2013 Vol.26(2)
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2013, 27(2).
Abstract:
Multiple crack identification plays an important role in vibration-based crack identification of structures. Traditional crack detection method of single crack is difficult to be used in multiple crack diagnosis. A three-step-meshing method for the multiple cracks identification in structures is presented. Firstly, the changes in natural frequency of a structure with various crack locations and depth are accurately obtained by means of wavelet finite element method, and then the damage coefficient method is used to determine the number and the region of cracks. Secondly, different regions in the cracked structure are divided into meshes with different scales, and then the small unit containing cracks in the damaged area is gradually located by iterative computation. Lastly, by finding the points of intersection of three frequency contour lines in the small unit, the crack location and depth are identified. In order to verify the effectiveness of the presented method, a multiple cracks identification experiment is carried out. The diagnostic tests on a cantilever beam under two working conditions show the accuracy of the proposed method: with a maximum error of crack location identification 2.7% and of depth identification 5.2%. The method is able to detect multiple crack of beam with less subdivision and higher precision, and can be developed as a multiple crack detection approach for complicated structures.
Multiple crack identification plays an important role in vibration-based crack identification of structures. Traditional crack detection method of single crack is difficult to be used in multiple crack diagnosis. A three-step-meshing method for the multiple cracks identification in structures is presented. Firstly, the changes in natural frequency of a structure with various crack locations and depth are accurately obtained by means of wavelet finite element method, and then the damage coefficient method is used to determine the number and the region of cracks. Secondly, different regions in the cracked structure are divided into meshes with different scales, and then the small unit containing cracks in the damaged area is gradually located by iterative computation. Lastly, by finding the points of intersection of three frequency contour lines in the small unit, the crack location and depth are identified. In order to verify the effectiveness of the presented method, a multiple cracks identification experiment is carried out. The diagnostic tests on a cantilever beam under two working conditions show the accuracy of the proposed method: with a maximum error of crack location identification 2.7% and of depth identification 5.2%. The method is able to detect multiple crack of beam with less subdivision and higher precision, and can be developed as a multiple crack detection approach for complicated structures.
2013, 27(2).
Abstract:
The research activities of the calculation of the elastic constants of metal are mainly focused on the elastic constants of crystal at the micro level. To the calculation of the macroscopic elastic constants of metal, although molecular dynamics method and quasicontinuum method can be used, but there are shortcomings in them, such as a large amount of computation and that the spatial scale of the study model is limited. Therefore, with a pure metal thin plate composed of a single layer of microscopic particles as research object, a new mechanical model is established after the interactions between microscopic particles of the thin plate are applied on the continuum mechanics model of the thin plate. According to this model, the calculation formulas for the microscopic elastic constants, which are the elastic constants of any triangle region in the model, are obtained. After the concept of the ideal micro structure is presented, the calculation formulas for the macroscopic elastic constants, the elastic modulus and the Poissons ratio of pure metal are obtained, where the Poissons ratio is the constant that is equal to 13. As an example, the elastic constants and the elastic modulus of pure copper are solved, where c11 is 175.811 GPa, c12 is 58.604 GPa, c33 is 58.604 GPa and E is 156.277 GPa, the rationality and the correctness of the model are verified. The model presented fully embodies the discreteness of the microstructure of solid, is a development to the continuum model, and is more suitable to reality, more simplified and more new to the study of the macroscopic elastic constants of pure metal.
The research activities of the calculation of the elastic constants of metal are mainly focused on the elastic constants of crystal at the micro level. To the calculation of the macroscopic elastic constants of metal, although molecular dynamics method and quasicontinuum method can be used, but there are shortcomings in them, such as a large amount of computation and that the spatial scale of the study model is limited. Therefore, with a pure metal thin plate composed of a single layer of microscopic particles as research object, a new mechanical model is established after the interactions between microscopic particles of the thin plate are applied on the continuum mechanics model of the thin plate. According to this model, the calculation formulas for the microscopic elastic constants, which are the elastic constants of any triangle region in the model, are obtained. After the concept of the ideal micro structure is presented, the calculation formulas for the macroscopic elastic constants, the elastic modulus and the Poissons ratio of pure metal are obtained, where the Poissons ratio is the constant that is equal to 13. As an example, the elastic constants and the elastic modulus of pure copper are solved, where c11 is 175.811 GPa, c12 is 58.604 GPa, c33 is 58.604 GPa and E is 156.277 GPa, the rationality and the correctness of the model are verified. The model presented fully embodies the discreteness of the microstructure of solid, is a development to the continuum model, and is more suitable to reality, more simplified and more new to the study of the macroscopic elastic constants of pure metal.
2013, 27(2).
Abstract:
Content-based 3D model retrieval is of great help to facilitate the reuse of existing designs and to inspire designers during conceptual design. However, there is still a gap to apply it in industry due to the low time efficiency. This paper presents two new methods with high efficiency to build a Content-based 3D model retrieval system. First, an improvement is made on the “Shape Distribution (D2)” algorithm, and a new algorithm named “Quick D2” is proposed. Four sample 3D mechanical models are used in an experiment to compare the time cost of the two algorithms. The result indicates that the time cost of Quick D2 is much lower than that of D2, while the descriptors extracted by the two algorithms are almost the same. Second, an expandable 3D model repository index method with high performance, namely, RBK index, is presented. On the basis of RBK index, the search space is pruned effectively during the search process, leading to a speed up of the whole system. The factors that influence the values of the key parameters of RBK index are discussed and an experimental method to find the optimal values of the key parameters is given. Finally, “3D Searcher”, a content-based 3D model retrieval system is developed. By using the methods proposed, the time cost for the system to respond one query online is reduced by 75% on average. The system has been implemented in a manufacturing enterprise, and practical query examples during a case of the automobile rear axle design are also shown. The research method presented shows a new research perspective and can effectively improve the content-based 3D model retrieval efficiency.
Content-based 3D model retrieval is of great help to facilitate the reuse of existing designs and to inspire designers during conceptual design. However, there is still a gap to apply it in industry due to the low time efficiency. This paper presents two new methods with high efficiency to build a Content-based 3D model retrieval system. First, an improvement is made on the “Shape Distribution (D2)” algorithm, and a new algorithm named “Quick D2” is proposed. Four sample 3D mechanical models are used in an experiment to compare the time cost of the two algorithms. The result indicates that the time cost of Quick D2 is much lower than that of D2, while the descriptors extracted by the two algorithms are almost the same. Second, an expandable 3D model repository index method with high performance, namely, RBK index, is presented. On the basis of RBK index, the search space is pruned effectively during the search process, leading to a speed up of the whole system. The factors that influence the values of the key parameters of RBK index are discussed and an experimental method to find the optimal values of the key parameters is given. Finally, “3D Searcher”, a content-based 3D model retrieval system is developed. By using the methods proposed, the time cost for the system to respond one query online is reduced by 75% on average. The system has been implemented in a manufacturing enterprise, and practical query examples during a case of the automobile rear axle design are also shown. The research method presented shows a new research perspective and can effectively improve the content-based 3D model retrieval efficiency.
2013, 27(2).
Abstract:
Autofrettage is an effective measure to even distribution of stresses and raise load-bearing capacity for (ultra-)high pressure apparatus. Currently, the research on autofrettage has focused mostly on specific engineering problems, while general theoretical study is rarely done. To discover the general law contained in autofrettage theory, by the aid of the authors’ previous work and according to the third strength theory, theoretical problems about autofrettage are studied including residual stresses and their equivalent stress, total stresses and their equivalent stress, etc. Because of the equation of optimum depth of plastic zone which is presented in the authors’ previous work, the equations for the residual stresses and their equivalent stress as well as the total stress and their equivalent stress are simplified greatly. Thus the law of distribution of the residual stresses and their equivalent stress as well as the total stress and their equivalent stress and the varying tendency of these stresses are discovered. The relation among various parameters are revealed. The safe and optimum load-bearing conditions for cylinders are obtained. According to the results obtained by theoretical analysis, it is shown that if the two parameters, namely ratio of outside to inside radius, k, and depth of plastic zone, kj, meet the equation of optimum depth of plastic zone, when the pressure contained in an autofrettaged cylinder is lower than two times the initial yield pressure of the unautofrettaged cylinder, the equivalent residual stress and the equivalent total stress at the inside surface as well as the elastic-plastic juncture of a cylinder are lower than yield strength. When an autofrettaged cylinder is subjected to just two times the initial yield pressure of the unautofrettaged cylinder, the equivalent total stress within the whole plastic zone is just identically equal to the yield strength, or it is a constant. The proposed research theoretically depicts the stress state of ultra-)high pressure autofrettaged cylinder more accurately and more reasonably and provides the reference for design of (ultra-)high pressure apparatus.
Autofrettage is an effective measure to even distribution of stresses and raise load-bearing capacity for (ultra-)high pressure apparatus. Currently, the research on autofrettage has focused mostly on specific engineering problems, while general theoretical study is rarely done. To discover the general law contained in autofrettage theory, by the aid of the authors’ previous work and according to the third strength theory, theoretical problems about autofrettage are studied including residual stresses and their equivalent stress, total stresses and their equivalent stress, etc. Because of the equation of optimum depth of plastic zone which is presented in the authors’ previous work, the equations for the residual stresses and their equivalent stress as well as the total stress and their equivalent stress are simplified greatly. Thus the law of distribution of the residual stresses and their equivalent stress as well as the total stress and their equivalent stress and the varying tendency of these stresses are discovered. The relation among various parameters are revealed. The safe and optimum load-bearing conditions for cylinders are obtained. According to the results obtained by theoretical analysis, it is shown that if the two parameters, namely ratio of outside to inside radius, k, and depth of plastic zone, kj, meet the equation of optimum depth of plastic zone, when the pressure contained in an autofrettaged cylinder is lower than two times the initial yield pressure of the unautofrettaged cylinder, the equivalent residual stress and the equivalent total stress at the inside surface as well as the elastic-plastic juncture of a cylinder are lower than yield strength. When an autofrettaged cylinder is subjected to just two times the initial yield pressure of the unautofrettaged cylinder, the equivalent total stress within the whole plastic zone is just identically equal to the yield strength, or it is a constant. The proposed research theoretically depicts the stress state of ultra-)high pressure autofrettaged cylinder more accurately and more reasonably and provides the reference for design of (ultra-)high pressure apparatus.
2013, 27(2).
Abstract:
The existing research of supply coordination under uncertain delivery time mainly focuses on the collaboration between the supplier and the manufacturer, which aim at minimizing the total cost of each side and finding comparative optimal solutions under decentralized decision. In the supply coordination, the collaboration between suppliers in assembly system is usually not considered. As a result, the manufacturer’s production is often delayed due to mismatching delivery of components between suppliers. Therefore, to ensure supply coordination in assembly system, collaboration between suppliers should be taken into consideration. In this paper, an assembly system with two suppliers and one manufacturer under uncertain delivery time is considered. The model is established and optimal solution is given under decentralized decision. Furthermore, the cost functions of two suppliers are both convex, and a unique Nash equilibrium exists between two suppliers. Then the optimal decision under supply coordination is analyzed, which is regarded as a benchmark for supply coordination. Additionally, the total cost of the assembly system is jointly convex in agreed delivery time. To achieve supply coordination a bonus policy is explored in the assembly system under uncertain delivery time, and the total cost under bonus policy must be lower than under decentralized decision. Finally the numerical and sensitivity analysis shows the cost of assembly system under bonus policy equals that under supply coordination, and the cost of each side in assembly system under bonus policy is lower compared to that under decentralized decision. The proposed research minimizes the total cost of each side with bonus policy in assembly system, ensures the supply coordination between suppliers and the manufacturer, and improves the competiveness of the whole supply chain.
The existing research of supply coordination under uncertain delivery time mainly focuses on the collaboration between the supplier and the manufacturer, which aim at minimizing the total cost of each side and finding comparative optimal solutions under decentralized decision. In the supply coordination, the collaboration between suppliers in assembly system is usually not considered. As a result, the manufacturer’s production is often delayed due to mismatching delivery of components between suppliers. Therefore, to ensure supply coordination in assembly system, collaboration between suppliers should be taken into consideration. In this paper, an assembly system with two suppliers and one manufacturer under uncertain delivery time is considered. The model is established and optimal solution is given under decentralized decision. Furthermore, the cost functions of two suppliers are both convex, and a unique Nash equilibrium exists between two suppliers. Then the optimal decision under supply coordination is analyzed, which is regarded as a benchmark for supply coordination. Additionally, the total cost of the assembly system is jointly convex in agreed delivery time. To achieve supply coordination a bonus policy is explored in the assembly system under uncertain delivery time, and the total cost under bonus policy must be lower than under decentralized decision. Finally the numerical and sensitivity analysis shows the cost of assembly system under bonus policy equals that under supply coordination, and the cost of each side in assembly system under bonus policy is lower compared to that under decentralized decision. The proposed research minimizes the total cost of each side with bonus policy in assembly system, ensures the supply coordination between suppliers and the manufacturer, and improves the competiveness of the whole supply chain.
2013, 27(2).
Abstract:
The vacuum sanitation is the safe and sound disposal approach of human excreta under the specific environments like flights, high speed trains and submarines. However, the propulsive force of current systems is not adjustable and the energy consumption does not adapt to the real time sewerage requirement. Therefore, it is important to study the sewerage force adjustment to improve the energy efficiency. This paper proposes an energy conservation design in vacuum sanitation systems with pneumatic ejector circuits. The sewerage force is controlled by changing the systematic vacuum degree according to the amount of the excreta. In particular, the amount of the excreta is tested by liquid level sensor and mass sensor. According to the amount of the excreta, the relationship between the excreta amount and the sewerage force is studied to provide proper propulsive force. In the other aspect, to provide variable vacuum degrees for different sanitation requirements, the suction and discharge system is designed with pneumatic vacuum ejector. On the basis of the static flow-rate characteristics and the vacuum generation model, the pressure response in the ejector circuit is studied by using the static flow rate characteristics of the ejector and air status equation. The relationship is obtained between supplied compressed air and systematic vacuum degree. When the compressed air is supplied to the ejector continuously, the systematic vacuum degree increases until the vacuum degree reaches the extreme value. Therefore, the variable systematic vacuum degree is obtained by controlling the compressed air supply of the ejector. To verify the effect of energy conservation, experiments are carried out in the artificial excreta collection, and the variable vacuum-degree design saves more than 30% of the energy supply. The energy conservation is realized effectively in the new vacuum sanitation systems with good application prospect. The proposed technology provides technological support for the energy conservation of vacuum sanitation systems.
The vacuum sanitation is the safe and sound disposal approach of human excreta under the specific environments like flights, high speed trains and submarines. However, the propulsive force of current systems is not adjustable and the energy consumption does not adapt to the real time sewerage requirement. Therefore, it is important to study the sewerage force adjustment to improve the energy efficiency. This paper proposes an energy conservation design in vacuum sanitation systems with pneumatic ejector circuits. The sewerage force is controlled by changing the systematic vacuum degree according to the amount of the excreta. In particular, the amount of the excreta is tested by liquid level sensor and mass sensor. According to the amount of the excreta, the relationship between the excreta amount and the sewerage force is studied to provide proper propulsive force. In the other aspect, to provide variable vacuum degrees for different sanitation requirements, the suction and discharge system is designed with pneumatic vacuum ejector. On the basis of the static flow-rate characteristics and the vacuum generation model, the pressure response in the ejector circuit is studied by using the static flow rate characteristics of the ejector and air status equation. The relationship is obtained between supplied compressed air and systematic vacuum degree. When the compressed air is supplied to the ejector continuously, the systematic vacuum degree increases until the vacuum degree reaches the extreme value. Therefore, the variable systematic vacuum degree is obtained by controlling the compressed air supply of the ejector. To verify the effect of energy conservation, experiments are carried out in the artificial excreta collection, and the variable vacuum-degree design saves more than 30% of the energy supply. The energy conservation is realized effectively in the new vacuum sanitation systems with good application prospect. The proposed technology provides technological support for the energy conservation of vacuum sanitation systems.
2013, 27(2).
Abstract:
The castings defects are affected by the melting volume change rate of material. The change rate has an important effect on running safety of the high temperature thermal storage chamber, too. But the characteristics of existing measuring installations are complex structure, troublesome operation and low precision. In order to measure the melting volume change rate of material accurately and conveniently, a self-designed measuring instrument, self-heating probe instrument, and measuring method are described. Temperature in heating cavity is controlled by PID temperature controller; melting volume change rate υ and molten density are calculated based on the melt volume which is measured by the instrument. Positive and negative υ represent expansion and shrinkage of the sample volume after melting, respectively. Taking eutectic LiFCaF2 for example, its melting volume change rate and melting density at 1 123 K are 20.6% and 2 651 kg•m–3 measured by this instrument, which is only 0.71% smaller than literature value. Density and melting volume change rate of industry pure aluminum at 973 K and analysis pure NaCl at 1 123 K are detected by the instrument too. The measure results are agreed with report values. Measuring error sources are analyzed and several improving measures are proposed. In theory, the measuring errors of the change rate and molten density which are measured by the self-designed instrument is nearly 120150 of that measured by the refitted mandril thermal expansion instrument. The self-designed instrument and method have the advantages of simple structure, being easy to operate, extensive applicability for material, relatively high accuracy, and most importantly, temperature and sample vapor pressure have little effect on the measurement accuracy. The presented instrument and method solve the problems of complicated structure and procedures, and large measuring errors for the samples with high vapor pressure by existing installations.
The castings defects are affected by the melting volume change rate of material. The change rate has an important effect on running safety of the high temperature thermal storage chamber, too. But the characteristics of existing measuring installations are complex structure, troublesome operation and low precision. In order to measure the melting volume change rate of material accurately and conveniently, a self-designed measuring instrument, self-heating probe instrument, and measuring method are described. Temperature in heating cavity is controlled by PID temperature controller; melting volume change rate υ and molten density are calculated based on the melt volume which is measured by the instrument. Positive and negative υ represent expansion and shrinkage of the sample volume after melting, respectively. Taking eutectic LiFCaF2 for example, its melting volume change rate and melting density at 1 123 K are 20.6% and 2 651 kg•m–3 measured by this instrument, which is only 0.71% smaller than literature value. Density and melting volume change rate of industry pure aluminum at 973 K and analysis pure NaCl at 1 123 K are detected by the instrument too. The measure results are agreed with report values. Measuring error sources are analyzed and several improving measures are proposed. In theory, the measuring errors of the change rate and molten density which are measured by the self-designed instrument is nearly 120150 of that measured by the refitted mandril thermal expansion instrument. The self-designed instrument and method have the advantages of simple structure, being easy to operate, extensive applicability for material, relatively high accuracy, and most importantly, temperature and sample vapor pressure have little effect on the measurement accuracy. The presented instrument and method solve the problems of complicated structure and procedures, and large measuring errors for the samples with high vapor pressure by existing installations.
2013, 27(2).
Abstract:
As the traditional graphite-based composites cannot meet the requirement of rapid developing modern industry, novel sliding electrical contact materials with high self-lubricating performance in multiple environments are eagerly required. Herein a copper-based composite with WS2 and graphite as solid lubricant are fabricated by powder metallurgy hot-pressed method. The friction and wear behaviors of the composites with and without current are investigated under the condition with sliding velocity of 10 ms and normal load of 2.5 Ncm2 in both air and vacuum. Morphologies of the worn surfaces are observed by optical microscope and compositions of the lubricating films are analyzed by XPS. Surface profile curves and roughness of the worn surfaces are obtained by 2205 surface profiler. The results of wear tests show that the friction coefficient and wear volume loss of the composites with current are greater than that without current in both air and vacuum due to the adverse effects of electrical current which damaged the lubricating film partially and roughed the worn surfaces. XPS results demonstrate that the lubricating film formed in air is composed of oxides of Cu, WS2, elemental S and graphite, while the lubricating film formed in vacuum is composed of Cu, WS2 and graphite. Because of the synergetic lubricating action of oxides of Cu, WS2 and graphite, the composites show low friction coefficient and wear volume loss in air condition. Owing to the fact that graphite loses its lubricity which makes WS2 become the only lubricant, severe adhesive and abrasive wear occur and result in a high value of wear rate in vacuum condition. The formation of the lubricating film on the contact interface between the brush and ring is one of the factors which can greatly affect the wear performance of the brushes. The low contact voltage drop of the composites in vacuum condition is attributed to the high content of Cu in the surface film. This study fabricated a kind of new sliding electrical contact self-lubricating composite with dual-lubricant which can work well in both air and vacuum environments and provides a comprehensive analysis on the lubrication mechanisms of the composite.
As the traditional graphite-based composites cannot meet the requirement of rapid developing modern industry, novel sliding electrical contact materials with high self-lubricating performance in multiple environments are eagerly required. Herein a copper-based composite with WS2 and graphite as solid lubricant are fabricated by powder metallurgy hot-pressed method. The friction and wear behaviors of the composites with and without current are investigated under the condition with sliding velocity of 10 ms and normal load of 2.5 Ncm2 in both air and vacuum. Morphologies of the worn surfaces are observed by optical microscope and compositions of the lubricating films are analyzed by XPS. Surface profile curves and roughness of the worn surfaces are obtained by 2205 surface profiler. The results of wear tests show that the friction coefficient and wear volume loss of the composites with current are greater than that without current in both air and vacuum due to the adverse effects of electrical current which damaged the lubricating film partially and roughed the worn surfaces. XPS results demonstrate that the lubricating film formed in air is composed of oxides of Cu, WS2, elemental S and graphite, while the lubricating film formed in vacuum is composed of Cu, WS2 and graphite. Because of the synergetic lubricating action of oxides of Cu, WS2 and graphite, the composites show low friction coefficient and wear volume loss in air condition. Owing to the fact that graphite loses its lubricity which makes WS2 become the only lubricant, severe adhesive and abrasive wear occur and result in a high value of wear rate in vacuum condition. The formation of the lubricating film on the contact interface between the brush and ring is one of the factors which can greatly affect the wear performance of the brushes. The low contact voltage drop of the composites in vacuum condition is attributed to the high content of Cu in the surface film. This study fabricated a kind of new sliding electrical contact self-lubricating composite with dual-lubricant which can work well in both air and vacuum environments and provides a comprehensive analysis on the lubrication mechanisms of the composite.
2013, 27(2).
Abstract:
SiC magnetic abrasive is used to polish surfaces of precise, complex parts which are hard, brittle and highly corrosion-resistant in magnetic abrasive finishing(MAF). Various techniques are employed to produce this magnetic abrasive, but few can meet production demands because they are usually time-consuming, complex with high cost, and the magnetic abrasives made by these techniques have irregular shape and low bonding strength that result in low processing efficiency and shorter service life. Therefore, an attempt is made by combining gas atomization and rapid solidification to fabricate a new iron-based SiC spherical composite magnetic abrasive. The experimental system to prepare this new magnetic abrasive is constructed according to the characteristics of gas atomization and rapid solidification process and the performance requirements of magnetic abrasive. The new iron-based SiC spherical composite magnetic abrasive is prepared successfully when the machining parameters and the composition proportion of the raw materials are controlled properly. Its morphology, microstructure, phase composition are characterized by scanning electron microscope(SEM) and X-ray diffraction(XRD) analysis. The MAF tests on plate of mold steel S136 are carried out without grinding lubricant to assess the finishing performance and service life of this new SiC magnetic abrasive. The surface roughness(Ra) of the plate worked is rapidly reduced to 0.051 μm from an initial value of 0.372 μm within 5 min. The MAF test is carried on to find that the service life of this new SiC magnetic abrasive reaches to 155 min. The results indicate that this process presented is feasible to prepare the new SiC magnetic abrasive; and compared with previous magnetic abrasives, the new SiC spherical composite magnetic abrasive has excellent finishing performance, high processing efficiency and longer service life. The presented method to fabricate magnetic abrasive through gas atomization and rapid solidification presented can significantly improve the finishing performance and service life of magnetic abrasive, and provide a more practical approach for large-scale industrial production of magnetic abrasive.
SiC magnetic abrasive is used to polish surfaces of precise, complex parts which are hard, brittle and highly corrosion-resistant in magnetic abrasive finishing(MAF). Various techniques are employed to produce this magnetic abrasive, but few can meet production demands because they are usually time-consuming, complex with high cost, and the magnetic abrasives made by these techniques have irregular shape and low bonding strength that result in low processing efficiency and shorter service life. Therefore, an attempt is made by combining gas atomization and rapid solidification to fabricate a new iron-based SiC spherical composite magnetic abrasive. The experimental system to prepare this new magnetic abrasive is constructed according to the characteristics of gas atomization and rapid solidification process and the performance requirements of magnetic abrasive. The new iron-based SiC spherical composite magnetic abrasive is prepared successfully when the machining parameters and the composition proportion of the raw materials are controlled properly. Its morphology, microstructure, phase composition are characterized by scanning electron microscope(SEM) and X-ray diffraction(XRD) analysis. The MAF tests on plate of mold steel S136 are carried out without grinding lubricant to assess the finishing performance and service life of this new SiC magnetic abrasive. The surface roughness(Ra) of the plate worked is rapidly reduced to 0.051 μm from an initial value of 0.372 μm within 5 min. The MAF test is carried on to find that the service life of this new SiC magnetic abrasive reaches to 155 min. The results indicate that this process presented is feasible to prepare the new SiC magnetic abrasive; and compared with previous magnetic abrasives, the new SiC spherical composite magnetic abrasive has excellent finishing performance, high processing efficiency and longer service life. The presented method to fabricate magnetic abrasive through gas atomization and rapid solidification presented can significantly improve the finishing performance and service life of magnetic abrasive, and provide a more practical approach for large-scale industrial production of magnetic abrasive.
2013, 27(2).
Abstract:
Although significant progress has been made in precision machining of free-form surfaces recently, inspection of such surfaces remains a difficult problem. In order to solve the problem that no specific standards for the verification of free-form surface profile are available, the profile parameters of free-form surface are proposed by referring to ISO standards regarding form tolerances and considering its complexity and non-rotational symmetry. Non-uniform rational basis spline(NURBS) for describing free-form surface is formulated. Crucial issues in surface inspection and profile error verification are localization between the design coordinate system(DCS) and measurement coordinate system(MCS) for searching the closest points on the design model corresponding to measured points. A quasi particle swarm optimization(QPSO) is proposed to search the transformation parameters to implement localization between DCS and MCS. Surface subdivide method which does the searching in a recursively reduced range of the parameters u and v of the NURBS design model is developed to find the closest points. In order to verify the effectiveness of the proposed methods, the design model is generated by NURBS and the measurement data of simulation example are generated by transforming the design model to arbitrary position and orientation, and the parts are machined based on the design model and are measured on CMM. The profile errors of simulation example and actual parts are calculated by the proposed method. The results verify that the evaluation precision of freeform surface profile error by the proposed method is higher 10%–22% than that by CMM software. The proposed method deals with the hard problem that it has a lower precision in profile error evaluation of free-form surface.
Although significant progress has been made in precision machining of free-form surfaces recently, inspection of such surfaces remains a difficult problem. In order to solve the problem that no specific standards for the verification of free-form surface profile are available, the profile parameters of free-form surface are proposed by referring to ISO standards regarding form tolerances and considering its complexity and non-rotational symmetry. Non-uniform rational basis spline(NURBS) for describing free-form surface is formulated. Crucial issues in surface inspection and profile error verification are localization between the design coordinate system(DCS) and measurement coordinate system(MCS) for searching the closest points on the design model corresponding to measured points. A quasi particle swarm optimization(QPSO) is proposed to search the transformation parameters to implement localization between DCS and MCS. Surface subdivide method which does the searching in a recursively reduced range of the parameters u and v of the NURBS design model is developed to find the closest points. In order to verify the effectiveness of the proposed methods, the design model is generated by NURBS and the measurement data of simulation example are generated by transforming the design model to arbitrary position and orientation, and the parts are machined based on the design model and are measured on CMM. The profile errors of simulation example and actual parts are calculated by the proposed method. The results verify that the evaluation precision of freeform surface profile error by the proposed method is higher 10%–22% than that by CMM software. The proposed method deals with the hard problem that it has a lower precision in profile error evaluation of free-form surface.
2013, 27(2).
Abstract:
Assembly path planning is a crucial problem in assembly related design and manufacturing processes. Sampling based motion planning algorithms are used for computational assembly path planning. However, the performance of such algorithms may degrade much in environments with complex product structure, narrow passages or other challenging scenarios. A computational path planner for automatic assembly path planning in complex 3D environments is presented. The global planning process is divided into three phases based on the environment and specific algorithms are proposed and utilized in each phase to solve the challenging issues. A novel ray test based stochastic collision detection method is proposed to evaluate the intersection between two polyhedral objects. This method avoids fake collisions in conventional methods and degrades the geometric constraint when a part has to be removed with surface contact with other parts. A refined history based rapidly-exploring random tree (RRT) algorithm which bias the growth of the tree based on its planning history is proposed and employed in the planning phase where the path is simple but the space is highly constrained. A novel adaptive RRT algorithm is developed for the path planning problem with challenging scenarios and uncertain environment. With extending values assigned on each tree node and extending schemes applied, the tree can adapts its growth to explore complex environments more efficiently. Experiments on the key algorithms are carried out and comparisons are made between the conventional path planning algorithms and the presented ones. The comparing results show that based on the proposed algorithms, the path planner can compute assembly path in challenging complex environments more efficiently and with higher success. This research provides the references to the study of computational assembly path planning under complex environments.
Assembly path planning is a crucial problem in assembly related design and manufacturing processes. Sampling based motion planning algorithms are used for computational assembly path planning. However, the performance of such algorithms may degrade much in environments with complex product structure, narrow passages or other challenging scenarios. A computational path planner for automatic assembly path planning in complex 3D environments is presented. The global planning process is divided into three phases based on the environment and specific algorithms are proposed and utilized in each phase to solve the challenging issues. A novel ray test based stochastic collision detection method is proposed to evaluate the intersection between two polyhedral objects. This method avoids fake collisions in conventional methods and degrades the geometric constraint when a part has to be removed with surface contact with other parts. A refined history based rapidly-exploring random tree (RRT) algorithm which bias the growth of the tree based on its planning history is proposed and employed in the planning phase where the path is simple but the space is highly constrained. A novel adaptive RRT algorithm is developed for the path planning problem with challenging scenarios and uncertain environment. With extending values assigned on each tree node and extending schemes applied, the tree can adapts its growth to explore complex environments more efficiently. Experiments on the key algorithms are carried out and comparisons are made between the conventional path planning algorithms and the presented ones. The comparing results show that based on the proposed algorithms, the path planner can compute assembly path in challenging complex environments more efficiently and with higher success. This research provides the references to the study of computational assembly path planning under complex environments.
2013, 27(2).
Abstract:
Considering the lack of theoretical models and ingredients necessary to explain the scaling of the results of propeller cavitation inception and cavitating hydroacoustics from model tests to full scale currently, and the insufficient reflection of the nuclei effects on cavitation in the numerical methods, the cavitating hydrodynamics and cavitation low frequency noise spectrum of three geometrically similar 7-bladed highly skewed propellers with non-uniform inflow are addressed. In this process, a numerical bridge from the multiphase viscous simulation of propeller cavitation hydrodynamics to its hydro-acoustics is built, and the scale effects on performances and the applicability of exist scaling law are analyzed. The effects of non-condensable gas(NCG) on cavitation inception are involved explicitly in the improved Sauers cavitation model, and the cavity volume acceleration related to its characteristic length is used to produce the noise spectrum. Results show that, with the same cavitation number, the cavity extension on propeller blades increases with diameter associated with an earlier shift of the beginning point of thrust decline induced by cavitation, while the three decline slopes of thrust breakdown curves are found to be nearly the same. The power of the scaling law based on local Reynolds number around 0.9R section is determined as 0.11. As for the smallest propeller, the predominant tonal noise is located at blade passing frequency(BPF), whereas 2BPF for the middle and both 2BPF and 3BPF for the largest, which shows the cavitating line spectrum is fully related to the interaction between non-uniform inflow and fluctuated cavity volume. The predicted spectrum level exceedance from the middle to the large propeller is 6.65 dB at BPF and 5.94 dB at 2BPF. Since it just differs less than 2 dB to the increment obtained by empirical scaling law, it is inferred that the scale effects on them are acceptable with a sufficient model scale, and so do the scaling law. The numerical implementation of cavitating hydrodynamics and hydro-acoustics prediction of propeller in big scale in wake has been completed.
Considering the lack of theoretical models and ingredients necessary to explain the scaling of the results of propeller cavitation inception and cavitating hydroacoustics from model tests to full scale currently, and the insufficient reflection of the nuclei effects on cavitation in the numerical methods, the cavitating hydrodynamics and cavitation low frequency noise spectrum of three geometrically similar 7-bladed highly skewed propellers with non-uniform inflow are addressed. In this process, a numerical bridge from the multiphase viscous simulation of propeller cavitation hydrodynamics to its hydro-acoustics is built, and the scale effects on performances and the applicability of exist scaling law are analyzed. The effects of non-condensable gas(NCG) on cavitation inception are involved explicitly in the improved Sauers cavitation model, and the cavity volume acceleration related to its characteristic length is used to produce the noise spectrum. Results show that, with the same cavitation number, the cavity extension on propeller blades increases with diameter associated with an earlier shift of the beginning point of thrust decline induced by cavitation, while the three decline slopes of thrust breakdown curves are found to be nearly the same. The power of the scaling law based on local Reynolds number around 0.9R section is determined as 0.11. As for the smallest propeller, the predominant tonal noise is located at blade passing frequency(BPF), whereas 2BPF for the middle and both 2BPF and 3BPF for the largest, which shows the cavitating line spectrum is fully related to the interaction between non-uniform inflow and fluctuated cavity volume. The predicted spectrum level exceedance from the middle to the large propeller is 6.65 dB at BPF and 5.94 dB at 2BPF. Since it just differs less than 2 dB to the increment obtained by empirical scaling law, it is inferred that the scale effects on them are acceptable with a sufficient model scale, and so do the scaling law. The numerical implementation of cavitating hydrodynamics and hydro-acoustics prediction of propeller in big scale in wake has been completed.
2013, 27(2).
Abstract:
Because the work environment of segment is complex, and the wear failures usually happen, the wear mechanism corresponding to the load is a key factor for the solution of this problem. At present, many researchers have investigated the failure of segment, but have not taken into account the compositive influences of matching and coiling process. To investigate the wear failure of the drum segment of the hot rolling coiler, the MMU-5G abrasion tester is applied to simulate the wear behavior under different temperatures, different loads and different stages, and the friction coefficients and wear rates are acquired. Scanning electron microscopy(SEM) is used to observe the micro-morphology of worn surface, X-ray energy dispersive spectroscopy(EDS) is used to analyze the chemical composition of worn surface, finally the wear mechanism of segment in working process is judged and the influence regulars of the environmental factors on the material wear behaviors are found. The test and analysis results show that under certain load, the wear of the segment changes into oxidation wear from abrasive wear step by step with the temperature increases, and the wear degree reduces; under certain temperature, the main wear mechanism of segment changes into spalling wear from abrasive wear with the load increases, and the wear degree slightly increases. The proposed research provides a theoretical foundation and a practical reference for optimizing the wear behavior and extending the working life of segment.
Because the work environment of segment is complex, and the wear failures usually happen, the wear mechanism corresponding to the load is a key factor for the solution of this problem. At present, many researchers have investigated the failure of segment, but have not taken into account the compositive influences of matching and coiling process. To investigate the wear failure of the drum segment of the hot rolling coiler, the MMU-5G abrasion tester is applied to simulate the wear behavior under different temperatures, different loads and different stages, and the friction coefficients and wear rates are acquired. Scanning electron microscopy(SEM) is used to observe the micro-morphology of worn surface, X-ray energy dispersive spectroscopy(EDS) is used to analyze the chemical composition of worn surface, finally the wear mechanism of segment in working process is judged and the influence regulars of the environmental factors on the material wear behaviors are found. The test and analysis results show that under certain load, the wear of the segment changes into oxidation wear from abrasive wear step by step with the temperature increases, and the wear degree reduces; under certain temperature, the main wear mechanism of segment changes into spalling wear from abrasive wear with the load increases, and the wear degree slightly increases. The proposed research provides a theoretical foundation and a practical reference for optimizing the wear behavior and extending the working life of segment.
2013, 27(2).
Abstract:
Order analysis for multi-Bennett linkages is a difficult topic in kinematics. Traditional methods fail to obtain the order of multi-Bennett linkages due to considering the special geometric distributions among joint axes. An order principle for multi-Bennett linkages is presented. For a summated multi-Bennett linkage, three procedures are included in the order principle. Firstly, a homogeneous screw equation is obtained by taking linear superposition operations and then the maximum order is determined according to linear dependency of all screws. Secondly, two theorems are employed to determine the maximum order, where the first is used to judge the linear independency of four-system screws and the second is fit for identifying the linear independency of five-system screws. Lastly, all possible cases in the order range are considered until the valid order is screened out. For a syncopated multi-Bennett linkage, an equivalent summated model is built and then the order analysis is the same as that of summated linkages. In order to verify the effectiveness of the presented order principle, the orders of summated 5R and 6R linkages as well as a syncopated 6R linkage are analyzed. The computed orders of the former two summated linkages are both 4 and the computed order of the last syncopated 6R linkage is 5. The results coincide with the prototype data. The advantage of the proposed principle is that it can get the correct order of a multi-Bennett linkage without solving the geometric conditions of joint axes and has wide application in variety of multi-Bennett linkages.
Order analysis for multi-Bennett linkages is a difficult topic in kinematics. Traditional methods fail to obtain the order of multi-Bennett linkages due to considering the special geometric distributions among joint axes. An order principle for multi-Bennett linkages is presented. For a summated multi-Bennett linkage, three procedures are included in the order principle. Firstly, a homogeneous screw equation is obtained by taking linear superposition operations and then the maximum order is determined according to linear dependency of all screws. Secondly, two theorems are employed to determine the maximum order, where the first is used to judge the linear independency of four-system screws and the second is fit for identifying the linear independency of five-system screws. Lastly, all possible cases in the order range are considered until the valid order is screened out. For a syncopated multi-Bennett linkage, an equivalent summated model is built and then the order analysis is the same as that of summated linkages. In order to verify the effectiveness of the presented order principle, the orders of summated 5R and 6R linkages as well as a syncopated 6R linkage are analyzed. The computed orders of the former two summated linkages are both 4 and the computed order of the last syncopated 6R linkage is 5. The results coincide with the prototype data. The advantage of the proposed principle is that it can get the correct order of a multi-Bennett linkage without solving the geometric conditions of joint axes and has wide application in variety of multi-Bennett linkages.
2013, 27(2).
Abstract:
The segment erector is a key part of the shield machines for tunnel engineering. The available segment erectors are all of serial configuration which is suffering from the problems of low rigidity and accumulative motion errors. The current research mainly focuses on improving assembly accuracy and control performance of serial segment erectors. An innovative design method is proposed featuring motion group-decoupling, based on which a new type of segment erector is developed and investigated. Firstly, the segment installation manipulation is analyzed and decomposed into three motion groups that are decoupled. Then the type synthesis for the 4-DOF motion group is performed based on the general function(GF) set theory and a new configuration of (1T⊕1R⊕1PS&3UPS) is attained according to the segment manipulation requirements. Consequently, the kinematic models are built and the reducibility and accuracy are analyzed. The dexterity is verified though numerical simulation and no singular points appear in the workspace. Finally, a positioning experiment is carried out by using the prototype developed in the lab that demonstrates a 13.1% improvement of positioning accuracy and the feasibility of the new segment erector. The presented group-decoupling design method is able to invent new type of hybrid segment erectors that avoid the accumulative motion error of erecting.
The segment erector is a key part of the shield machines for tunnel engineering. The available segment erectors are all of serial configuration which is suffering from the problems of low rigidity and accumulative motion errors. The current research mainly focuses on improving assembly accuracy and control performance of serial segment erectors. An innovative design method is proposed featuring motion group-decoupling, based on which a new type of segment erector is developed and investigated. Firstly, the segment installation manipulation is analyzed and decomposed into three motion groups that are decoupled. Then the type synthesis for the 4-DOF motion group is performed based on the general function(GF) set theory and a new configuration of (1T⊕1R⊕1PS&3UPS) is attained according to the segment manipulation requirements. Consequently, the kinematic models are built and the reducibility and accuracy are analyzed. The dexterity is verified though numerical simulation and no singular points appear in the workspace. Finally, a positioning experiment is carried out by using the prototype developed in the lab that demonstrates a 13.1% improvement of positioning accuracy and the feasibility of the new segment erector. The presented group-decoupling design method is able to invent new type of hybrid segment erectors that avoid the accumulative motion error of erecting.
2013, 27(2).
Abstract:
Knock in spark-ignition(SI) engines severely limits engine performance and thermal efficiency. The researches on knock of downsized SI engine have mainly focused on structural design, performance optimization and advanced combustion modes, however there is little for simulation study on the effect of cooled exhaust gas recirculation(EGR) combined with downsizing technologies on SI engine performance. On the basis of mean pressure and oscillating pressure during combustion process, the effect of different levels of cooled EGR ratio, supercharging and compression ratio on engine dynamic and knock characteristic is researched with three- dimensional KIVA-3V program coupled with pressure wave equation. The cylinder pressure, combustion temperature, ignition delay timing, combustion duration, maximum mean pressure, and maximum oscillating pressure at different initial conditions are discussed and analyzed to investigate potential approaches to inhibiting engine knock while improving power output. The calculation results of the effect of just cooled EGR on knock characteristic show that appropriate levels of cooled EGR ratio can effectively suppress cylinder high-frequency pressure oscillations without obvious decrease in mean pressure. Analysis of the synergistic effect of cooled EGR, supercharging and compression ratio on knock characteristic indicates that under the condition of high supercharging and compression ratio, several times more cooled EGR ratio than that under the original condition is necessarily utilized to suppress knock occurrence effectively. The proposed method of synergistic effect of cooled EGR and downsizing technologies on knock characteristic, analyzed from the aspects of mean pressure and oscillating pressure, is an effective way to study downsized SI engine knock and provides knock inhibition approaches in practical engineering.
Knock in spark-ignition(SI) engines severely limits engine performance and thermal efficiency. The researches on knock of downsized SI engine have mainly focused on structural design, performance optimization and advanced combustion modes, however there is little for simulation study on the effect of cooled exhaust gas recirculation(EGR) combined with downsizing technologies on SI engine performance. On the basis of mean pressure and oscillating pressure during combustion process, the effect of different levels of cooled EGR ratio, supercharging and compression ratio on engine dynamic and knock characteristic is researched with three- dimensional KIVA-3V program coupled with pressure wave equation. The cylinder pressure, combustion temperature, ignition delay timing, combustion duration, maximum mean pressure, and maximum oscillating pressure at different initial conditions are discussed and analyzed to investigate potential approaches to inhibiting engine knock while improving power output. The calculation results of the effect of just cooled EGR on knock characteristic show that appropriate levels of cooled EGR ratio can effectively suppress cylinder high-frequency pressure oscillations without obvious decrease in mean pressure. Analysis of the synergistic effect of cooled EGR, supercharging and compression ratio on knock characteristic indicates that under the condition of high supercharging and compression ratio, several times more cooled EGR ratio than that under the original condition is necessarily utilized to suppress knock occurrence effectively. The proposed method of synergistic effect of cooled EGR and downsizing technologies on knock characteristic, analyzed from the aspects of mean pressure and oscillating pressure, is an effective way to study downsized SI engine knock and provides knock inhibition approaches in practical engineering.
2013, 27(2).
Abstract:
The limit working parameters and service life of axial piston pump are determined by the carrying ability and lubrication characteristic of its key friction pairs. Therefore, the design and optimization of the key friction pairs are always a key and difficult problem in the research on axial piston pump. In the traditional research on piston/cylinder pair, the assembly relationship of piston and cylinder bore is simplified into ideal cylindrical pair, which can not be used to analyze the influences of radial micro-motion of piston on the distribution characteristics of oil-film thickness and pressure in details. In this paper, based on the lubrication theory of the oil film, a numerical simulation model is built, taking the influences of roughness, elastic deformation of piston and pressure-viscosity effect into consideration. With the simulation model, the dynamic characteristics of the radial micro-motion and pressure distribution are analyzed, and the relationships between radial micro-motion and carrying ability, lubrication condition, and abrasion are discussed. Furthermore, a model pump for pressure distribution measurement of oil film between piston and cylinder bore is designed. The comparison of simulation and experimental results of pressure distribution shows that the simulation model has high accuracy. The experiment and simulation results demonstrate that the pressure distribution has peak values that are much higher than the boundary pressure in the piston chamber due to the radial micro-motion, and the abrasion of piston takes place mainly on the hand close to piston ball. In addition, improvement of manufacturing roundness and straightness of piston and cylinder bore is helpful to improve the carrying ability of piston/cylinder pair. The proposed research provides references for designing piston/cylinder pair, and helps to prolong the service life of axial piston pump.
The limit working parameters and service life of axial piston pump are determined by the carrying ability and lubrication characteristic of its key friction pairs. Therefore, the design and optimization of the key friction pairs are always a key and difficult problem in the research on axial piston pump. In the traditional research on piston/cylinder pair, the assembly relationship of piston and cylinder bore is simplified into ideal cylindrical pair, which can not be used to analyze the influences of radial micro-motion of piston on the distribution characteristics of oil-film thickness and pressure in details. In this paper, based on the lubrication theory of the oil film, a numerical simulation model is built, taking the influences of roughness, elastic deformation of piston and pressure-viscosity effect into consideration. With the simulation model, the dynamic characteristics of the radial micro-motion and pressure distribution are analyzed, and the relationships between radial micro-motion and carrying ability, lubrication condition, and abrasion are discussed. Furthermore, a model pump for pressure distribution measurement of oil film between piston and cylinder bore is designed. The comparison of simulation and experimental results of pressure distribution shows that the simulation model has high accuracy. The experiment and simulation results demonstrate that the pressure distribution has peak values that are much higher than the boundary pressure in the piston chamber due to the radial micro-motion, and the abrasion of piston takes place mainly on the hand close to piston ball. In addition, improvement of manufacturing roundness and straightness of piston and cylinder bore is helpful to improve the carrying ability of piston/cylinder pair. The proposed research provides references for designing piston/cylinder pair, and helps to prolong the service life of axial piston pump.
2013, 27(2).
Abstract:
The current research of configurable product design mainly focuses on how to convert a predefined set of components into a valid set of product structures. With the scale and complexity of configurable products increasing, the interdependencies between customer demands and product structures grow up as well. The result is that existing product structures fails to satisfy the individual customer requirements and hence product variants are needed. This paper is aimed to build a bridge between customer demands and product structures in order to make demand-driven fast response design feasible. First of all, multi-hierarchical models of configurable product design are established with customer demand model, technical requirement model and product structure model. Then, the transition of multi-hierarchical models among customer demand model, technical requirement model and product structure model is solved with fuzzy analytic hierarchy process (FAHP) and the algorithm of multi-level matching. Finally, optimal structure according to the customer demands is obtained with the calculation of Euclidean distance and similarity of some cases. In practice, the configuration design of a clamping unit of injection molding machine successfully performs an optimal search strategy for the product variants with reasonable satisfaction to individual customer demands. The proposed method can automatically generate a configuration design with better alternatives for each product structures, and shorten the time of finding the configuration of a product.
The current research of configurable product design mainly focuses on how to convert a predefined set of components into a valid set of product structures. With the scale and complexity of configurable products increasing, the interdependencies between customer demands and product structures grow up as well. The result is that existing product structures fails to satisfy the individual customer requirements and hence product variants are needed. This paper is aimed to build a bridge between customer demands and product structures in order to make demand-driven fast response design feasible. First of all, multi-hierarchical models of configurable product design are established with customer demand model, technical requirement model and product structure model. Then, the transition of multi-hierarchical models among customer demand model, technical requirement model and product structure model is solved with fuzzy analytic hierarchy process (FAHP) and the algorithm of multi-level matching. Finally, optimal structure according to the customer demands is obtained with the calculation of Euclidean distance and similarity of some cases. In practice, the configuration design of a clamping unit of injection molding machine successfully performs an optimal search strategy for the product variants with reasonable satisfaction to individual customer demands. The proposed method can automatically generate a configuration design with better alternatives for each product structures, and shorten the time of finding the configuration of a product.
2013, 27(2).
Abstract:
As children mature, bike products for children in the market develop at the same time, and the conditions are frequently updated. Certain problems occur when using a bike, such as cycle overlapping, repeating function, and short life cycle, which go against the principles of energy conservation and the environmental protection intensive design concept. In this paper, a rational multi-function method of design through functional superposition, transformation, and technical implementation is proposed. An organic combination of frog-style scooter and children’s tricycle is developed using the multi-function method. From the ergonomic perspective, the paper elaborates on the body size of children aged 5 to 12 and effectively extracts data for a multi-function children’s bike, which can be used for gliding and riding. By inverting the body, parts can be interchanged between the handles and the pedals of the bike. Finally, the paper provides a detailed analysis of the components and structural design, body material, and processing technology of the bike. The study of Industrial Product Innovation Design provides an effective design method to solve the bicycle problems, extends the function problems, improves the product market situation, and enhances the energy saving feature while implementing intensive product development effectively at the same time.
As children mature, bike products for children in the market develop at the same time, and the conditions are frequently updated. Certain problems occur when using a bike, such as cycle overlapping, repeating function, and short life cycle, which go against the principles of energy conservation and the environmental protection intensive design concept. In this paper, a rational multi-function method of design through functional superposition, transformation, and technical implementation is proposed. An organic combination of frog-style scooter and children’s tricycle is developed using the multi-function method. From the ergonomic perspective, the paper elaborates on the body size of children aged 5 to 12 and effectively extracts data for a multi-function children’s bike, which can be used for gliding and riding. By inverting the body, parts can be interchanged between the handles and the pedals of the bike. Finally, the paper provides a detailed analysis of the components and structural design, body material, and processing technology of the bike. The study of Industrial Product Innovation Design provides an effective design method to solve the bicycle problems, extends the function problems, improves the product market situation, and enhances the energy saving feature while implementing intensive product development effectively at the same time.
2013, 27(2).
Abstract:
Great attention has been paid on fabricating diamond wire by using the brazing diamond because of its strong chemical bonding strength and controllability of grits distribution. Although several serving performances of brazed diamond wire have been reported, seldom do these studies refer to its process characteristics. Sawing performances of a brazed diamond wire are investigated and compared with those of a sintered diamond wire on a wire saw machine. The surface topographies of beads selected from the two wires are micro observed before sawing. The sawing tests are carried out in constant feed rate feeding(CFF) and constant normal force feeding(CNFF). In CFF test, sawing force, power, and the cut depths of positions on contact curve are measured. Then, coupled with the observations of beads topographies, sawing force and its ratio, relations of power against material removal rate, and contact curve linearity are compared and discussed. In CNFF test, the sawing rates of the two wires are investigated. The results indicate that the brazed wire performs with lower sawing force(less 16% of tangential force and 28% of normal force), more energy efficiency(nearly one-fifth of sawing power is saved), at a higher sawing rate (the rate is doubled) and with better contact curve linearity as compared with the sintered wire. This proposed research experimentally evaluates the sawing performances of brazed diamond wire from the aspect of process parameters, which can provide a basis for popularizing the brazed diamond wire.
Great attention has been paid on fabricating diamond wire by using the brazing diamond because of its strong chemical bonding strength and controllability of grits distribution. Although several serving performances of brazed diamond wire have been reported, seldom do these studies refer to its process characteristics. Sawing performances of a brazed diamond wire are investigated and compared with those of a sintered diamond wire on a wire saw machine. The surface topographies of beads selected from the two wires are micro observed before sawing. The sawing tests are carried out in constant feed rate feeding(CFF) and constant normal force feeding(CNFF). In CFF test, sawing force, power, and the cut depths of positions on contact curve are measured. Then, coupled with the observations of beads topographies, sawing force and its ratio, relations of power against material removal rate, and contact curve linearity are compared and discussed. In CNFF test, the sawing rates of the two wires are investigated. The results indicate that the brazed wire performs with lower sawing force(less 16% of tangential force and 28% of normal force), more energy efficiency(nearly one-fifth of sawing power is saved), at a higher sawing rate (the rate is doubled) and with better contact curve linearity as compared with the sintered wire. This proposed research experimentally evaluates the sawing performances of brazed diamond wire from the aspect of process parameters, which can provide a basis for popularizing the brazed diamond wire.
2013, 27(2).
Abstract:
Vehicle state and tire-road adhesion are of great use and importance to vehicle active safety control systems. However, it is always not easy to obtain the information with high accuracy and low expense. Recently, many estimation methods have been put forward to solve such problems, in which Kalman filter becomes one of the most popular techniques. Nevertheless, the use of complicated model always leads to poor real-time estimation while the role of road friction coefficient is often ignored. For the purpose of enhancing the real time performance of the algorithm and pursuing precise estimation of vehicle states, a model-based estimator is proposed to conduct combined estimation of vehicle states and road friction coefficients. The estimator is designed based on a three-DOF vehicle model coupled with the Highway Safety Research Institute(HSRI) tire model; the dual extended Kalman filter (DEKF) technique is employed, which can be regarded as two extended Kalman filters operating and communicating simultaneously. Effectiveness of the estimation is firstly examined by comparing the outputs of the estimator with the responses of the vehicle model in CarSim under three typical road adhesion conditions(high-friction, low-friction, and joint-friction). On this basis, driving simulator experiments are carried out to further investigate the practical application of the estimator. Numerical results from CarSim and driving simulator both demonstrate that the estimator designed is capable of estimating the vehicle states and road friction coefficient with reasonable accuracy. The DEKF-based estimator proposed provides the essential information for the vehicle active control system with low expense and decent precision, and offers the possibility of real car application in future.
Vehicle state and tire-road adhesion are of great use and importance to vehicle active safety control systems. However, it is always not easy to obtain the information with high accuracy and low expense. Recently, many estimation methods have been put forward to solve such problems, in which Kalman filter becomes one of the most popular techniques. Nevertheless, the use of complicated model always leads to poor real-time estimation while the role of road friction coefficient is often ignored. For the purpose of enhancing the real time performance of the algorithm and pursuing precise estimation of vehicle states, a model-based estimator is proposed to conduct combined estimation of vehicle states and road friction coefficients. The estimator is designed based on a three-DOF vehicle model coupled with the Highway Safety Research Institute(HSRI) tire model; the dual extended Kalman filter (DEKF) technique is employed, which can be regarded as two extended Kalman filters operating and communicating simultaneously. Effectiveness of the estimation is firstly examined by comparing the outputs of the estimator with the responses of the vehicle model in CarSim under three typical road adhesion conditions(high-friction, low-friction, and joint-friction). On this basis, driving simulator experiments are carried out to further investigate the practical application of the estimator. Numerical results from CarSim and driving simulator both demonstrate that the estimator designed is capable of estimating the vehicle states and road friction coefficient with reasonable accuracy. The DEKF-based estimator proposed provides the essential information for the vehicle active control system with low expense and decent precision, and offers the possibility of real car application in future.
2013, 27(2).
Abstract:
A generally applicable criterion for all mechanism mobility has been an active domain in mechanism theory lasting more than 150 years. It is stated that the Modified Grübler-Kutzbach criterion for mobility has been successfully used to solve the mobility of many more kinds of mechanisms, but never before has anyone proven the applicability and generality of the Modified Grübler-Kutzbach criterion in theory. In order to fill the gap, the applicability and generality of the Modified Grübler-Kutzbach Criterion of mechanism mobility is systematically demonstrated. Firstly, the mobility research background and the Modified Grübler-Kutzbach criterion are introduced. Secondly, some new definitions, such as half local freedom, non-common constraint space of a mechanism and common motion space of a mechanism, etc, are given to demonstrate the correctness and broad applicability of the Modified Grübler-Kutzbach criterion. Thirdly, the general applicability of the Modified Grübler-Kutzbach criterion is demonstrated based on screw theory. The mobilities of the classical DELASSUS mechanisms and a modern planar parallel mechanism, are determined through the Modified Grübler-Kutzbach criterion, which are as examples to show the practical application of the Modified Grübler-Kutzbach criterion.
A generally applicable criterion for all mechanism mobility has been an active domain in mechanism theory lasting more than 150 years. It is stated that the Modified Grübler-Kutzbach criterion for mobility has been successfully used to solve the mobility of many more kinds of mechanisms, but never before has anyone proven the applicability and generality of the Modified Grübler-Kutzbach criterion in theory. In order to fill the gap, the applicability and generality of the Modified Grübler-Kutzbach Criterion of mechanism mobility is systematically demonstrated. Firstly, the mobility research background and the Modified Grübler-Kutzbach criterion are introduced. Secondly, some new definitions, such as half local freedom, non-common constraint space of a mechanism and common motion space of a mechanism, etc, are given to demonstrate the correctness and broad applicability of the Modified Grübler-Kutzbach criterion. Thirdly, the general applicability of the Modified Grübler-Kutzbach criterion is demonstrated based on screw theory. The mobilities of the classical DELASSUS mechanisms and a modern planar parallel mechanism, are determined through the Modified Grübler-Kutzbach criterion, which are as examples to show the practical application of the Modified Grübler-Kutzbach criterion.
2013, 27(2).
Abstract:
Non-obstacle design is critical to tailor physically handicapped workers in manufacturing system. Simultaneous consideration of variability in physically disabled users, machines and environment of the manufacturing system is extremely complex and generally requires modeling of physically handicapped interaction with the system. Most current modeling either concentrates on the task results or functional disability. The integration of physical constraints with task constraints is far more complex because of functional disability and its extended influence on adjacent body parts. A framework is proposed to integrate the two constraints and thus model the specific behavior of the physical handicapped in virtual environment generated by product specifications. Within the framework a simplified model of physical disabled body is constructed, and body motion is generated based on 3 levels of constraints(effecter constraints, kinematics constraints and physical constraints). The kinematics and dynamic calculations are made and optimized based on the weighting manipulated by the kinematics constraints and dynamic constraints. With object transferring task as example, the model is validated in Jack 6.0. Modelled task motion elements except for squatting and overreaching well matched with captured motion elements. The proposed modeling method can model the complex behavior of the physically handicapped by integrating both task and physical disability constraints.
Non-obstacle design is critical to tailor physically handicapped workers in manufacturing system. Simultaneous consideration of variability in physically disabled users, machines and environment of the manufacturing system is extremely complex and generally requires modeling of physically handicapped interaction with the system. Most current modeling either concentrates on the task results or functional disability. The integration of physical constraints with task constraints is far more complex because of functional disability and its extended influence on adjacent body parts. A framework is proposed to integrate the two constraints and thus model the specific behavior of the physical handicapped in virtual environment generated by product specifications. Within the framework a simplified model of physical disabled body is constructed, and body motion is generated based on 3 levels of constraints(effecter constraints, kinematics constraints and physical constraints). The kinematics and dynamic calculations are made and optimized based on the weighting manipulated by the kinematics constraints and dynamic constraints. With object transferring task as example, the model is validated in Jack 6.0. Modelled task motion elements except for squatting and overreaching well matched with captured motion elements. The proposed modeling method can model the complex behavior of the physically handicapped by integrating both task and physical disability constraints.
2013, 27(2).
Abstract:
The present research on moulded case circuit breaker(MCCB) focuses on the enhancement of current-limiting interrupting performance during short circuit, overload, under voltage and phase failure, involving electrics, magnetic, mechanics, thermal, material, friction, arc extinguishing, impact vibration, skin effect, etc. The rigid-flexible coupling of the parts and components of the metamorphic manipulating mechanism in multi-fields leads to the non-rigid, high frequency, high damping, singularity of the Euler-Lagrange equations which represents the multi-body dynamics. The small step iteration which is used for obtaining the instantaneous and short time critical interrupting performance of metamorphic mechanism appears inaccuracy. It is difficult to realize top-down design by existing CAD systems. Therefore, a metamorphic manipulating mechanism design method for MCCB using index reduced iteration(IRI) is put forward. The metamorphic manipulating mechanism of MCCB is decomposed into three mechanisms: main switch connector mechanism, electromagnet-drawbar-jump buckle mechanism, and bimetallic strip-drawbar mechanism, which is respectively described by electro-dynamic force, electromagnet force, and bimetallic strip force. The dummy part(virtual rigid) without moment of inertia and mass is employed as intermediate to join the flexible body and rigid body. The model of rigid-flexible coupling metamorphic mechanism multi-body dynamics is built. The differential algebraic equations(DAEs) of the multibody dynamics model are converted to pure ordinary differential equations(ODEs) by coordinate partition. Order reduced integration with multi-step and variable step-size is preceded based on IRI. The non-linear algebraic equations are solved in each integration step by Newton-Rapson iteration. There is no ill-condition and singularity of Jacobian matrix when step size reduces to zero. The independent prototype design system using ACIS R13, HOOPS V11.0 and Visual C++.NET 2003 has been developed, which verifies the effectiveness of the proposed method. The proposed method enhances the current-limiting interrupting performance of MCCB, and has reference significance for multi-body dynamics design for similar flexible metamorphic mechanisms in multi-fields.
The present research on moulded case circuit breaker(MCCB) focuses on the enhancement of current-limiting interrupting performance during short circuit, overload, under voltage and phase failure, involving electrics, magnetic, mechanics, thermal, material, friction, arc extinguishing, impact vibration, skin effect, etc. The rigid-flexible coupling of the parts and components of the metamorphic manipulating mechanism in multi-fields leads to the non-rigid, high frequency, high damping, singularity of the Euler-Lagrange equations which represents the multi-body dynamics. The small step iteration which is used for obtaining the instantaneous and short time critical interrupting performance of metamorphic mechanism appears inaccuracy. It is difficult to realize top-down design by existing CAD systems. Therefore, a metamorphic manipulating mechanism design method for MCCB using index reduced iteration(IRI) is put forward. The metamorphic manipulating mechanism of MCCB is decomposed into three mechanisms: main switch connector mechanism, electromagnet-drawbar-jump buckle mechanism, and bimetallic strip-drawbar mechanism, which is respectively described by electro-dynamic force, electromagnet force, and bimetallic strip force. The dummy part(virtual rigid) without moment of inertia and mass is employed as intermediate to join the flexible body and rigid body. The model of rigid-flexible coupling metamorphic mechanism multi-body dynamics is built. The differential algebraic equations(DAEs) of the multibody dynamics model are converted to pure ordinary differential equations(ODEs) by coordinate partition. Order reduced integration with multi-step and variable step-size is preceded based on IRI. The non-linear algebraic equations are solved in each integration step by Newton-Rapson iteration. There is no ill-condition and singularity of Jacobian matrix when step size reduces to zero. The independent prototype design system using ACIS R13, HOOPS V11.0 and Visual C++.NET 2003 has been developed, which verifies the effectiveness of the proposed method. The proposed method enhances the current-limiting interrupting performance of MCCB, and has reference significance for multi-body dynamics design for similar flexible metamorphic mechanisms in multi-fields.
2013, 27(2).
Abstract:
Typical multidisciplinary design optimization(MDO) has gradually been proposed to balance performances of lightweight, noise, vibration and harshness(NVH) and safety for instrument panel(IP) structure in the automotive development. Nevertheless, plastic constitutive relation of Polypropylene(PP) under different strain rates, has not been taken into consideration in current reliability-based and collaborative IP MDO design. In this paper, based on tensile test under different strain rates, the constitutive relation of Polypropylene material is studied. Impact simulation tests for head and knee bolster are carried out to meet the regulation of FMVSS 201 and FMVSS 208, respectively. NVH analysis is performed to obtain mainly the natural frequencies and corresponding mode shapes, while the crashworthiness analysis is employed to examine the crash behavior of IP structure. With the consideration of lightweight, NVH, head and knee bolster impact performance, design of experiment(DOE), response surface model(RSM), and collaborative optimization(CO) are applied to realize the determined and reliability-based optimizations, respectively. Furthermore, based on multi-objective genetic algorithm(MOGA), the optimal Pareto sets are completed to solve the multi-objective optimization(MOO) problem. The proposed research ensures the smoothness of Pareto set, enhances the ability of engineers to make a comprehensive decision about multi-objectives and choose the optimal design, and improves the quality and efficiency of MDO.
Typical multidisciplinary design optimization(MDO) has gradually been proposed to balance performances of lightweight, noise, vibration and harshness(NVH) and safety for instrument panel(IP) structure in the automotive development. Nevertheless, plastic constitutive relation of Polypropylene(PP) under different strain rates, has not been taken into consideration in current reliability-based and collaborative IP MDO design. In this paper, based on tensile test under different strain rates, the constitutive relation of Polypropylene material is studied. Impact simulation tests for head and knee bolster are carried out to meet the regulation of FMVSS 201 and FMVSS 208, respectively. NVH analysis is performed to obtain mainly the natural frequencies and corresponding mode shapes, while the crashworthiness analysis is employed to examine the crash behavior of IP structure. With the consideration of lightweight, NVH, head and knee bolster impact performance, design of experiment(DOE), response surface model(RSM), and collaborative optimization(CO) are applied to realize the determined and reliability-based optimizations, respectively. Furthermore, based on multi-objective genetic algorithm(MOGA), the optimal Pareto sets are completed to solve the multi-objective optimization(MOO) problem. The proposed research ensures the smoothness of Pareto set, enhances the ability of engineers to make a comprehensive decision about multi-objectives and choose the optimal design, and improves the quality and efficiency of MDO.
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