2012 Vol.25(5)
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2012, 26(5).
Abstract:
The current research of large eddy simulation (LES) of turbulent flow in pumps mainly concentrates in applying conventional subgrid-scale (SGS) model to simulate turbulent flow, which aims at obtaining the flow field in pump. The selection of SGS model is usually not considered seriously, so the accuracy and efficiency of the simulation cannot be ensured. Three SGS models including Smagorinsky-Lilly model, dynamic Smagorinsky model and dynamic mixed model are comparably studied by using the commercial CFD code Fluent combined with its user define function. The simulations are performed for the turbulent flow in a centrifugal pump impeller. The simulation results indicate that the mean flows predicted by the three SGS models agree well with the experimental data obtained from the test that detailed measurements of the flow inside the rotating passages of a six-bladed shrouded centrifugal pump impeller performed using particle image velocimetry (PIV) and laser Doppler velocimetry (LDV). The comparable results show that dynamic mixed model gives the most accurate results for mean flow in the centrifugal pump impeller. The SGS stress of dynamic mixed model is decompose into the scale similar part and the eddy viscous part. The scale similar part of SGS stress plays a significant role in high curvature regions, such as the leading edge and training edge of pump blade. It is also found that the dynamic mixed model is more adaptive to compute turbulence in the pump impeller. The research results presented is useful to improve the computational accuracy and efficiency of LES for centrifugal pumps, and provide important reference for carrying out simulation in similar fluid machineries.
The current research of large eddy simulation (LES) of turbulent flow in pumps mainly concentrates in applying conventional subgrid-scale (SGS) model to simulate turbulent flow, which aims at obtaining the flow field in pump. The selection of SGS model is usually not considered seriously, so the accuracy and efficiency of the simulation cannot be ensured. Three SGS models including Smagorinsky-Lilly model, dynamic Smagorinsky model and dynamic mixed model are comparably studied by using the commercial CFD code Fluent combined with its user define function. The simulations are performed for the turbulent flow in a centrifugal pump impeller. The simulation results indicate that the mean flows predicted by the three SGS models agree well with the experimental data obtained from the test that detailed measurements of the flow inside the rotating passages of a six-bladed shrouded centrifugal pump impeller performed using particle image velocimetry (PIV) and laser Doppler velocimetry (LDV). The comparable results show that dynamic mixed model gives the most accurate results for mean flow in the centrifugal pump impeller. The SGS stress of dynamic mixed model is decompose into the scale similar part and the eddy viscous part. The scale similar part of SGS stress plays a significant role in high curvature regions, such as the leading edge and training edge of pump blade. It is also found that the dynamic mixed model is more adaptive to compute turbulence in the pump impeller. The research results presented is useful to improve the computational accuracy and efficiency of LES for centrifugal pumps, and provide important reference for carrying out simulation in similar fluid machineries.
2012, 26(5).
Abstract:
The production process plan design and configurations of reconfigurable machine tool (RMT) interact with each other. Reasonable process plans with suitable configurations of RMT help to improve product quality and reduce production cost. Therefore, a cooperative strategy is needed to concurrently solve the above issue. In this paper, the cooperative optimization model for RMT configurations and production process plan is presented. Its objectives take into account both impacts of process and configuration. Moreover, a novel genetic algorithm is also developed to provide optimal or near-optimal solutions: firstly, its chromosome is redesigned which is composed of three parts, operations, process plan and configurations of RMTs, respectively; secondly, its new selection, crossover and mutation operators are also developed to deal with the process constraints from operation processes (OP) graph, otherwise these operators could generate illegal solutions violating the limits; eventually the optimal configurations for RMT under optimal process plan design can be obtained. At last, a manufacturing line case is applied which is composed of three RMTs. It is shown from the case that the optimal process plan and configurations of RMT are concurrently obtained, and the production cost decreases 6.28% and nonmonetary performance increases 22%. The proposed method can figure out both RMT configurations and production process, improve production capacity, functions and equipment utilization for RMT.
The production process plan design and configurations of reconfigurable machine tool (RMT) interact with each other. Reasonable process plans with suitable configurations of RMT help to improve product quality and reduce production cost. Therefore, a cooperative strategy is needed to concurrently solve the above issue. In this paper, the cooperative optimization model for RMT configurations and production process plan is presented. Its objectives take into account both impacts of process and configuration. Moreover, a novel genetic algorithm is also developed to provide optimal or near-optimal solutions: firstly, its chromosome is redesigned which is composed of three parts, operations, process plan and configurations of RMTs, respectively; secondly, its new selection, crossover and mutation operators are also developed to deal with the process constraints from operation processes (OP) graph, otherwise these operators could generate illegal solutions violating the limits; eventually the optimal configurations for RMT under optimal process plan design can be obtained. At last, a manufacturing line case is applied which is composed of three RMTs. It is shown from the case that the optimal process plan and configurations of RMT are concurrently obtained, and the production cost decreases 6.28% and nonmonetary performance increases 22%. The proposed method can figure out both RMT configurations and production process, improve production capacity, functions and equipment utilization for RMT.
2012, 26(5).
Abstract:
The machine tool coolers are the best managers of coolant temperature in avoiding the deviation of spindle centerline for machine tools. However, the machine coolers are facing the compressed schedule to phase out the HCFC (hydro-chloro-floro-carbon) refrigerant and little attention has been paid to comparative study on sizing capillary tube for retrofitted HFC (hydro-floro-carbon) refrigerant. In this paper, the adiabatic flow in capillary tube is analyzed and modeled for retrofitting of HFC-407C refrigerant in a machine tool cooler system. A computer code including determining the length of sub-cooled flow region and the two phase region of capillary tube is developed. Comparative study of HCFC-22 and HFC-407C in a capillary tube is derived and conducted to simplify the traditional trial-and-error method of predicting the length of capillary tubes. Besides, experimental investigation is carried out by field tests to verify the simulation model and cooling performance of the machine tool cooler system. The results from the experiments reveal that the numerical model provides an effective approach to determine the performance data of capillary tube specific for retrofitting a HFC-407C machine tool cooler. The developed machine tool cooler system is not only directly compatible with new HFC-407C refrigerant, but can also perform a cost-effective temperature control specific for industrial machines.
The machine tool coolers are the best managers of coolant temperature in avoiding the deviation of spindle centerline for machine tools. However, the machine coolers are facing the compressed schedule to phase out the HCFC (hydro-chloro-floro-carbon) refrigerant and little attention has been paid to comparative study on sizing capillary tube for retrofitted HFC (hydro-floro-carbon) refrigerant. In this paper, the adiabatic flow in capillary tube is analyzed and modeled for retrofitting of HFC-407C refrigerant in a machine tool cooler system. A computer code including determining the length of sub-cooled flow region and the two phase region of capillary tube is developed. Comparative study of HCFC-22 and HFC-407C in a capillary tube is derived and conducted to simplify the traditional trial-and-error method of predicting the length of capillary tubes. Besides, experimental investigation is carried out by field tests to verify the simulation model and cooling performance of the machine tool cooler system. The results from the experiments reveal that the numerical model provides an effective approach to determine the performance data of capillary tube specific for retrofitting a HFC-407C machine tool cooler. The developed machine tool cooler system is not only directly compatible with new HFC-407C refrigerant, but can also perform a cost-effective temperature control specific for industrial machines.
2012, 26(5).
Abstract:
Discontinuous tape winding, which has obvious advantages in large extension ratio winding, is widely used in the molding of composites. Therefore, the research on technological parameters becomes the focus of many scholars. However, how to accomplish the variable tension control is usually not fully considered. Accordingly, the constant extension ratio and the smoothness of winding process cannot be ensured. Aiming at the problem of tension control, this paper first gives a comparatively deep research on the control method and the interaction mechanism of tension, extension ratio, automatic lap and automatic rectification. Then, according to the winding process features, the mechanical device and the mathematical model of tension control system are established respectively. With regard to the characteristics of PID controller and fuzzy controller, the fuzzy self-tuning PID controller is designed. As a result, the variable tension control is realized during the winding and lapping process, and the constant extension ratio is guaranteed. Finally, a sample application is presented for demonstration. By presenting the variable tension control techniques for discontinuous tape winding, the constant extension ratio of tapes is achieved, the consecution and the automation degree of winding process is improved as well. Thus, the quality of wound products is guaranteed.
Discontinuous tape winding, which has obvious advantages in large extension ratio winding, is widely used in the molding of composites. Therefore, the research on technological parameters becomes the focus of many scholars. However, how to accomplish the variable tension control is usually not fully considered. Accordingly, the constant extension ratio and the smoothness of winding process cannot be ensured. Aiming at the problem of tension control, this paper first gives a comparatively deep research on the control method and the interaction mechanism of tension, extension ratio, automatic lap and automatic rectification. Then, according to the winding process features, the mechanical device and the mathematical model of tension control system are established respectively. With regard to the characteristics of PID controller and fuzzy controller, the fuzzy self-tuning PID controller is designed. As a result, the variable tension control is realized during the winding and lapping process, and the constant extension ratio is guaranteed. Finally, a sample application is presented for demonstration. By presenting the variable tension control techniques for discontinuous tape winding, the constant extension ratio of tapes is achieved, the consecution and the automation degree of winding process is improved as well. Thus, the quality of wound products is guaranteed.
2012, 26(5).
Abstract:
Journal bearings are important parts to keep the high dynamic performance of rotor machinery. Some methods have already been proposed to analysis the flow field of journal bearings, and in most of these methods simplified physical model and classic Reynolds equation are always applied. While the application of the general computational fluid dynamics (CFD)-fluid structure interaction (FSI) techniques is more beneficial for analysis of the fluid field in a journal bearing when more detailed solutions are needed. This paper deals with the quasi-coupling calculation of transient fluid dynamics of oil film in journal bearings and rotor dynamics with CFD-FSI techniques. The fluid dynamics of oil film is calculated by applying the so-called ‘‘dynamic mesh’’ technique. A new mesh movement approach is presented while the dynamic mesh models provided by FLUENT are not suitable for the transient oil flow in journal bearings. The proposed mesh movement approach is based on the structured mesh. When the journal moves, the movement distance of every grid in the flow field of bearing can be calculated, and then the update of the volume mesh can be handled automatically by user defined function (UDF). The journal displacement at each time step is obtained by solving the moving equations of the rotor-bearing system under the known oil film force condition. A case study is carried out to calculate the locus of the journal center and pressure distribution of the journal in order to prove the feasibility of this method. The calculating results indicate that the proposed method can predict the transient flow field of a journal bearing in a rotor-bearing system where more realistic models are involved. The presented calculation method provides a basis for studying the nonlinear dynamic behavior of a general rotor-bearing system.
Journal bearings are important parts to keep the high dynamic performance of rotor machinery. Some methods have already been proposed to analysis the flow field of journal bearings, and in most of these methods simplified physical model and classic Reynolds equation are always applied. While the application of the general computational fluid dynamics (CFD)-fluid structure interaction (FSI) techniques is more beneficial for analysis of the fluid field in a journal bearing when more detailed solutions are needed. This paper deals with the quasi-coupling calculation of transient fluid dynamics of oil film in journal bearings and rotor dynamics with CFD-FSI techniques. The fluid dynamics of oil film is calculated by applying the so-called ‘‘dynamic mesh’’ technique. A new mesh movement approach is presented while the dynamic mesh models provided by FLUENT are not suitable for the transient oil flow in journal bearings. The proposed mesh movement approach is based on the structured mesh. When the journal moves, the movement distance of every grid in the flow field of bearing can be calculated, and then the update of the volume mesh can be handled automatically by user defined function (UDF). The journal displacement at each time step is obtained by solving the moving equations of the rotor-bearing system under the known oil film force condition. A case study is carried out to calculate the locus of the journal center and pressure distribution of the journal in order to prove the feasibility of this method. The calculating results indicate that the proposed method can predict the transient flow field of a journal bearing in a rotor-bearing system where more realistic models are involved. The presented calculation method provides a basis for studying the nonlinear dynamic behavior of a general rotor-bearing system.
2012, 26(5).
Abstract:
Although conventional model reference adaptive control (MRAC) achieves good tracking performance for cylinder control, the controller structure is much more complicated and has less robustness to disturbance in real applications. This paper discusses the use of simple adaptive control (SAC) for positioning a water hydraulic servo cylinder system. Compared with MRAC, SAC has a simpler and lower order structure, i.e., higher feasibility. The control performance of SAC is examined and evaluated on a water hydraulic servo cylinder system. With the recent increased concerns over global environmental problems, the water hydraulic technique using pure tap water as a pressure medium has become a new drive source comparable to electric, oil hydraulic, and pneumatic drive systems. This technique is also preferred because of its high power density, high safety against fire hazards in production plants, and easy availability. However, the main problems for precise control in a water hydraulic system are steady state errors and overshoot due to its large friction torque and considerable leakage flow. MRAC has been already applied to compensate for these effects, and better control performances have been obtained. However, there have been no reports on the application of SAC for water hydraulics. To make clear the merits of SAC, the tracking control performance and robustness are discussed based on experimental results. SAC is confirmed to give better tracking performance compared with PI control, and a control precision comparable to MRAC (within 10 m of the reference position) and higher robustness to parameter change, despite the simple controller. The research results ensure a wider application of simple adaptive control in real mechanical systems.
Although conventional model reference adaptive control (MRAC) achieves good tracking performance for cylinder control, the controller structure is much more complicated and has less robustness to disturbance in real applications. This paper discusses the use of simple adaptive control (SAC) for positioning a water hydraulic servo cylinder system. Compared with MRAC, SAC has a simpler and lower order structure, i.e., higher feasibility. The control performance of SAC is examined and evaluated on a water hydraulic servo cylinder system. With the recent increased concerns over global environmental problems, the water hydraulic technique using pure tap water as a pressure medium has become a new drive source comparable to electric, oil hydraulic, and pneumatic drive systems. This technique is also preferred because of its high power density, high safety against fire hazards in production plants, and easy availability. However, the main problems for precise control in a water hydraulic system are steady state errors and overshoot due to its large friction torque and considerable leakage flow. MRAC has been already applied to compensate for these effects, and better control performances have been obtained. However, there have been no reports on the application of SAC for water hydraulics. To make clear the merits of SAC, the tracking control performance and robustness are discussed based on experimental results. SAC is confirmed to give better tracking performance compared with PI control, and a control precision comparable to MRAC (within 10 m of the reference position) and higher robustness to parameter change, despite the simple controller. The research results ensure a wider application of simple adaptive control in real mechanical systems.
2012, 26(5).
Abstract:
With the increasing demand for the clean sustainable power, the turbine design urgently turns to increase the capability significantly toward higher head for generating larger power. Currently, there are many studies in the field of the bulb turbine with single-stage runner, though reports about counter-rotating tandem-runner are rare. However, the further high-head application with the single-stage runner is very difficult to achieve due to the limit of the specific speed. In this paper, a new bulb turbine with the tandem-runner is designed in order to substantially increase the applicable limit toward higher head with larger power. A half of the net head is absorbed by the frontal runner which can generate output power, while the remaining half is absorbed by the rear runner. To generate the Euler energy required for the rear runner, the frontal runner has the counter-rotation against the rear runner so that the counter-rotating tandem-runner can meet the purpose of double head and power under the same size as the conventional bulb turbine. Supply and demand of Euler energy between the two runners are thoroughly optimized through the detailed flow analysis, in order to secure the stable operation. As a result, the interference of Euler energies between the outflow from the frontal runner and the inflow to the rear runner is confirmed to be very small on the counter-rotating interface between the two runners. The prediction method of on-cam performance between the two adjustable runners is also developed numerically, which provides optimal flow between the two runners. This research provides a theoretical basis for the optimal design and operation of the counter-rotating tandem-runner bulb turbines.
With the increasing demand for the clean sustainable power, the turbine design urgently turns to increase the capability significantly toward higher head for generating larger power. Currently, there are many studies in the field of the bulb turbine with single-stage runner, though reports about counter-rotating tandem-runner are rare. However, the further high-head application with the single-stage runner is very difficult to achieve due to the limit of the specific speed. In this paper, a new bulb turbine with the tandem-runner is designed in order to substantially increase the applicable limit toward higher head with larger power. A half of the net head is absorbed by the frontal runner which can generate output power, while the remaining half is absorbed by the rear runner. To generate the Euler energy required for the rear runner, the frontal runner has the counter-rotation against the rear runner so that the counter-rotating tandem-runner can meet the purpose of double head and power under the same size as the conventional bulb turbine. Supply and demand of Euler energy between the two runners are thoroughly optimized through the detailed flow analysis, in order to secure the stable operation. As a result, the interference of Euler energies between the outflow from the frontal runner and the inflow to the rear runner is confirmed to be very small on the counter-rotating interface between the two runners. The prediction method of on-cam performance between the two adjustable runners is also developed numerically, which provides optimal flow between the two runners. This research provides a theoretical basis for the optimal design and operation of the counter-rotating tandem-runner bulb turbines.
2012, 26(5).
Abstract:
Smart structure with active materials embedded in a rotating composite thin-walled beam is a class of typical structure which is using in study of vibration control of helicopter blades and wind turbine blades. The dynamic behavior investigation of these structures has significance in theory and practice. However, so far dynamic study on the above-mentioned structures is limited only the rotating composite beams with piezoelectric actuation. The free vibration of the rotating composite thin-walled beams with shape memory alloy(SMA) fiber actuation is studied. SMA fiber actuators are embedded into the walls of the composite beam. The equations of motion are derived based on Hamilton’s principle and the asymptotically correct constitutive relation of single-cell cross-section accounting for SMA fiber actuation. The partial differential equations of motion are reduced to the ordinary differential equations of motion by using the Galerkin’s method. The formulation for free vibration analysis includes anisotropy, pitch and precone angle, centrifugal force and SMA actuation effect. Numerical results of natural frequency are obtained for two configuration composite beams. It is shown that natural frequencies of the composite thin-walled beam decrease as SMA fiber volume and initial strain increase and the decrease in natural frequency becomes more significant as SMA fiber volume increases. The actuation performance of SMA fibers is found to be closely related to the rotational speeds and ply-angle. In addition, the effect of the pitch angle appears to be more significant for the lower-bending mode ones. Finally, in all cases, the precone angle appears to have marginal effect on free vibration frequencies. The developed model can be capable of describing natural vibration behaviors of rotating composite thin-walled beam with active SMA fiber actuation. The present work extends the previous analysis done for modeling passive rotating composite thin-walled beam.
Smart structure with active materials embedded in a rotating composite thin-walled beam is a class of typical structure which is using in study of vibration control of helicopter blades and wind turbine blades. The dynamic behavior investigation of these structures has significance in theory and practice. However, so far dynamic study on the above-mentioned structures is limited only the rotating composite beams with piezoelectric actuation. The free vibration of the rotating composite thin-walled beams with shape memory alloy(SMA) fiber actuation is studied. SMA fiber actuators are embedded into the walls of the composite beam. The equations of motion are derived based on Hamilton’s principle and the asymptotically correct constitutive relation of single-cell cross-section accounting for SMA fiber actuation. The partial differential equations of motion are reduced to the ordinary differential equations of motion by using the Galerkin’s method. The formulation for free vibration analysis includes anisotropy, pitch and precone angle, centrifugal force and SMA actuation effect. Numerical results of natural frequency are obtained for two configuration composite beams. It is shown that natural frequencies of the composite thin-walled beam decrease as SMA fiber volume and initial strain increase and the decrease in natural frequency becomes more significant as SMA fiber volume increases. The actuation performance of SMA fibers is found to be closely related to the rotational speeds and ply-angle. In addition, the effect of the pitch angle appears to be more significant for the lower-bending mode ones. Finally, in all cases, the precone angle appears to have marginal effect on free vibration frequencies. The developed model can be capable of describing natural vibration behaviors of rotating composite thin-walled beam with active SMA fiber actuation. The present work extends the previous analysis done for modeling passive rotating composite thin-walled beam.
2012, 26(5).
Abstract:
The method of acquiring the real-time data has influenced the implementation of the manufacturing execution system (MES). Accompanied with turning the MES into service-oriented manufacturing execution system (so-MES), real-time e-quality tracking (e-QT), in which real-time data are computed, has played more and more important roles in manufacturing. This paper presents an e-QT model through the study of real-time status data tracking and quality data collecting. An implementing architecture of the e-QT model is constructed on the basis of radio frequency identification devices (RFID) data-tracking network. In order to develop the e-QT system, some key enabling technologies, such as configuration, data collection, and data processing, etc, are studied. The relation schema between hardware is built for the RFID data-tracking network based on the configuration technique. Real-time data are sampled by using data collecting technique. Furthermore, real-time status and quality data in a shop-floor can be acquired in terms of using the real-time data computing method. Finally, a prototype system is developed and a running example is given so as to verify the feasibility of methods proposed in this paper. The proposed research provides effective e-quality tracking theoretical foundation through the use of RFID technology for the discrete manufacturing.
The method of acquiring the real-time data has influenced the implementation of the manufacturing execution system (MES). Accompanied with turning the MES into service-oriented manufacturing execution system (so-MES), real-time e-quality tracking (e-QT), in which real-time data are computed, has played more and more important roles in manufacturing. This paper presents an e-QT model through the study of real-time status data tracking and quality data collecting. An implementing architecture of the e-QT model is constructed on the basis of radio frequency identification devices (RFID) data-tracking network. In order to develop the e-QT system, some key enabling technologies, such as configuration, data collection, and data processing, etc, are studied. The relation schema between hardware is built for the RFID data-tracking network based on the configuration technique. Real-time data are sampled by using data collecting technique. Furthermore, real-time status and quality data in a shop-floor can be acquired in terms of using the real-time data computing method. Finally, a prototype system is developed and a running example is given so as to verify the feasibility of methods proposed in this paper. The proposed research provides effective e-quality tracking theoretical foundation through the use of RFID technology for the discrete manufacturing.
2012, 26(5).
Abstract:
As one of the bases of gradient-based optimization algorithms, sensitivity analysis is usually required to calculate the derivatives of the system response with respect to the machining parameters. The most widely used approaches for sensitivity analysis are based on time-consuming numerical methods, such as finite difference methods. This paper presents a semi-analytical method for calculation of the sensitivity of the stability boundary in milling. After transforming the delay-differential equation with time-periodic coefficients governing the dynamic milling process into the integral form, the Floquet transition matrix is constructed by using the numerical integration method. Then, the analytical expressions of derivatives of the Floquet transition matrix with respect to the machining parameters are obtained. Thereafter, the classical analytical expression of the sensitivity of matrix eigenvalues is employed to calculate the sensitivity of the stability lobe diagram. The two-degree-of-freedom milling example illustrates the accuracy and efficiency of the proposed method. Compared with the existing methods, the unique merit of the proposed method is that it can be used for analytically computing the sensitivity of the stability boundary in milling, without employing any finite difference methods. Therefore, the high accuracy and high efficiency are both achieved. The proposed method can serve as an effective tool for machining parameter optimization and uncertainty analysis in high-speed milling.
As one of the bases of gradient-based optimization algorithms, sensitivity analysis is usually required to calculate the derivatives of the system response with respect to the machining parameters. The most widely used approaches for sensitivity analysis are based on time-consuming numerical methods, such as finite difference methods. This paper presents a semi-analytical method for calculation of the sensitivity of the stability boundary in milling. After transforming the delay-differential equation with time-periodic coefficients governing the dynamic milling process into the integral form, the Floquet transition matrix is constructed by using the numerical integration method. Then, the analytical expressions of derivatives of the Floquet transition matrix with respect to the machining parameters are obtained. Thereafter, the classical analytical expression of the sensitivity of matrix eigenvalues is employed to calculate the sensitivity of the stability lobe diagram. The two-degree-of-freedom milling example illustrates the accuracy and efficiency of the proposed method. Compared with the existing methods, the unique merit of the proposed method is that it can be used for analytically computing the sensitivity of the stability boundary in milling, without employing any finite difference methods. Therefore, the high accuracy and high efficiency are both achieved. The proposed method can serve as an effective tool for machining parameter optimization and uncertainty analysis in high-speed milling.
Influence of Weave Structures on the Tribological Properties of Hybrid KevlarPTFE Fabric Composites
2012, 26(5).
Abstract:
The existing research of the woven fabric self-lubricating liner mainly focus on the tribological performance improvements and the service life raised by changing different fiber type combinations, adding additive modification, and performing fiber surface modification. As fabric composites, the weave structures play an important role in the mechanical and tribological performances of the liners. However, hardly any literature is available on the friction and wear behavior of such composites with different weave structures. In this paper, three weave structures (plain, twill 13 and satin 85) of hybrid KevlarPTFE fabric composites are selected and pin-on-flat linear reciprocating wear studies are done on a CETR tester under different pressures and different frequencies. The relationship between the tensile strength and the wear performance are studied. The morphologies of the worn surfaces under the typical test conditions are analyzed by means of scanning electron microscopy (SEM). The analysis results show that at 10 MPa, satin 85 performs the best in friction-reduction and antiwear performance, and plain is the worst. At 30 MPa, however, the antiwear performance is reversed and satin 85 does not even complete the 2 h wear test at 16 Hz. There is no clear evidence proving that the tensile strength has an influence on the wear performance. So the different tribological performance of the three weave structures of fabric composites may be attributed to the different PTFE proportions in the fabric surface and the different wear mechanisms. The fabric composites are divided into three regions: the lubrication region, the reinforced region and the bonding region. The major mechanisms are fatigue wear and the shear effects of the friction force in the lubrication region. In the reinforced region fiber-matrix de-bonding and fiber breakage are involved. The proposed research proposes a regional wear model and further indicates the wear process and the wear mechanism of fabric composites.
The existing research of the woven fabric self-lubricating liner mainly focus on the tribological performance improvements and the service life raised by changing different fiber type combinations, adding additive modification, and performing fiber surface modification. As fabric composites, the weave structures play an important role in the mechanical and tribological performances of the liners. However, hardly any literature is available on the friction and wear behavior of such composites with different weave structures. In this paper, three weave structures (plain, twill 13 and satin 85) of hybrid KevlarPTFE fabric composites are selected and pin-on-flat linear reciprocating wear studies are done on a CETR tester under different pressures and different frequencies. The relationship between the tensile strength and the wear performance are studied. The morphologies of the worn surfaces under the typical test conditions are analyzed by means of scanning electron microscopy (SEM). The analysis results show that at 10 MPa, satin 85 performs the best in friction-reduction and antiwear performance, and plain is the worst. At 30 MPa, however, the antiwear performance is reversed and satin 85 does not even complete the 2 h wear test at 16 Hz. There is no clear evidence proving that the tensile strength has an influence on the wear performance. So the different tribological performance of the three weave structures of fabric composites may be attributed to the different PTFE proportions in the fabric surface and the different wear mechanisms. The fabric composites are divided into three regions: the lubrication region, the reinforced region and the bonding region. The major mechanisms are fatigue wear and the shear effects of the friction force in the lubrication region. In the reinforced region fiber-matrix de-bonding and fiber breakage are involved. The proposed research proposes a regional wear model and further indicates the wear process and the wear mechanism of fabric composites.
2012, 26(5).
Abstract:
The existing researches of hot ring rolling process are mainly based on forged billet. Compared with the existing process, the new ring casting-rolling compound forming process has significant advantages in saving materials and energy, reducing emission and reducing the production cost. The microstructure evolution of the casting materials during hot deformation is the basis of the research of the new process. However, the researches on the casting materials are rare. The metadynamic recrystallization of the as-cast 42CrMo steel after normalizing and tempering during the hot compression is investigated. The tests are performed on the Gleeble-1500 thermal-mechanical simulator. The influence rule of the deformation parameters on the metadynamic recrystallization is obtained by analyzing the experimental data. The kinetic model of the metadynamic recrystallization is deduced. The analysis results show that the metadynamic recrystallization fraction increases with the increase of the deformation temperature and the strain rate. The metallographic experiments are used to investigate the influence rule of the deformation parameters on the grain size of the metadynamic recrystallization. The experimental results show that the grain of the metadynamic recrystallization could be refined with the increase of the strain rate and the decrease of the deformation temperature during hot compression. The occurrence of the metadynamic recrystallization during the hot deformation is more difficult in as-cast 42CrMo steel than in forged 42CrMo steel. The research can provide the foundation for the further research of the hot deformation behaviors of the as-cast structure and theoretical support for the new ring casting-rolling compound process.
The existing researches of hot ring rolling process are mainly based on forged billet. Compared with the existing process, the new ring casting-rolling compound forming process has significant advantages in saving materials and energy, reducing emission and reducing the production cost. The microstructure evolution of the casting materials during hot deformation is the basis of the research of the new process. However, the researches on the casting materials are rare. The metadynamic recrystallization of the as-cast 42CrMo steel after normalizing and tempering during the hot compression is investigated. The tests are performed on the Gleeble-1500 thermal-mechanical simulator. The influence rule of the deformation parameters on the metadynamic recrystallization is obtained by analyzing the experimental data. The kinetic model of the metadynamic recrystallization is deduced. The analysis results show that the metadynamic recrystallization fraction increases with the increase of the deformation temperature and the strain rate. The metallographic experiments are used to investigate the influence rule of the deformation parameters on the grain size of the metadynamic recrystallization. The experimental results show that the grain of the metadynamic recrystallization could be refined with the increase of the strain rate and the decrease of the deformation temperature during hot compression. The occurrence of the metadynamic recrystallization during the hot deformation is more difficult in as-cast 42CrMo steel than in forged 42CrMo steel. The research can provide the foundation for the further research of the hot deformation behaviors of the as-cast structure and theoretical support for the new ring casting-rolling compound process.
2012, 26(5).
Abstract:
How to simulate interior aerodynamic noise accurately is an important question of a car interior noise reduction. The unsteady aerodynamic pressure on body surfaces is proved to be the key effect factor of car interior aerodynamic noise control in high frequency on high speed. In this paper, a detail statistical energy analysis (SEA) model is built. And the vibra-acoustic power inputs are loaded on the model for the valid result of car interior noise analysis. The model is the solid foundation for further optimization on car interior noise control. After the most sensitive subsystems for the power contribution to car interior noise are pointed by SEA comprehensive analysis, the sound pressure level of car interior aerodynamic noise can be reduced by improving their sound and damping characteristics. The further vehicle testing results show that it is available to improve the interior acoustic performance by using detailed SEA model, which comprised by more than 80 subsystems, with the unsteady aerodynamic pressure calculation on body surfaces and the materials improvement of sound/damping properties. It is able to acquire more than 2 dB reduction on the central frequency in the spectrum over 800 Hz. The proposed optimization method can be looked as a reference of car interior aerodynamic noise control by the detail SEA model integrated unsteady computational fluid dynamics (CFD) and sensitivity analysis of acoustic contribution.
How to simulate interior aerodynamic noise accurately is an important question of a car interior noise reduction. The unsteady aerodynamic pressure on body surfaces is proved to be the key effect factor of car interior aerodynamic noise control in high frequency on high speed. In this paper, a detail statistical energy analysis (SEA) model is built. And the vibra-acoustic power inputs are loaded on the model for the valid result of car interior noise analysis. The model is the solid foundation for further optimization on car interior noise control. After the most sensitive subsystems for the power contribution to car interior noise are pointed by SEA comprehensive analysis, the sound pressure level of car interior aerodynamic noise can be reduced by improving their sound and damping characteristics. The further vehicle testing results show that it is available to improve the interior acoustic performance by using detailed SEA model, which comprised by more than 80 subsystems, with the unsteady aerodynamic pressure calculation on body surfaces and the materials improvement of sound/damping properties. It is able to acquire more than 2 dB reduction on the central frequency in the spectrum over 800 Hz. The proposed optimization method can be looked as a reference of car interior aerodynamic noise control by the detail SEA model integrated unsteady computational fluid dynamics (CFD) and sensitivity analysis of acoustic contribution.
2012, 26(5).
Abstract:
The hydraulic excavator energy-saving research mainly embodies the following three measures: to improve the performance of diesel engine and hydraulic component, to improve the hydraulic system, and to improve the power matching of diesel-hydraulic system-actuator. Although the above measures have certain energy-saving effect, but because the hydraulic excavator load changes frequently and fluctuates dramatically, so the diesel engine often works in high-speed and light load condition, and the fuel consumption is higher. Therefore, in order to improve the economy of diesel engine in light load, and reduce the fuel consumption of hydraulic excavator, energy management concept is proposed based on diesel engine cylinder deactivation technology. By comparing the universal characteristic under diesel normal and deactivated cylinder condition, the mechanism that fuel consumption can be reduced significantly by adopting cylinder deactivation technology under part of loads condition can be clarified. The simulation models for hydraulic system and diesel engine are established by using AMESim software, and fuel combustion consumption by using cylinder-deactivation-technology is studied through digital simulation approach. In this way, the zone of cylinder deactivation is specified. The testing system for the excavator with this technology is set up based on simulated results, and the results show that the diesel engine can still work at high efficiency with part of loads after adopting this technology; fuel consumption is dropped down to 11% and 13% under economic and heavy-load mode respectively under the condition of driving requirements. The research provides references to the energy-saving study of the hydraulic excavators.
The hydraulic excavator energy-saving research mainly embodies the following three measures: to improve the performance of diesel engine and hydraulic component, to improve the hydraulic system, and to improve the power matching of diesel-hydraulic system-actuator. Although the above measures have certain energy-saving effect, but because the hydraulic excavator load changes frequently and fluctuates dramatically, so the diesel engine often works in high-speed and light load condition, and the fuel consumption is higher. Therefore, in order to improve the economy of diesel engine in light load, and reduce the fuel consumption of hydraulic excavator, energy management concept is proposed based on diesel engine cylinder deactivation technology. By comparing the universal characteristic under diesel normal and deactivated cylinder condition, the mechanism that fuel consumption can be reduced significantly by adopting cylinder deactivation technology under part of loads condition can be clarified. The simulation models for hydraulic system and diesel engine are established by using AMESim software, and fuel combustion consumption by using cylinder-deactivation-technology is studied through digital simulation approach. In this way, the zone of cylinder deactivation is specified. The testing system for the excavator with this technology is set up based on simulated results, and the results show that the diesel engine can still work at high efficiency with part of loads after adopting this technology; fuel consumption is dropped down to 11% and 13% under economic and heavy-load mode respectively under the condition of driving requirements. The research provides references to the energy-saving study of the hydraulic excavators.
2012, 26(5).
Abstract:
The most common booster is called input pressure reduced (IPR) booster. However, this type of booster has its own shortages, such as its small output flow, when the boosting ratio is higher, the shortage becomes more distinct. Recent research on pneumatic boosters mainly focused on the factors that influence the characteristics of the boosters, some new kinds of pneumatic booster structures were designed, but the efficiency and output flow of these boosters are still not improved sufficiently. In order to improve the output flow of the pneumatic booster, a new kind of booster, expansion energy used (EEU) booster, is proposed. Non-linear differential equations of the pneumatic booster are set up. By using the software MATLAB/Simulink for simulation, the motion characteristics of the pistons, the characteristics of the output flow of the boosters are obtained for analysis of a principle. The principle, which is used to elevate the output flow of the two kinds of boosters, is that the average pressure of the air in the driving chambers of the EEU booster is higher than that of the IPR booster. The simulation and experimental research of the output flow characteristics are done. The simulation and experimental results are in a good accordance. And the simulation and experimental results show that when the air source pressure and the output pressure are set at 0.6 MPa and 0.8 MPa, respectively, with the increase of the terminal pressure of the air in the driving chamber, the output flow of the IPR booster ascends stably. As the terminal pressure of the air in the driving chamber goes up, the output flow of the EEU booster rises, and later it almost remains constant. In addition, with the same terminal pressure, the output flow of the EEU booster is greater than that of the IPR booster, and the difference decreases when the terminal pressure grows. At last, the output pressure is set at 0.8 MPa, under the optimum work state of the EEU booster, the output flow of the two kinds of boosters all declines with the rise of the boosting ratio. Furthermore, the output flow of the EEU booster is higher than that of IPR booster by 95 Lmin approximately. The proposed research lays the foundation for optimistic of the EEU booster.
The most common booster is called input pressure reduced (IPR) booster. However, this type of booster has its own shortages, such as its small output flow, when the boosting ratio is higher, the shortage becomes more distinct. Recent research on pneumatic boosters mainly focused on the factors that influence the characteristics of the boosters, some new kinds of pneumatic booster structures were designed, but the efficiency and output flow of these boosters are still not improved sufficiently. In order to improve the output flow of the pneumatic booster, a new kind of booster, expansion energy used (EEU) booster, is proposed. Non-linear differential equations of the pneumatic booster are set up. By using the software MATLAB/Simulink for simulation, the motion characteristics of the pistons, the characteristics of the output flow of the boosters are obtained for analysis of a principle. The principle, which is used to elevate the output flow of the two kinds of boosters, is that the average pressure of the air in the driving chambers of the EEU booster is higher than that of the IPR booster. The simulation and experimental research of the output flow characteristics are done. The simulation and experimental results are in a good accordance. And the simulation and experimental results show that when the air source pressure and the output pressure are set at 0.6 MPa and 0.8 MPa, respectively, with the increase of the terminal pressure of the air in the driving chamber, the output flow of the IPR booster ascends stably. As the terminal pressure of the air in the driving chamber goes up, the output flow of the EEU booster rises, and later it almost remains constant. In addition, with the same terminal pressure, the output flow of the EEU booster is greater than that of the IPR booster, and the difference decreases when the terminal pressure grows. At last, the output pressure is set at 0.8 MPa, under the optimum work state of the EEU booster, the output flow of the two kinds of boosters all declines with the rise of the boosting ratio. Furthermore, the output flow of the EEU booster is higher than that of IPR booster by 95 Lmin approximately. The proposed research lays the foundation for optimistic of the EEU booster.
2012, 26(5).
Abstract:
The design of existing tribometer mainly focuses on normal pressure and environmental conditions, and aims to measure the effect of load and speed on material performance. The effect of gas pressure and environmental condition on performance of materials is usually not considered. Thus, data from friction tests are not precise. In this paper, a new atmosphere tribometer is developed to study the tribological behavior of materials under severe rugged atmosphere. A fail-safe analysis is performed through reproducibility, comparability, and sensitivity tests. The tribometer allows tests to be performed in block-circle disc line contact, pin-circle disc line contact, and block-circle disc face contact configurations at controlled atmosphere and gas pressure. A self-centering plant is designed to settle the poor contact problem. A pin-on-disk test is conducted, and the test results indicate that the proposed design is efficient. A combined sealing style is introduced to control gas leaks. Compared with other sealing styles, the combined sealing is found to meet the experiment requirements best. And the reproducibility, comparability, and sensitivity tests validate the performance of the tribometer. The designed atmosphere tribometer reliably simulates the friction test under extremely harsh conditions, enhances the ability for material tribological properties test, and ensures accuracy of the tribological data.
The design of existing tribometer mainly focuses on normal pressure and environmental conditions, and aims to measure the effect of load and speed on material performance. The effect of gas pressure and environmental condition on performance of materials is usually not considered. Thus, data from friction tests are not precise. In this paper, a new atmosphere tribometer is developed to study the tribological behavior of materials under severe rugged atmosphere. A fail-safe analysis is performed through reproducibility, comparability, and sensitivity tests. The tribometer allows tests to be performed in block-circle disc line contact, pin-circle disc line contact, and block-circle disc face contact configurations at controlled atmosphere and gas pressure. A self-centering plant is designed to settle the poor contact problem. A pin-on-disk test is conducted, and the test results indicate that the proposed design is efficient. A combined sealing style is introduced to control gas leaks. Compared with other sealing styles, the combined sealing is found to meet the experiment requirements best. And the reproducibility, comparability, and sensitivity tests validate the performance of the tribometer. The designed atmosphere tribometer reliably simulates the friction test under extremely harsh conditions, enhances the ability for material tribological properties test, and ensures accuracy of the tribological data.
2012, 26(5).
Abstract:
The existing research of the motion optimization of multi-axis machine tools is mainly based on geometric and kinematic constraints, which aim at obtaining minimum-time trajectories and finding obstacle-free paths. In motion optimization, the stiffness characteristics of the whole machining system, including machine tool and cutter, are not considered. The paper presents a new method to establish a general stiffness model of multi-axis machining system. An analytical stiffness model is established by Jacobi and point transformation matrix method. Based on the stiffness model, feed-direction stiffness index is calculated by the intersection of force ellipsoid and the cutting feed direction at the cutter tip. The stiffness index can help analyze the stiffness performance of the whole machining system in the available workspace. Based on the analysis of the stiffness performance, multi-axis motion optimization along tool paths is accomplished by mixed programming using Matlab and Visual C++. The effectiveness of the motion optimization method is verified by the experimental research about the machining performance of a 7-axis 5-linkage machine tool. The proposed research showed that machining stability and production efficiency can be improved by multi-axis motion optimization based on the anisotropic force ellipsoid of the whole machining system.
The existing research of the motion optimization of multi-axis machine tools is mainly based on geometric and kinematic constraints, which aim at obtaining minimum-time trajectories and finding obstacle-free paths. In motion optimization, the stiffness characteristics of the whole machining system, including machine tool and cutter, are not considered. The paper presents a new method to establish a general stiffness model of multi-axis machining system. An analytical stiffness model is established by Jacobi and point transformation matrix method. Based on the stiffness model, feed-direction stiffness index is calculated by the intersection of force ellipsoid and the cutting feed direction at the cutter tip. The stiffness index can help analyze the stiffness performance of the whole machining system in the available workspace. Based on the analysis of the stiffness performance, multi-axis motion optimization along tool paths is accomplished by mixed programming using Matlab and Visual C++. The effectiveness of the motion optimization method is verified by the experimental research about the machining performance of a 7-axis 5-linkage machine tool. The proposed research showed that machining stability and production efficiency can be improved by multi-axis motion optimization based on the anisotropic force ellipsoid of the whole machining system.
2012, 26(5).
Abstract:
The existing soot models are either too complex and can not be applied to the internal combustion engine, or too simple to make calculation errors. Exploring the soot model becomes the pursuit of the goal of many researchers within the error range in the current computer speed. On the basis of the latest experimental results, TP (temperature phases) model is presented as a new soot model to carry out optimization calculation for a high-pressure common rail diesel engine. Temperature and excess air factor are the most important two parameters in this model. When zone temperature T1 500 K and excess air factor Ф0.6, only the soot precursors—polycyclic aromatic hydrocarbons(PAH) is created and there is no soot emission. When zone temperature T ≥ 1 500 K and excess air factor Ф0.6, PAHs and soot source terms (particle inception, surface growth, oxidation, coagulation) are calculated. The TP model is then implemented in KIVA code instead of original model to carry out optimizing. KIVA standard model and experimental data are analyzed for the results of cylinder pressures, the corresponding heat release rates, and soot with variation of injection time, variation of rail pressure and variation of speed among TP models. The experimental results indicate that the TP model can carry out optimization and computational fluid dynamics can be a tool to calculate for a high-pressure common rail directed injection diesel engine. The TP model result is closer than the use of the original KIVA-3V results of soot model accuracy by about 50% and TP model gives a new method for engine researchers.
The existing soot models are either too complex and can not be applied to the internal combustion engine, or too simple to make calculation errors. Exploring the soot model becomes the pursuit of the goal of many researchers within the error range in the current computer speed. On the basis of the latest experimental results, TP (temperature phases) model is presented as a new soot model to carry out optimization calculation for a high-pressure common rail diesel engine. Temperature and excess air factor are the most important two parameters in this model. When zone temperature T1 500 K and excess air factor Ф0.6, only the soot precursors—polycyclic aromatic hydrocarbons(PAH) is created and there is no soot emission. When zone temperature T ≥ 1 500 K and excess air factor Ф0.6, PAHs and soot source terms (particle inception, surface growth, oxidation, coagulation) are calculated. The TP model is then implemented in KIVA code instead of original model to carry out optimizing. KIVA standard model and experimental data are analyzed for the results of cylinder pressures, the corresponding heat release rates, and soot with variation of injection time, variation of rail pressure and variation of speed among TP models. The experimental results indicate that the TP model can carry out optimization and computational fluid dynamics can be a tool to calculate for a high-pressure common rail directed injection diesel engine. The TP model result is closer than the use of the original KIVA-3V results of soot model accuracy by about 50% and TP model gives a new method for engine researchers.
2012, 26(5).
Abstract:
Straightness error is an important parameter in measuring high-precision shafts. New generation geometrical product specification(GPS) requires the measurement uncertainty characterizing the reliability of the results should be given together when the measurement result is given. Nowadays most researches on straightness focus on error calculation and only several research projects evaluate the measurement uncertainty based on “The Guide to the Expression of Uncertainty in Measurement(GUM)”. In order to compute spatial straightness error(SSE) accurately and rapidly and overcome the limitations of GUM, a quasi particle swarm optimization(QPSO) is proposed to solve the minimum zone SSE and Monte Carlo Method(MCM) is developed to estimate the measurement uncertainty. The mathematical model of minimum zone SSE is formulated. In QPSO quasi-random sequences are applied to the generation of the initial position and velocity of particles and their velocities are modified by the constriction factor approach. The flow of measurement uncertainty evaluation based on MCM is proposed, where the heart is repeatedly sampling from the probability density function(PDF) for every input quantity and evaluating the model in each case. The minimum zone SSE of a shaft measured on a Coordinate Measuring Machine(CMM) is calculated by QPSO and the measurement uncertainty is evaluated by MCM on the basis of analyzing the uncertainty contributors. The results show that the uncertainty directly influences the product judgment result. Therefore it is scientific and reasonable to consider the influence of the uncertainty in judging whether the parts are accepted or rejected, especially for those located in the uncertainty zone. The proposed method is especially suitable when the PDF of the measurand cannot adequately be approximated by a Gaussian distribution or a scaled and shifted t-distribution and the measurement model is non-linear.
Straightness error is an important parameter in measuring high-precision shafts. New generation geometrical product specification(GPS) requires the measurement uncertainty characterizing the reliability of the results should be given together when the measurement result is given. Nowadays most researches on straightness focus on error calculation and only several research projects evaluate the measurement uncertainty based on “The Guide to the Expression of Uncertainty in Measurement(GUM)”. In order to compute spatial straightness error(SSE) accurately and rapidly and overcome the limitations of GUM, a quasi particle swarm optimization(QPSO) is proposed to solve the minimum zone SSE and Monte Carlo Method(MCM) is developed to estimate the measurement uncertainty. The mathematical model of minimum zone SSE is formulated. In QPSO quasi-random sequences are applied to the generation of the initial position and velocity of particles and their velocities are modified by the constriction factor approach. The flow of measurement uncertainty evaluation based on MCM is proposed, where the heart is repeatedly sampling from the probability density function(PDF) for every input quantity and evaluating the model in each case. The minimum zone SSE of a shaft measured on a Coordinate Measuring Machine(CMM) is calculated by QPSO and the measurement uncertainty is evaluated by MCM on the basis of analyzing the uncertainty contributors. The results show that the uncertainty directly influences the product judgment result. Therefore it is scientific and reasonable to consider the influence of the uncertainty in judging whether the parts are accepted or rejected, especially for those located in the uncertainty zone. The proposed method is especially suitable when the PDF of the measurand cannot adequately be approximated by a Gaussian distribution or a scaled and shifted t-distribution and the measurement model is non-linear.
2012, 26(5).
Abstract:
Oil flow through pipe bends is found in many engineering applications. However, up to now, the studies of oil flow field in the pipe bend appear to be relatively sparse, although the oil flow field and the associated losses of pipe bend are very important in practice. In this paper, the relationships between the turbulent flow of hydraulic oil in a bend and the Reynolds number Re and the curvature ratio are studied by using computational fluid dynamics (CFD). A particular emphasis is put on hydraulic oil, which differs from air or water, flowing through 90° circular-sectional bend, with the purpose of determining the turbulent flow characteristics as well as losses. Three turbulence models, namely, RNG k- model, realizable k- model, and Reynolds stress model (RSM), are used respectively. The simulation results in the form of contour and vector plots for all the three turbulence models for pipe bends having curvature ratio of 0.5, and the detailed pressure fields and total pressure losses for different Re and for RSM are presented. The RSM can predict the stronger secondary flow in the bend better than other models. As Re increases, the pressure gradient changes rapidly, and the pressure magnitude increases at inner and outer wall of the bend. When decreases, two transition points or transition zones of pressure gradient arise at inner wall, meanwhile, the transition point moves towards the inlet at outer wall of the bend. Owing to secondary flow, the total pressure loss factor k increases as the bend tightens, on the contrary, as Re increases, factor k decreases due to higher velocity heads, and the rapid change of pressure gradient on the surface of the bend leads to increasing of friction and separation effects, and magnified swirl intensity of secondary flow. A new mathematical model is proposed for predicting pressure loss in terms of Re and in order to provide support to the one-dimensional simulation software. The proposed research provides reference for the analysis of oil flow with higher Re in the large bends.
Oil flow through pipe bends is found in many engineering applications. However, up to now, the studies of oil flow field in the pipe bend appear to be relatively sparse, although the oil flow field and the associated losses of pipe bend are very important in practice. In this paper, the relationships between the turbulent flow of hydraulic oil in a bend and the Reynolds number Re and the curvature ratio are studied by using computational fluid dynamics (CFD). A particular emphasis is put on hydraulic oil, which differs from air or water, flowing through 90° circular-sectional bend, with the purpose of determining the turbulent flow characteristics as well as losses. Three turbulence models, namely, RNG k- model, realizable k- model, and Reynolds stress model (RSM), are used respectively. The simulation results in the form of contour and vector plots for all the three turbulence models for pipe bends having curvature ratio of 0.5, and the detailed pressure fields and total pressure losses for different Re and for RSM are presented. The RSM can predict the stronger secondary flow in the bend better than other models. As Re increases, the pressure gradient changes rapidly, and the pressure magnitude increases at inner and outer wall of the bend. When decreases, two transition points or transition zones of pressure gradient arise at inner wall, meanwhile, the transition point moves towards the inlet at outer wall of the bend. Owing to secondary flow, the total pressure loss factor k increases as the bend tightens, on the contrary, as Re increases, factor k decreases due to higher velocity heads, and the rapid change of pressure gradient on the surface of the bend leads to increasing of friction and separation effects, and magnified swirl intensity of secondary flow. A new mathematical model is proposed for predicting pressure loss in terms of Re and in order to provide support to the one-dimensional simulation software. The proposed research provides reference for the analysis of oil flow with higher Re in the large bends.
2012, 26(5).
Abstract:
Walking is the basic skill of a legged robot, and one of the promising ways to improve the walking performance and its adaptation to environment changes is to let the robot learn its walking by itself. Currently, most of the walking learning methods are based on robot vision system or some external sensing equipment to estimate the walking performance of certain walking parameters, and therefore are usually only applicable under laboratory condition, where environment can be pre-defined. Inspired by the rhythmic swing movement during walking of legged animals and the behavior of their adjusting their walking gait on different walking surfaces, a concept of walking rhythmic pattern(WRP) is proposed to evaluate the walking specialty of legged robot, which is just based on the walking dynamics of the robot. Based on the onboard acceleration sensor data, a method to calculate WRP using power spectrum in frequency domain and diverse smooth filters is also presented. Since the evaluation of WRP is only based on the walking dynamics data of the robot’s body, the proposed method doesn’t require prior knowledge of environment and thus can be applied in unknown environment. A gait learning approach of legged robots based on WRP and evolution algorithm(EA) is introduced. By using the proposed approach, a quadruped robot can learn its locomotion by its onboard sensing in an unknown environment, where the robot has no prior knowledge about this place. The experimental result proves proportional relationship exits between WRP match score and walking performance of legged robot, which can be used to evaluate the walking performance in walking optimization under unknown environment.
Walking is the basic skill of a legged robot, and one of the promising ways to improve the walking performance and its adaptation to environment changes is to let the robot learn its walking by itself. Currently, most of the walking learning methods are based on robot vision system or some external sensing equipment to estimate the walking performance of certain walking parameters, and therefore are usually only applicable under laboratory condition, where environment can be pre-defined. Inspired by the rhythmic swing movement during walking of legged animals and the behavior of their adjusting their walking gait on different walking surfaces, a concept of walking rhythmic pattern(WRP) is proposed to evaluate the walking specialty of legged robot, which is just based on the walking dynamics of the robot. Based on the onboard acceleration sensor data, a method to calculate WRP using power spectrum in frequency domain and diverse smooth filters is also presented. Since the evaluation of WRP is only based on the walking dynamics data of the robot’s body, the proposed method doesn’t require prior knowledge of environment and thus can be applied in unknown environment. A gait learning approach of legged robots based on WRP and evolution algorithm(EA) is introduced. By using the proposed approach, a quadruped robot can learn its locomotion by its onboard sensing in an unknown environment, where the robot has no prior knowledge about this place. The experimental result proves proportional relationship exits between WRP match score and walking performance of legged robot, which can be used to evaluate the walking performance in walking optimization under unknown environment.
2012, 26(5).
Abstract:
The dynamic characteristic parameters of Up-time of Flight Counter (U-ToFC) are important for research of structure optimization and reliability. However, the current simulation is performed based on homogenous material and simplified constraint model, the correct and reliability of results are difficult to be guaranteed. The finite element method based on identification of material parameters is proposed for this investigation on dynamic analysis, simulation and vibration experiment of the U-ToFC. The structure of the U-ToFC is complicated. Its’ outside is made of aluminum alloy and inside contains electronic components such as capacitors, resistors, inductors, and integrated circuits. The accurate material parameters of model are identified difficultly. Hence, the parameters identification tests are performed to obtain the material parameters of this structure. On the basis of the above parameters, the experiment and FEA are conducted to the U-ToFC. In terms of the flight acceptance test level, and two kinds of joints condition between the U-ToFC and fixture are considered. The natural frequencies, vibration shapes and the response of the power spectral density of the U-ToFC are obtained. The results show simulation which is based on parameters identification is similar with vibration experiment in natural frequencies and responses. The errors are less than 10% . The vibration modes of simulation and experiment are consistent. The paper provides a more reliable computing method for the dynamic characteristic analysis of large complicated structure.
The dynamic characteristic parameters of Up-time of Flight Counter (U-ToFC) are important for research of structure optimization and reliability. However, the current simulation is performed based on homogenous material and simplified constraint model, the correct and reliability of results are difficult to be guaranteed. The finite element method based on identification of material parameters is proposed for this investigation on dynamic analysis, simulation and vibration experiment of the U-ToFC. The structure of the U-ToFC is complicated. Its’ outside is made of aluminum alloy and inside contains electronic components such as capacitors, resistors, inductors, and integrated circuits. The accurate material parameters of model are identified difficultly. Hence, the parameters identification tests are performed to obtain the material parameters of this structure. On the basis of the above parameters, the experiment and FEA are conducted to the U-ToFC. In terms of the flight acceptance test level, and two kinds of joints condition between the U-ToFC and fixture are considered. The natural frequencies, vibration shapes and the response of the power spectral density of the U-ToFC are obtained. The results show simulation which is based on parameters identification is similar with vibration experiment in natural frequencies and responses. The errors are less than 10% . The vibration modes of simulation and experiment are consistent. The paper provides a more reliable computing method for the dynamic characteristic analysis of large complicated structure.
2012, 26(5).
Abstract:
The traditional method of mechanical gear driving simulation includes gear pair method and solid to solid contact method. The former has higher solving efficiency but lower results accuracy; the latter usually obtains higher precision of results while the calculation process is complex, also it is not easy to converge. Currently, most of the researches are focused on the description of geometric models and the definition of boundary conditions. However, none of them can solve the problems fundamentally. To improve the simulation efficiency while ensure the results with high accuracy, a mixed model method which uses gear tooth profiles to take the place of the solid gear to simulate gear movement is presented under these circumstances. In the process of modeling, build the solid models of the mechanism in the SolidWorks firstly; Then collect the point coordinates of outline curves of the gear using SolidWorks API and create fit curves in Adams based on the point coordinates; Next, adjust the position of those fitting curves according to the position of the contact area; Finally, define the loading conditions, boundary conditions and simulation parameters. The method provides gear shape information by tooth profile curves; simulates the mesh process through tooth profile curve to curve contact and offer mass as well as inertia data via solid gear models. This simulation process combines the two models to complete the gear driving analysis. In order to verify the validity of the method presented, both theoretical derivation and numerical simulation on a runaway escapement are conducted. The results show that the computational efficiency of the mixed model method is 1.4 times over the traditional method which contains solid to solid contact. Meanwhile, the simulation results are more closely to theoretical calculations. Consequently, mixed model method has a high application value regarding to the study of the dynamics of gear mechanism.
The traditional method of mechanical gear driving simulation includes gear pair method and solid to solid contact method. The former has higher solving efficiency but lower results accuracy; the latter usually obtains higher precision of results while the calculation process is complex, also it is not easy to converge. Currently, most of the researches are focused on the description of geometric models and the definition of boundary conditions. However, none of them can solve the problems fundamentally. To improve the simulation efficiency while ensure the results with high accuracy, a mixed model method which uses gear tooth profiles to take the place of the solid gear to simulate gear movement is presented under these circumstances. In the process of modeling, build the solid models of the mechanism in the SolidWorks firstly; Then collect the point coordinates of outline curves of the gear using SolidWorks API and create fit curves in Adams based on the point coordinates; Next, adjust the position of those fitting curves according to the position of the contact area; Finally, define the loading conditions, boundary conditions and simulation parameters. The method provides gear shape information by tooth profile curves; simulates the mesh process through tooth profile curve to curve contact and offer mass as well as inertia data via solid gear models. This simulation process combines the two models to complete the gear driving analysis. In order to verify the validity of the method presented, both theoretical derivation and numerical simulation on a runaway escapement are conducted. The results show that the computational efficiency of the mixed model method is 1.4 times over the traditional method which contains solid to solid contact. Meanwhile, the simulation results are more closely to theoretical calculations. Consequently, mixed model method has a high application value regarding to the study of the dynamics of gear mechanism.
Discrete Artificial Bee Colony Algorithm for Lot-streaming Flowshop with Total Flowtime Minimization
2012, 26(5).
Abstract:
Unlike a traditional flowshop problem where a job is assumed to be indivisible, in the lot-streaming flowshop problem, a job is allowed to overlap its operations between successive machines by splitting it into a number of smaller sub-lots and moving the completed portion of the sub-lots to downstream machine. In this way, the production is accelerated. This paper presents a discrete artificial bee colony (DABC) algorithm for a lot-streaming flowshop scheduling problem with total flowtime criterion. Unlike the basic ABC algorithm, the proposed DABC algorithm represents a solution as a discrete job permutation. An efficient initialization scheme based on the extended Nawaz-Enscore-Ham heuristic is utilized to produce an initial population with a certain level of quality and diversity. Employed and onlooker bees generate new solutions in their neighborhood, whereas scout bees generate new solutions by performing insert operator and swap operator to the best solution found so far. Moreover, a simple but effective local search is embedded in the algorithm to enhance local exploitation capability. A comparative experiment is carried out with the existing discrete particle swarm optimization, hybrid genetic algorithm, threshold accepting, simulated annealing and ant colony optimization algorithms based on a total of 160 randomly generated instances. The experimental results show that the proposed DABC algorithm is quite effective for the lot-streaming flowshop with total flowtime criterion in terms of searching quality, robustness and effectiveness. This research provides the references to the optimization research on lot-streaming flowshop.
Unlike a traditional flowshop problem where a job is assumed to be indivisible, in the lot-streaming flowshop problem, a job is allowed to overlap its operations between successive machines by splitting it into a number of smaller sub-lots and moving the completed portion of the sub-lots to downstream machine. In this way, the production is accelerated. This paper presents a discrete artificial bee colony (DABC) algorithm for a lot-streaming flowshop scheduling problem with total flowtime criterion. Unlike the basic ABC algorithm, the proposed DABC algorithm represents a solution as a discrete job permutation. An efficient initialization scheme based on the extended Nawaz-Enscore-Ham heuristic is utilized to produce an initial population with a certain level of quality and diversity. Employed and onlooker bees generate new solutions in their neighborhood, whereas scout bees generate new solutions by performing insert operator and swap operator to the best solution found so far. Moreover, a simple but effective local search is embedded in the algorithm to enhance local exploitation capability. A comparative experiment is carried out with the existing discrete particle swarm optimization, hybrid genetic algorithm, threshold accepting, simulated annealing and ant colony optimization algorithms based on a total of 160 randomly generated instances. The experimental results show that the proposed DABC algorithm is quite effective for the lot-streaming flowshop with total flowtime criterion in terms of searching quality, robustness and effectiveness. This research provides the references to the optimization research on lot-streaming flowshop.
2012, 26(5).
Abstract:
The existing research on dynamics and slip ratio of wheeled mobile robot (WMR) are derived without considering the effect of height, and the existing models can not be used to analyze the dynamics performance of the robot with variable height while moving such as NOROS-Ⅱ. The existing method of dynamics modeling is improved by adding the constraint equation between perpendicular displacement of body and horizontal displacement of wheel into the constraint conditions. The dynamic model of NOROS–Ⅱ in wheel motion is built by the Lagrange method under nonholonomic constraints. The inverse dynamics is calculated in three different paths based on this model, and the results demonstrate that torques of hip pitching joints are inversely proportional to the height of robot. The relative error of calculated torques is less than 2% compared with that of ADAMS simulation, by which the validity of dynamic model is verified. Moreover, the relative horizontal motion between forehind wheels and body is produced when the height is changed, and thus the accurate slip ratio can not be obtained by the traditional equation. The improved slip ratio equations with the parameter of the vertical velocity of body are introduced for fore wheels and hind wheels respectively. Numerical simulations of slip ratios are conducted to reveal the effect of varied height on slip ratios of different wheels. The result shows that the slip ratios of forehind wheels become largersmaller respectively as the height increases, and as the height is reduced, the reverse applies. The proposed research of dynamic model and slip ratio based on the robot height provides the effective method to analyze the dynamics of WMRs with varying height.
The existing research on dynamics and slip ratio of wheeled mobile robot (WMR) are derived without considering the effect of height, and the existing models can not be used to analyze the dynamics performance of the robot with variable height while moving such as NOROS-Ⅱ. The existing method of dynamics modeling is improved by adding the constraint equation between perpendicular displacement of body and horizontal displacement of wheel into the constraint conditions. The dynamic model of NOROS–Ⅱ in wheel motion is built by the Lagrange method under nonholonomic constraints. The inverse dynamics is calculated in three different paths based on this model, and the results demonstrate that torques of hip pitching joints are inversely proportional to the height of robot. The relative error of calculated torques is less than 2% compared with that of ADAMS simulation, by which the validity of dynamic model is verified. Moreover, the relative horizontal motion between forehind wheels and body is produced when the height is changed, and thus the accurate slip ratio can not be obtained by the traditional equation. The improved slip ratio equations with the parameter of the vertical velocity of body are introduced for fore wheels and hind wheels respectively. Numerical simulations of slip ratios are conducted to reveal the effect of varied height on slip ratios of different wheels. The result shows that the slip ratios of forehind wheels become largersmaller respectively as the height increases, and as the height is reduced, the reverse applies. The proposed research of dynamic model and slip ratio based on the robot height provides the effective method to analyze the dynamics of WMRs with varying height.
2012, 26(5).
Abstract:
An efficient prediction mechanical performance of coating structures has been a constant concern since the dawn of surface engineering. However, predictive models presented by initial research are normally based on traditional solid mechanics, and thus cannot predict coating performance accurately. Also, the high computational costs that originate from the exclusive structure of surface coating systems (a big difference in the order of coating and substrate) are not well addressed by these models. To fill the needs for accurate prediction and low computational costs, a multi-axial continuum damage mechanics (CDM)-based constitutive model is introduced for the investigation of the load bearing capacity and fracture properties of coatings. Material parameters within the proposed constitutive model are determined for a typical coating (TiN) and substrate (Cu) system. An efficient numerical subroutine is developed to implement the determined constitutive model into the commercial FE solver, ABAQUS, through the user-defined subroutine, VUMAT. By changing the geometrical sizes of FE models, a series of computations are carried out to investigate (1) loading features, (2) stress distributions, and (3) failure features of the coating system. The results show that there is a critical displacement corresponding to each FE model size, and only if the applied normal loading displacement is smaller than the critical displacement, a reasonable prediction can be achieved. Finally, a 3D map of the critical displacement is generated to provide guidance for users to determine an FE model with suitable geometrical size for surface coating simulations. This paper presents an effective modelling approach for the prediction of mechanical performance of surface coatings.
An efficient prediction mechanical performance of coating structures has been a constant concern since the dawn of surface engineering. However, predictive models presented by initial research are normally based on traditional solid mechanics, and thus cannot predict coating performance accurately. Also, the high computational costs that originate from the exclusive structure of surface coating systems (a big difference in the order of coating and substrate) are not well addressed by these models. To fill the needs for accurate prediction and low computational costs, a multi-axial continuum damage mechanics (CDM)-based constitutive model is introduced for the investigation of the load bearing capacity and fracture properties of coatings. Material parameters within the proposed constitutive model are determined for a typical coating (TiN) and substrate (Cu) system. An efficient numerical subroutine is developed to implement the determined constitutive model into the commercial FE solver, ABAQUS, through the user-defined subroutine, VUMAT. By changing the geometrical sizes of FE models, a series of computations are carried out to investigate (1) loading features, (2) stress distributions, and (3) failure features of the coating system. The results show that there is a critical displacement corresponding to each FE model size, and only if the applied normal loading displacement is smaller than the critical displacement, a reasonable prediction can be achieved. Finally, a 3D map of the critical displacement is generated to provide guidance for users to determine an FE model with suitable geometrical size for surface coating simulations. This paper presents an effective modelling approach for the prediction of mechanical performance of surface coatings.
2012, 26(5).
Abstract:
The conventional prediction of milling stability has been extensively studied based on the assumptions that the milling process dynamics is time invariant. However, nominal cutting parameters cannot guarantee the stability of milling process at the shop floor level since there exists many uncertain factors in a practical manufacturing environment. This paper proposes a novel numerical method to estimate the upper and lower bounds of Lobe diagram, which is used to predict the milling stability in a robust way by taking into account the uncertain parameters of milling system. Time finite element method, a milling stability theory is adopted as the conventional deterministic model. The uncertain dynamics parameters are dealt with by the non-probabilistic model in which the parameters with uncertainties are assumed to be bounded and there is no need for probabilistic distribution densities functions. By doing so, interval instead of deterministic stability Lobe is obtained, which guarantees the stability of milling process in an uncertain milling environment. In the simulations, the upper and lower bounds of Lobe diagram obtained by the changes of modal parameters of spindle-tool system and cutting coefficients are given, respectively. The simulation results show that the proposed method is effective and can obtain satisfying bounds of Lobe diagrams. The proposed method is helpful for researchers at shop floor to making decision on machining parameters selection.
The conventional prediction of milling stability has been extensively studied based on the assumptions that the milling process dynamics is time invariant. However, nominal cutting parameters cannot guarantee the stability of milling process at the shop floor level since there exists many uncertain factors in a practical manufacturing environment. This paper proposes a novel numerical method to estimate the upper and lower bounds of Lobe diagram, which is used to predict the milling stability in a robust way by taking into account the uncertain parameters of milling system. Time finite element method, a milling stability theory is adopted as the conventional deterministic model. The uncertain dynamics parameters are dealt with by the non-probabilistic model in which the parameters with uncertainties are assumed to be bounded and there is no need for probabilistic distribution densities functions. By doing so, interval instead of deterministic stability Lobe is obtained, which guarantees the stability of milling process in an uncertain milling environment. In the simulations, the upper and lower bounds of Lobe diagram obtained by the changes of modal parameters of spindle-tool system and cutting coefficients are given, respectively. The simulation results show that the proposed method is effective and can obtain satisfying bounds of Lobe diagrams. The proposed method is helpful for researchers at shop floor to making decision on machining parameters selection.
2012, 26(5).
Abstract:
The cutting force prediction is essential to optimize the process parameters of machining such as feed rate optimization, etc. Due to the significant influences of the runout effect on cutting force variation in milling process, it is necessary to incorporate the cutter runout parameters into the prediction model of cutting forces. However, the determination of cutter runout parameters is still a challenge task until now. In this paper, cutting process geometry models, such as uncut chip thickness and pitch angle, are established based on the true trajectory of the cutting edge considering the cutter runout effect. A new algorithm is then presented to compute the cutter runout parameters for flat-end mill utilizing the sampled data of cutting forces and derived process geometry parameters. Further, three-axis and five-axis milling experiments were conducted on a machining centre, and resulting cutting forces were sampled by a three-component dynamometer. After computing the corresponding cutter runout parameters, cutter forces are simulated embracing the cutter runout parameters obtained from the proposed algorithm. The predicted cutting forces show good agreements with the sampled data both in magnitude and shape, which validates the feasibility and effectivity of the proposed new algorithm of determining cutter runout parameters and the new way to accurately predict cutting forces. The proposed method for computing the cutter runout parameters provides the significant references for the cutting force prediction in the cutting process.
The cutting force prediction is essential to optimize the process parameters of machining such as feed rate optimization, etc. Due to the significant influences of the runout effect on cutting force variation in milling process, it is necessary to incorporate the cutter runout parameters into the prediction model of cutting forces. However, the determination of cutter runout parameters is still a challenge task until now. In this paper, cutting process geometry models, such as uncut chip thickness and pitch angle, are established based on the true trajectory of the cutting edge considering the cutter runout effect. A new algorithm is then presented to compute the cutter runout parameters for flat-end mill utilizing the sampled data of cutting forces and derived process geometry parameters. Further, three-axis and five-axis milling experiments were conducted on a machining centre, and resulting cutting forces were sampled by a three-component dynamometer. After computing the corresponding cutter runout parameters, cutter forces are simulated embracing the cutter runout parameters obtained from the proposed algorithm. The predicted cutting forces show good agreements with the sampled data both in magnitude and shape, which validates the feasibility and effectivity of the proposed new algorithm of determining cutter runout parameters and the new way to accurately predict cutting forces. The proposed method for computing the cutter runout parameters provides the significant references for the cutting force prediction in the cutting process.
2012, 26(5).
Abstract:
Highly versatile machines, such as wheel loaders, forklifts, and mining haulers, are subject to many kinds of working conditions, as well as indefinite factors that lead to the complexity of the load. The load probability distribution function (PDF) of transmission gears has many distributions centers; thus, its PDF cannot be well represented by just a single-peak function. For the purpose of representing the distribution characteristics of the complicated phenomenon accurately, this paper proposes a novel method to establish a mixture model. Based on linear regression models and correlation coefficients, the proposed method can be used to automatically select the best-fitting function in the mixture model. Coefficient of determination, the mean square error, and the maximum deviation are chosen and then used as judging criteria to describe the fitting precision between the theoretical distribution and the corresponding histogram of the available load data. The applicability of this modeling method is illustrated by the field testing data of a wheel loader. Meanwhile, the load spectra based on the mixture model are compiled. The comparison results show that the mixture model is more suitable for the description of the load-distribution characteristics. The proposed research improves the flexibility and intelligence of modeling, reduces the statistical error and enhances the fitting accuracy, and the load spectra complied by this method can better reflect the actual load characteristic of the gear component.
Highly versatile machines, such as wheel loaders, forklifts, and mining haulers, are subject to many kinds of working conditions, as well as indefinite factors that lead to the complexity of the load. The load probability distribution function (PDF) of transmission gears has many distributions centers; thus, its PDF cannot be well represented by just a single-peak function. For the purpose of representing the distribution characteristics of the complicated phenomenon accurately, this paper proposes a novel method to establish a mixture model. Based on linear regression models and correlation coefficients, the proposed method can be used to automatically select the best-fitting function in the mixture model. Coefficient of determination, the mean square error, and the maximum deviation are chosen and then used as judging criteria to describe the fitting precision between the theoretical distribution and the corresponding histogram of the available load data. The applicability of this modeling method is illustrated by the field testing data of a wheel loader. Meanwhile, the load spectra based on the mixture model are compiled. The comparison results show that the mixture model is more suitable for the description of the load-distribution characteristics. The proposed research improves the flexibility and intelligence of modeling, reduces the statistical error and enhances the fitting accuracy, and the load spectra complied by this method can better reflect the actual load characteristic of the gear component.
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