2010 Vol.23(3)
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2010, 24(3).
Abstract:
The complex eigenvalue analysis is currently a common approach to predict squealing vibration and noise. There are two methods for modeling friction contact in the complex eigenvalue analysis of friction systems. In one method, contact springs are used to simulate friction contact. In another method, no contact spring is used. However, it has been uncertain whether these two modeling methods can predict approximately identical results. In order to clarify the uncertainty, two finite element models of the same brake system for the brake squeal prediction are established and simulated by using ABAQUS and NASTRAN software tools, respectively. In the ABAQUS model, friction coupling is applied to determine normal contact force and no contact spring is assumed. Whilst in the NASTRAN model, the contact spring is assumed by the penalty method to simulate contact connection. Through the numerical simulations, it is recognized that even if the same mesh geometry is applied, generally, these two finite element approaches are not capable of predicting approximately identical unstable frequencies. The ABAQUS approach can predict instabilities of high frequency up to 20 kHz or more, while the NASTRAN approach can only predict some instabilities of high frequency, not all. Moreover, the simulation results also show that both the contact spring stiffness and mesh size have influences to some extent on the prediction results of squeal. The present comparative work illuminates that the modeling method without contact springs is more suitable to predict squealing vibration and noise, comparing to the modeling method with contact springs. It is proposed that one should prefer using the modeling method without contact springs to predict squealing vibration and noise. The proposed study provides the reference for predicting squealing vibration and noise.
The complex eigenvalue analysis is currently a common approach to predict squealing vibration and noise. There are two methods for modeling friction contact in the complex eigenvalue analysis of friction systems. In one method, contact springs are used to simulate friction contact. In another method, no contact spring is used. However, it has been uncertain whether these two modeling methods can predict approximately identical results. In order to clarify the uncertainty, two finite element models of the same brake system for the brake squeal prediction are established and simulated by using ABAQUS and NASTRAN software tools, respectively. In the ABAQUS model, friction coupling is applied to determine normal contact force and no contact spring is assumed. Whilst in the NASTRAN model, the contact spring is assumed by the penalty method to simulate contact connection. Through the numerical simulations, it is recognized that even if the same mesh geometry is applied, generally, these two finite element approaches are not capable of predicting approximately identical unstable frequencies. The ABAQUS approach can predict instabilities of high frequency up to 20 kHz or more, while the NASTRAN approach can only predict some instabilities of high frequency, not all. Moreover, the simulation results also show that both the contact spring stiffness and mesh size have influences to some extent on the prediction results of squeal. The present comparative work illuminates that the modeling method without contact springs is more suitable to predict squealing vibration and noise, comparing to the modeling method with contact springs. It is proposed that one should prefer using the modeling method without contact springs to predict squealing vibration and noise. The proposed study provides the reference for predicting squealing vibration and noise.
Discrete Stress-strength Interference Model of Reliability Analysis under Multi-operating Conditions
2010, 24(3).
Abstract:
The conventional stress-strength interference(SSI) model is a basic model for reliability analysis of mechanical components. In this model, the component reliability is defined as the probability of the strength being larger than the stress, where the component stress is generally represented by a single random variable(RV). But for a component under multi-operating conditions, its reliability can not be calculated directly by using the SSI model. The problem arises from that the stress on a component under multi-operating conditions can not be described by a single RV properly. Current research concerning the SSI model mainly focuses on the calculation of the static or dynamic reliability of the component under single operation condition. To evaluate the component reliability under multi-operating conditions, this paper uses multiple discrete RVs based on the actual stress range of the component firstly. These discrete RVs have identical possible values and different corresponding probability value, which are used to represent the multi-operating conditions of the component. Then the component reliability under each operating condition is calculated, respectively, by employing the discrete SSI model and the universal generating function technique, and from this the discrete SSI model under multi-operating conditions is proposed. Finally the proposed model is applied to evaluate the reliability of a transmission component of the decelerator installed in an aeroengine. The reliability of this component during taking-off, cruising and landing phases of an aircraft are calculated, respectively. With this model, a basic method for reliability analysis of the component under complex load condition is provided, and the application range of the conventional SSI model is extended.
The conventional stress-strength interference(SSI) model is a basic model for reliability analysis of mechanical components. In this model, the component reliability is defined as the probability of the strength being larger than the stress, where the component stress is generally represented by a single random variable(RV). But for a component under multi-operating conditions, its reliability can not be calculated directly by using the SSI model. The problem arises from that the stress on a component under multi-operating conditions can not be described by a single RV properly. Current research concerning the SSI model mainly focuses on the calculation of the static or dynamic reliability of the component under single operation condition. To evaluate the component reliability under multi-operating conditions, this paper uses multiple discrete RVs based on the actual stress range of the component firstly. These discrete RVs have identical possible values and different corresponding probability value, which are used to represent the multi-operating conditions of the component. Then the component reliability under each operating condition is calculated, respectively, by employing the discrete SSI model and the universal generating function technique, and from this the discrete SSI model under multi-operating conditions is proposed. Finally the proposed model is applied to evaluate the reliability of a transmission component of the decelerator installed in an aeroengine. The reliability of this component during taking-off, cruising and landing phases of an aircraft are calculated, respectively. With this model, a basic method for reliability analysis of the component under complex load condition is provided, and the application range of the conventional SSI model is extended.
2010, 24(3).
Abstract:
The introduction of surface engineering is expected to be an effective strategy against fretting damage. A large number of studies show that the low gas multi-component (such as carbon, nitrogen, sulphur and oxygen, etc) thermo-chemical treatment(LTGMTT) can overcome the brittleness of nitriding process, and upgrade the surface hardness and improve the wear resistance and fatigue properties of the work-pieces significantly. However, there are few reports on the anti-fretting properties of the LTGMTT modified layer up to now, which limits the applications of fretting. So this paper discusses the fretting wear behavior of modified layer on the surface of LZ50 (0.48%C) steel prepared by low temperature gas multi-component thermo-chemical treatment (LTGMTT) technology. The fretting wear tests of the modified layer flat specimens and its substrate (LZ50 steel) against 52100 steel balls with diameter of 40 mm are carried out under normal load of 150 N and displacement amplitudes varied from 2 μm to 40 μm. Characterization of the modified layer and dynamic analyses in combination with microscopic examinations were performed through the means of scanning electron microscope(SEM), optical microscope(OM), X-ray diffraction(XRD) and surface profilometer. The experimental results showed that the modified layer with a total thickness of 60 μm was consisted of three parts, i.e., loose layer, compound layer and diffusion layer. Compared with the substrate, the range of the mixed fretting regime(MFR) of the LTGMTT modified layer diminished, and the slip regime(SR) of the modified layer shifted to the direction of smaller displacement amplitude. The coefficient of friction(COF) of the modified layer was lower than that of the substrate in the initial stage. For the modified layer, the damage in partial slip regime(PSR) was very slight. The fretting wear mechanism of the modified layer both in MFR and SR was abrasive wear and delamination. The modified layer presented better wear resistance than the substrate in PSR and MFR; however, in SR, the wear resistance of the modified layer decreased with the increase of the displacement amplitudes. The experimental results can provide some experimental bases for promoting industrial application of LTGMTT modified layer in anti-fretting wear.
The introduction of surface engineering is expected to be an effective strategy against fretting damage. A large number of studies show that the low gas multi-component (such as carbon, nitrogen, sulphur and oxygen, etc) thermo-chemical treatment(LTGMTT) can overcome the brittleness of nitriding process, and upgrade the surface hardness and improve the wear resistance and fatigue properties of the work-pieces significantly. However, there are few reports on the anti-fretting properties of the LTGMTT modified layer up to now, which limits the applications of fretting. So this paper discusses the fretting wear behavior of modified layer on the surface of LZ50 (0.48%C) steel prepared by low temperature gas multi-component thermo-chemical treatment (LTGMTT) technology. The fretting wear tests of the modified layer flat specimens and its substrate (LZ50 steel) against 52100 steel balls with diameter of 40 mm are carried out under normal load of 150 N and displacement amplitudes varied from 2 μm to 40 μm. Characterization of the modified layer and dynamic analyses in combination with microscopic examinations were performed through the means of scanning electron microscope(SEM), optical microscope(OM), X-ray diffraction(XRD) and surface profilometer. The experimental results showed that the modified layer with a total thickness of 60 μm was consisted of three parts, i.e., loose layer, compound layer and diffusion layer. Compared with the substrate, the range of the mixed fretting regime(MFR) of the LTGMTT modified layer diminished, and the slip regime(SR) of the modified layer shifted to the direction of smaller displacement amplitude. The coefficient of friction(COF) of the modified layer was lower than that of the substrate in the initial stage. For the modified layer, the damage in partial slip regime(PSR) was very slight. The fretting wear mechanism of the modified layer both in MFR and SR was abrasive wear and delamination. The modified layer presented better wear resistance than the substrate in PSR and MFR; however, in SR, the wear resistance of the modified layer decreased with the increase of the displacement amplitudes. The experimental results can provide some experimental bases for promoting industrial application of LTGMTT modified layer in anti-fretting wear.
2010, 24(3).
Abstract:
The optimization of boards by grades plays an important role in the production for cross cutting boards, and the outturn rate and utilization of boards are directly affected by the optimization results of boards by grades. At present, the OptiCut series fully automatic optimizing cross-cut saw(FAOCCS) from Germany Weinig Group occupies the main markets in the world, but no report about the relative theories on the optimization technology and its algorithms is available. There exist some disadvantages in woodworking machinery and equipment used for cross cutting boards in China, for example, low sawing precision, outturn rate of boards and productivity, and difficulty in making statistics on the sawing results. Three optimization modes are presented for the optimization algorithms for FAOCCS, namely, optimization of fixed length, optimization of finger-jointed lumber and mixed optimization. Mathematical models are then established for these three optimization modes, and the corresponding software for realizing the optimization is prepared. Finally, Synthetic evaluation on the established mathematical models is presented through three practical examples. The results of synthetic evaluation indicate that FAOCCS using the optimization modes may raise the outturn rate of boards approximately 8% and the productivity obviously, and allows accurate statistics on the cross cut products of boards. The mathematical models of above three optimization modes are useful for increasing the outturn rate and utilization ratio of boards.
The optimization of boards by grades plays an important role in the production for cross cutting boards, and the outturn rate and utilization of boards are directly affected by the optimization results of boards by grades. At present, the OptiCut series fully automatic optimizing cross-cut saw(FAOCCS) from Germany Weinig Group occupies the main markets in the world, but no report about the relative theories on the optimization technology and its algorithms is available. There exist some disadvantages in woodworking machinery and equipment used for cross cutting boards in China, for example, low sawing precision, outturn rate of boards and productivity, and difficulty in making statistics on the sawing results. Three optimization modes are presented for the optimization algorithms for FAOCCS, namely, optimization of fixed length, optimization of finger-jointed lumber and mixed optimization. Mathematical models are then established for these three optimization modes, and the corresponding software for realizing the optimization is prepared. Finally, Synthetic evaluation on the established mathematical models is presented through three practical examples. The results of synthetic evaluation indicate that FAOCCS using the optimization modes may raise the outturn rate of boards approximately 8% and the productivity obviously, and allows accurate statistics on the cross cut products of boards. The mathematical models of above three optimization modes are useful for increasing the outturn rate and utilization ratio of boards.
2010, 24(3).
Abstract:
Currently, simultaneously ensuring the machining accuracy and efficiency of thin-walled structures especially high performance parts still remains a challenge. Existing compensating methods are mainly focusing on 3-aixs machining, which sometimes only take one given point as the compensative point at each given cutter location. This paper presents a redesigned surface based machining strategy for peripheral milling of thin-walled parts. Based on an improved cutting force/heat model and finite element method(FEM) simulation environment, a deflection error prediction model, which takes sequence of cutter contact lines as compensation targets, is established. And an iterative algorithm is presented to determine feasible cutter axis positions. The final redesigned surface is subsequently generated by skinning all discrete cutter axis vectors after compensating by using the proposed algorithm. The proposed machining strategy incorporates the thermo-mechanical coupled effect in deflection prediction, and is also validated with flank milling experiment by using five-axis machine tool. At the same time, the deformation error is detected by using three-coordinate measuring machine. Error prediction values and experimental results indicate that they have a good consistency and the proposed approach is able to significantly reduce the dimension error under the same machining conditions compared with conventional methods. The proposed machining strategy has potential in high-efficiency precision machining of thin-walled parts.
Currently, simultaneously ensuring the machining accuracy and efficiency of thin-walled structures especially high performance parts still remains a challenge. Existing compensating methods are mainly focusing on 3-aixs machining, which sometimes only take one given point as the compensative point at each given cutter location. This paper presents a redesigned surface based machining strategy for peripheral milling of thin-walled parts. Based on an improved cutting force/heat model and finite element method(FEM) simulation environment, a deflection error prediction model, which takes sequence of cutter contact lines as compensation targets, is established. And an iterative algorithm is presented to determine feasible cutter axis positions. The final redesigned surface is subsequently generated by skinning all discrete cutter axis vectors after compensating by using the proposed algorithm. The proposed machining strategy incorporates the thermo-mechanical coupled effect in deflection prediction, and is also validated with flank milling experiment by using five-axis machine tool. At the same time, the deformation error is detected by using three-coordinate measuring machine. Error prediction values and experimental results indicate that they have a good consistency and the proposed approach is able to significantly reduce the dimension error under the same machining conditions compared with conventional methods. The proposed machining strategy has potential in high-efficiency precision machining of thin-walled parts.
2010, 24(3).
Abstract:
Currently, many studies have been made for years on dimensions of pneumatic nozzle, which influence the flow characteristic of blowing system. For the purpose of outputting the same blowing force, the supply pressure could be reduced by decreasing the ratio of length to diameter of nozzle. The friction between high speed air and pipe wall would be reduced if the nozzle is designed to be converging shape comparing with straight shape. But the volume flow and pressure, discussed in these studies, do not describe energy loss of the blowing system directly. Pneumatic power is an innovative principle to estimate pneumatic system’s energy consumption directly. Based on the above principle, a pulse blowing method is put forward for saving energy. A flow experiment is carried out, in which the high speed air flows from the pulse blowing system and continuous blowing system respectively to a plate with grease on top. Supply pressure and the volume of air used for removing the grease are measured to calculate energy consumption. From the experiment result, the pulse blowing system performs to conserve energy comparing with the continuous blowing system. The frequency and duty ratio of pulse flow influence the blowing characteristic. The pulse blowing system performs to be the most efficient at the specified frequency and duty ratio. Then a pneumatic self-oscillated method based on air operated valve is put forward to generate pulse flow. A simulation is made about dynamic modeling the air operated valve and calculating the motion of the valve core and output pressure. The simulation result verifies the system to be able to generate pulse flow, and predicts the key parameters of the frequency and duty ratio measured by experiment well. Finally, on the basis of simplifying and solution of the pulse blowing system’s mathematic model, the relationship between system’s frequency duty ratio and the dimensions of components is simply described with four algebraic equations. The system could be designed with specified frequency and duty ratio according to the four equations. This study provides theoretical basis for designing energy-saving air blowing system.
Currently, many studies have been made for years on dimensions of pneumatic nozzle, which influence the flow characteristic of blowing system. For the purpose of outputting the same blowing force, the supply pressure could be reduced by decreasing the ratio of length to diameter of nozzle. The friction between high speed air and pipe wall would be reduced if the nozzle is designed to be converging shape comparing with straight shape. But the volume flow and pressure, discussed in these studies, do not describe energy loss of the blowing system directly. Pneumatic power is an innovative principle to estimate pneumatic system’s energy consumption directly. Based on the above principle, a pulse blowing method is put forward for saving energy. A flow experiment is carried out, in which the high speed air flows from the pulse blowing system and continuous blowing system respectively to a plate with grease on top. Supply pressure and the volume of air used for removing the grease are measured to calculate energy consumption. From the experiment result, the pulse blowing system performs to conserve energy comparing with the continuous blowing system. The frequency and duty ratio of pulse flow influence the blowing characteristic. The pulse blowing system performs to be the most efficient at the specified frequency and duty ratio. Then a pneumatic self-oscillated method based on air operated valve is put forward to generate pulse flow. A simulation is made about dynamic modeling the air operated valve and calculating the motion of the valve core and output pressure. The simulation result verifies the system to be able to generate pulse flow, and predicts the key parameters of the frequency and duty ratio measured by experiment well. Finally, on the basis of simplifying and solution of the pulse blowing system’s mathematic model, the relationship between system’s frequency duty ratio and the dimensions of components is simply described with four algebraic equations. The system could be designed with specified frequency and duty ratio according to the four equations. This study provides theoretical basis for designing energy-saving air blowing system.
2010, 24(3).
Abstract:
Roller chain drives are widely used in various high-speed, high-load and power transmission applications, but their complex dynamic behavior is not well researched. Most studies were only focused on the analysis of the vibration of chain tight span, and in these models, many factors are neglected. In this paper, a mathematical model is developed to calculate the dynamic response of a roller chain drive working at constant or variable speed condition. In the model, the complete chain transmission with two sprockets and the necessary tight and slack spans is used. The effect of the flexibility of input shaft on dynamic response of the chain system is taken into account, as well as the elastic deformation in the chain, the inertial forces, the gravity and the torque on driven shaft. The nonlinear equations of movement are derived from using Lagrange equations and solved numerically. Given the center distance and the two initial position angles of teeth on driving and driven sprockets corresponding to the first seating roller on each side of the tight span, dynamics of any roller chain drive with two sprockets and two spans can be analyzed by the procedure. Finally, a numerical example is given and the validity of the procedure developed is demonstrated by analyzing the dynamic behavior of a typical roller chain drive. The model can well simulate the transverse and longitudinal vibration of the chain spans and the torsional vibration of the sprockets. This study can provide an effective method for the analysis of the dynamic characteristics of all the chain drive systems.
Roller chain drives are widely used in various high-speed, high-load and power transmission applications, but their complex dynamic behavior is not well researched. Most studies were only focused on the analysis of the vibration of chain tight span, and in these models, many factors are neglected. In this paper, a mathematical model is developed to calculate the dynamic response of a roller chain drive working at constant or variable speed condition. In the model, the complete chain transmission with two sprockets and the necessary tight and slack spans is used. The effect of the flexibility of input shaft on dynamic response of the chain system is taken into account, as well as the elastic deformation in the chain, the inertial forces, the gravity and the torque on driven shaft. The nonlinear equations of movement are derived from using Lagrange equations and solved numerically. Given the center distance and the two initial position angles of teeth on driving and driven sprockets corresponding to the first seating roller on each side of the tight span, dynamics of any roller chain drive with two sprockets and two spans can be analyzed by the procedure. Finally, a numerical example is given and the validity of the procedure developed is demonstrated by analyzing the dynamic behavior of a typical roller chain drive. The model can well simulate the transverse and longitudinal vibration of the chain spans and the torsional vibration of the sprockets. This study can provide an effective method for the analysis of the dynamic characteristics of all the chain drive systems.
2010, 24(3).
Abstract:
In the energy regulation based varibable-speed electrohydraulic drive system, the supply energy and the demanded energy, which will affect the control performance greatly, are crucial. However, they are hard to be obtained via conventional methods for some reasons. This paper tries to a new route: the definitive numerical values of the supply energy and the demanded energy are not required, except for their relationship which is called energy state. A three-layer back propagation(BP) neural network was built up to act as an energy analysis unit to deduce the energy state. The neural network has three inputs: the reference displacement, the actual displacement of cylinder rod and the system flowrate supply. The output of the neural network is energy state. A Chebyshev type II filter was designed to calculate the cylinder speed for the estimation of system flowrate supply. The training and testing samples of neural network were collected by the system accurate simulation model. After off-line training, the neural network was tested by the testing data. And the testing result demonstrates that the designed neural network was successful. Then, the neural network acts as the energy analysis unit in real-time experiments of cylinder position control, where it works efficiently under square-wave and sine-wave reference displacement. The experimental results validate its feasibility and adaptability. Only a position sensor and some pressure sensors, which are cheap and have quick dynamic response, are necessary for the system control. And the neural network plays the role of identifying the energy state.
In the energy regulation based varibable-speed electrohydraulic drive system, the supply energy and the demanded energy, which will affect the control performance greatly, are crucial. However, they are hard to be obtained via conventional methods for some reasons. This paper tries to a new route: the definitive numerical values of the supply energy and the demanded energy are not required, except for their relationship which is called energy state. A three-layer back propagation(BP) neural network was built up to act as an energy analysis unit to deduce the energy state. The neural network has three inputs: the reference displacement, the actual displacement of cylinder rod and the system flowrate supply. The output of the neural network is energy state. A Chebyshev type II filter was designed to calculate the cylinder speed for the estimation of system flowrate supply. The training and testing samples of neural network were collected by the system accurate simulation model. After off-line training, the neural network was tested by the testing data. And the testing result demonstrates that the designed neural network was successful. Then, the neural network acts as the energy analysis unit in real-time experiments of cylinder position control, where it works efficiently under square-wave and sine-wave reference displacement. The experimental results validate its feasibility and adaptability. Only a position sensor and some pressure sensors, which are cheap and have quick dynamic response, are necessary for the system control. And the neural network plays the role of identifying the energy state.
2010, 24(3).
Abstract:
It is well known that the human auditory system possesses remarkable capabilities to analyze and identify signals. Therefore, it would be significant to build an auditory model based on the mechanism of human auditory systems, which may improve the effects of mechanical signal analysis and enrich the methods of mechanical faults features extraction. However the existing methods are all based on explicit senses of mathematics or physics, and have some shortages on distinguishing different faults, stability, and suppressing the disturbance noise, etc. For the purpose of improving the performances of the work of feature extraction, an auditory model, early auditory(EA) model, is introduced for the first time. This auditory model transforms time domain signal into auditory spectrum via bandpass filtering, nonlinear compressing, and lateral inhibiting by simulating the principle of the human auditory system. The EA model is developed with the Gammatone filterbank as the basilar membrane. According to the characteristics of vibration signals, a method is proposed for determining the parameter of inner hair cells model of EA model. The performance of EA model is evaluated through experiments on four rotor faults, including misalignment, rotor-to-stator rubbing, oil film whirl, and pedestal looseness. The results show that the auditory spectrum, output of EA model, can effectively distinguish different faults with satisfactory stability and has the ability to suppress the disturbance noise. Then, it is feasible to apply auditory model, as a new method, to the feature extraction for mechanical faults diagnosis with effect.
It is well known that the human auditory system possesses remarkable capabilities to analyze and identify signals. Therefore, it would be significant to build an auditory model based on the mechanism of human auditory systems, which may improve the effects of mechanical signal analysis and enrich the methods of mechanical faults features extraction. However the existing methods are all based on explicit senses of mathematics or physics, and have some shortages on distinguishing different faults, stability, and suppressing the disturbance noise, etc. For the purpose of improving the performances of the work of feature extraction, an auditory model, early auditory(EA) model, is introduced for the first time. This auditory model transforms time domain signal into auditory spectrum via bandpass filtering, nonlinear compressing, and lateral inhibiting by simulating the principle of the human auditory system. The EA model is developed with the Gammatone filterbank as the basilar membrane. According to the characteristics of vibration signals, a method is proposed for determining the parameter of inner hair cells model of EA model. The performance of EA model is evaluated through experiments on four rotor faults, including misalignment, rotor-to-stator rubbing, oil film whirl, and pedestal looseness. The results show that the auditory spectrum, output of EA model, can effectively distinguish different faults with satisfactory stability and has the ability to suppress the disturbance noise. Then, it is feasible to apply auditory model, as a new method, to the feature extraction for mechanical faults diagnosis with effect.
2010, 24(3).
Abstract:
Because of long driving chain and great system load inertia, the serial manipulator has a serious time delay problem which leads to significant real-time tracking control errors and damages the welding quality finally. In order to solve the time delay problem and enhance the welding quality, an adaptive real-time predictive compensation control(ARTPCC) is presented in this paper. The ARTPCC technique combines offline identification and online compensation. Based on the neural network system identification technique, the ARTPCC technique identifies the dynamic joint model of the 6-DOF serial arc welding manipulator offline. With the identified dynamic joint model, the ARTPCC technique predicts and compensates the tracking error online using the adaptive friction compensation technique. The ARTPCC technique is proposed in detail in this paper and applied in the real-time tracking control experiment of the 6-DOF serial arc welding manipulator. The tracking control experiment results of the end-effector reference point of the manipulator show that the presented control technique reduces the tracking error, enhances the system response and tracking accuracy efficiently. Meanwhile, the welding experiment results show that the welding seam turns more continuous, uniform and smooth after using the ARTPCC technique. With the ARTPCC technique, the welding quality of the 6-DOF serial arc welding manipulator is highly improved.
Because of long driving chain and great system load inertia, the serial manipulator has a serious time delay problem which leads to significant real-time tracking control errors and damages the welding quality finally. In order to solve the time delay problem and enhance the welding quality, an adaptive real-time predictive compensation control(ARTPCC) is presented in this paper. The ARTPCC technique combines offline identification and online compensation. Based on the neural network system identification technique, the ARTPCC technique identifies the dynamic joint model of the 6-DOF serial arc welding manipulator offline. With the identified dynamic joint model, the ARTPCC technique predicts and compensates the tracking error online using the adaptive friction compensation technique. The ARTPCC technique is proposed in detail in this paper and applied in the real-time tracking control experiment of the 6-DOF serial arc welding manipulator. The tracking control experiment results of the end-effector reference point of the manipulator show that the presented control technique reduces the tracking error, enhances the system response and tracking accuracy efficiently. Meanwhile, the welding experiment results show that the welding seam turns more continuous, uniform and smooth after using the ARTPCC technique. With the ARTPCC technique, the welding quality of the 6-DOF serial arc welding manipulator is highly improved.
2010, 24(3).
Abstract:
Reaction bonded SiC(RBSiC) is attractive for optical application because of its favorable properties and low fabrication cost. However, the difficultness and cost involved in RBSiC grinding limit its application. The investigation on high efficient and low-cost machining with good grinding quality is desired. Generally, high efficient machining for RBSiC is realized by using coarse grain size grinding wheels, but serious grinding damage is inevitable. In this paper, monolayer nickel electroplated coarse grain size diamond grinding wheels with grain sizes of 46 μm, 91 μm, and 151 μm were applied to the grinding of RBSiC. An electrolytic in-process dressing(ELID) assisted conditioning technique was first developed by using cup shape copper bonded conditioning wheels with grain sizes of 15 m and 91 m to generate the conditioned coarse grain size wheels with minimized wheel run-out error within 2 m, constant wheel peripheral envelop as well as top-flattened diamond grains. Then, the grinding experiments on RBSiC were carried out to investigate the grinding performance and material removal mechanism. The experimental results indicate that the developed conditioning technique is applicable and feasible to condition the coarse grain size diamond wheels under optimal conditioning parameters, and the material removal mechanism involved in RBSiC grinding is the combination of brittle fracture and ductile deformation to generate smooth ground surface. This research is significant for the high efficient and low-cost precision grinding of RBSiC with good ground surface quality.
Reaction bonded SiC(RBSiC) is attractive for optical application because of its favorable properties and low fabrication cost. However, the difficultness and cost involved in RBSiC grinding limit its application. The investigation on high efficient and low-cost machining with good grinding quality is desired. Generally, high efficient machining for RBSiC is realized by using coarse grain size grinding wheels, but serious grinding damage is inevitable. In this paper, monolayer nickel electroplated coarse grain size diamond grinding wheels with grain sizes of 46 μm, 91 μm, and 151 μm were applied to the grinding of RBSiC. An electrolytic in-process dressing(ELID) assisted conditioning technique was first developed by using cup shape copper bonded conditioning wheels with grain sizes of 15 m and 91 m to generate the conditioned coarse grain size wheels with minimized wheel run-out error within 2 m, constant wheel peripheral envelop as well as top-flattened diamond grains. Then, the grinding experiments on RBSiC were carried out to investigate the grinding performance and material removal mechanism. The experimental results indicate that the developed conditioning technique is applicable and feasible to condition the coarse grain size diamond wheels under optimal conditioning parameters, and the material removal mechanism involved in RBSiC grinding is the combination of brittle fracture and ductile deformation to generate smooth ground surface. This research is significant for the high efficient and low-cost precision grinding of RBSiC with good ground surface quality.
2010, 24(3).
Abstract:
Abrasive is the one of key influencing factors during chemical mechanical polishing(CMP) process. Currently, α-Alumina (α-Al2O3) particle, as a kind of abrasive, has been widely used in CMP slurries, but their high hardness and poor dispersion stability often lead to more surface defects. After being polished with composite particles, the surface defects of work pieces decrease obviously. So the composite particles as abrasives in slurry have been paid more attention. In order to reduce defect caused by pure α-Al2O3 abrasive, α-alumina-g-polystyrene sulfonic acid (α-Al2O3-g-PSS) composite abrasive was prepared by surface graft polymerization. The composition, structure and morphology of the product were characterized by Fourier transform infrared spectroscopy(FTIR), X-ray photoelectron spectroscopy(XPS), time-of-flight secondary ion mass spectroscopy(TOF-SIMS), and scanning electron microscopy(SEM), respectively. The results show that polystyrene sulfonic acid grafts onto α-Al2O3, and has well dispersibility. Then, the chemical mechanical polishing performances of the composite abrasive on glass substrate were investigated with a SPEEDFAM-16B-4M CMP machine. Atomic force microscopy(AFM) images indicate that the average roughness of the polished glass substrate surface can be decreased from 0.835 nm for pure α-Al2O3 abrasive to 0.583 nm for prepared α-Al2O3-g-PSS core-shell abrasive. The research provides a new and effect way to improve the surface qualities during CMP.
Abrasive is the one of key influencing factors during chemical mechanical polishing(CMP) process. Currently, α-Alumina (α-Al2O3) particle, as a kind of abrasive, has been widely used in CMP slurries, but their high hardness and poor dispersion stability often lead to more surface defects. After being polished with composite particles, the surface defects of work pieces decrease obviously. So the composite particles as abrasives in slurry have been paid more attention. In order to reduce defect caused by pure α-Al2O3 abrasive, α-alumina-g-polystyrene sulfonic acid (α-Al2O3-g-PSS) composite abrasive was prepared by surface graft polymerization. The composition, structure and morphology of the product were characterized by Fourier transform infrared spectroscopy(FTIR), X-ray photoelectron spectroscopy(XPS), time-of-flight secondary ion mass spectroscopy(TOF-SIMS), and scanning electron microscopy(SEM), respectively. The results show that polystyrene sulfonic acid grafts onto α-Al2O3, and has well dispersibility. Then, the chemical mechanical polishing performances of the composite abrasive on glass substrate were investigated with a SPEEDFAM-16B-4M CMP machine. Atomic force microscopy(AFM) images indicate that the average roughness of the polished glass substrate surface can be decreased from 0.835 nm for pure α-Al2O3 abrasive to 0.583 nm for prepared α-Al2O3-g-PSS core-shell abrasive. The research provides a new and effect way to improve the surface qualities during CMP.
2010, 24(3).
Abstract:
The gas in plastics mould has great influence on performance, appearance and lifespan of the injection molded parts. Venting channel and its appendix system should be used for gas exhausting in general. However, the dependence on the venting system complicates the mould design. Furthermore in certain condition, it is difficult to integrate the venting system into the mould. Currently a kind of mold material which has gas permeability has been developed in abroad, but the applications of this mold material were restricted by its higher cost and smaller size. In this research, a porous material which was made by powder metallurgy was applied to plastic mould to replace the venting system. Permeability of the steel with different secondary processing was tested and compared with a special apparatus. The metallographic samples of the steel with different secondary processing were prepared and investigated. Finally an actual injection set was established to investigate the applications of permeable steel. The metallographies indicate that the micro-holes inside permeable steel were interconnected. Moulds made of permeable steel exhibit good permeability in the plastic-injection experiments and gas generated in the mould cavity was smoothly exhausted. The melted plastic did not penetrate into the mould or block in the micro-holes. After several times of plastic-injection experiments, the mould still retained good permeability. The strength of this permeable steel is between 200–250 MPa and suitable for industrial applications. The venting systems simplified by permeable steel in plastic-injection have simple structures, which can be applied into any place that requires gas exhausting.
The gas in plastics mould has great influence on performance, appearance and lifespan of the injection molded parts. Venting channel and its appendix system should be used for gas exhausting in general. However, the dependence on the venting system complicates the mould design. Furthermore in certain condition, it is difficult to integrate the venting system into the mould. Currently a kind of mold material which has gas permeability has been developed in abroad, but the applications of this mold material were restricted by its higher cost and smaller size. In this research, a porous material which was made by powder metallurgy was applied to plastic mould to replace the venting system. Permeability of the steel with different secondary processing was tested and compared with a special apparatus. The metallographic samples of the steel with different secondary processing were prepared and investigated. Finally an actual injection set was established to investigate the applications of permeable steel. The metallographies indicate that the micro-holes inside permeable steel were interconnected. Moulds made of permeable steel exhibit good permeability in the plastic-injection experiments and gas generated in the mould cavity was smoothly exhausted. The melted plastic did not penetrate into the mould or block in the micro-holes. After several times of plastic-injection experiments, the mould still retained good permeability. The strength of this permeable steel is between 200–250 MPa and suitable for industrial applications. The venting systems simplified by permeable steel in plastic-injection have simple structures, which can be applied into any place that requires gas exhausting.
2010, 24(3).
Abstract:
The Al-Si-Mg alloy which can be strengthened by heat treatment is widely applied to the key components of aerospace and aeronautics. Iron-rich intermetallic compounds are well known to be strongly influential on mechanical properties in Al-Si-Mg alloys. But intermetallic compounds in cast Al-Si-Mg alloy intermetallics are often misidentified in previous metallurgical studies. It was described as many different compounds, such as AlFeSi, Al8Fe2Si, Al5(Fe, Mn)3Si2 and so on. For the purpose of solving this problem, the intermetallic compounds in cast Al-Si alloys containing 0.5% Mg were investigated in this study. The iron-rich compounds in Al-Si-Mg casting alloys were characterized by optical microscope(OM), scanning electron microscope(SEM), energy dispersive X-ray spectrometer(EDS), electron backscatter diffraction(EBSD) and X-ray powder diffraction(XRD). The electron backscatter diffraction patterns were used to assess the crystallographic characteristics of intermetallic compounds. The compound which contains Fe/Mg-rich particles with coarse morphologies was Al8FeMg3Si6 in the alloy by using EBSD. The compound belongs to hexagonal system, space group P6(_)2m, with the lattice parameter a0.662 nm, c0.792 nm. The β-phase is indexed as tetragonal Al3FeSi2, space group I4/mcm, a0.607 nm and c0.950 nm. The XRD data indicate that Al8FeMg3Si6 and Al3FeSi2 are present in the microstructure of Al-7Si-Mg alloy, which confirms the identification result of EBSD. The present study identified the iron-rich compound in Al-Si-Mg alloy, which provides a reliable method to identify the intermetallic compounds in short time in Al-Si-Mg alloy. Study results are helpful for identification of complex compounds in alloys.
The Al-Si-Mg alloy which can be strengthened by heat treatment is widely applied to the key components of aerospace and aeronautics. Iron-rich intermetallic compounds are well known to be strongly influential on mechanical properties in Al-Si-Mg alloys. But intermetallic compounds in cast Al-Si-Mg alloy intermetallics are often misidentified in previous metallurgical studies. It was described as many different compounds, such as AlFeSi, Al8Fe2Si, Al5(Fe, Mn)3Si2 and so on. For the purpose of solving this problem, the intermetallic compounds in cast Al-Si alloys containing 0.5% Mg were investigated in this study. The iron-rich compounds in Al-Si-Mg casting alloys were characterized by optical microscope(OM), scanning electron microscope(SEM), energy dispersive X-ray spectrometer(EDS), electron backscatter diffraction(EBSD) and X-ray powder diffraction(XRD). The electron backscatter diffraction patterns were used to assess the crystallographic characteristics of intermetallic compounds. The compound which contains Fe/Mg-rich particles with coarse morphologies was Al8FeMg3Si6 in the alloy by using EBSD. The compound belongs to hexagonal system, space group P6(_)2m, with the lattice parameter a0.662 nm, c0.792 nm. The β-phase is indexed as tetragonal Al3FeSi2, space group I4/mcm, a0.607 nm and c0.950 nm. The XRD data indicate that Al8FeMg3Si6 and Al3FeSi2 are present in the microstructure of Al-7Si-Mg alloy, which confirms the identification result of EBSD. The present study identified the iron-rich compound in Al-Si-Mg alloy, which provides a reliable method to identify the intermetallic compounds in short time in Al-Si-Mg alloy. Study results are helpful for identification of complex compounds in alloys.
2010, 24(3).
Abstract:
As actuator of the force-rebalanced servo loop, the electrostatic force generator of the micro-accelerometer shows high nonlinearity while the interpole of the micro-electro-mechanical system(MEMS) sensor is far away from its balance position. The control system cannot rebalance itself with the limited bandwidth after an external long overload, because the characteristics of the force generator differ from normal case. Although for similar problems, solutions with cascading lead-lag blocks, with the anti-windup(AW) technology, or with the sliding-mode control, are widely reported, the problems such as performance loss or difficulty to synthesize a digital controller still remain. Based on existing researches, remedies are developed by analyzing the characteristic of the system not only near the balance position, but also corresponding to the whole moveable range of the interpole, and a new controller is proposed. The solution is compared with the common solutions of cascading lead-lag blocks method, AW methods, and sliding mode methods. Comparison results show that the proposed solution avoid performance loss, compared to cascading lead-lag blocks solution; the proposed solution is easily synthesized and implemented in the analog servo loop of the micro-accelerometer, compared to digital AW methods; at the same time, the proposed solution avoids suffering the chattering effect problem but just utilize it, compared to the sliding-mode control solution. Nevertheless, comparison results show the solution is lack of commonality, since the solution is only more suitable to micro electrostatic force-rebalance system. The SIMULINK models with and without the proposed solution, taking typical micro-accelerometer parameters, have been set up for simulation; corresponding experiments utilizing electrometric method are also conducted after the successful simulations. Simulation and experiment results verify that the micro-accelerometer will reliably return to normal operation after external long overload with the proposed solution. Therefore, it is expected to design the analog servo loop of high performance micro electrostatic force-rebalance system so as to ensure the rebalance after long overload without performance loss.
As actuator of the force-rebalanced servo loop, the electrostatic force generator of the micro-accelerometer shows high nonlinearity while the interpole of the micro-electro-mechanical system(MEMS) sensor is far away from its balance position. The control system cannot rebalance itself with the limited bandwidth after an external long overload, because the characteristics of the force generator differ from normal case. Although for similar problems, solutions with cascading lead-lag blocks, with the anti-windup(AW) technology, or with the sliding-mode control, are widely reported, the problems such as performance loss or difficulty to synthesize a digital controller still remain. Based on existing researches, remedies are developed by analyzing the characteristic of the system not only near the balance position, but also corresponding to the whole moveable range of the interpole, and a new controller is proposed. The solution is compared with the common solutions of cascading lead-lag blocks method, AW methods, and sliding mode methods. Comparison results show that the proposed solution avoid performance loss, compared to cascading lead-lag blocks solution; the proposed solution is easily synthesized and implemented in the analog servo loop of the micro-accelerometer, compared to digital AW methods; at the same time, the proposed solution avoids suffering the chattering effect problem but just utilize it, compared to the sliding-mode control solution. Nevertheless, comparison results show the solution is lack of commonality, since the solution is only more suitable to micro electrostatic force-rebalance system. The SIMULINK models with and without the proposed solution, taking typical micro-accelerometer parameters, have been set up for simulation; corresponding experiments utilizing electrometric method are also conducted after the successful simulations. Simulation and experiment results verify that the micro-accelerometer will reliably return to normal operation after external long overload with the proposed solution. Therefore, it is expected to design the analog servo loop of high performance micro electrostatic force-rebalance system so as to ensure the rebalance after long overload without performance loss.
2010, 24(3).
Abstract:
The capability of docking, refueling, repairing, and updating microsatellites using automatic autonomous vehicles will be of significance critical value for design and operation of several space systems in the near feature. Automatic docking capability was successfully tested by many institutions such as National Space Development Agency in Japan, European Space Agency, National Aeronautics and Space Administration in USA, etc. However, there is still much more space for improvement of degree of automation during the process of docking with large deviations of the initial attitude. A novel automatic autonomous probe-cone docking mechanism used for microsatellite docking is proposed. This docking mechanism is designed according to the design indices such as miniaturization, degree of automation and automatic capture capability within large deviation of the initial attitude. On the basis of the virtual work principle, the dynamics modeling of the docking process is presented. The position of the contact point is then analyzed. Comprehensive system level simulation is conducted in the 13 kinds of typical operating conditions with the initial deviations. Capture performance is analyzed. The simulation results show that the docking mechanism can be smoothly captured within 2 s in all cases of large attitude deviation between the active and passive spacecrafts. A virtual prototype model of the docking mechanism is established through ADAMS for further verifying the correctness of the buffer parameter model and the autonomous docking capability. A laboratory platform is designed for on-the-ground experimental validation of the property of mini probe-cone docking mechanism. Repeated docking tests prove the proposed design of the mini probe-cone docking mechanism system for its high reliability, and automatic capture capability within large attitude range. The kinetic model of the docking capture process and the mechanism structure could provide some references for similar mechanism design of in-orbit spacecraft.
The capability of docking, refueling, repairing, and updating microsatellites using automatic autonomous vehicles will be of significance critical value for design and operation of several space systems in the near feature. Automatic docking capability was successfully tested by many institutions such as National Space Development Agency in Japan, European Space Agency, National Aeronautics and Space Administration in USA, etc. However, there is still much more space for improvement of degree of automation during the process of docking with large deviations of the initial attitude. A novel automatic autonomous probe-cone docking mechanism used for microsatellite docking is proposed. This docking mechanism is designed according to the design indices such as miniaturization, degree of automation and automatic capture capability within large deviation of the initial attitude. On the basis of the virtual work principle, the dynamics modeling of the docking process is presented. The position of the contact point is then analyzed. Comprehensive system level simulation is conducted in the 13 kinds of typical operating conditions with the initial deviations. Capture performance is analyzed. The simulation results show that the docking mechanism can be smoothly captured within 2 s in all cases of large attitude deviation between the active and passive spacecrafts. A virtual prototype model of the docking mechanism is established through ADAMS for further verifying the correctness of the buffer parameter model and the autonomous docking capability. A laboratory platform is designed for on-the-ground experimental validation of the property of mini probe-cone docking mechanism. Repeated docking tests prove the proposed design of the mini probe-cone docking mechanism system for its high reliability, and automatic capture capability within large attitude range. The kinetic model of the docking capture process and the mechanism structure could provide some references for similar mechanism design of in-orbit spacecraft.
2010, 24(3).
Abstract:
Accidental or frequent shift often occurs when the shifting rule is built based on traditional two parameters (i.e., velocity and throttle), because the speed of engine varies slower than change of throttle opening. Currently, modifying shift point velocity value or throttle by throttle change rate is one of common methods, but the results are not so satisfactory in some working condition such as uphill. The reason is that these methods merely consider throttle change rate which is not enough for a car driving in driver-vehicle-road environment system. So a novel fuzzy control modification strategy is proposed to avoid or reduce those abnormal shift actions. It can adjust shifting rule by the change rate of throttle, current gear position and road environment information, while different gear position and driving environment get corresponding modification value. In order to compare the results of shifting actions, fuel consumption and braking distance, emergent braking in level road and extra-urban driving cycle(EUDC) working conditions with fuzzy shifting schedule modification strategy are simulated digitally. Furthermore, a hardware-in-the-loop simulation platform is introduced to verify its effect in slope road condition according to the ON/OFF numbers of solenoid valve in hydraulic system. The simulation results show that the problem of unexpected shift in those working conditions may be resolved by fuzzy modification strategy. At last, it is concluded that although there is some slight decline in power performance in uphill situation, this fuzzy modification strategy could correctly identify slope of road, decrease braking distance, improve vehicle comfort and fuel economy effectively and prolong the life of clutch system. So, this fuzzy logic shifting strategy provides important references for vehicle intelligent shifting schedule.
Accidental or frequent shift often occurs when the shifting rule is built based on traditional two parameters (i.e., velocity and throttle), because the speed of engine varies slower than change of throttle opening. Currently, modifying shift point velocity value or throttle by throttle change rate is one of common methods, but the results are not so satisfactory in some working condition such as uphill. The reason is that these methods merely consider throttle change rate which is not enough for a car driving in driver-vehicle-road environment system. So a novel fuzzy control modification strategy is proposed to avoid or reduce those abnormal shift actions. It can adjust shifting rule by the change rate of throttle, current gear position and road environment information, while different gear position and driving environment get corresponding modification value. In order to compare the results of shifting actions, fuel consumption and braking distance, emergent braking in level road and extra-urban driving cycle(EUDC) working conditions with fuzzy shifting schedule modification strategy are simulated digitally. Furthermore, a hardware-in-the-loop simulation platform is introduced to verify its effect in slope road condition according to the ON/OFF numbers of solenoid valve in hydraulic system. The simulation results show that the problem of unexpected shift in those working conditions may be resolved by fuzzy modification strategy. At last, it is concluded that although there is some slight decline in power performance in uphill situation, this fuzzy modification strategy could correctly identify slope of road, decrease braking distance, improve vehicle comfort and fuel economy effectively and prolong the life of clutch system. So, this fuzzy logic shifting strategy provides important references for vehicle intelligent shifting schedule.
2010, 24(3).
Abstract:
Nano-particles which can largely improve the microstructure and oxidation resistance of materials are often used as a strengthening component in metal matrix composites. However, few studies were reported on its application in the bond coat of duplex structure thermal barrier coating(TBC). Three kinds of NiCoCrAlY coatings strengthened by different nano-particles with the same addition (1%, mass fraction) were prepared by the laser cladding technique on Ni-based superalloy substrates, aiming to study the effects of the nano-particles on microstructure and oxidation resistance of NiCoCrAlY coatings (the bond coat of the duplex structure thermal barrier coatings). Scanning electron microscope (SEM), X-ray diffractometer(XRD) and thermogravimetry were employed to investigate their morphologies, phases and cyclic oxidation behaviors in atmosphere at 1 050℃, compared with the coating without nano-particles. With the addition of nano-particles, the growth pattern of the grains at the interface changed from epitaxial growth to non-epitaxial growth or part-epitaxial growth; slender dendrites were broken and cellularized; cracks and pores were restrained; and the oxidation weight-gain and the stripping resistance of the oxide scale were improved as well. Among the three kinds of nano-particles, the SiC nano-particles showed the most improvement on microstructure, while the CeO2 nano-particles were insufficient, but its effects on the oxidation resistance are the same as those of the SiC nano-particles. Based on the discussions of the influence mechanism, it is believed that CeO2 nano-particles would show better improvement than SiC nano-particles if the proper amount is added and the proper preparation technique of micro-nanometer composite powders is adopted, with the synergistic action of nanometer effect and reactive element effect.
Nano-particles which can largely improve the microstructure and oxidation resistance of materials are often used as a strengthening component in metal matrix composites. However, few studies were reported on its application in the bond coat of duplex structure thermal barrier coating(TBC). Three kinds of NiCoCrAlY coatings strengthened by different nano-particles with the same addition (1%, mass fraction) were prepared by the laser cladding technique on Ni-based superalloy substrates, aiming to study the effects of the nano-particles on microstructure and oxidation resistance of NiCoCrAlY coatings (the bond coat of the duplex structure thermal barrier coatings). Scanning electron microscope (SEM), X-ray diffractometer(XRD) and thermogravimetry were employed to investigate their morphologies, phases and cyclic oxidation behaviors in atmosphere at 1 050℃, compared with the coating without nano-particles. With the addition of nano-particles, the growth pattern of the grains at the interface changed from epitaxial growth to non-epitaxial growth or part-epitaxial growth; slender dendrites were broken and cellularized; cracks and pores were restrained; and the oxidation weight-gain and the stripping resistance of the oxide scale were improved as well. Among the three kinds of nano-particles, the SiC nano-particles showed the most improvement on microstructure, while the CeO2 nano-particles were insufficient, but its effects on the oxidation resistance are the same as those of the SiC nano-particles. Based on the discussions of the influence mechanism, it is believed that CeO2 nano-particles would show better improvement than SiC nano-particles if the proper amount is added and the proper preparation technique of micro-nanometer composite powders is adopted, with the synergistic action of nanometer effect and reactive element effect.
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