2008 Vol.21(3)
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2008, 22(3).
Abstract:
The isothermal oxidizing kinetics of Co-40Cr alloy and its yttrium ion-implanted samples are studied at 1 000 ℃ in air by thermal-gravity analysis (TGA). Scanning electronic microscopy (SEM) is used to examine the Cr2O3 oxide film’s morphology after oxidation. Acoustic emission (AE) method is used in situ for monitoring the cracking and spalling of oxide films formed on both samples during oxidizing and subsequent air-cooling stages. Theoretical model is proposed relating to the film fracture process and is used for analyzing the acoustic emission spectrum both on time domain and on AE-event number domain. It is found that yttrium implantation remarkably reduces the isothermal oxidizing rate of Co-40Cr and improves the anti-cracking and anti-spalling properties of Cr2O3 oxide film. The reasons for the improvement are mainly that the implanted yttrium reduced the grain size of Cr2O3 oxide, increased the high temperature plasticity of oxide film, and remarkably reduced the number and size of Cr2O3/Co-40Cr interfacial defects.
The isothermal oxidizing kinetics of Co-40Cr alloy and its yttrium ion-implanted samples are studied at 1 000 ℃ in air by thermal-gravity analysis (TGA). Scanning electronic microscopy (SEM) is used to examine the Cr2O3 oxide film’s morphology after oxidation. Acoustic emission (AE) method is used in situ for monitoring the cracking and spalling of oxide films formed on both samples during oxidizing and subsequent air-cooling stages. Theoretical model is proposed relating to the film fracture process and is used for analyzing the acoustic emission spectrum both on time domain and on AE-event number domain. It is found that yttrium implantation remarkably reduces the isothermal oxidizing rate of Co-40Cr and improves the anti-cracking and anti-spalling properties of Cr2O3 oxide film. The reasons for the improvement are mainly that the implanted yttrium reduced the grain size of Cr2O3 oxide, increased the high temperature plasticity of oxide film, and remarkably reduced the number and size of Cr2O3/Co-40Cr interfacial defects.
2008, 22(3).
Abstract:
An application for achieving on-machine truing/dressing and monitoring of diamond wheel is dealt with in dry grinding. A dry electrical discharge (ED) assisted truing and dressing method is adopted in preparation of diamond grinding wheels. Effective and precise truing/dressing of a diamond wheel is carried out on a CNC curve grinding machine by utilizing an ED assisted diamond dresser. The dressed wheel is monitored online by a CCD vision system. It detects the topography changes of a wheel surface. The wear condition is evaluated by analyzing the edge deviation of a wheel image. The benefits of the proposed methods are confirmed by the grinding experiments. The designed truing/dressing device has high material removal rate, low dresser wear, and hence guarantees a desired wheel surface. Real-time monitoring of the wheel profile facilitates determining the optimum dressing amount, dressing interval, and the compensation error.
An application for achieving on-machine truing/dressing and monitoring of diamond wheel is dealt with in dry grinding. A dry electrical discharge (ED) assisted truing and dressing method is adopted in preparation of diamond grinding wheels. Effective and precise truing/dressing of a diamond wheel is carried out on a CNC curve grinding machine by utilizing an ED assisted diamond dresser. The dressed wheel is monitored online by a CCD vision system. It detects the topography changes of a wheel surface. The wear condition is evaluated by analyzing the edge deviation of a wheel image. The benefits of the proposed methods are confirmed by the grinding experiments. The designed truing/dressing device has high material removal rate, low dresser wear, and hence guarantees a desired wheel surface. Real-time monitoring of the wheel profile facilitates determining the optimum dressing amount, dressing interval, and the compensation error.
2008, 22(3).
Abstract:
A combined algorithm for battery state of charge (SOC) estimation is proposed to solve the critical issue of hybrid electric vehicle (HEV). To obtain a more accurate SOC, both coulomb-accumulation and battery resistance-capacitor (RC) model are weighted combined to compensate the deficiencies of individual methods. In order to solve the key issue of coulomb-accumulation, the battery thermal model is used. Based on the principle of energy conservation, the heat generated from battery charge and discharge process is converted into the equivalent electricity to calculate charge and discharge efficiency under variable current. The extended Kalman filter (EKF) as a closed loop algorithm is applied to estimate the parameters of resistance-capacitor model. The input variables do not increase much computing difficulty. The proposed combined algorithm is implemented by adjusting the weighting factor of coulomb- accumulation and resistance-capacitor model. In the end, four different methods including Ah-efficiency, Ah-Equip, RC-SOC and Combined-SOC are compared in federal testing procedure (FTP) drive cycle. The experiment results show that the proposed method has good robustness and high accuracy which is suitable for HEV application.
A combined algorithm for battery state of charge (SOC) estimation is proposed to solve the critical issue of hybrid electric vehicle (HEV). To obtain a more accurate SOC, both coulomb-accumulation and battery resistance-capacitor (RC) model are weighted combined to compensate the deficiencies of individual methods. In order to solve the key issue of coulomb-accumulation, the battery thermal model is used. Based on the principle of energy conservation, the heat generated from battery charge and discharge process is converted into the equivalent electricity to calculate charge and discharge efficiency under variable current. The extended Kalman filter (EKF) as a closed loop algorithm is applied to estimate the parameters of resistance-capacitor model. The input variables do not increase much computing difficulty. The proposed combined algorithm is implemented by adjusting the weighting factor of coulomb- accumulation and resistance-capacitor model. In the end, four different methods including Ah-efficiency, Ah-Equip, RC-SOC and Combined-SOC are compared in federal testing procedure (FTP) drive cycle. The experiment results show that the proposed method has good robustness and high accuracy which is suitable for HEV application.
2008, 22(3).
Abstract:
A method for measurement of ultra-low flying height in head-disk spacing is described. Three different wavelengths are selected out from white light by filters to measure the spacing simultaneously. Besides solving the ambiguity problem, a more reliable result is achieved by using weighted average of measurement results from three different wavelengths, where the weight is dependent upon spacing. Fringe-bunching correction algorithm (FBC) and spot-tilling technique are adopted to suppress calibration and random errors. Moreover, incident bandwidth correction (IBC) method is introduced to compensate the error caused by low monochromaticity of incident light. Based on dynamic flying height tester (DFHT II), with the redesigned of photo-electric conversion and signal acquirement module, an instrument has been developed. And comparing the experimental data from the instrument with those from a KLA-FHT D6, the discrepancy is less than 5%. It indicates that the instrument is suitable to perform ultra-low flying height measurement and satisfies the requirement of magnetic heads manufacturing.
A method for measurement of ultra-low flying height in head-disk spacing is described. Three different wavelengths are selected out from white light by filters to measure the spacing simultaneously. Besides solving the ambiguity problem, a more reliable result is achieved by using weighted average of measurement results from three different wavelengths, where the weight is dependent upon spacing. Fringe-bunching correction algorithm (FBC) and spot-tilling technique are adopted to suppress calibration and random errors. Moreover, incident bandwidth correction (IBC) method is introduced to compensate the error caused by low monochromaticity of incident light. Based on dynamic flying height tester (DFHT II), with the redesigned of photo-electric conversion and signal acquirement module, an instrument has been developed. And comparing the experimental data from the instrument with those from a KLA-FHT D6, the discrepancy is less than 5%. It indicates that the instrument is suitable to perform ultra-low flying height measurement and satisfies the requirement of magnetic heads manufacturing.
2008, 22(3).
Abstract:
The flow field of the oil film between frictional pairs in the hydroviscous drive test rig is investigated. A three-dimensional Navier-Stokes(N-S) equation considering viscous force and inertial force rather than Reynolds equation or modified Reynolds equation is presented to model the flow field. Pressure and temperature distribution in radial and circumferential direction under three different conditions, i.e., isothermal, that considering viscosity-temperature characteristic as well as shear thinning non-Newtonian fluid are simulated, respectively, by utilizing the commercial computational fluid dynamics(CFD) software FLUENT. The results reveal that the grooves on the driven plate make the pressure, temperature distribution present periodic variation. The oil temperature and shear rate have important effects on the flow field between frictional pairs, and the oil temperature is more important parameter. The simulation results lay a theoretical foundation for the reasonable designs of hydroviscous drive.
The flow field of the oil film between frictional pairs in the hydroviscous drive test rig is investigated. A three-dimensional Navier-Stokes(N-S) equation considering viscous force and inertial force rather than Reynolds equation or modified Reynolds equation is presented to model the flow field. Pressure and temperature distribution in radial and circumferential direction under three different conditions, i.e., isothermal, that considering viscosity-temperature characteristic as well as shear thinning non-Newtonian fluid are simulated, respectively, by utilizing the commercial computational fluid dynamics(CFD) software FLUENT. The results reveal that the grooves on the driven plate make the pressure, temperature distribution present periodic variation. The oil temperature and shear rate have important effects on the flow field between frictional pairs, and the oil temperature is more important parameter. The simulation results lay a theoretical foundation for the reasonable designs of hydroviscous drive.
2008, 22(3).
Abstract:
A specially designed fluid damper used as negative shock pulse generator in the shock resistance test system to dissipate the shock input energy in transient time duration is presented. The theoretical modeling based on the three-dimensional equation of heat transfer through a fluid element is created to predict the viscous heating in the fluid damper under shock conditions. A comprehensive experimental program that investigates the problem of viscous heating in the fluid damper under different shock conditions is conducted on the shock test machine to validate the analytical expression. Temperature histories for the fluid within the damper at two locations, the annular-orifice and the-end-of stroke of the damper, are recorded. The experimental results show that the theoretical model can offer a very dependable prediction for the temperature histories in the damper for increasing input velocity. The theoretical model and experimental data both clearly indicate that the viscous heating in the damper is directly related to the maximum shock velocity input and the pressure between the two sides of the piston head.
A specially designed fluid damper used as negative shock pulse generator in the shock resistance test system to dissipate the shock input energy in transient time duration is presented. The theoretical modeling based on the three-dimensional equation of heat transfer through a fluid element is created to predict the viscous heating in the fluid damper under shock conditions. A comprehensive experimental program that investigates the problem of viscous heating in the fluid damper under different shock conditions is conducted on the shock test machine to validate the analytical expression. Temperature histories for the fluid within the damper at two locations, the annular-orifice and the-end-of stroke of the damper, are recorded. The experimental results show that the theoretical model can offer a very dependable prediction for the temperature histories in the damper for increasing input velocity. The theoretical model and experimental data both clearly indicate that the viscous heating in the damper is directly related to the maximum shock velocity input and the pressure between the two sides of the piston head.
2008, 22(3).
Abstract:
Based on the mathematical model of a novel cosine gear drive, a few characteristics, such as the contact ratio, the sliding coefficient, and the contact and bending stresses, of this drive are analyzed. A comparison study of these characteristics with the involute gear drive is also carried out. The influences of design parameters including the number of teeth and the pressure angle on the contact and bending stresses are studied. The following conclusions are achieved: the contact ratio of the cosine gear drive is about 1.2 to 1.3, which is reduced by about 20% in comparison with that of the involute gear drive. The sliding coefficient of the cosine gear drive is smaller than that of the involute gear drive. The contact and bending stresses of the cosine gear drive are lower than those of the involute gear drive. The contact and bending stresses decrease with the growth of the number of teeth and the pressure angle.
Based on the mathematical model of a novel cosine gear drive, a few characteristics, such as the contact ratio, the sliding coefficient, and the contact and bending stresses, of this drive are analyzed. A comparison study of these characteristics with the involute gear drive is also carried out. The influences of design parameters including the number of teeth and the pressure angle on the contact and bending stresses are studied. The following conclusions are achieved: the contact ratio of the cosine gear drive is about 1.2 to 1.3, which is reduced by about 20% in comparison with that of the involute gear drive. The sliding coefficient of the cosine gear drive is smaller than that of the involute gear drive. The contact and bending stresses of the cosine gear drive are lower than those of the involute gear drive. The contact and bending stresses decrease with the growth of the number of teeth and the pressure angle.
2008, 22(3).
Abstract:
Mechanical analysis of cylinders being upset between spherical concave platen and concave supporting plate is conducted. Rigid-plastic mechanical models for cylinders are presented. When the ratio of height to diameter, is larger than 1, there exists two-dimensional tensile stress in the deformed body, when the ratio is smaller than 1, there exists shear stress in static hydraulic zone. The former breaks through the theory that there is three-dimensional compressive stress irrespective of any ratio of height to diameter. The latter satisfactorily explains the mechanism of layer-like cracks in disk-shaped forgings and the flanges of forged gear axles. The representation of the two models makes the upsetting theory into correct and perfect stage.
Mechanical analysis of cylinders being upset between spherical concave platen and concave supporting plate is conducted. Rigid-plastic mechanical models for cylinders are presented. When the ratio of height to diameter, is larger than 1, there exists two-dimensional tensile stress in the deformed body, when the ratio is smaller than 1, there exists shear stress in static hydraulic zone. The former breaks through the theory that there is three-dimensional compressive stress irrespective of any ratio of height to diameter. The latter satisfactorily explains the mechanism of layer-like cracks in disk-shaped forgings and the flanges of forged gear axles. The representation of the two models makes the upsetting theory into correct and perfect stage.
2008, 22(3).
Abstract:
Varying contact-length backup roll and linearly variable crown work roll are provided for improving the mill performance of profile and flatness control. Integrated with theses technologies, relevant profile and flatness control models are developed for hot strip mills on the basis of large amount of finite element calculation. These models include shape setup control model in process control system, bending force feedforward control model, crown feedback control model and flatness feedback control model in basis automation system. Such a profile and flatness control system with full functions is applied in 1 700 mm industrial hot strip mills of Ansteel. Large amount of production data shows that the crown precision with the tolerance of 18 m is over 90%, the strip percentage which the actual flatness is within 25 I-unit surpasses 96%, and general roll consume is reduced by 28% by using the profile and flatness control system. In addition, schedule-free rolling is realized.
Varying contact-length backup roll and linearly variable crown work roll are provided for improving the mill performance of profile and flatness control. Integrated with theses technologies, relevant profile and flatness control models are developed for hot strip mills on the basis of large amount of finite element calculation. These models include shape setup control model in process control system, bending force feedforward control model, crown feedback control model and flatness feedback control model in basis automation system. Such a profile and flatness control system with full functions is applied in 1 700 mm industrial hot strip mills of Ansteel. Large amount of production data shows that the crown precision with the tolerance of 18 m is over 90%, the strip percentage which the actual flatness is within 25 I-unit surpasses 96%, and general roll consume is reduced by 28% by using the profile and flatness control system. In addition, schedule-free rolling is realized.
2008, 22(3).
Abstract:
Unsteady flows and rotating stall of a low-speed centrifugal compressor are investigated by measuring vaneless diffuser wall static pressure fluctuation and internal flow fields at different small flow fluxes. During the experiment, firstly the real time static pressure fluctuations on the vaneless diffuser shroud at different circumferential and radial position were acquired by high-frequency dynamic pressure transducers. Discrete Fourier transformation analysis and cross-correlation analysis were applied to the experimental results to ascertain the rotating stall beginning operation conditions and stall cells numbers and rotating speed. Secondly, the vaneless diffuser inlet flow angle distribution along diffuser width direction was acquired by single hotwire, which was compared with SENOO’s analysis results. At last, the internal flow fields of the centrifugal compressor were investigated with a particle image velocimetry (PIV) system at different small flow fluxes. The flow field development of vaneless diffuser and blade flow passage are given at rotating stall conditions. The experiments enrich the understanding of rotating stall flow phenomenon of the low-speed centrifugal compressor and provide full experiment data for designing high performance centrifugal compressor.
Unsteady flows and rotating stall of a low-speed centrifugal compressor are investigated by measuring vaneless diffuser wall static pressure fluctuation and internal flow fields at different small flow fluxes. During the experiment, firstly the real time static pressure fluctuations on the vaneless diffuser shroud at different circumferential and radial position were acquired by high-frequency dynamic pressure transducers. Discrete Fourier transformation analysis and cross-correlation analysis were applied to the experimental results to ascertain the rotating stall beginning operation conditions and stall cells numbers and rotating speed. Secondly, the vaneless diffuser inlet flow angle distribution along diffuser width direction was acquired by single hotwire, which was compared with SENOO’s analysis results. At last, the internal flow fields of the centrifugal compressor were investigated with a particle image velocimetry (PIV) system at different small flow fluxes. The flow field development of vaneless diffuser and blade flow passage are given at rotating stall conditions. The experiments enrich the understanding of rotating stall flow phenomenon of the low-speed centrifugal compressor and provide full experiment data for designing high performance centrifugal compressor.
2008, 22(3).
Abstract:
A novel method based on the improved Laplacian eigenmap algorithm for fault pattern classification is proposed. Via modifying the Laplacian eigenmap algorithm to replace Euclidean distance with kernel-based geometric distance in the neighbor graph construction, the method can preserve the consistency of local neighbor information and effectively extract the low-dimensional manifold features embedded in the high-dimensional nonlinear data sets. A nonlinear dimensionality reduction algorithm based on the improved Laplacian eigenmap is to directly learn high-dimensional fault signals and extract the intrinsic manifold features from them. The method greatly preserves the global geometry structure information embedded in the signals, and obviously improves the classification performance of fault pattern recognition. The experimental results on both simulation and engineering indicate the feasibility and effectiveness of the new method.
A novel method based on the improved Laplacian eigenmap algorithm for fault pattern classification is proposed. Via modifying the Laplacian eigenmap algorithm to replace Euclidean distance with kernel-based geometric distance in the neighbor graph construction, the method can preserve the consistency of local neighbor information and effectively extract the low-dimensional manifold features embedded in the high-dimensional nonlinear data sets. A nonlinear dimensionality reduction algorithm based on the improved Laplacian eigenmap is to directly learn high-dimensional fault signals and extract the intrinsic manifold features from them. The method greatly preserves the global geometry structure information embedded in the signals, and obviously improves the classification performance of fault pattern recognition. The experimental results on both simulation and engineering indicate the feasibility and effectiveness of the new method.
2008, 22(3).
Abstract:
The Beijing spectrometer Ⅲ (BESⅢ) beam pipe is in the center of the BESⅢ, which is the detector of the upgrade project of Beijing electron and positron collider (BEPCⅡ). Electrons and positrons collide in the BESⅢ beam pipe. According to the demands of the BEPCⅡ, a key program of Chinese Academy of Sciences, the BESⅢ beam pipe is designed based on the finite elements analysis. The BESⅢ beam pipe is installed in the inner cylinder of the BESⅢ drift chamber. As a vacuum tube, the BESⅢ beam pipe is designed as 1 000 mm in length, 63 mm in inner diameter and 114 mm in outer diameter, respectively. The BESⅢ beam pipe consists of a central beryllium pipe cooled by EDM-1, the oil No.1 for electric discharge machining, and two extended copper pipes cooled by deionized water (DW). The three parts are jointed by vacuum welding. Factors taken into account in the design are as follows. ① The wall thickness of the central beryllium pipe should be designed as small as possible to reduce the multi-scattering and improve the particle momentum resolution. And the wall thickness of the extended copper pipe should be designed as large as possible to protect the detectors from the backgrounds. ② The BESⅢ beam pipe must be sufficiently cooled to avoid the damage and prevents its influence to the BESⅢ drift chamber (DC) operation. The inner surface temperature of the DC inner cylinder must be maintained at 293±2 K. ③ The magnetic permeability of the materials used in the BESⅢ beam pipe must be less than 1.05 H/m to avoid large magnetic field distortions. ④ The static pressure of the vacuum chamber of the BESⅢ beam pipe must be less than 800 Pa. The simulating results show that the designed structure of the BESⅢ beam pipe satisfies the requirements mentioned above. The structure design scheme is evaluated and adopted by the headquarters of BEPCⅡ.
The Beijing spectrometer Ⅲ (BESⅢ) beam pipe is in the center of the BESⅢ, which is the detector of the upgrade project of Beijing electron and positron collider (BEPCⅡ). Electrons and positrons collide in the BESⅢ beam pipe. According to the demands of the BEPCⅡ, a key program of Chinese Academy of Sciences, the BESⅢ beam pipe is designed based on the finite elements analysis. The BESⅢ beam pipe is installed in the inner cylinder of the BESⅢ drift chamber. As a vacuum tube, the BESⅢ beam pipe is designed as 1 000 mm in length, 63 mm in inner diameter and 114 mm in outer diameter, respectively. The BESⅢ beam pipe consists of a central beryllium pipe cooled by EDM-1, the oil No.1 for electric discharge machining, and two extended copper pipes cooled by deionized water (DW). The three parts are jointed by vacuum welding. Factors taken into account in the design are as follows. ① The wall thickness of the central beryllium pipe should be designed as small as possible to reduce the multi-scattering and improve the particle momentum resolution. And the wall thickness of the extended copper pipe should be designed as large as possible to protect the detectors from the backgrounds. ② The BESⅢ beam pipe must be sufficiently cooled to avoid the damage and prevents its influence to the BESⅢ drift chamber (DC) operation. The inner surface temperature of the DC inner cylinder must be maintained at 293±2 K. ③ The magnetic permeability of the materials used in the BESⅢ beam pipe must be less than 1.05 H/m to avoid large magnetic field distortions. ④ The static pressure of the vacuum chamber of the BESⅢ beam pipe must be less than 800 Pa. The simulating results show that the designed structure of the BESⅢ beam pipe satisfies the requirements mentioned above. The structure design scheme is evaluated and adopted by the headquarters of BEPCⅡ.
2008, 22(3).
Abstract:
To investigate the dynamic characteristics and damping theory of the passive hydraulic engine mount (PHEM), numerical prediction is performed through lumped parameter model. System parameters, including volume compliance of the decoupler chamber, effective piston area, fluid inertia and resistance of inertia track and direct-decoupler, are identified by means of experiments and finite element method (FEM). Dynamic behaviors are tested with elastomer test system for purpose of validating PHEM. With incorporation of inertia track and direct-decoupler, PHEM behaves effective and efficient vibration isolation in range of both low and high frequencies. The comparison of the numerical results with the experimental observations shows that the present PHEM achieves fairly good performance for the engine vibration isolation.
To investigate the dynamic characteristics and damping theory of the passive hydraulic engine mount (PHEM), numerical prediction is performed through lumped parameter model. System parameters, including volume compliance of the decoupler chamber, effective piston area, fluid inertia and resistance of inertia track and direct-decoupler, are identified by means of experiments and finite element method (FEM). Dynamic behaviors are tested with elastomer test system for purpose of validating PHEM. With incorporation of inertia track and direct-decoupler, PHEM behaves effective and efficient vibration isolation in range of both low and high frequencies. The comparison of the numerical results with the experimental observations shows that the present PHEM achieves fairly good performance for the engine vibration isolation.
2008, 22(3).
Abstract:
To achieve information integration, process integration and application integration of enterprise, an enterprise integration platform (EIP) based on service-oriented architecture (SOA) is built. The enterprise integration model depending on encapsulating the business processes as well as the enterprise applications by the neutral and standard web services is presented. The problem how to discover the existed enterprise resources and share them was resolved depending on the mechanism of publishing and discovering the services. The EIP is integrated closely with product lifecycle management (PLM) system so that the process integration as well as orchestration of the business process services is implemented by encapsulating the workflow engine of PLM system. Not only process integration and application integration, but also information integration based on the bill of material (BOM) conversion driven by process are achieved. Finally, an interpretive, qualitative case study on EIP is conducted for this research.
To achieve information integration, process integration and application integration of enterprise, an enterprise integration platform (EIP) based on service-oriented architecture (SOA) is built. The enterprise integration model depending on encapsulating the business processes as well as the enterprise applications by the neutral and standard web services is presented. The problem how to discover the existed enterprise resources and share them was resolved depending on the mechanism of publishing and discovering the services. The EIP is integrated closely with product lifecycle management (PLM) system so that the process integration as well as orchestration of the business process services is implemented by encapsulating the workflow engine of PLM system. Not only process integration and application integration, but also information integration based on the bill of material (BOM) conversion driven by process are achieved. Finally, an interpretive, qualitative case study on EIP is conducted for this research.
2008, 22(3).
Abstract:
Experiments are used to study the fabrication of polymer microfluidic chip with hot embossing method. The pattern fidelity with respect to the process parameters is analyzed. Experiment results show that the relationship between the imprint temperature and the microchannel width is approximately exponential. However, the depth of micro channel isn’t sensitive to the imprint temperature. When the imprint pressure is larger than 1 MPa and the imprint time is longer than 2 min, the increasing of imprint pressure and holding time has little impact on the microchannel width. So over long holding time is not needed in hot embossing. Based on the experiment analysis, a series of optimization process parameters is obtained and a fine microfluidic chip is fabricated. The electrophoresis separation experiment are used to verify the microfluidic chip performance after bonding. The results show that 100bp-ladder DNA sample can be separated in less than 5 min successfully.
Experiments are used to study the fabrication of polymer microfluidic chip with hot embossing method. The pattern fidelity with respect to the process parameters is analyzed. Experiment results show that the relationship between the imprint temperature and the microchannel width is approximately exponential. However, the depth of micro channel isn’t sensitive to the imprint temperature. When the imprint pressure is larger than 1 MPa and the imprint time is longer than 2 min, the increasing of imprint pressure and holding time has little impact on the microchannel width. So over long holding time is not needed in hot embossing. Based on the experiment analysis, a series of optimization process parameters is obtained and a fine microfluidic chip is fabricated. The electrophoresis separation experiment are used to verify the microfluidic chip performance after bonding. The results show that 100bp-ladder DNA sample can be separated in less than 5 min successfully.
2008, 22(3).
Abstract:
Ni-TiN nanocomposite coatings were prepared by ultrasonic electrodeposition, and the effects of the surfactants on the coatings were investigated and the microstructure and micro rigidity of the coatings were characterized. Samples were also submitted to corrosion tests in 3% NaCl solution. The results showed that the surfactants had great effects on Ni-TiN nanocomposite coatings. The composite coatings prepared by ultrasonic electrodeposition with the surfactants were better than that of the coatings prepared without surfactants. The favorable properties of Ni-TiN nanocomposite coatings were prepared with the mixing of the non-ion and positive ion surfactants. The concentration of the mixing was 80 mg/L, and the ratio of the non-ion and positive ion surfactants was 1: 2.
Ni-TiN nanocomposite coatings were prepared by ultrasonic electrodeposition, and the effects of the surfactants on the coatings were investigated and the microstructure and micro rigidity of the coatings were characterized. Samples were also submitted to corrosion tests in 3% NaCl solution. The results showed that the surfactants had great effects on Ni-TiN nanocomposite coatings. The composite coatings prepared by ultrasonic electrodeposition with the surfactants were better than that of the coatings prepared without surfactants. The favorable properties of Ni-TiN nanocomposite coatings were prepared with the mixing of the non-ion and positive ion surfactants. The concentration of the mixing was 80 mg/L, and the ratio of the non-ion and positive ion surfactants was 1: 2.
2008, 22(3).
Abstract:
Adaptable design aims to extend the utilities of design and product. The specific methods are developed for practical applications of adaptable design in the design of mechanical structures, including adaptable platform, interface and module designs. Adaptable redesign problems are formulated as adaptable platform design under adaptability bound constraints. Analysis tools are then suggested for the implementation of the redesign of machine tool structures, including variation techniques based sensitivity analysis, similarity-based commonality analysis, performance improvement, and adaptability measures. The specific measure of adaptability for machine tool structures is measured through the quantification of the structural similarity and performance improvement gained from adaptable design. The method provides designers with an approach that brings adaptability into the design process, with considering the cost and benefits of such adaptability. The redesign of CNC spiral bevel gear cutting machine structures has been included to illustrate these concepts and methods.
Adaptable design aims to extend the utilities of design and product. The specific methods are developed for practical applications of adaptable design in the design of mechanical structures, including adaptable platform, interface and module designs. Adaptable redesign problems are formulated as adaptable platform design under adaptability bound constraints. Analysis tools are then suggested for the implementation of the redesign of machine tool structures, including variation techniques based sensitivity analysis, similarity-based commonality analysis, performance improvement, and adaptability measures. The specific measure of adaptability for machine tool structures is measured through the quantification of the structural similarity and performance improvement gained from adaptable design. The method provides designers with an approach that brings adaptability into the design process, with considering the cost and benefits of such adaptability. The redesign of CNC spiral bevel gear cutting machine structures has been included to illustrate these concepts and methods.
2008, 22(3).
Abstract:
The transformation between time and space is discussed. To improve real-time response speed of intelligent measuring system, the concept of exchanging program execution time with more circuitry is presented working in cycle mode. Displacement measuring by magnification is achieved with period measurement by magnification. To change the condition that traditional precision measurement depends on machining precision greatly, the concept of measuring space with time and theory of time-space coordinate transformation are proposed. Guided by the idea of measuring space with time, differential frequency measurement system and time grating displacement sensor are developed based on the proposed novel methods. And high-precision measurement is achieved without high-precision manufacture, which embeds the remarkable characteristics of low cost but high precision to the devices. Experiment and test results conform the validity of the proposed time-space concept.
The transformation between time and space is discussed. To improve real-time response speed of intelligent measuring system, the concept of exchanging program execution time with more circuitry is presented working in cycle mode. Displacement measuring by magnification is achieved with period measurement by magnification. To change the condition that traditional precision measurement depends on machining precision greatly, the concept of measuring space with time and theory of time-space coordinate transformation are proposed. Guided by the idea of measuring space with time, differential frequency measurement system and time grating displacement sensor are developed based on the proposed novel methods. And high-precision measurement is achieved without high-precision manufacture, which embeds the remarkable characteristics of low cost but high precision to the devices. Experiment and test results conform the validity of the proposed time-space concept.
2008, 22(3).
Abstract:
A complex mechatronics system Bayesian plan of demonstration test is studied based on the mixed beta distribution. During product design and improvement various information is appropriately considered by introducing inheritance factor, moreover, the inheritance factor is thought as a random variable, and the Bayesian decision of the qualification test plan is obtained, and the correctness of a Bayesian model presented is verified. The results show that the quantity of the test is too conservative according to classical methods under small binomial samples. Although traditional Bayesian analysis can consider test information of related or similar products, it ignores differences between such products. The method has solved the above problem, furthermore, considering the requirement in many practical projects, the differences among this method, the classical method and Bayesian with beta distribution are compared according to the plan of reliability acceptance test.
A complex mechatronics system Bayesian plan of demonstration test is studied based on the mixed beta distribution. During product design and improvement various information is appropriately considered by introducing inheritance factor, moreover, the inheritance factor is thought as a random variable, and the Bayesian decision of the qualification test plan is obtained, and the correctness of a Bayesian model presented is verified. The results show that the quantity of the test is too conservative according to classical methods under small binomial samples. Although traditional Bayesian analysis can consider test information of related or similar products, it ignores differences between such products. The method has solved the above problem, furthermore, considering the requirement in many practical projects, the differences among this method, the classical method and Bayesian with beta distribution are compared according to the plan of reliability acceptance test.
2008, 22(3).
Abstract:
The fluid-structure coupling finite element model and the boundary element model of a complex gearbox’s housing are built based on the theory of fluid-structure coupling finite element method and boundary element method. At the same time, the exciting forces of the housing are analyzed and applied to the finite element models. Firstly, vibration of the housing is calculated by the fluid-structure coupling finite element model; secondly, the calculated result is verified by the experiment; finally, sound radiation of the housing is calculated by the boundary element. According to the calculated results, the housing adds some ribs not only to increase the strength, but also to reduce the sound radiation of the housing. At last, the sound radiation of the modified housing is calculated, which shows that the sound radiation of the modified housing with ribs is lower.
The fluid-structure coupling finite element model and the boundary element model of a complex gearbox’s housing are built based on the theory of fluid-structure coupling finite element method and boundary element method. At the same time, the exciting forces of the housing are analyzed and applied to the finite element models. Firstly, vibration of the housing is calculated by the fluid-structure coupling finite element model; secondly, the calculated result is verified by the experiment; finally, sound radiation of the housing is calculated by the boundary element. According to the calculated results, the housing adds some ribs not only to increase the strength, but also to reduce the sound radiation of the housing. At last, the sound radiation of the modified housing is calculated, which shows that the sound radiation of the modified housing with ribs is lower.
2008, 22(3).
Abstract:
A new milling methodology with the equivalent normal curvature milling model machining freeform surfaces is proposed based on the normal curvature theorems on differential geometry. Moreover, a specialized whirlwind milling tool and a 5-axis CNC horizontal milling machine are introduced. This new milling model can efficiently enlarge the material removal volume at the tip of the whirlwind milling tool and improve the producing capacity. The machining strategy of this model is to regulate the orientation of the whirlwind milling tool relatively to the principal directions of the workpiece surface at the point of contact, so as to create a full match with collision avoidance between the workpiece surface and the symmetric rotational surface of the milling tool. The practical results show that this new milling model is an effective method in machining complex three- dimensional surfaces. This model has a good improvement on finishing machining time and scallop height in machining the freeform surfaces over other milling processes. Some actual examples for manufacturing the freeform surfaces with this new model are given.
A new milling methodology with the equivalent normal curvature milling model machining freeform surfaces is proposed based on the normal curvature theorems on differential geometry. Moreover, a specialized whirlwind milling tool and a 5-axis CNC horizontal milling machine are introduced. This new milling model can efficiently enlarge the material removal volume at the tip of the whirlwind milling tool and improve the producing capacity. The machining strategy of this model is to regulate the orientation of the whirlwind milling tool relatively to the principal directions of the workpiece surface at the point of contact, so as to create a full match with collision avoidance between the workpiece surface and the symmetric rotational surface of the milling tool. The practical results show that this new milling model is an effective method in machining complex three- dimensional surfaces. This model has a good improvement on finishing machining time and scallop height in machining the freeform surfaces over other milling processes. Some actual examples for manufacturing the freeform surfaces with this new model are given.
2008, 22(3).
Abstract:
A particular emphasis is put on a novel wearable exoskeleton arm, ZJUESA, with 6 degrees of freedom, which is used for the robot teleoperation with the force-feedback in the unknown environment. In this external structure mechanism, the 3-revolution-prismatic-spherical (3RPS) parallel mechanism is devised from the concept of the human upper-limb anatomy and applied for the shoulder 3-DOF joint. Meanwhile, the orthogonal experiment design method is introduced for its optimal design. Aiming at enhancing the performance of teleoperation, the force feedback is employed by the pneumatic system on ZJUESA to produce the vivid feeling in addition to the soft control interface. Due to the compressibility and nonlinearity of the pneumatic force feedback system, a novel hybrid fuzzy controller for the precise force control is proposed and realized based on the Mega8 microcontroller units as the units of the distributed control system on ZJUESA. With the results of several experiments for master-slave control with force feedback, the feasibility of ZJUESA system and the effect of its hybrid fuzzy controller are verified.
A particular emphasis is put on a novel wearable exoskeleton arm, ZJUESA, with 6 degrees of freedom, which is used for the robot teleoperation with the force-feedback in the unknown environment. In this external structure mechanism, the 3-revolution-prismatic-spherical (3RPS) parallel mechanism is devised from the concept of the human upper-limb anatomy and applied for the shoulder 3-DOF joint. Meanwhile, the orthogonal experiment design method is introduced for its optimal design. Aiming at enhancing the performance of teleoperation, the force feedback is employed by the pneumatic system on ZJUESA to produce the vivid feeling in addition to the soft control interface. Due to the compressibility and nonlinearity of the pneumatic force feedback system, a novel hybrid fuzzy controller for the precise force control is proposed and realized based on the Mega8 microcontroller units as the units of the distributed control system on ZJUESA. With the results of several experiments for master-slave control with force feedback, the feasibility of ZJUESA system and the effect of its hybrid fuzzy controller are verified.
2008, 22(3).
Abstract:
Compared to fixed virtual window algorithm (FVWA), the dynamic virtual window algorithm (DVWA) determines the length of each virtual container according to the sizes of goods of each order, which saves space of virtual containers and improves the picking efficiency. However, the interval of consecutive goods caused by dispensers on conveyor can not be eliminated by DVWA, which limits a further improvement of picking efficiency. In order to solve this problem, a compressible virtual window algorithm (CVWA) is presented. It not only inherits the merit of DVWA but also compresses the length of virtual containers without congestion of order accumulation by advancing the beginning time of order picking and reasonably coordinating the pace of order accumulation. The simulation result proves that the picking efficiency of automated sorting system is greatly improved by CVWA.
Compared to fixed virtual window algorithm (FVWA), the dynamic virtual window algorithm (DVWA) determines the length of each virtual container according to the sizes of goods of each order, which saves space of virtual containers and improves the picking efficiency. However, the interval of consecutive goods caused by dispensers on conveyor can not be eliminated by DVWA, which limits a further improvement of picking efficiency. In order to solve this problem, a compressible virtual window algorithm (CVWA) is presented. It not only inherits the merit of DVWA but also compresses the length of virtual containers without congestion of order accumulation by advancing the beginning time of order picking and reasonably coordinating the pace of order accumulation. The simulation result proves that the picking efficiency of automated sorting system is greatly improved by CVWA.
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