2013 Vol.26(6)
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2013, 27(6).
Abstract:
Current researches have not yet found the effect law of the cutter parameters and machining parameters on the interference in gear slicing, the interference between the cutter and machined gear often happens because the appropriate cutter parameters and machining parameters cannot be set, which reduces the gear machining accuracy. The relative position between the major flank face and edge-sweeping surface, distribution law of the interference area in forming process of edge-sweeping surface, and effect law of relative positions among edge-sweeping surfaces on the interference are studied by graphical analysis. The effect law of the cutter parameters and machining parameters on the interference is found. The effect law shows that the interference in gear slicing can be controlled when the relief angle measured on the top edge and feed of every rotation are chosen respectively larger than 9 and smaller than 0.15 mm/r. An internal helical gear is sliced with the spur slice cutter and the cutter parameters and machining parameters are set based on above the effect law. The machined gear is measured in Gear Measuring Center and the detection result shows that the comprehensive accuracy reaches GB/T Class 7, where some reach GB/T Class 6. The result can meet the gear machining accuracy requirement and shows that the effect law found is valid. The problem of the interference in gear slicing is solved and the gear machining accuracy can be improved.
Current researches have not yet found the effect law of the cutter parameters and machining parameters on the interference in gear slicing, the interference between the cutter and machined gear often happens because the appropriate cutter parameters and machining parameters cannot be set, which reduces the gear machining accuracy. The relative position between the major flank face and edge-sweeping surface, distribution law of the interference area in forming process of edge-sweeping surface, and effect law of relative positions among edge-sweeping surfaces on the interference are studied by graphical analysis. The effect law of the cutter parameters and machining parameters on the interference is found. The effect law shows that the interference in gear slicing can be controlled when the relief angle measured on the top edge and feed of every rotation are chosen respectively larger than 9 and smaller than 0.15 mm/r. An internal helical gear is sliced with the spur slice cutter and the cutter parameters and machining parameters are set based on above the effect law. The machined gear is measured in Gear Measuring Center and the detection result shows that the comprehensive accuracy reaches GB/T Class 7, where some reach GB/T Class 6. The result can meet the gear machining accuracy requirement and shows that the effect law found is valid. The problem of the interference in gear slicing is solved and the gear machining accuracy can be improved.
Distributed Collaborative Response Surface Method for Mechanical Dynamic Assembly Reliability Design
2013, 27(6).
Abstract:
Because of the randomness of many impact factors influencing the dynamic assembly relationship of complex machinery, the reliability analysis of dynamic assembly relationship needs to be accomplished considering the randomness from a probabilistic perspective. To improve the accuracy and efficiency of dynamic assembly relationship reliability analysis, the mechanical dynamic assembly reliability(MDAR) theory and a distributed collaborative response surface method(DCRSM) are proposed. The mathematic model of DCRSM is established based on the quadratic response surface function, and verified by the assembly relationship reliability analysis of aeroengine high pressure turbine(HPT) blade-tip radial running clearance(BTRRC). Through the comparison of the DCRSM, traditional response surface method(RSM) and Monte Carlo Method(MCM), the results show that the DCRSM is not able to accomplish the computational task which is impossible for the other methods when the number of simulation is more than 100 000 times, but also the computational precision for the DCRSM is basically consistent with the MCM and improved by 0.40~4.63% to the RSM, furthermore, the computational efficiency of DCRSM is up to about 188 times of the MCM and 55 times of the RSM under 10000 times simulations. The DCRSM is demonstrated to be a feasible and effective approach for markedly improving the computational efficiency and accuracy of MDAR analysis. Thus, the proposed research provides the promising theory and method for the MDAR design and optimization, and opens a novel research direction of probabilistic analysis for developing the high-performance and high-reliability of aeroengine.
Because of the randomness of many impact factors influencing the dynamic assembly relationship of complex machinery, the reliability analysis of dynamic assembly relationship needs to be accomplished considering the randomness from a probabilistic perspective. To improve the accuracy and efficiency of dynamic assembly relationship reliability analysis, the mechanical dynamic assembly reliability(MDAR) theory and a distributed collaborative response surface method(DCRSM) are proposed. The mathematic model of DCRSM is established based on the quadratic response surface function, and verified by the assembly relationship reliability analysis of aeroengine high pressure turbine(HPT) blade-tip radial running clearance(BTRRC). Through the comparison of the DCRSM, traditional response surface method(RSM) and Monte Carlo Method(MCM), the results show that the DCRSM is not able to accomplish the computational task which is impossible for the other methods when the number of simulation is more than 100 000 times, but also the computational precision for the DCRSM is basically consistent with the MCM and improved by 0.40~4.63% to the RSM, furthermore, the computational efficiency of DCRSM is up to about 188 times of the MCM and 55 times of the RSM under 10000 times simulations. The DCRSM is demonstrated to be a feasible and effective approach for markedly improving the computational efficiency and accuracy of MDAR analysis. Thus, the proposed research provides the promising theory and method for the MDAR design and optimization, and opens a novel research direction of probabilistic analysis for developing the high-performance and high-reliability of aeroengine.
2013, 27(6).
Abstract:
Current studies of fan performance optimization mainly focus on two aspects: one is to improve the blade profile, and another is only to consider the influence of single impeller structural parameter on fan performance. However, there are few studies on the comprehensive effect of the key parameters such as blade number, exit stagger angle of blade and the impeller outlet width on the fan performance. The G4-73 backward centrifugal fan widely used in power plants is selected as the research object. Based on orthogonal design and BP neural network, a model for predicting the centrifugal fan performance parameters is established, and the maximum relative errors of the total pressure and efficiency are 0.974% and 0.333%, respectively. Multi-objective optimization of total pressure and efficiency of the fan is conducted with genetic algorithm, and the optimum combination of impeller structural parameters is proposed. The optimized parameters of blade number, exit stagger angle of blade and the impeller outlet width are seperately 14, 43.9, and 21 cm. The experiments on centrifugal fan performance and noise are conducted before and after the installation of the new impeller. The experimental results show that with the new impeller, the total pressure of fan increases significantly in total range of the flow rate, and the fan efficiency is improved when the relative flow is above 75%, also the high efficiency area is broadened. Additionally, in 65% 100% relative flow, the fan noise is reduced. Under the design operating condition, total pressure and efficiency of the fan are improved by 6.91% and 0.5%, respectively. This research sheds light on the considering of comprehensive effect of impeller structrual parameters on fan performance, and a new impeller can be designed to satisfy the engineering demand such as energy-saving, noise reduction or solving air pressure insufficiency for power plants.
Current studies of fan performance optimization mainly focus on two aspects: one is to improve the blade profile, and another is only to consider the influence of single impeller structural parameter on fan performance. However, there are few studies on the comprehensive effect of the key parameters such as blade number, exit stagger angle of blade and the impeller outlet width on the fan performance. The G4-73 backward centrifugal fan widely used in power plants is selected as the research object. Based on orthogonal design and BP neural network, a model for predicting the centrifugal fan performance parameters is established, and the maximum relative errors of the total pressure and efficiency are 0.974% and 0.333%, respectively. Multi-objective optimization of total pressure and efficiency of the fan is conducted with genetic algorithm, and the optimum combination of impeller structural parameters is proposed. The optimized parameters of blade number, exit stagger angle of blade and the impeller outlet width are seperately 14, 43.9, and 21 cm. The experiments on centrifugal fan performance and noise are conducted before and after the installation of the new impeller. The experimental results show that with the new impeller, the total pressure of fan increases significantly in total range of the flow rate, and the fan efficiency is improved when the relative flow is above 75%, also the high efficiency area is broadened. Additionally, in 65% 100% relative flow, the fan noise is reduced. Under the design operating condition, total pressure and efficiency of the fan are improved by 6.91% and 0.5%, respectively. This research sheds light on the considering of comprehensive effect of impeller structrual parameters on fan performance, and a new impeller can be designed to satisfy the engineering demand such as energy-saving, noise reduction or solving air pressure insufficiency for power plants.
2013, 27(6).
Abstract:
In the classical process for stability studies on the rotor-bearing system with crack faults, the simple discrete model is adopted for research on such problems, which neglect some needful dynamical influence factor, such as the material damping, shearing effect and gyroscopic effects, etc. Therefore, it is necessary to find a precise calculation model for simulation of the rotor-bearing system with cracks faults. In this paper, instead of the traditional simple discrete model, finite element (FE) model is adopted to investigate the motion stability of a nonlinear rotor system with crack fault. According to finite element theory, the FE model of the cracked rotor system is established firstly. It should be pointed out that the element where the crack occurs is modeled by a particular crack element and the supports at both ends are simulated by two nonlinear loads. Then, based on dimensionless and dimensionality reduction, the Newmark- method and the shooting method are employed to study the effect of eccentricity and the depth of crack on instability speed and bifurcation feature. Furthermore, the simulation results are verified by some corresponding experiments. The simulation and experimental results show that instability speed does not change monotonically, but decreases firstly and then increases when the amount of eccentricity increases. Moreover, as the type of instability changes, the instability speed jumps concomitantly. Additionally, the presence of crack fault can disturb the oil whirl, as a result, instability speed tends to increase slightly, but it does not affect the type of instability and jumping phenomenon. This research presents an effective and convenient method which uses the finite element method (FEM) to research the motion stability of the nonlinear rotor-bearing system with cracked faults and other nonlinear force, and the proposed method can provide a theoretical reference for stability analysis and vibration control in more complex relevant rotor-bearing system.
In the classical process for stability studies on the rotor-bearing system with crack faults, the simple discrete model is adopted for research on such problems, which neglect some needful dynamical influence factor, such as the material damping, shearing effect and gyroscopic effects, etc. Therefore, it is necessary to find a precise calculation model for simulation of the rotor-bearing system with cracks faults. In this paper, instead of the traditional simple discrete model, finite element (FE) model is adopted to investigate the motion stability of a nonlinear rotor system with crack fault. According to finite element theory, the FE model of the cracked rotor system is established firstly. It should be pointed out that the element where the crack occurs is modeled by a particular crack element and the supports at both ends are simulated by two nonlinear loads. Then, based on dimensionless and dimensionality reduction, the Newmark- method and the shooting method are employed to study the effect of eccentricity and the depth of crack on instability speed and bifurcation feature. Furthermore, the simulation results are verified by some corresponding experiments. The simulation and experimental results show that instability speed does not change monotonically, but decreases firstly and then increases when the amount of eccentricity increases. Moreover, as the type of instability changes, the instability speed jumps concomitantly. Additionally, the presence of crack fault can disturb the oil whirl, as a result, instability speed tends to increase slightly, but it does not affect the type of instability and jumping phenomenon. This research presents an effective and convenient method which uses the finite element method (FEM) to research the motion stability of the nonlinear rotor-bearing system with cracked faults and other nonlinear force, and the proposed method can provide a theoretical reference for stability analysis and vibration control in more complex relevant rotor-bearing system.
2013, 27(6).
Abstract:
The application of the adaptive growth method is limited because several key techniques during the design process need manual intervention of designers. Key techniques of the method including the ground structure construction and seed selection are studied, so as to make it possible to improve the effectiveness and applicability of the adaptive growth method in stiffener layout design optimization of plates and shells. Three schemes of ground structures, which are comprised by different shell elements and beam elements, are proposed. It is found that the main stiffener layouts resulted from different ground structures are almost the same, but the ground structure comprised by 8-nodes shell elements and both 3-nodes and 2-nodes beam elements can result in clearest stiffener layout, and has good adaptability and low computational cost. An automatic seed selection approach is proposed, which is based on such selection rules that the seeds should be positioned on where the structural strain energy is great for the minimum compliance problem, and satisfy the dispersancy requirement. The adaptive growth method with the suggested key techniques is integrated into an ANSYS-based program, which provides a design tool for the stiffener layout design optimization of plates and shells. Typical design examples, including plate and shell structures to achieve minimum compliance and maximum bulking stability are illustrated. In addition, as a practical mechanical structural design example, the stiffener layout of an inlet structure for a large-scale electrostatic precipitator is also demonstrated. The design results show that the adaptive growth method integrated with the suggested key techniques can effectively and flexibly deal with stiffener layout design problem for plates and shells with complex geometrical shape and loading conditions to achieve various design objectives, thus it provides a new solution method for engineering structural topology design optimization.
The application of the adaptive growth method is limited because several key techniques during the design process need manual intervention of designers. Key techniques of the method including the ground structure construction and seed selection are studied, so as to make it possible to improve the effectiveness and applicability of the adaptive growth method in stiffener layout design optimization of plates and shells. Three schemes of ground structures, which are comprised by different shell elements and beam elements, are proposed. It is found that the main stiffener layouts resulted from different ground structures are almost the same, but the ground structure comprised by 8-nodes shell elements and both 3-nodes and 2-nodes beam elements can result in clearest stiffener layout, and has good adaptability and low computational cost. An automatic seed selection approach is proposed, which is based on such selection rules that the seeds should be positioned on where the structural strain energy is great for the minimum compliance problem, and satisfy the dispersancy requirement. The adaptive growth method with the suggested key techniques is integrated into an ANSYS-based program, which provides a design tool for the stiffener layout design optimization of plates and shells. Typical design examples, including plate and shell structures to achieve minimum compliance and maximum bulking stability are illustrated. In addition, as a practical mechanical structural design example, the stiffener layout of an inlet structure for a large-scale electrostatic precipitator is also demonstrated. The design results show that the adaptive growth method integrated with the suggested key techniques can effectively and flexibly deal with stiffener layout design problem for plates and shells with complex geometrical shape and loading conditions to achieve various design objectives, thus it provides a new solution method for engineering structural topology design optimization.
2013, 27(6).
Abstract:
Test is one of methods to acquire human-seat pressure distribution in driving, with the deficiency of being uneasy to obtain the stress information of soft tissue inside human body and the sheer force of interface between human and seat, which can be obtained by simulation. But current simulation method focuses mainly on calculation itself other than combining it with posture prediction and cab packaging parameters, which cause it difficult to acquire accurate pressure calculation results without accurate posture of human body, and make it almost meaningless to design optimization. Therefore, a human body geometric model with posture change capability is built and linked up with Cascade Prediction Model(CPM), which takes cab packaging parameters as inputs. A detailed finite element model of driver human body is constructed and used to conduct the driver-seat interaction simulation between human body and seat. Good accordance of pressure distribution is observed between simulation and test, which validates the simulation. In addition to the distribution pattern, curves on key sections are used to analyze the pressure and shear stress on the seat surface, as well as soft tissue stress inside human body. The simulation shows that the maximum stress of buttocks locates under the ischial tuberosity, and the maximum stress of trunk occurs near the scapula posterior and the lower waist. These are the places where fatigue usually occurs. The maximum pressure of seat appears at the driver-seat contact area corresponding to the drivers maximum skin tissue stress. In order to guide the seat design and cab packaging and study the influence of posture to pressure distribution, finite element models for different levels of cab packaging parameters are created by using CPM. The pressure distributions are calculated and their tendencies varying with cab packaging parameters are obtained. The method presented provides a new way to accurately simulate the interaction between driver human body and seat, and to guide the seat design and cab packaging so as to improve seating comfort.
Test is one of methods to acquire human-seat pressure distribution in driving, with the deficiency of being uneasy to obtain the stress information of soft tissue inside human body and the sheer force of interface between human and seat, which can be obtained by simulation. But current simulation method focuses mainly on calculation itself other than combining it with posture prediction and cab packaging parameters, which cause it difficult to acquire accurate pressure calculation results without accurate posture of human body, and make it almost meaningless to design optimization. Therefore, a human body geometric model with posture change capability is built and linked up with Cascade Prediction Model(CPM), which takes cab packaging parameters as inputs. A detailed finite element model of driver human body is constructed and used to conduct the driver-seat interaction simulation between human body and seat. Good accordance of pressure distribution is observed between simulation and test, which validates the simulation. In addition to the distribution pattern, curves on key sections are used to analyze the pressure and shear stress on the seat surface, as well as soft tissue stress inside human body. The simulation shows that the maximum stress of buttocks locates under the ischial tuberosity, and the maximum stress of trunk occurs near the scapula posterior and the lower waist. These are the places where fatigue usually occurs. The maximum pressure of seat appears at the driver-seat contact area corresponding to the drivers maximum skin tissue stress. In order to guide the seat design and cab packaging and study the influence of posture to pressure distribution, finite element models for different levels of cab packaging parameters are created by using CPM. The pressure distributions are calculated and their tendencies varying with cab packaging parameters are obtained. The method presented provides a new way to accurately simulate the interaction between driver human body and seat, and to guide the seat design and cab packaging so as to improve seating comfort.
2013, 27(6).
Abstract:
Many methods are proposed to deal with the type synthesis of parallel kinematic mechanisms(PKMs), but most of them are less intuitive to some extent. Thus, to propose a concise and intuitive type synthesis method for engineering application is a very challenging issue, which should be further studied in the field. Grassmann line geometry, which can investigate the dimensions of spatial line-clusters in a concise way, is taken as the mathematic foundation. Atlas method is introduced to visually describe the degrees of freedom(DOFs) and constraints of a mechanism, and the dual rule is brought in to realize the mutual conversion of the freedom-space and constraint-space. Consequently, a systematic method based on Grassmann line geometry and Atlas method is generated and the entire type synthesis process is presented. Three type 4-DOF PKMs, i.e., 1T3R, 2T2R and 3T1R(T: translational DOF; R: rotational DOF), are classified according to the different combinations of the translational DOFs and rotational DOFs. The type synthesis of 4-DOF PKMs is carried out and the possible configurations are thoroughly investigated. Some new PKMs with useful functions are generated during this procedure. The type synthesis method based on Grassmann line geometry and Atlas method is intuitive and concise, and can reduce the complexity of the PKMs type synthesis. Moreover, this method can provide theoretical guidance for other PKMs type synthesis and engineering application. A novel type synthesis method is proposed, which solves the existing methods problems in terms of complicated, not intuitive and unsuitable for practical application.
Many methods are proposed to deal with the type synthesis of parallel kinematic mechanisms(PKMs), but most of them are less intuitive to some extent. Thus, to propose a concise and intuitive type synthesis method for engineering application is a very challenging issue, which should be further studied in the field. Grassmann line geometry, which can investigate the dimensions of spatial line-clusters in a concise way, is taken as the mathematic foundation. Atlas method is introduced to visually describe the degrees of freedom(DOFs) and constraints of a mechanism, and the dual rule is brought in to realize the mutual conversion of the freedom-space and constraint-space. Consequently, a systematic method based on Grassmann line geometry and Atlas method is generated and the entire type synthesis process is presented. Three type 4-DOF PKMs, i.e., 1T3R, 2T2R and 3T1R(T: translational DOF; R: rotational DOF), are classified according to the different combinations of the translational DOFs and rotational DOFs. The type synthesis of 4-DOF PKMs is carried out and the possible configurations are thoroughly investigated. Some new PKMs with useful functions are generated during this procedure. The type synthesis method based on Grassmann line geometry and Atlas method is intuitive and concise, and can reduce the complexity of the PKMs type synthesis. Moreover, this method can provide theoretical guidance for other PKMs type synthesis and engineering application. A novel type synthesis method is proposed, which solves the existing methods problems in terms of complicated, not intuitive and unsuitable for practical application.
2013, 27(6).
Abstract:
Most researches on micro-arc oxidation mainly focus on the application rather than discovering the evolution of residual stresses. However, residual stresses in the surface coatings of structural components have adverse effects on their properties, such as fatigue life, dimensional stability and corrosion resistance, etc. The micro-arc oxidation ceramic coatings are produced on the surfaces of 6061 aluminum alloy by a homemade asymmetric AC type of micro-arc oxidation equipment of 20 kW. A constant current density of 4.40.1 Adm2 and a self-regulated composite electrolyte are used. The micro-arc oxidation treatment period ranges from 10 min to 40 min, and the thickness of the ceramic coatings is more than 20 m. Residual stresses attributed to -Al2O3 constituent in the coatings at different micro-arc oxidation periods are analyzed by an X-ray diffractometer using the sin2 method. The analysis results show that the residual stress in the ceramic coatings is compressive in nature, and it increases first and then decreases with micro-arc oxidation time increase. The maximum stress value is 1 66720 MPa for period of 20 min. Through analyzing the coating thickness, surface morphology and phase composition, it is found that the residual stress in the ceramic coatings is linked closely with the coating growth, the phase composition and the micro cracks formed. It is also found that both the heat treatment and the ultrasonic action release remarkably the residual compressive stress. The heat treatment makes the residual compressive stress value decrease 1 378 MPa. The ultrasonic action even alters the nature of the residual stress, making the residual compressive stress change into a residual tensile stress.
Most researches on micro-arc oxidation mainly focus on the application rather than discovering the evolution of residual stresses. However, residual stresses in the surface coatings of structural components have adverse effects on their properties, such as fatigue life, dimensional stability and corrosion resistance, etc. The micro-arc oxidation ceramic coatings are produced on the surfaces of 6061 aluminum alloy by a homemade asymmetric AC type of micro-arc oxidation equipment of 20 kW. A constant current density of 4.40.1 Adm2 and a self-regulated composite electrolyte are used. The micro-arc oxidation treatment period ranges from 10 min to 40 min, and the thickness of the ceramic coatings is more than 20 m. Residual stresses attributed to -Al2O3 constituent in the coatings at different micro-arc oxidation periods are analyzed by an X-ray diffractometer using the sin2 method. The analysis results show that the residual stress in the ceramic coatings is compressive in nature, and it increases first and then decreases with micro-arc oxidation time increase. The maximum stress value is 1 66720 MPa for period of 20 min. Through analyzing the coating thickness, surface morphology and phase composition, it is found that the residual stress in the ceramic coatings is linked closely with the coating growth, the phase composition and the micro cracks formed. It is also found that both the heat treatment and the ultrasonic action release remarkably the residual compressive stress. The heat treatment makes the residual compressive stress value decrease 1 378 MPa. The ultrasonic action even alters the nature of the residual stress, making the residual compressive stress change into a residual tensile stress.
2013, 27(6).
Abstract:
The current research of micro-grinding mainly focuses on the optimal processing technology for different materials. However, the material removal mechanism in micro-grinding is the base of achieving high quality processing surface. Therefore, a novel method for predicting surface roughness in micro-grinding of hard brittle materials considering micro-grinding tool grains protrusion topography is proposed in this paper. The differences of material removal mechanism between convention grinding process and micro-grinding process are analyzed. Topography characterization has been done on micro-grinding tools which are fabricated by electroplating. Models of grain density generation and grain interval are built, and new predicting model of micro-grinding surface roughness is developed. In order to verify the precision and application effect of the surface roughness prediction model proposed, a micro-grinding orthogonally experiment on soda-lime glass is designed and conducted. A series of micro-machining surfaces which are 78 nm to 0.98 m roughness of brittle material is achieved. It is found that experimental roughness results and the predicting roughness data have an evident coincidence, and the component variable of describing the size effects in predicting model is calculated to be 1.5 107 by reverse method based on the experimental results. The proposed model builds a set of distribution to consider grains distribution densities in different protrusion heights. Finally, the characterization of micro-grinding tools which are used in the experiment has been done based on the distribution set. It is concluded that there is a significant coincidence between surface prediction data from the proposed model and measurements from experiment results. Therefore, the effectiveness of the model is demonstrated. This paper proposes a novel method for predicting surface roughness in micro-grinding of hard brittle materials considering micro-grinding tool grains protrusion topography, which would provide significant research theory and experimental reference of material removal mechanism in micro-grinding of soda-lime glass.
The current research of micro-grinding mainly focuses on the optimal processing technology for different materials. However, the material removal mechanism in micro-grinding is the base of achieving high quality processing surface. Therefore, a novel method for predicting surface roughness in micro-grinding of hard brittle materials considering micro-grinding tool grains protrusion topography is proposed in this paper. The differences of material removal mechanism between convention grinding process and micro-grinding process are analyzed. Topography characterization has been done on micro-grinding tools which are fabricated by electroplating. Models of grain density generation and grain interval are built, and new predicting model of micro-grinding surface roughness is developed. In order to verify the precision and application effect of the surface roughness prediction model proposed, a micro-grinding orthogonally experiment on soda-lime glass is designed and conducted. A series of micro-machining surfaces which are 78 nm to 0.98 m roughness of brittle material is achieved. It is found that experimental roughness results and the predicting roughness data have an evident coincidence, and the component variable of describing the size effects in predicting model is calculated to be 1.5 107 by reverse method based on the experimental results. The proposed model builds a set of distribution to consider grains distribution densities in different protrusion heights. Finally, the characterization of micro-grinding tools which are used in the experiment has been done based on the distribution set. It is concluded that there is a significant coincidence between surface prediction data from the proposed model and measurements from experiment results. Therefore, the effectiveness of the model is demonstrated. This paper proposes a novel method for predicting surface roughness in micro-grinding of hard brittle materials considering micro-grinding tool grains protrusion topography, which would provide significant research theory and experimental reference of material removal mechanism in micro-grinding of soda-lime glass.
2013, 27(6).
Abstract:
The discrete Fourier transform(DFT) is used for fractional Brownian motion(FBM) surface synthesis in tribology(i.e., contact, sliding, and sealing, etc). However, the relationship between fractal parameters(fractal dimension and scale factor) and traditional parameters, the influence of fractal parameters on surface appearance, have not been deeply discussed yet. These lead to some kind of difficulty to ensure the synthesized surfaces with ideal fractal characteristic, required traditional parameters and geometric appearance. A quantitative relationship between fractal parameters and the root mean square deviation of surface (Sq) is derived based on the energy conservation property between the space and frequency domain of DFT. Under the stability assumption, the power spectrum of a FBM surface is composed of concentric circles strictly, a series of FBM surfaces with prescribed Sq could be synthesized with given fractal dimension, scale factor, and sampling numbers, but the ten-point height(Sz), the skewness(Ssk) and the kurtosis(Sku) are still in random, where the probability distributions of Sz and Ssk are approximately normal distribution. Furthermore, by iterative searching, a surface with desired Abbott-Firestone curve could be obtained among those surfaces. An intuitive explanation for the influence of fractal dimension and scale factor on surface appearance is obtained by discussing the effects on the ratio of energy between high and low frequency components. Based on the relationship between Sq and surface energy, a filtering method of surface with controllable Sq is proposed. The proposed research ensures the synthesized surfaces possess ideal FBM properties with prescribed Sq, offers a method for selecting desired Abbott-Firestone curve of synthesized fractal surfaces, and makes it possible to control the Sq of surfaces after filtering.
The discrete Fourier transform(DFT) is used for fractional Brownian motion(FBM) surface synthesis in tribology(i.e., contact, sliding, and sealing, etc). However, the relationship between fractal parameters(fractal dimension and scale factor) and traditional parameters, the influence of fractal parameters on surface appearance, have not been deeply discussed yet. These lead to some kind of difficulty to ensure the synthesized surfaces with ideal fractal characteristic, required traditional parameters and geometric appearance. A quantitative relationship between fractal parameters and the root mean square deviation of surface (Sq) is derived based on the energy conservation property between the space and frequency domain of DFT. Under the stability assumption, the power spectrum of a FBM surface is composed of concentric circles strictly, a series of FBM surfaces with prescribed Sq could be synthesized with given fractal dimension, scale factor, and sampling numbers, but the ten-point height(Sz), the skewness(Ssk) and the kurtosis(Sku) are still in random, where the probability distributions of Sz and Ssk are approximately normal distribution. Furthermore, by iterative searching, a surface with desired Abbott-Firestone curve could be obtained among those surfaces. An intuitive explanation for the influence of fractal dimension and scale factor on surface appearance is obtained by discussing the effects on the ratio of energy between high and low frequency components. Based on the relationship between Sq and surface energy, a filtering method of surface with controllable Sq is proposed. The proposed research ensures the synthesized surfaces possess ideal FBM properties with prescribed Sq, offers a method for selecting desired Abbott-Firestone curve of synthesized fractal surfaces, and makes it possible to control the Sq of surfaces after filtering.
2013, 27(6).
Abstract:
In order to get a rapid assessment on the storage reliability of high-reliable and long-life products within the storage period, accelerated degradation test data with a large amount of reliability information of product is adopted. Conducting a constant-stress accelerated degradation test(CSADT) is generally very costly as it requires a large sample size and long time for test. To overcome this problem, it is necessary to carry out research on modeling and statistical analysis methods of step-stress accelerated degradation test (SSADT). Taking electrical connectors as the object, a research is conducted on statistical model and assessment method for SSADT. On the basis of mixed-effect degradation path model, the statistical model of SSADT for electrical connectors is presented, the maximum likelihood method for SSADT data based on mixed-effect degradation model is proposed. SSADT accelerated by temperature stress is conducted to Y11X-1419 type of electrical connectors, and the storage reliability is assessed with the SSADT data. Compared with the result obtained from accelerated life test, the reliability estimation of 32-year storage period for electrical connectors obtained from SSADT data only have a difference of 0.869%, which validates the accuracy of the degradation model and the feasibility of the test data statistic analysis method put forward.
In order to get a rapid assessment on the storage reliability of high-reliable and long-life products within the storage period, accelerated degradation test data with a large amount of reliability information of product is adopted. Conducting a constant-stress accelerated degradation test(CSADT) is generally very costly as it requires a large sample size and long time for test. To overcome this problem, it is necessary to carry out research on modeling and statistical analysis methods of step-stress accelerated degradation test (SSADT). Taking electrical connectors as the object, a research is conducted on statistical model and assessment method for SSADT. On the basis of mixed-effect degradation path model, the statistical model of SSADT for electrical connectors is presented, the maximum likelihood method for SSADT data based on mixed-effect degradation model is proposed. SSADT accelerated by temperature stress is conducted to Y11X-1419 type of electrical connectors, and the storage reliability is assessed with the SSADT data. Compared with the result obtained from accelerated life test, the reliability estimation of 32-year storage period for electrical connectors obtained from SSADT data only have a difference of 0.869%, which validates the accuracy of the degradation model and the feasibility of the test data statistic analysis method put forward.
2013, 27(6).
Abstract:
Modelica-based object-orient method is proved to be rapid, accurate and easy to modify, which is suitable for prototype modeling and simulation of rotor system, whose parameters need to be modified frequently. Classical non-object-orient method appears to be inefficient because the code is difficult to modify and reuse. An adequate library for object-orient modeling of rotor system with multi-faults is established, a comparison with non-object-orient method on Jeffcott rotor system and a case study on turbo expander with multi-faults are implemented. The relative tolerance between object-orient method and non-object-orient is less than 0.03%, which proves that these two methods are as accurate as each other. Object-orient modeling and simulation is implemented on turbo expander with crack, rub-impact, pedestal looseness and multi-faults simultaneously. It can be conclude from the case study that when acting on compress side of turbo expander separately, expand wheel is not influenced greatly by crack fault, the existence of rub-impact fault forces expand wheel into quasi-periodic motion and the orbit of expand wheel is deformed and enhanced almost 1.5 times due to pedestal looseness. When acting simultaneously, multi-faults cannot be totally decomposed but can be diagnosed from the feature of vibration. Object-orient method can enhance the efficiency of modeling and simulation of rotor system with multi-faults, which provides an efficient method on prototype modeling and simulation.
Modelica-based object-orient method is proved to be rapid, accurate and easy to modify, which is suitable for prototype modeling and simulation of rotor system, whose parameters need to be modified frequently. Classical non-object-orient method appears to be inefficient because the code is difficult to modify and reuse. An adequate library for object-orient modeling of rotor system with multi-faults is established, a comparison with non-object-orient method on Jeffcott rotor system and a case study on turbo expander with multi-faults are implemented. The relative tolerance between object-orient method and non-object-orient is less than 0.03%, which proves that these two methods are as accurate as each other. Object-orient modeling and simulation is implemented on turbo expander with crack, rub-impact, pedestal looseness and multi-faults simultaneously. It can be conclude from the case study that when acting on compress side of turbo expander separately, expand wheel is not influenced greatly by crack fault, the existence of rub-impact fault forces expand wheel into quasi-periodic motion and the orbit of expand wheel is deformed and enhanced almost 1.5 times due to pedestal looseness. When acting simultaneously, multi-faults cannot be totally decomposed but can be diagnosed from the feature of vibration. Object-orient method can enhance the efficiency of modeling and simulation of rotor system with multi-faults, which provides an efficient method on prototype modeling and simulation.
2013, 27(6).
Abstract:
The accelerated degradation in the front cells of a polymer electrolyte membrane fuel cell(PEMFC) stack seriously reduces the reliability and durability of the whole stack. Most researches only focus on the size and configuration of the gas intake manifold, which may lead to the maldistribution of flow and pressure. In order to find out the mechanisms of the accelerated degradation in the front cells, an extensive program of experimental and simulation work is initiated and the results are reported. It is found that after long-term lifetime tests the accelerated degradation in the front cells occurs in all three fuel cell stacks with different flow-fields under the U-type feed configuration. Compared with the rear cells of the stack, the voltage of the front cells is much lower at the same current densities and the membrane electrode assembly(MEA) has smaller active area, more catalyst particle agglomeration and higher ohmic impedance. For further investigation, a series of three dimensional isothermal numerical models are built to investigate the degradation mechanisms based on the experimental data. The simulation results reveal that the dry working condition of the membrane and the effect of high-speed gas scouring the MEA are the main causes of the accelerated degradation in the front cells of a PEM fuel cell stack under the U-type feed configuration. Several mitigation strategies that would mitigate these phenomena are presented: removing cells that have failed and replacing them with those of the same aging condition as the average of the stack; choosing a Z-type feed pattern instead of a U-type one; putting several air flow-field plates without MEA in the front of the stack; or exchanging the gas inlet and outlet alternately at a certain interval. This paper specifies the causes of the accelerated degradation in the front cells and provides the mitigation strategies.
The accelerated degradation in the front cells of a polymer electrolyte membrane fuel cell(PEMFC) stack seriously reduces the reliability and durability of the whole stack. Most researches only focus on the size and configuration of the gas intake manifold, which may lead to the maldistribution of flow and pressure. In order to find out the mechanisms of the accelerated degradation in the front cells, an extensive program of experimental and simulation work is initiated and the results are reported. It is found that after long-term lifetime tests the accelerated degradation in the front cells occurs in all three fuel cell stacks with different flow-fields under the U-type feed configuration. Compared with the rear cells of the stack, the voltage of the front cells is much lower at the same current densities and the membrane electrode assembly(MEA) has smaller active area, more catalyst particle agglomeration and higher ohmic impedance. For further investigation, a series of three dimensional isothermal numerical models are built to investigate the degradation mechanisms based on the experimental data. The simulation results reveal that the dry working condition of the membrane and the effect of high-speed gas scouring the MEA are the main causes of the accelerated degradation in the front cells of a PEM fuel cell stack under the U-type feed configuration. Several mitigation strategies that would mitigate these phenomena are presented: removing cells that have failed and replacing them with those of the same aging condition as the average of the stack; choosing a Z-type feed pattern instead of a U-type one; putting several air flow-field plates without MEA in the front of the stack; or exchanging the gas inlet and outlet alternately at a certain interval. This paper specifies the causes of the accelerated degradation in the front cells and provides the mitigation strategies.
2013, 27(6).
Abstract:
The determination of virtual constraints is always one of the key and difficult problems in traditional mobility calculation. To make mobility calculation simple, considering avoiding virtual constraints, some new formulae have been presented, however these formulae can hardly intuitively reflect general link groups restrictions on output member and its influences on independence of output parameters, which is premise to the judgment of the properties of mobility. Towards the problem to reveal the intrinsic relationship between the degree of freedom(DOF) of a mechanism, the link group, and the dimension of output parameters, also to avoid determination of virtual constraint, based on the new concepts of the DOF of general link group and node parameters, a new formula in the calculation of the mobility of mechanisms is presented that is expressed with DOFs of the general link groups and rank of motion parameters of base point of the output link. It is named GOM(mobility of groups and output parameter) formula. On the basis of new concepts of effective parameters and invalid parameters, a rule is put forward for solving the DOF of mechanisms with invalid parameters by GOM formula, that is, the base point parameters are the subset of effective parameters of link group. Thereafter, several examples are enumerated and the results coincide with the prototype data, which proves the validity of the proposed formula. Meanwhile, it is obtained that the necessary and sufficient condition for the judgment of output parameters independence is that each of the DOF of the link group is not less than zero. The proposed formula which is simple in calculation provides theoretical basis for the judgment of independence of output parameters and provides references for type synthesis of novel parallel mechanisms with independence requirements of their output parameters.
The determination of virtual constraints is always one of the key and difficult problems in traditional mobility calculation. To make mobility calculation simple, considering avoiding virtual constraints, some new formulae have been presented, however these formulae can hardly intuitively reflect general link groups restrictions on output member and its influences on independence of output parameters, which is premise to the judgment of the properties of mobility. Towards the problem to reveal the intrinsic relationship between the degree of freedom(DOF) of a mechanism, the link group, and the dimension of output parameters, also to avoid determination of virtual constraint, based on the new concepts of the DOF of general link group and node parameters, a new formula in the calculation of the mobility of mechanisms is presented that is expressed with DOFs of the general link groups and rank of motion parameters of base point of the output link. It is named GOM(mobility of groups and output parameter) formula. On the basis of new concepts of effective parameters and invalid parameters, a rule is put forward for solving the DOF of mechanisms with invalid parameters by GOM formula, that is, the base point parameters are the subset of effective parameters of link group. Thereafter, several examples are enumerated and the results coincide with the prototype data, which proves the validity of the proposed formula. Meanwhile, it is obtained that the necessary and sufficient condition for the judgment of output parameters independence is that each of the DOF of the link group is not less than zero. The proposed formula which is simple in calculation provides theoretical basis for the judgment of independence of output parameters and provides references for type synthesis of novel parallel mechanisms with independence requirements of their output parameters.
2013, 27(6).
Abstract:
In current research about nanofluid convection heat transfer, random motion of nanoparticles in the liquid distribution problem mostly was not considered. In order to study on the distribution of nanoparticles in liquid, nanofluid transport model in pipe is established by using the continuity equation, momentum equation and Fokker-Planck equation. The velocity distribution and the nanoparticles distribution in liquid are obtained by numerical calculation, and the effect of particle size and particle volume fraction on convection heat transfer coefficient of nanofluids is analyzed. The result shows that in high volume fraction ( ), the velocity distribution of nanofluids characterizes as a cork-shaped structure, which is significantly different from viscous fluid with a parabolic distribution. The convection heat transfer coefficient increases while the particle size of nanoparticle in nanofluids decreases. And the convection heat transfer coefficient of nanofluids is in good agreement with the experimental result both in low ( ) and high ( ) volume fractions. In presented model, Brown motion, the effect of interactions between nanoparticles and fluid coupling, is also considered, but any phenomenological parameter is not introduced. Nanoparticles in liquid transport distribution can be quantitatively calculated by this model.
In current research about nanofluid convection heat transfer, random motion of nanoparticles in the liquid distribution problem mostly was not considered. In order to study on the distribution of nanoparticles in liquid, nanofluid transport model in pipe is established by using the continuity equation, momentum equation and Fokker-Planck equation. The velocity distribution and the nanoparticles distribution in liquid are obtained by numerical calculation, and the effect of particle size and particle volume fraction on convection heat transfer coefficient of nanofluids is analyzed. The result shows that in high volume fraction ( ), the velocity distribution of nanofluids characterizes as a cork-shaped structure, which is significantly different from viscous fluid with a parabolic distribution. The convection heat transfer coefficient increases while the particle size of nanoparticle in nanofluids decreases. And the convection heat transfer coefficient of nanofluids is in good agreement with the experimental result both in low ( ) and high ( ) volume fractions. In presented model, Brown motion, the effect of interactions between nanoparticles and fluid coupling, is also considered, but any phenomenological parameter is not introduced. Nanoparticles in liquid transport distribution can be quantitatively calculated by this model.
2013, 27(6).
Abstract:
The current researches of the wear and spalling behaviors of wheel/rail materials focus on the field investigation rather than the mechanism. However, it is necessary and significant for clarifying the mechanism and relationship between the wear and spalling damage of railway wheel to test and reproduce the wheel damages in laboratory. The objective of this paper is to investigate the wear and spalling damage behaviors of railway wheel using a JD-1 wheel/rail simulation facility, which consists of a small wheel serving as rolling stock wheel, and a larger wheel serving as rail. The damage process of wheel roller is explored in terms of the creep ratio, axle load, and carbon content by means of various microscopic examinations. The experimental results show that the wear volume growth of wheel roller is proved to be proportional to the increase of the creep ratio and normal load between simulating wheel and rail. The increase of carbon content of wheel material causes a linear reduction in the wear volume. The microscopic examinations indicate that the rolling wear mechanism transfers from abrasive wear to adhesive and fatigue wear with an increase of tangential friction force, which results in the initiation of fatigue crack, and then aggravates spalling damage on the wheel roller surface. The surface hardness of material depends strongly upon its carbon content. The decrease of the carbon content of wheel material may alleviate spalling damage, but can cause a significant growth in the wear volume of wheel roller. Therefore, there is a competitive relationship between the wear and spalling damage of wheel material. This research proposes an important measure for alleviating or preventing the wear and spalling damage of railway wheel material.
The current researches of the wear and spalling behaviors of wheel/rail materials focus on the field investigation rather than the mechanism. However, it is necessary and significant for clarifying the mechanism and relationship between the wear and spalling damage of railway wheel to test and reproduce the wheel damages in laboratory. The objective of this paper is to investigate the wear and spalling damage behaviors of railway wheel using a JD-1 wheel/rail simulation facility, which consists of a small wheel serving as rolling stock wheel, and a larger wheel serving as rail. The damage process of wheel roller is explored in terms of the creep ratio, axle load, and carbon content by means of various microscopic examinations. The experimental results show that the wear volume growth of wheel roller is proved to be proportional to the increase of the creep ratio and normal load between simulating wheel and rail. The increase of carbon content of wheel material causes a linear reduction in the wear volume. The microscopic examinations indicate that the rolling wear mechanism transfers from abrasive wear to adhesive and fatigue wear with an increase of tangential friction force, which results in the initiation of fatigue crack, and then aggravates spalling damage on the wheel roller surface. The surface hardness of material depends strongly upon its carbon content. The decrease of the carbon content of wheel material may alleviate spalling damage, but can cause a significant growth in the wear volume of wheel roller. Therefore, there is a competitive relationship between the wear and spalling damage of wheel material. This research proposes an important measure for alleviating or preventing the wear and spalling damage of railway wheel material.
2013, 27(6).
Abstract:
Nanoscale sliding contacts of smooth surfaces or between a single asperity and a smooth surface have been widely investigated by molecular dynamics simulations, while there are few studies on the sliding contacts between two rough surfaces. Actually, the friction of two rough surfaces considering interactions between more asperities should be more realistic. By using multiscale method, friction characteristics of two dimensional nanoscale sliding contacts between rigid multi-asperity tips and elastic textured surfaces are investigated. Four nanoscale textured surfaces with different texture shapes are designed, and six multi-asperity tips composed of cylindrical asperities with different radii are used to slide on the textured surfaces. Friction forces are compared for different tips, and effects of the asperity radii on the friction characteristics are investigated. Average friction forces for all the cases are listed and compared, and effects of texture shapes of the textured surfaces are discussed. The results show that textured surface II has a better structure to reduce friction forces. The multi-asperity tips composed of asperities with R20r0 (r00.227 7 nm) or R30r0 get higher friction forces compared with other cases, and more atoms of the textured surfaces are taken away by these two tips, which are harmful to reduce friction or wear. For the case of R10r0, friction forces are also high due to large contact areas, but the sliding processes are stable and few atoms are taken away by the tip. The proposed research considers interactions between more asperities to make the model approach to the real sliding contact problems. The results will help to vary or even control friction characteristics by textured surfaces, or provide references to the design of textured surfaces.
Nanoscale sliding contacts of smooth surfaces or between a single asperity and a smooth surface have been widely investigated by molecular dynamics simulations, while there are few studies on the sliding contacts between two rough surfaces. Actually, the friction of two rough surfaces considering interactions between more asperities should be more realistic. By using multiscale method, friction characteristics of two dimensional nanoscale sliding contacts between rigid multi-asperity tips and elastic textured surfaces are investigated. Four nanoscale textured surfaces with different texture shapes are designed, and six multi-asperity tips composed of cylindrical asperities with different radii are used to slide on the textured surfaces. Friction forces are compared for different tips, and effects of the asperity radii on the friction characteristics are investigated. Average friction forces for all the cases are listed and compared, and effects of texture shapes of the textured surfaces are discussed. The results show that textured surface II has a better structure to reduce friction forces. The multi-asperity tips composed of asperities with R20r0 (r00.227 7 nm) or R30r0 get higher friction forces compared with other cases, and more atoms of the textured surfaces are taken away by these two tips, which are harmful to reduce friction or wear. For the case of R10r0, friction forces are also high due to large contact areas, but the sliding processes are stable and few atoms are taken away by the tip. The proposed research considers interactions between more asperities to make the model approach to the real sliding contact problems. The results will help to vary or even control friction characteristics by textured surfaces, or provide references to the design of textured surfaces.
2013, 27(6).
Abstract:
Electro-hydraulic control systems are nonlinear in nature and their mathematic models have unknown parameters. Existing research of modeling and identification of the electro-hydraulic control system is mainly based on theoretical state space model, and the parameters identification is hard due to its demand on internal states measurement. Moreover, there are also some hard-to-model nonlinearities in theoretical model, which needs to be overcome. Modeling and identification of the electro-hydraulic control system of an excavator arm based on block-oriented nonlinear(BONL) models is investigated. The nonlinear state space model of the system is built first, and field tests are carried out to reveal the nonlinear characteristics of the system. Based on the physic insight into the system, three BONL models are adopted to describe the highly nonlinear system. The Hammerstein model is composed of a two-segment polynomial nonlinearity followed by a linear dynamic subsystem. The Hammerstein-Wiener(H-W) model is represented by the Hammerstein model in cascade with another single polynomial nonlinearity. A novel Pseudo-Hammerstein-Wiener(P-H-W) model is developed by replacing the single polynomial of the H-W model by a non-smooth backlash function. The key term separation principle is applied to simplify the BONL models into linear-in-parameters structures. Then, a modified recursive least square algorithm(MRLSA) with iterative estimation of internal variables is developed to identify the all the parameters simultaneously. The identification results demonstrate that the BONL models with two-segment polynomial nonlinearities are able to capture the system behavior, and the P-H-W model has the best prediction accuracy. Comparison experiments show that the velocity prediction error of the P-H-W model is reduced by 14%, 30% and 75% to the H-W model, Hammerstein model, and extended auto-regressive (ARX) model, respectively. This research is helpful in controller design, system monitoring and diagnosis.
Electro-hydraulic control systems are nonlinear in nature and their mathematic models have unknown parameters. Existing research of modeling and identification of the electro-hydraulic control system is mainly based on theoretical state space model, and the parameters identification is hard due to its demand on internal states measurement. Moreover, there are also some hard-to-model nonlinearities in theoretical model, which needs to be overcome. Modeling and identification of the electro-hydraulic control system of an excavator arm based on block-oriented nonlinear(BONL) models is investigated. The nonlinear state space model of the system is built first, and field tests are carried out to reveal the nonlinear characteristics of the system. Based on the physic insight into the system, three BONL models are adopted to describe the highly nonlinear system. The Hammerstein model is composed of a two-segment polynomial nonlinearity followed by a linear dynamic subsystem. The Hammerstein-Wiener(H-W) model is represented by the Hammerstein model in cascade with another single polynomial nonlinearity. A novel Pseudo-Hammerstein-Wiener(P-H-W) model is developed by replacing the single polynomial of the H-W model by a non-smooth backlash function. The key term separation principle is applied to simplify the BONL models into linear-in-parameters structures. Then, a modified recursive least square algorithm(MRLSA) with iterative estimation of internal variables is developed to identify the all the parameters simultaneously. The identification results demonstrate that the BONL models with two-segment polynomial nonlinearities are able to capture the system behavior, and the P-H-W model has the best prediction accuracy. Comparison experiments show that the velocity prediction error of the P-H-W model is reduced by 14%, 30% and 75% to the H-W model, Hammerstein model, and extended auto-regressive (ARX) model, respectively. This research is helpful in controller design, system monitoring and diagnosis.
2013, 27(6).
Abstract:
Compared with the conventional single-roller spinning process, the double-roller clamping spinning(DRCS) process can effectively prevent the sheet metal surface wrinkling and improve the the production efficiency and the shape precision of final spun part. Based on ABAQUS/Explicit nonlinear finite element software, the finite element model of the multi-pass DRCS for the sheet metal is established, and the material model, the contact definition, the mesh generation, the loading trajectory and other key technical problems are solved. The simulations on the multi-pass DRCS of the ordinary Q235A steel cylindrical part with the arc-shaped surface flange are carried out. The effects of number of spinning passes on the production efficiency, the spinning moment, the shape error of the workpiece, and the wall thickness distribution of the final part are obtained. It is indicated definitely that with the increase of the number of spinning passes the geometrical precision of the spun part increases while the production efficiency reduces. Moreover, the variations of the spinning forces and the distributions of the stresses, strains, wall thickness during the multi-pass DRCS process are revealed. It is indicated that during the DRCS process the radical force is the largest, and the whole deformation area shows the tangential tensile strain and the radial compressive strain, while the thickness strain changes along the generatrix directions from the compressive strain on the outer edge of the flange to the tensile strain on the inner edge of the flange. Based on the G-CNC6135 NC lathe, the three-axis linkage computer-controlled experimental device for DRCS which is driven by the AC servo motor is developed. And then using the experimental device, the Q235A cylindrical parts with the arc-shape surface flange are formed by the DRCS. The simulation results of spun parts have good consistency with the experimental results, which verifies the feasibility of DRCS process and the reliability of the finite element model for DRCS.
Compared with the conventional single-roller spinning process, the double-roller clamping spinning(DRCS) process can effectively prevent the sheet metal surface wrinkling and improve the the production efficiency and the shape precision of final spun part. Based on ABAQUS/Explicit nonlinear finite element software, the finite element model of the multi-pass DRCS for the sheet metal is established, and the material model, the contact definition, the mesh generation, the loading trajectory and other key technical problems are solved. The simulations on the multi-pass DRCS of the ordinary Q235A steel cylindrical part with the arc-shaped surface flange are carried out. The effects of number of spinning passes on the production efficiency, the spinning moment, the shape error of the workpiece, and the wall thickness distribution of the final part are obtained. It is indicated definitely that with the increase of the number of spinning passes the geometrical precision of the spun part increases while the production efficiency reduces. Moreover, the variations of the spinning forces and the distributions of the stresses, strains, wall thickness during the multi-pass DRCS process are revealed. It is indicated that during the DRCS process the radical force is the largest, and the whole deformation area shows the tangential tensile strain and the radial compressive strain, while the thickness strain changes along the generatrix directions from the compressive strain on the outer edge of the flange to the tensile strain on the inner edge of the flange. Based on the G-CNC6135 NC lathe, the three-axis linkage computer-controlled experimental device for DRCS which is driven by the AC servo motor is developed. And then using the experimental device, the Q235A cylindrical parts with the arc-shape surface flange are formed by the DRCS. The simulation results of spun parts have good consistency with the experimental results, which verifies the feasibility of DRCS process and the reliability of the finite element model for DRCS.
2013, 27(6).
Abstract:
Nonnegative Tucker3 decomposition(NTD) has attracted lots of attentions for its good performance in 3D data array analysis. However, further research is still necessary to solve the problems of overfitting and slow convergence under the anharmonic vibration circumstance occurred in the field of mechanical fault diagnosis. To decompose a large-scale tensor and extract available bispectrum feature, a method of conjugating Choi-Williams kernel function with Gauss-Newton Cartesian product based on nonnegative Tucker3 decomposition(NTD_EDF) is investigated. The complexity of the proposed method is reduced from in 3D spaces to in 1D vectors due to its low rank form of the Tucker-product convolution. Meanwhile, a simultaneously updating algorithm is given to overcome the overfitting, slow convergence and low efficiency existing in the conventional one-by-one updating algorithm. Furthermore, the technique of spectral phase analysis for quadratic coupling estimation is used to explain the feature spectrum extracted from the gearbox fault data by the proposed method in detail. The simulated and experimental results show that the sparser and more inerratic feature distribution of basis images can be obtained with core tensor by the NTD_EDF method compared with the one by the other methods in bispectrum feature extraction, and a legible fault expression can also be performed by power spectral density(PSD) function. Besides, the deviations of successive relative error(DSRE) of NTD_EDF achieves 81.66 dB against 15.17 dB by beta-divergences based on NTD(NTD_Beta) and the time-cost of NTD_EDF is only 129.3 s, which is far less than 1 747.9 s by hierarchical alternative least square based on NTD (NTD_HALS). The NTD_EDF method proposed not only avoids the data overfitting and improves the computation efficiency but also can be used to extract more inerratic and sparser bispectrum features of the gearbox fault.
Nonnegative Tucker3 decomposition(NTD) has attracted lots of attentions for its good performance in 3D data array analysis. However, further research is still necessary to solve the problems of overfitting and slow convergence under the anharmonic vibration circumstance occurred in the field of mechanical fault diagnosis. To decompose a large-scale tensor and extract available bispectrum feature, a method of conjugating Choi-Williams kernel function with Gauss-Newton Cartesian product based on nonnegative Tucker3 decomposition(NTD_EDF) is investigated. The complexity of the proposed method is reduced from in 3D spaces to in 1D vectors due to its low rank form of the Tucker-product convolution. Meanwhile, a simultaneously updating algorithm is given to overcome the overfitting, slow convergence and low efficiency existing in the conventional one-by-one updating algorithm. Furthermore, the technique of spectral phase analysis for quadratic coupling estimation is used to explain the feature spectrum extracted from the gearbox fault data by the proposed method in detail. The simulated and experimental results show that the sparser and more inerratic feature distribution of basis images can be obtained with core tensor by the NTD_EDF method compared with the one by the other methods in bispectrum feature extraction, and a legible fault expression can also be performed by power spectral density(PSD) function. Besides, the deviations of successive relative error(DSRE) of NTD_EDF achieves 81.66 dB against 15.17 dB by beta-divergences based on NTD(NTD_Beta) and the time-cost of NTD_EDF is only 129.3 s, which is far less than 1 747.9 s by hierarchical alternative least square based on NTD (NTD_HALS). The NTD_EDF method proposed not only avoids the data overfitting and improves the computation efficiency but also can be used to extract more inerratic and sparser bispectrum features of the gearbox fault.
2013, 27(6).
Abstract:
Axial piston pump with pre-compression volume(PCV) has lower flow ripple in large scale of operating condition than the traditional one. However, there is lack of precise simulation model of the axial piston pump with PCV, so the parameters of PCV are difficult to be determined. A finite element simulation model for piston pump with PCV is built by considering the piston movement, the fluid characteristic(including fluid compressibility and viscosity) and the leakage flow rate. Then a test of the pump flow ripple called the secondary source method is implemented to validate the simulation model. Thirdly, by comparing results among the simulation results, test results and results from other publications at the same operating condition, the simulation model is validated and used in optimizing the axial piston pump with PCV. According to the pump flow ripples obtained by the simulation model with different PCV parameters, the flow ripple is the smallest when the PCV angle is 13, the PCV volume is 1.3104 m3 at such operating condition that the pump suction pressure is 2 MPa, the pump delivery pressure 15 MPa, the pump speed 1 000 r/min, the swash plate angle 13. At the same time, the flow ripple can be reduced when the pump suction pressure is 2 MPa, the pump delivery pressure is 5 MPa,15 MPa, 22 MPa, pump speed is 400 r/min, 1 000 r/min, 1 500 r/min, the swash plate angle is 11, 13, 15 and 17, respectively. The finite element simulation model proposed provides a method for optimizing the PCV structure and guiding for designing a quieter axial piston pump.
Axial piston pump with pre-compression volume(PCV) has lower flow ripple in large scale of operating condition than the traditional one. However, there is lack of precise simulation model of the axial piston pump with PCV, so the parameters of PCV are difficult to be determined. A finite element simulation model for piston pump with PCV is built by considering the piston movement, the fluid characteristic(including fluid compressibility and viscosity) and the leakage flow rate. Then a test of the pump flow ripple called the secondary source method is implemented to validate the simulation model. Thirdly, by comparing results among the simulation results, test results and results from other publications at the same operating condition, the simulation model is validated and used in optimizing the axial piston pump with PCV. According to the pump flow ripples obtained by the simulation model with different PCV parameters, the flow ripple is the smallest when the PCV angle is 13, the PCV volume is 1.3104 m3 at such operating condition that the pump suction pressure is 2 MPa, the pump delivery pressure 15 MPa, the pump speed 1 000 r/min, the swash plate angle 13. At the same time, the flow ripple can be reduced when the pump suction pressure is 2 MPa, the pump delivery pressure is 5 MPa,15 MPa, 22 MPa, pump speed is 400 r/min, 1 000 r/min, 1 500 r/min, the swash plate angle is 11, 13, 15 and 17, respectively. The finite element simulation model proposed provides a method for optimizing the PCV structure and guiding for designing a quieter axial piston pump.
2013, 27(6).
Abstract:
Currently, most researches use signals, such as the coil current or voltage of solenoid, to identify parameters; typically, parameter identification method based on variation rate of coil current is applied for position estimation. The problem exists in these researches that the detected signals are prone to interference and difficult to obtain. This paper proposes a new method for detecting the core position by using flux characteristic quantity, which adds a new group of secondary winding to the coil of the ordinary switching electromagnet. On the basis of electromagnetic coupling theory analysis and simulation research of the magnetic field regarding the primary and secondary winding coils, and in accordance with the fact that under PWM control mode varying core position and operating current of windings produce different characteristic of flux increment of the secondary winding. The flux increment of the electromagnet winding can be obtained by conducting time domain integration for the induced voltage signal of the extracted secondary winding, and the core position from the two-dimensional fitting curve of the operating winding current and flux-linkage characteristic quantity of solenoid are calculated. The detecting and testing system of solenoid core position is developed based on the theoretical research. The testing results show that the flux characteristic quantity of switching electromagnet magnetic circuit is able to effectively show the core position and thus to accomplish the non-displacement transducer detection of the said core position of the switching electromagnet. This paper proposes a new method for detecting the core position by using flux characteristic quantity, which provides a new theory and method for switch solenoid to control the proportional valve.
Currently, most researches use signals, such as the coil current or voltage of solenoid, to identify parameters; typically, parameter identification method based on variation rate of coil current is applied for position estimation. The problem exists in these researches that the detected signals are prone to interference and difficult to obtain. This paper proposes a new method for detecting the core position by using flux characteristic quantity, which adds a new group of secondary winding to the coil of the ordinary switching electromagnet. On the basis of electromagnetic coupling theory analysis and simulation research of the magnetic field regarding the primary and secondary winding coils, and in accordance with the fact that under PWM control mode varying core position and operating current of windings produce different characteristic of flux increment of the secondary winding. The flux increment of the electromagnet winding can be obtained by conducting time domain integration for the induced voltage signal of the extracted secondary winding, and the core position from the two-dimensional fitting curve of the operating winding current and flux-linkage characteristic quantity of solenoid are calculated. The detecting and testing system of solenoid core position is developed based on the theoretical research. The testing results show that the flux characteristic quantity of switching electromagnet magnetic circuit is able to effectively show the core position and thus to accomplish the non-displacement transducer detection of the said core position of the switching electromagnet. This paper proposes a new method for detecting the core position by using flux characteristic quantity, which provides a new theory and method for switch solenoid to control the proportional valve.
2013, 27(6).
Abstract:
The large capacity servo press is traditionally realized by means of redundant actuation, however there exist the over-constraint problem and interference among actuators, which increases the control difficulty and the product cost. A new type of press mechanism with parallel topology is presented to develop the mechanical servo press with high stamping capacity. The dynamic model considering gravity counterbalance is proposed based on the virtual work principle, and then the effect of counterbalance cylinder on the dynamic performance of the servo press is studied. It is found that the motor torque required to operate the press is a lot less than the others when the ratio of the counterbalance force to the gravity of ram is in the vicinity of 1.0. The stamping force of the real press prototype can reach up to 25 MN on the position of 13 mm away from the bottom dead center. The typical deep-drawing process with 1 200 mm stroke at 8 strokes per minute is proposed by means of five order polynomial. On this process condition, the driving torques are calculated based on the above dynamic model and the torque measuring test is also carried out on the prototype. It is shown that the curve trend of calculation torque is consistent to the measured result and that the average error is less than 15%. The parallel mechanism is introduced into the development of large capacity servo press to avoid the over-constraint and interference of traditional redundant actuation, and its dynamic characteristics with gravity counterbalance are presented.
The large capacity servo press is traditionally realized by means of redundant actuation, however there exist the over-constraint problem and interference among actuators, which increases the control difficulty and the product cost. A new type of press mechanism with parallel topology is presented to develop the mechanical servo press with high stamping capacity. The dynamic model considering gravity counterbalance is proposed based on the virtual work principle, and then the effect of counterbalance cylinder on the dynamic performance of the servo press is studied. It is found that the motor torque required to operate the press is a lot less than the others when the ratio of the counterbalance force to the gravity of ram is in the vicinity of 1.0. The stamping force of the real press prototype can reach up to 25 MN on the position of 13 mm away from the bottom dead center. The typical deep-drawing process with 1 200 mm stroke at 8 strokes per minute is proposed by means of five order polynomial. On this process condition, the driving torques are calculated based on the above dynamic model and the torque measuring test is also carried out on the prototype. It is shown that the curve trend of calculation torque is consistent to the measured result and that the average error is less than 15%. The parallel mechanism is introduced into the development of large capacity servo press to avoid the over-constraint and interference of traditional redundant actuation, and its dynamic characteristics with gravity counterbalance are presented.
2013, 27(6).
Abstract:
There is seldom approach developed for the initial topology design of flexure-based compliant mechanisms. The most commonly-used approaches, which start with an existing rigid-body mechanism, do not consider the performances between different topologies. Moreover, they rely heavily on the rigid-body topology, therefore limit the diversity of compliant mechanisms topology. To obtain the optimal initial topology of such mechanisms directly from problem specifications without referencing to the existing mechanism topologies, a spring-joint method is presented for a restricted class of the serial passive flexure-based compliant mechanisms, which are the building blocks of parallel compliant mechanisms. The topology of the compliant mechanisms is represented by a serial spring-joint mechanism(SSJM) that is a traditional rigid-body mechanism with a torsional spring acting on each joint, and is described by position vectors of the spring-joints. A simplified compliance matrix, determined by the position vectors, is used to characterize the tip of the SSJM kinematically, and is optimized to ensure the desired freedoms of the compliant mechanisms during optimization. The topology optimization problem is formulated as finding out the optimal position of the spring-joints in a blank design domain with an objective function derived from the simplified compliance matrix. In design examples, syntheses of the compliant mechanisms with both single freedom and two decoupled freedoms are presented to illustrate the proposed method. The proposed method provides a new way for the initial design of flexure-based compliant mechanisms.
There is seldom approach developed for the initial topology design of flexure-based compliant mechanisms. The most commonly-used approaches, which start with an existing rigid-body mechanism, do not consider the performances between different topologies. Moreover, they rely heavily on the rigid-body topology, therefore limit the diversity of compliant mechanisms topology. To obtain the optimal initial topology of such mechanisms directly from problem specifications without referencing to the existing mechanism topologies, a spring-joint method is presented for a restricted class of the serial passive flexure-based compliant mechanisms, which are the building blocks of parallel compliant mechanisms. The topology of the compliant mechanisms is represented by a serial spring-joint mechanism(SSJM) that is a traditional rigid-body mechanism with a torsional spring acting on each joint, and is described by position vectors of the spring-joints. A simplified compliance matrix, determined by the position vectors, is used to characterize the tip of the SSJM kinematically, and is optimized to ensure the desired freedoms of the compliant mechanisms during optimization. The topology optimization problem is formulated as finding out the optimal position of the spring-joints in a blank design domain with an objective function derived from the simplified compliance matrix. In design examples, syntheses of the compliant mechanisms with both single freedom and two decoupled freedoms are presented to illustrate the proposed method. The proposed method provides a new way for the initial design of flexure-based compliant mechanisms.
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