinear dynamic model including the air damping force is established. On the base of Navier-Stokes equation and nonlinear dynamical equation, a coupled fluid-solid numerical simulation method is developed and demonstrates that damping force is a vital factor in micro-comb structures. Compared with existing experimental result, the nonlinear numerical value has quite good agreement with it. The differences of the amplitudes (peak) between the experimental data and the results by the linear model and the nonlinear model are 74.5% and 6% respectively. Nonlinear nu-merical value is more exact than linear value and the method can be applied in other mi-cro-electro-mechanical systeme (MEMS) structures to simulate the dynamic performance.
2007, 21(3).
Abstract:
A new concept of multi-shop (M ) is put forward which contains all basic shops including open shop (O), job shop (J ), flow shop (F ) and hybrid flow shop (H ) so that these basic shop can be scheduled together. Several algorithms including ant colony optimization (ACO), most work remaining (MWR), least work remaining (LWR), longest processing time (LPT) and shortest processing time (SPT) are used for scheduling the M. Numerical experiments of the M adopting data of some car and reC series benchmark instances are tested. The results show that the ACO algorithm has better performance for scheduling the M than the other algorithms, if minimizing the makespan ( ) is taken as the objective function. As a comparison, the separate shops contained in the M are also scheduled by the ACO algorithm for the same objective function, when the completing time of the jobs in the previous shop is taken as the ready time of these jobs in the following shop. The results show that the M has the advantage of shortening the makespan upon separate shops.
A new concept of multi-shop (M ) is put forward which contains all basic shops including open shop (O), job shop (J ), flow shop (F ) and hybrid flow shop (H ) so that these basic shop can be scheduled together. Several algorithms including ant colony optimization (ACO), most work remaining (MWR), least work remaining (LWR), longest processing time (LPT) and shortest processing time (SPT) are used for scheduling the M. Numerical experiments of the M adopting data of some car and reC series benchmark instances are tested. The results show that the ACO algorithm has better performance for scheduling the M than the other algorithms, if minimizing the makespan ( ) is taken as the objective function. As a comparison, the separate shops contained in the M are also scheduled by the ACO algorithm for the same objective function, when the completing time of the jobs in the previous shop is taken as the ready time of these jobs in the following shop. The results show that the M has the advantage of shortening the makespan upon separate shops.
2007, 21(3).
Abstract:
A novel fault-tolerant adaptive control methodology against the actuator faults is proposed. The actuator effectiveness factors (AEFs) are introduced to denote the healthy of actuator, and the unscented Kalman filter (UKF) is employed for online estimation of both the motion states and the AEFs of mobile robot. A square root version of the UKF is introduced to improve efficiency and numerical stability. Using the information from the UKF, the reconfigurable controller is designed automatically based on an enhancement inverse dynamic control (IDC) methodology. The experiment on a 3-DOF omni-directional mobile robot is performed, and the effectiveness of the proposed method is demonstrated.
A novel fault-tolerant adaptive control methodology against the actuator faults is proposed. The actuator effectiveness factors (AEFs) are introduced to denote the healthy of actuator, and the unscented Kalman filter (UKF) is employed for online estimation of both the motion states and the AEFs of mobile robot. A square root version of the UKF is introduced to improve efficiency and numerical stability. Using the information from the UKF, the reconfigurable controller is designed automatically based on an enhancement inverse dynamic control (IDC) methodology. The experiment on a 3-DOF omni-directional mobile robot is performed, and the effectiveness of the proposed method is demonstrated.
2007, 21(3).
Abstract:
To alleviate the chattering problem, a new type of fuzzy global sliding mode controller (FGSMC) is presented. In this controller, the switching gain is estimated by fuzzy logic system based on the reachable conditions of sliding mode controller(SMC), and genetic algorithm (GA) is used to optimize scaling factor of the switching gain, thus the switch chattering of SMC can be alleviated. Moreover, global sliding mode is realized by designing an exponential dynamic sliding surface. Simulation and real-time application for flight simulator servo system with Lugre friction are given to indicate that the proposed controller can guarantee high robust performance all the time and can alleviate chattering phenomenon effectively.
To alleviate the chattering problem, a new type of fuzzy global sliding mode controller (FGSMC) is presented. In this controller, the switching gain is estimated by fuzzy logic system based on the reachable conditions of sliding mode controller(SMC), and genetic algorithm (GA) is used to optimize scaling factor of the switching gain, thus the switch chattering of SMC can be alleviated. Moreover, global sliding mode is realized by designing an exponential dynamic sliding surface. Simulation and real-time application for flight simulator servo system with Lugre friction are given to indicate that the proposed controller can guarantee high robust performance all the time and can alleviate chattering phenomenon effectively.
2007, 21(3).
Abstract:
A new self-mixing micro-interferometer based on external phase modulation is presented. Self-mixing interference occurs in a laser diode (LD) by reflecting the light from a mirror-like target in front of the laser. Sinusoidal phase modulation of the beam is obtained by an electro-optic crystal (EOC) in the external cavity. The phase of the interference signal is demodulated by Fourier analysis method. The combination of the modulation and demodulation decreases the sensitivity of the instrument to fluctuations of the laser power and the noise induced by environment. Experimentally, the new micro-interferometer is applied to measure the micro-displacement of a high precision commercial PZT with an accuracy of <10 nm.
A new self-mixing micro-interferometer based on external phase modulation is presented. Self-mixing interference occurs in a laser diode (LD) by reflecting the light from a mirror-like target in front of the laser. Sinusoidal phase modulation of the beam is obtained by an electro-optic crystal (EOC) in the external cavity. The phase of the interference signal is demodulated by Fourier analysis method. The combination of the modulation and demodulation decreases the sensitivity of the instrument to fluctuations of the laser power and the noise induced by environment. Experimentally, the new micro-interferometer is applied to measure the micro-displacement of a high precision commercial PZT with an accuracy of <10 nm.
2007, 21(3).
Abstract:
In order to avoid the accuracy deterioration or tool damage caused by milling chatter, it is necessary to have an efficient and reliable diagnosis system that can on-line predict/detect the occurrence of chatter. The diagnosis/predicting system proposed is to on-line process and analysis the vibration signals of the milling machine measured by accelerometers. According to the analysis results, the system will be able to detect/predict the occurrence of the chatter. The diagnosis algorithm is, first, collecting both the normal signals and chatter signals from milling processes, and then, converting the signals through wavelet transform and fast Fourier transform (FFT). Since the converted chatter sig-nals exhibit different characteristics from the normal signals, through defining the characteristic val-ues, such as root-mean-square value, max value, and ratio of peak value to root-mean-square value, etc, a diagnosis reference library that contains the distribution of these characteristic values is built for diagnosis. When a diagnosis is executing, the characteristic value of the measured signals is con-trasted with the diagnosis reference. The approach index which shows the possibility of occurrence of milling chatter will, then, be calculated through the diagnosis system. Cutting experiments are con-ducted to verify the proposed diagnosis system. The results show the success of early chatter detecting for the system.
In order to avoid the accuracy deterioration or tool damage caused by milling chatter, it is necessary to have an efficient and reliable diagnosis system that can on-line predict/detect the occurrence of chatter. The diagnosis/predicting system proposed is to on-line process and analysis the vibration signals of the milling machine measured by accelerometers. According to the analysis results, the system will be able to detect/predict the occurrence of the chatter. The diagnosis algorithm is, first, collecting both the normal signals and chatter signals from milling processes, and then, converting the signals through wavelet transform and fast Fourier transform (FFT). Since the converted chatter sig-nals exhibit different characteristics from the normal signals, through defining the characteristic val-ues, such as root-mean-square value, max value, and ratio of peak value to root-mean-square value, etc, a diagnosis reference library that contains the distribution of these characteristic values is built for diagnosis. When a diagnosis is executing, the characteristic value of the measured signals is con-trasted with the diagnosis reference. The approach index which shows the possibility of occurrence of milling chatter will, then, be calculated through the diagnosis system. Cutting experiments are con-ducted to verify the proposed diagnosis system. The results show the success of early chatter detecting for the system.
2007, 21(3).
Abstract:
Analytical simulation and corresponding proof-test are adopted to study the principle of the curing process of photopolymer resin diamond tools. The influence of the diamond as abrasives in photopolymer resin owing to the absorptivity of the diamond for the UV light on the photopolymer resin curing process is discussed. Based on the above, a kind of diamond tool—dicing blade is selected to analyze the curing process of photopolymer bond diamond tools. An analytical model of curing process is developed and a correlation curve between the depth of polymerization of the photopolymer resin diamond tools and the exposure time to represent the curing process of photopolymer bond dicing blade. A test is done to proof-test the validity of the analytical model and the correlation curve. The simulated data fit the experimental results, which demonstrates the analytical models and numerical algorithm are of high reliability. The analytical simulation method could possibly be used to optimize the curing cycle and improve the quality of the photopolymers resin bond diamond tools.
Analytical simulation and corresponding proof-test are adopted to study the principle of the curing process of photopolymer resin diamond tools. The influence of the diamond as abrasives in photopolymer resin owing to the absorptivity of the diamond for the UV light on the photopolymer resin curing process is discussed. Based on the above, a kind of diamond tool—dicing blade is selected to analyze the curing process of photopolymer bond diamond tools. An analytical model of curing process is developed and a correlation curve between the depth of polymerization of the photopolymer resin diamond tools and the exposure time to represent the curing process of photopolymer bond dicing blade. A test is done to proof-test the validity of the analytical model and the correlation curve. The simulated data fit the experimental results, which demonstrates the analytical models and numerical algorithm are of high reliability. The analytical simulation method could possibly be used to optimize the curing cycle and improve the quality of the photopolymers resin bond diamond tools.
2007, 21(3).
Abstract:
The experiments of high throughput drilling of Ti-6Al-4V at 183 m/min cutting speed and 156 mm3/s material removal rate using a 4 mm diameter WC-Co spiral point drill are conducted. At this material removal rate, it took only 0.57 s to drill a hole in a 6.35 mm thick Ti plate. Supplying the cutting fluid via through-the-drill holes and the balance of cutting speed and feed have proven to be critical for drill life. An inverse heat transfer model is developed to predict the heat flux and the drill temperature distribution in drilling. A three-dimensional finite element modeling of drilling is conducted to predict the thrust force and torque. Experimental result demonstrates that, using proper machining process parameters, tool geometry, and fine-grained WC-Co tool material, the high throughput machining of Ti alloy is technically feasible.
The experiments of high throughput drilling of Ti-6Al-4V at 183 m/min cutting speed and 156 mm3/s material removal rate using a 4 mm diameter WC-Co spiral point drill are conducted. At this material removal rate, it took only 0.57 s to drill a hole in a 6.35 mm thick Ti plate. Supplying the cutting fluid via through-the-drill holes and the balance of cutting speed and feed have proven to be critical for drill life. An inverse heat transfer model is developed to predict the heat flux and the drill temperature distribution in drilling. A three-dimensional finite element modeling of drilling is conducted to predict the thrust force and torque. Experimental result demonstrates that, using proper machining process parameters, tool geometry, and fine-grained WC-Co tool material, the high throughput machining of Ti alloy is technically feasible.
2007, 21(3).
Abstract:
A set of indices for performance evaluation for business processes with multiple inputs and multiple outputs is proposed, which are found in machinery manufacturers. Based on the traditional methods of data envelopment analysis (DEA) and analytical hierarchical process (AHP), a hybrid model called DEA/AHP model is proposed to deal with the evaluation of business process performance. With the proposed method, the DEA is firstly used to develop a pairwise comparison matrix, and then the AHP is applied to evaluate the performance of business process using the pairwise comparison matrix. The significant advantage of this hybrid model is the use of objective data instead of subjective human judgment for performance evaluation. In the case study, a project of business process reengineering (BPR) with a hydraulic machinery manufacturer is used to demonstrate the effectiveness of the DEA/AHP model.
A set of indices for performance evaluation for business processes with multiple inputs and multiple outputs is proposed, which are found in machinery manufacturers. Based on the traditional methods of data envelopment analysis (DEA) and analytical hierarchical process (AHP), a hybrid model called DEA/AHP model is proposed to deal with the evaluation of business process performance. With the proposed method, the DEA is firstly used to develop a pairwise comparison matrix, and then the AHP is applied to evaluate the performance of business process using the pairwise comparison matrix. The significant advantage of this hybrid model is the use of objective data instead of subjective human judgment for performance evaluation. In the case study, a project of business process reengineering (BPR) with a hydraulic machinery manufacturer is used to demonstrate the effectiveness of the DEA/AHP model.
2007, 21(3).
Abstract:
Nanoimprint lithography (NIL) is recognized as one of the most promising candidates for the next generation lithography (NGL) to obtain sub-100 nm patterns because of its simplicity, high-throughput and low-cost. While substantial effort has been expending on NIL for producing smaller and smaller feature sizes, considerably less effort has been devoted to the equally important issue—alignment between template and substrate. A homemade prototype nanoimprint lithography tool with a high precision automatic alignment system based on Moiré signals is presented. Coarse and fine pitch gratings are adopted to produce Moiré signals to control macro and micro actuators and enable the substrate to move towards the desired position automatically. Linear motors with 300 mm travel range and 1 μm step resolution are used as macro actuators, and piezoelectric translators with 50 μm travel range and 1 nm step resolution are used as micro actuators. In addition, the prototype provides one translation (z displacement) and two tilting motion( and ) to automatically bring uniform intact contact between the template and substrate surfaces by using a flexure stage. As a result, 10 μm coarse alignment accuracy and 20 nm fine alignment accuracy can be achieved. Finally, some results of nanostructures and micro devices such as nanoscale trenches and holes, gratings and microlens array fabricated using the prototype tool are presented, and hot embossing lithography, one typical NIL technology, are depicted by taking nanoscale gratings fabrication as an example.
Nanoimprint lithography (NIL) is recognized as one of the most promising candidates for the next generation lithography (NGL) to obtain sub-100 nm patterns because of its simplicity, high-throughput and low-cost. While substantial effort has been expending on NIL for producing smaller and smaller feature sizes, considerably less effort has been devoted to the equally important issue—alignment between template and substrate. A homemade prototype nanoimprint lithography tool with a high precision automatic alignment system based on Moiré signals is presented. Coarse and fine pitch gratings are adopted to produce Moiré signals to control macro and micro actuators and enable the substrate to move towards the desired position automatically. Linear motors with 300 mm travel range and 1 μm step resolution are used as macro actuators, and piezoelectric translators with 50 μm travel range and 1 nm step resolution are used as micro actuators. In addition, the prototype provides one translation (z displacement) and two tilting motion( and ) to automatically bring uniform intact contact between the template and substrate surfaces by using a flexure stage. As a result, 10 μm coarse alignment accuracy and 20 nm fine alignment accuracy can be achieved. Finally, some results of nanostructures and micro devices such as nanoscale trenches and holes, gratings and microlens array fabricated using the prototype tool are presented, and hot embossing lithography, one typical NIL technology, are depicted by taking nanoscale gratings fabrication as an example.
2007, 21(3).
Abstract:
Collaborative design is recommended to solve multiphysics problems (MPPS). Firstly, mathematical model of MPPS is constructed and solved by a proposed partitioned method, analysis of which suggests that collaborative design be feasible to solve MPPS. As the key technology of collaborative design of MPPS, a task collaboration algorithm is then proposed. To develop the application framework of collaborative design, applied unified process(AUP) is proposed based on rational unified process(RUP). Then AUP is used to develop the collaborative design platform, whose function framework is constructed according to the process of project management. Finally three MPPS are solved on this platform and the results suggest that the proposed model, algorithm and framework be feasible.
Collaborative design is recommended to solve multiphysics problems (MPPS). Firstly, mathematical model of MPPS is constructed and solved by a proposed partitioned method, analysis of which suggests that collaborative design be feasible to solve MPPS. As the key technology of collaborative design of MPPS, a task collaboration algorithm is then proposed. To develop the application framework of collaborative design, applied unified process(AUP) is proposed based on rational unified process(RUP). Then AUP is used to develop the collaborative design platform, whose function framework is constructed according to the process of project management. Finally three MPPS are solved on this platform and the results suggest that the proposed model, algorithm and framework be feasible.
2007, 21(3).
Abstract:
A coupling thermo-mechanical model of wheel/rail in rolling-sliding contact is put forward using finite element method. The normal contact pressure is idealized as the Hertzian distribution, and the tangential force presented by Carter is used. In order to obtain thermal-elastic stress, the ther-mal-elastic plane stress problem is transformed to an elastic plane stress problem with equivalent fictitious thermal body force and fictitious boundary distributed force. The temperature rise and ther-mal-elastic stress of wheel and rail in rolling-sliding are analyzed. The non-steady state heat transfer between the contact surfaces of wheel and rail, heat-convection and radiation between the wheel/rail and the ambient are taken into consideration. The influences of the wheel rolling speed and wear rate on friction temperature and thermal-elastic stress are investigated. The results show the following: ① For rolling-sliding case, the thermal stress in the thin layer near the contact patch due to the friction temperature rise is severe. The higher rolling speed leads to the lower friction temperature rise and thermal stress in the wheel; ② For sliding case, the friction temperature and thermal stress of the wheel rise quickly in the initial sliding stage, and then get into a steady state gradually. The expansion of the contact patch, due to material wear, can affect the friction temperature rise and the thermal stress during wear process. The higher wear rate generates lower stress. The results can help under-stand the influence of friction temperature and thermal-elastic stress on wheel and rail damage.
A coupling thermo-mechanical model of wheel/rail in rolling-sliding contact is put forward using finite element method. The normal contact pressure is idealized as the Hertzian distribution, and the tangential force presented by Carter is used. In order to obtain thermal-elastic stress, the ther-mal-elastic plane stress problem is transformed to an elastic plane stress problem with equivalent fictitious thermal body force and fictitious boundary distributed force. The temperature rise and ther-mal-elastic stress of wheel and rail in rolling-sliding are analyzed. The non-steady state heat transfer between the contact surfaces of wheel and rail, heat-convection and radiation between the wheel/rail and the ambient are taken into consideration. The influences of the wheel rolling speed and wear rate on friction temperature and thermal-elastic stress are investigated. The results show the following: ① For rolling-sliding case, the thermal stress in the thin layer near the contact patch due to the friction temperature rise is severe. The higher rolling speed leads to the lower friction temperature rise and thermal stress in the wheel; ② For sliding case, the friction temperature and thermal stress of the wheel rise quickly in the initial sliding stage, and then get into a steady state gradually. The expansion of the contact patch, due to material wear, can affect the friction temperature rise and the thermal stress during wear process. The higher wear rate generates lower stress. The results can help under-stand the influence of friction temperature and thermal-elastic stress on wheel and rail damage.
2007, 21(3).
Abstract:
To improve the diagnosis accuracy and self-adaptability of fatigue crack in ulterior place of the supporting shaft, time series and neural network are attempted to be applied in research on diagnosing the fatigue crack’s degree based on analyzing the vibration characteristics of the supporting shaft. By analyzing the characteristic parameter which is easy to be detected from the supporting shaft’s exte-rior, the time series model parameter which is hypersensitive to the situation of fatigue crack in ulterior place of the supporting shaft is the target input of neural network, and the fatigue crack’s degree value of supporting shaft is the output. The BP network model can be built and network can be trained after the structural parameters of network are selected. Furthermore, choosing the other two different group data can test the network. The test result will verify the validity of the BP network model. The result of experiment shows that the method of time series and neural network are effective to diagnose the occurrence and the development of the fatigue crack’s degree in ulterior place of the supporting shaft.
To improve the diagnosis accuracy and self-adaptability of fatigue crack in ulterior place of the supporting shaft, time series and neural network are attempted to be applied in research on diagnosing the fatigue crack’s degree based on analyzing the vibration characteristics of the supporting shaft. By analyzing the characteristic parameter which is easy to be detected from the supporting shaft’s exte-rior, the time series model parameter which is hypersensitive to the situation of fatigue crack in ulterior place of the supporting shaft is the target input of neural network, and the fatigue crack’s degree value of supporting shaft is the output. The BP network model can be built and network can be trained after the structural parameters of network are selected. Furthermore, choosing the other two different group data can test the network. The test result will verify the validity of the BP network model. The result of experiment shows that the method of time series and neural network are effective to diagnose the occurrence and the development of the fatigue crack’s degree in ulterior place of the supporting shaft.
2007, 21(3).
Abstract:
Due to the increasing amount and complexity of knowledge in product design, the know- ledge map based on design process is presented as a tool to reuse product design process, promote the product design knowledge sharing. The relationship between design task flow and knowledge flow is discussed; A knowledge organizing method based on design task decomposition and a visualization method to support the knowledge retrieving and sharing in product design are proposed. And a knowledge map system to manage the knowledge in product design process is built with Visual C++ and SVG. Finally, a brief case study is provided to illustrate the construction and application of knowledge map in fuel pump design.
Due to the increasing amount and complexity of knowledge in product design, the know- ledge map based on design process is presented as a tool to reuse product design process, promote the product design knowledge sharing. The relationship between design task flow and knowledge flow is discussed; A knowledge organizing method based on design task decomposition and a visualization method to support the knowledge retrieving and sharing in product design are proposed. And a knowledge map system to manage the knowledge in product design process is built with Visual C++ and SVG. Finally, a brief case study is provided to illustrate the construction and application of knowledge map in fuel pump design.
2007, 21(3).
Abstract:
Aiming at the problem of reverse-design of mechanism, a method based on the matching of trajectory code-chains is presented. The motion trajectory of mechanism is described with code-chain, which is normalized to simplify the operation of geometric transformation. The geometric transformation formulas of scale, mirror and rotation for trajectory code-chain are defined, and the reverse design for mechanism trajectory is realized through the analysis and solution of similarity matching between the desired trajectory and the predefined trajectory. The algorithm program and prototype system of reverse design for mechanism trajectory are developed. Application samples show that the method can break the restriction of trajectory patterns in matching, meet the demand of partial matching, and overcome the influence of geometric transformation of trajectory on the reverse design for mechanism.
Aiming at the problem of reverse-design of mechanism, a method based on the matching of trajectory code-chains is presented. The motion trajectory of mechanism is described with code-chain, which is normalized to simplify the operation of geometric transformation. The geometric transformation formulas of scale, mirror and rotation for trajectory code-chain are defined, and the reverse design for mechanism trajectory is realized through the analysis and solution of similarity matching between the desired trajectory and the predefined trajectory. The algorithm program and prototype system of reverse design for mechanism trajectory are developed. Application samples show that the method can break the restriction of trajectory patterns in matching, meet the demand of partial matching, and overcome the influence of geometric transformation of trajectory on the reverse design for mechanism.
2007, 21(3).
Abstract:
Optimal synthesis of a 3-DOF 4 limbs planar parallel mechanism with actuated redundancy is studied. The kinematics equation of the mechanism is developed and the topology of the mechanism is classified. The kinematics and force properties of the mechanisms according to the topologies are compared. Furthermore, a global optimizing formulation is derived from the condition number that is a local index usually used to scaling the manipulability isotropy quantitatively. The optimization is solved by genetic algorithm. The numerical results show that the topology of the mechanisms can influence the kinematics and force property considerably, and the manipulation dexterity of the mechanisms can be improved distinctly by the given formulations and the suggested optimization algorithm.
Optimal synthesis of a 3-DOF 4 limbs planar parallel mechanism with actuated redundancy is studied. The kinematics equation of the mechanism is developed and the topology of the mechanism is classified. The kinematics and force properties of the mechanisms according to the topologies are compared. Furthermore, a global optimizing formulation is derived from the condition number that is a local index usually used to scaling the manipulability isotropy quantitatively. The optimization is solved by genetic algorithm. The numerical results show that the topology of the mechanisms can influence the kinematics and force property considerably, and the manipulation dexterity of the mechanisms can be improved distinctly by the given formulations and the suggested optimization algorithm.
2007, 21(3).
Abstract:
Experiments are conducted to develop an understanding of how split injections can affect the combustion and emission characteristics of a D.I. diesel engine with a common-rail injection system. The ratio of the amount of fuel injected between two injection pulses and the injection interval is varied keeping the injected fuel quantity constant. Results show that under the 70D90-10 injection pattern, the engine achieves the lower NOx-smoke emissions and BSFC compared with the single injection pattern. The heat release rate and the temperature show that the split injections increase the initial premixed burn and retards the diffusion burn. With the balance of these two effects, the maximum in-cylinder temperature decreases while the 50% heat release point is held at almost the same crank angle. Therefore, both NOx emission and BSFC are improved while keeping the smoke emission at the same level
Experiments are conducted to develop an understanding of how split injections can affect the combustion and emission characteristics of a D.I. diesel engine with a common-rail injection system. The ratio of the amount of fuel injected between two injection pulses and the injection interval is varied keeping the injected fuel quantity constant. Results show that under the 70D90-10 injection pattern, the engine achieves the lower NOx-smoke emissions and BSFC compared with the single injection pattern. The heat release rate and the temperature show that the split injections increase the initial premixed burn and retards the diffusion burn. With the balance of these two effects, the maximum in-cylinder temperature decreases while the 50% heat release point is held at almost the same crank angle. Therefore, both NOx emission and BSFC are improved while keeping the smoke emission at the same level
2007, 21(3).
Abstract:
The loads acting on the sealing elements of balanced mechanical seals are analyzed. When the balance factor approaches the back pressure factor, the spring pressure will become main part of the face pressure. The leakage model of balanced mechanical seals is established on the base of M-B model for rough surface. Several GY-70 type balanced mechanical seals are tested. The influences of the spring pressure both on the leakage rate and on the friction characteristic of balanced mechanical seals are investigated. The research results indicate that as spring pressure increases, both the clearance between two end faces and the leakage rate will decrease, and the friction will be more serious because lubrication medium between the rotating ring and the stationary ring reduces, though the increase of the spring pressure may not be enough to change the face friction state of mechanical seals. There exists an optimum spring pressure for mechanical seal operation. Under this spring pres-sure, not only leakage rate is small, but also the seal end surfaces have a fine friction characteristic. Under different operating conditions, identical type mechanical seals may possess different spring pressure. Appropriate selection of spring pressure is valuable to realize long-period and small leakage rate operating of balanced mechanical seals.
The loads acting on the sealing elements of balanced mechanical seals are analyzed. When the balance factor approaches the back pressure factor, the spring pressure will become main part of the face pressure. The leakage model of balanced mechanical seals is established on the base of M-B model for rough surface. Several GY-70 type balanced mechanical seals are tested. The influences of the spring pressure both on the leakage rate and on the friction characteristic of balanced mechanical seals are investigated. The research results indicate that as spring pressure increases, both the clearance between two end faces and the leakage rate will decrease, and the friction will be more serious because lubrication medium between the rotating ring and the stationary ring reduces, though the increase of the spring pressure may not be enough to change the face friction state of mechanical seals. There exists an optimum spring pressure for mechanical seal operation. Under this spring pres-sure, not only leakage rate is small, but also the seal end surfaces have a fine friction characteristic. Under different operating conditions, identical type mechanical seals may possess different spring pressure. Appropriate selection of spring pressure is valuable to realize long-period and small leakage rate operating of balanced mechanical seals.
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