2015 Vol.28(02)
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2015, 29(02).
doi: 10.3901/CJME.2015.0105.004
Abstract:
Reliability allocation of computerized numerical controlled(CNC) lathes is very important in industry. Traditional allocation methods only focus on high-failure rate components rather than moderate failure rate components, which is not applicable in some conditions. Aiming at solving the problem of CNC lathes reliability allocating, a comprehensive reliability allocation method based on cubic transformed functions of failure modes and effects analysis(FMEA) is presented. Firstly, conventional reliability allocation methods are introduced. Then the limitations of direct combination of comprehensive allocation method with the exponential transformed FMEA method are investigated. Subsequently, a cubic transformed function is established in order to overcome these limitations. Properties of the new transformed functions are discussed by considering the failure severity and the failure occurrence. Designers can choose appropriate transform amplitudes according to their requirements. Finally, a CNC lathe and a spindle system are used as an example to verify the new allocation method. Seven criteria are considered to compare the results of the new method with traditional methods. The allocation results indicate that the new method is more flexible than traditional methods. By employing the new cubic transformed function, the method covers a wider range of problems in CNC reliability allocation without losing the advantages of traditional methods.
Reliability allocation of computerized numerical controlled(CNC) lathes is very important in industry. Traditional allocation methods only focus on high-failure rate components rather than moderate failure rate components, which is not applicable in some conditions. Aiming at solving the problem of CNC lathes reliability allocating, a comprehensive reliability allocation method based on cubic transformed functions of failure modes and effects analysis(FMEA) is presented. Firstly, conventional reliability allocation methods are introduced. Then the limitations of direct combination of comprehensive allocation method with the exponential transformed FMEA method are investigated. Subsequently, a cubic transformed function is established in order to overcome these limitations. Properties of the new transformed functions are discussed by considering the failure severity and the failure occurrence. Designers can choose appropriate transform amplitudes according to their requirements. Finally, a CNC lathe and a spindle system are used as an example to verify the new allocation method. Seven criteria are considered to compare the results of the new method with traditional methods. The allocation results indicate that the new method is more flexible than traditional methods. By employing the new cubic transformed function, the method covers a wider range of problems in CNC reliability allocation without losing the advantages of traditional methods.
2015, 29(02).
doi: 10.3901/CJME.2014.1201.174
Abstract:
Selective Catalyst Reduction(SCR) Urea Dosing System(UDS) directly affects the system accuracy and the dynamic response performance of a vehicle. However, the UDS dynamic response is hard to keep up with the changes of the engine’s operating conditions. That will lead to low NOX conversion efficiency or NH3 slip. In order to optimize the injection accuracy and the response speed of the UDS in dynamic conditions, an advanced control strategy based on an air-assisted volumetric UDS is presented. It covers the methods of flow compensation and switching working conditions. The strategy is authenticated on an UDS and tested in different dynamic conditions. The result shows that the control strategy discussed results in higher dynamic accuracy and faster dynamic response speed of UDS. The inject deviation range is improved from being between –8% and 10% to –4% and 2% and became more stable than before, and the dynamic response time was shortened from 200 ms to 150 ms . The ETC cycle result shows that after using the new strategy the NH3 emission is reduced by 60%, and the NOX emission remains almost unchanged. The trade-off between NOX conversion efficiency and NH3 slip is mitigated. The studied flow compensation and switching working conditions can improve the dynamic performance of the UDS significantly and make the UDS dynamic response keep up with the changes of the engine’s operating conditions quickly.
Selective Catalyst Reduction(SCR) Urea Dosing System(UDS) directly affects the system accuracy and the dynamic response performance of a vehicle. However, the UDS dynamic response is hard to keep up with the changes of the engine’s operating conditions. That will lead to low NOX conversion efficiency or NH3 slip. In order to optimize the injection accuracy and the response speed of the UDS in dynamic conditions, an advanced control strategy based on an air-assisted volumetric UDS is presented. It covers the methods of flow compensation and switching working conditions. The strategy is authenticated on an UDS and tested in different dynamic conditions. The result shows that the control strategy discussed results in higher dynamic accuracy and faster dynamic response speed of UDS. The inject deviation range is improved from being between –8% and 10% to –4% and 2% and became more stable than before, and the dynamic response time was shortened from 200 ms to 150 ms . The ETC cycle result shows that after using the new strategy the NH3 emission is reduced by 60%, and the NOX emission remains almost unchanged. The trade-off between NOX conversion efficiency and NH3 slip is mitigated. The studied flow compensation and switching working conditions can improve the dynamic performance of the UDS significantly and make the UDS dynamic response keep up with the changes of the engine’s operating conditions quickly.
2015, 29(02).
doi: 10.3901/CJME.2014.1216.180
Abstract:
The influence of fuel pressure fluctuation on multi-injection fuel mass deviation has been studied a lot, but the fuel pressure fluctuation at injector inlet is still not eliminated efficiently. In this paper, a new type of hydraulic filter consisting of a damping hole and a chamber is developed for elimination of fuel pressure fluctuation and multi-injection fuel mass deviation. Linear model of the improved high pressure common-rail system(HPCRS) including injector, the pipe connecting common-rail with injector and the hydraulic filter is built. Fuel pressure fluctuation at injector inlet, on which frequency domain analysis is conducted through fast Fourier transformation, is acquired at different target pressure and different damping hole diameter experimentally. The linear model is validated and can predict the natural frequencies of the system. Influence of damping hole diameter on fuel pressure fluctuation is analyzed qualitatively based on the linear model, and it can be inferred that an optimal diameter of the damping hole for elimination of fuel pressure fluctuation exists. Fuel pressure fluctuation and fuel mass deviation under different damping hole diameters are measured experimentally, and it is testified that the amplitude of both fuel pressure fluctuation and fuel mass deviation decreases first and then increases with the increasing of damping hole diameter. The amplitude of main injection fuel mass deviation can be reduced by 73% at most under pilot-main injection mode, and the amplitude of post injection fuel mass deviation can be reduced by 92% at most under main-post injection mode. Fuel mass of a single injection increases with the increasing of the damping hole diameter. The hydraulic filter proposed by this research can be potentially used to eliminate fuel pressure fluctuation at injector inlet and improve the stability of HPCRS fuel injection.
The influence of fuel pressure fluctuation on multi-injection fuel mass deviation has been studied a lot, but the fuel pressure fluctuation at injector inlet is still not eliminated efficiently. In this paper, a new type of hydraulic filter consisting of a damping hole and a chamber is developed for elimination of fuel pressure fluctuation and multi-injection fuel mass deviation. Linear model of the improved high pressure common-rail system(HPCRS) including injector, the pipe connecting common-rail with injector and the hydraulic filter is built. Fuel pressure fluctuation at injector inlet, on which frequency domain analysis is conducted through fast Fourier transformation, is acquired at different target pressure and different damping hole diameter experimentally. The linear model is validated and can predict the natural frequencies of the system. Influence of damping hole diameter on fuel pressure fluctuation is analyzed qualitatively based on the linear model, and it can be inferred that an optimal diameter of the damping hole for elimination of fuel pressure fluctuation exists. Fuel pressure fluctuation and fuel mass deviation under different damping hole diameters are measured experimentally, and it is testified that the amplitude of both fuel pressure fluctuation and fuel mass deviation decreases first and then increases with the increasing of damping hole diameter. The amplitude of main injection fuel mass deviation can be reduced by 73% at most under pilot-main injection mode, and the amplitude of post injection fuel mass deviation can be reduced by 92% at most under main-post injection mode. Fuel mass of a single injection increases with the increasing of the damping hole diameter. The hydraulic filter proposed by this research can be potentially used to eliminate fuel pressure fluctuation at injector inlet and improve the stability of HPCRS fuel injection.
2015, 29(02).
doi: 10.3901/CJME.2014.1210.178
Abstract:
Corrosion failure, especially stress corrosion cracking and corrosion fatigue, is the main cause of centrifugal compressor impeller failure. And it is concealed and destructive. This paper summarizes the main theories of stress corrosion cracking and corrosion fatigue and its latest developments, and it also points out that existing stress corrosion cracking theories can be reduced to the anodic dissolution (AD), the hydrogen-induced cracking (HIC), and the combined AD and HIC mechanisms. The corrosion behavior and the mechanism of corrosion fatigue in the crack propagation stage are similar to stress corrosion cracking. The effects of stress ratio, loading frequency, and corrosive medium on the corrosion fatigue crack propagation rate are analyzed and summarized. The corrosion behavior and the mechanism of stress corrosion cracking and corrosion fatigue in corrosive environments, which contain sulfide, chlorides, and carbonate, are analyzed. The working environments of the centrifugal compressor impeller show the behavior and the mechanism of stress corrosion cracking and corrosion fatigue in different corrosive environments. The current research methods for centrifugal compressor impeller corrosion failure are analyzed. Physical analysis, numerical simulation, and the fluid-structure interaction method play an increasingly important role in the research on impeller deformation and stress distribution caused by the joint action of aerodynamic load and centrifugal load.
Corrosion failure, especially stress corrosion cracking and corrosion fatigue, is the main cause of centrifugal compressor impeller failure. And it is concealed and destructive. This paper summarizes the main theories of stress corrosion cracking and corrosion fatigue and its latest developments, and it also points out that existing stress corrosion cracking theories can be reduced to the anodic dissolution (AD), the hydrogen-induced cracking (HIC), and the combined AD and HIC mechanisms. The corrosion behavior and the mechanism of corrosion fatigue in the crack propagation stage are similar to stress corrosion cracking. The effects of stress ratio, loading frequency, and corrosive medium on the corrosion fatigue crack propagation rate are analyzed and summarized. The corrosion behavior and the mechanism of stress corrosion cracking and corrosion fatigue in corrosive environments, which contain sulfide, chlorides, and carbonate, are analyzed. The working environments of the centrifugal compressor impeller show the behavior and the mechanism of stress corrosion cracking and corrosion fatigue in different corrosive environments. The current research methods for centrifugal compressor impeller corrosion failure are analyzed. Physical analysis, numerical simulation, and the fluid-structure interaction method play an increasingly important role in the research on impeller deformation and stress distribution caused by the joint action of aerodynamic load and centrifugal load.
2015, 29(02).
doi: 10.3901/CJME.2015.0105.003
Abstract:
For a spherical four-bar linkage, the maximum number of the spherical RR dyad (R: revolute joint) of five-orientation motion generation can be at most 6. However, complete real solution of this problem has seldom been studied. In order to obtain six real RR dyads, based on Strum’s theorem, the relationships between the design parameters are derived from a 6th-degree univariate polynomial equation that is deduced from the constraint equations of the spherical RR dyad by using Dixon resultant method. Moreover, the Grashof condition and the circuit defect condition are taken into account. Given the relationships between the design parameters and the aforementioned two conditions, two objective functions are constructed and optimized by the adaptive genetic algorithm(AGA). Two examples with six real spherical RR dyads are obtained by optimization, and the results verify the feasibility of the proposed method. The paper provides a method to synthesize the complete real solution of the five-orientation motion generation,which is also applicable to the problem that deduces to a univariate polynomial equation and requires the generation of as many as real roots.
For a spherical four-bar linkage, the maximum number of the spherical RR dyad (R: revolute joint) of five-orientation motion generation can be at most 6. However, complete real solution of this problem has seldom been studied. In order to obtain six real RR dyads, based on Strum’s theorem, the relationships between the design parameters are derived from a 6th-degree univariate polynomial equation that is deduced from the constraint equations of the spherical RR dyad by using Dixon resultant method. Moreover, the Grashof condition and the circuit defect condition are taken into account. Given the relationships between the design parameters and the aforementioned two conditions, two objective functions are constructed and optimized by the adaptive genetic algorithm(AGA). Two examples with six real spherical RR dyads are obtained by optimization, and the results verify the feasibility of the proposed method. The paper provides a method to synthesize the complete real solution of the five-orientation motion generation,which is also applicable to the problem that deduces to a univariate polynomial equation and requires the generation of as many as real roots.
2015, 29(02).
doi: 10.3901/CJME.2014.1206.176
Abstract:
The stretchable sensor wrapped around a foldable airfoil or embedded inside of it has great potential for use in the monitoring of the structural status of the foldable airfoil. The design methodology is important to the development of the stretchable sensor for status monitoring on the foldable airfoil. According to the requirement of mechanical flexibility of the sensor, the combined use of a layered flexible structural formation and a strain isolation layer is implemented. An analytical higher-order model is proposed to predict the stresses of the strain-isolation layer based on the shear-lag model for the safe design of the flexible and stretchable sensors. The normal stress and shear stress equations in the constructed structure of the sensors are obtained by the proposed model. The stress distribution in the structure is investigated when bending load is applied to the structures. The numerical results show that the proposed model can predict the variation of normal stress and shear stress along the thickness of the strain-isolation (polydimethylsiloxane) layer accurately. The results by the proposed model are in good agreement with the finite element method, in which the normal stress is variable while the shear stress is invariable along the thickness direction of strain-isolation layer. The high-order model is proposed to predict the stresses of the layered structure of the flexible and stretchable sensor for monitoring the status of the foldable airfoil.
The stretchable sensor wrapped around a foldable airfoil or embedded inside of it has great potential for use in the monitoring of the structural status of the foldable airfoil. The design methodology is important to the development of the stretchable sensor for status monitoring on the foldable airfoil. According to the requirement of mechanical flexibility of the sensor, the combined use of a layered flexible structural formation and a strain isolation layer is implemented. An analytical higher-order model is proposed to predict the stresses of the strain-isolation layer based on the shear-lag model for the safe design of the flexible and stretchable sensors. The normal stress and shear stress equations in the constructed structure of the sensors are obtained by the proposed model. The stress distribution in the structure is investigated when bending load is applied to the structures. The numerical results show that the proposed model can predict the variation of normal stress and shear stress along the thickness of the strain-isolation (polydimethylsiloxane) layer accurately. The results by the proposed model are in good agreement with the finite element method, in which the normal stress is variable while the shear stress is invariable along the thickness direction of strain-isolation layer. The high-order model is proposed to predict the stresses of the layered structure of the flexible and stretchable sensor for monitoring the status of the foldable airfoil.
2015, 29(02).
doi: 10.3901/CJME.2015.0104.001
Abstract:
High-pressure solenoid valve with high flow rate and high speed is a key component in an underwater driving system. However, traditional single spool pilot operated valve cannot meet the demands of both high flow rate and high speed simultaneously. A new structure for a high pressure solenoid valve is needed to meet the demand of the underwater driving system. A novel parallel-spool pilot operated high-pressure solenoid valve is proposed to overcome the drawback of the current single spool design. Mathematical models of the opening process and flow rate of the valve are established. Opening response time of the valve is subdivided into 4 parts to analyze the properties of the opening response. Corresponding formulas to solve 4 parts of the response time are derived. Key factors that influence the opening response time are analyzed. According to the mathematical model of the valve, a simulation of the opening process is carried out by MATLAB. Parameters are chosen based on theoretical analysis to design the test prototype of the new type of valve. Opening response time of the designed valve is tested by verifying response of the current in the coil and displacement of the main valve spool. The experimental results are in agreement with the simulated results, therefore the validity of the theoretical analysis is verified. Experimental opening response time of the valve is 48.3 ms at working pressure of 10 MPa. The flow capacity test shows that the largest effective area is 126 mm2 and the largest air flow rate is 2320 L/s. According to the result of the load driving test, the valve can meet the demands of the driving system. The proposed valve with parallel spools provides a new method for the design of a high-pressure valve with fast response and large flow rate.
High-pressure solenoid valve with high flow rate and high speed is a key component in an underwater driving system. However, traditional single spool pilot operated valve cannot meet the demands of both high flow rate and high speed simultaneously. A new structure for a high pressure solenoid valve is needed to meet the demand of the underwater driving system. A novel parallel-spool pilot operated high-pressure solenoid valve is proposed to overcome the drawback of the current single spool design. Mathematical models of the opening process and flow rate of the valve are established. Opening response time of the valve is subdivided into 4 parts to analyze the properties of the opening response. Corresponding formulas to solve 4 parts of the response time are derived. Key factors that influence the opening response time are analyzed. According to the mathematical model of the valve, a simulation of the opening process is carried out by MATLAB. Parameters are chosen based on theoretical analysis to design the test prototype of the new type of valve. Opening response time of the designed valve is tested by verifying response of the current in the coil and displacement of the main valve spool. The experimental results are in agreement with the simulated results, therefore the validity of the theoretical analysis is verified. Experimental opening response time of the valve is 48.3 ms at working pressure of 10 MPa. The flow capacity test shows that the largest effective area is 126 mm2 and the largest air flow rate is 2320 L/s. According to the result of the load driving test, the valve can meet the demands of the driving system. The proposed valve with parallel spools provides a new method for the design of a high-pressure valve with fast response and large flow rate.
2015, 29(02).
doi: 10.3901/CJME.2014.1029.160
Abstract:
Traditional computing method is inefficient for getting key dynamical parameters of complicated structure. Pseudo Excitation Method(PEM) is an effective method for calculation of random vibration. Due to complicated and coupling random vibration in rocket or shuttle launching, the new staging white noise mathematical model is deduced according to the practical launch environment. This deduced model is applied for PEM to calculate the specific structure of Time of Flight Counter(ToFC). The responses of power spectral density and the relevant dynamic characteristic parameters of ToFC are obtained in terms of the flight acceptance test level. Considering stiffness of fixture structure, the random vibration experiments are conducted in three directions to compare with the revised PEM. The experimental results show the structure can bear the random vibration caused by launch without any damage and key dynamical parameters of ToFC are obtained. The revised PEM is similar with random vibration experiment in dynamical parameters and responses are proved by comparative results. The maximum error is within 9%. The reasons of errors are analyzed to improve reliability of calculation. This research provides an effective method for solutions of computing dynamical characteristic parameters of complicated structure in the process of rocket or shuttle launching.
Traditional computing method is inefficient for getting key dynamical parameters of complicated structure. Pseudo Excitation Method(PEM) is an effective method for calculation of random vibration. Due to complicated and coupling random vibration in rocket or shuttle launching, the new staging white noise mathematical model is deduced according to the practical launch environment. This deduced model is applied for PEM to calculate the specific structure of Time of Flight Counter(ToFC). The responses of power spectral density and the relevant dynamic characteristic parameters of ToFC are obtained in terms of the flight acceptance test level. Considering stiffness of fixture structure, the random vibration experiments are conducted in three directions to compare with the revised PEM. The experimental results show the structure can bear the random vibration caused by launch without any damage and key dynamical parameters of ToFC are obtained. The revised PEM is similar with random vibration experiment in dynamical parameters and responses are proved by comparative results. The maximum error is within 9%. The reasons of errors are analyzed to improve reliability of calculation. This research provides an effective method for solutions of computing dynamical characteristic parameters of complicated structure in the process of rocket or shuttle launching.
2015, 29(02).
doi: 10.3901/CJME.2015.0107.007
Abstract:
Recent research on the grinding force involved in cylindrical plunge grinding has focused mainly on steady-state conditions. Unlike in conventional external cylindrical plunge grinding, the conditions between the grinding wheel and the crankpin change periodically in path controlled grinding because of the eccentricity of the crankpin and the constant rotational speed of the crankshaft. The objective of this study is to investigate the effects of various grinding conditions on the characteristics of the grinding force during continuous path controlled grinding. Path controlled plunge grinding is conducted at a constant rotational speed using a cubic boron nitride (CBN) wheel. The grinding force is determined by measuring the torque. The experimental results show that the force and torque vary sinusoidally during dry grinding and load grinding. The variations in the results reveal that the resultant grinding force and torque decrease with higher grinding speeds and increase with higher peripheral speeds of the pin and higher grinding depths. In path controlled grinding, unlike in conventional external cylindrical plunge grinding, the axial grinding force cannot be disregarded. The speeds and speed ratios of the workpiece and wheel are also analyzed, and the analysis results show that up-grinding and down-grinding occur during the grinding process. This paper proposes a method for describing the force behavior under varied process conditions during continuous path controlled grinding, which provides a beneficial reference for describing the material removal mechanism and for optimizing continuous controlled crankpin grinding.
Recent research on the grinding force involved in cylindrical plunge grinding has focused mainly on steady-state conditions. Unlike in conventional external cylindrical plunge grinding, the conditions between the grinding wheel and the crankpin change periodically in path controlled grinding because of the eccentricity of the crankpin and the constant rotational speed of the crankshaft. The objective of this study is to investigate the effects of various grinding conditions on the characteristics of the grinding force during continuous path controlled grinding. Path controlled plunge grinding is conducted at a constant rotational speed using a cubic boron nitride (CBN) wheel. The grinding force is determined by measuring the torque. The experimental results show that the force and torque vary sinusoidally during dry grinding and load grinding. The variations in the results reveal that the resultant grinding force and torque decrease with higher grinding speeds and increase with higher peripheral speeds of the pin and higher grinding depths. In path controlled grinding, unlike in conventional external cylindrical plunge grinding, the axial grinding force cannot be disregarded. The speeds and speed ratios of the workpiece and wheel are also analyzed, and the analysis results show that up-grinding and down-grinding occur during the grinding process. This paper proposes a method for describing the force behavior under varied process conditions during continuous path controlled grinding, which provides a beneficial reference for describing the material removal mechanism and for optimizing continuous controlled crankpin grinding.
2015, 29(02).
doi: 10.3901/CJME.2014.1212.179
Abstract:
Nowadays, most researchers focus on the cavity shedding mechanisms of unsteady cavitating flows over different objects, such as 2D/3D hydrofoils, venturi-type section, axisymmetric bodies with different headforms, and so on. But few of them pay attention to the differences of cavity shedding modality under different cavitation numbers in unsteady cavitating flows over the same object. In the present study, two kinds of shedding patterns are investigated experimentally. A high speed camera system is used to observe the cavitating flows over an axisymmetric blunt body and the velocity fields are measured by a particle image velocimetry (PIV) technique in a water tunnel for different cavitation conditions. The U-type cavitating vortex shedding is observed in unsteady cavitating flows. When the cavitation number is 0.7, there is a large scale cavity rolling up and shedding, which cause the instability and dramatic fluctuation of the flows, while at cavitation number of 0.6, the detached cavities can be conjunct with the attached part to induce the break-off behavior again at the tail of the attached cavity, as a result, the final shedding is in the form of small scale cavity and keeps a relatively steady flow field. It is also found that the interaction between the re-entrant flow and the attached cavity plays an important role in the unsteady cavity shedding modality. When the attached cavity scale is insufficient to overcome the re-entrant flow, it deserves the large cavity rolling up and shedding just as that at cavitation number of 0.7. Otherwise, the re-entrant flow is defeated by large enough cavity to induce the cavity-combined process and small scale cavity vortexes shedding just as that of the cavitation number of 0.6. This research shows the details of two different cavity shedding modalities which is worthful and meaningful for the further study of unsteady cavitation.
Nowadays, most researchers focus on the cavity shedding mechanisms of unsteady cavitating flows over different objects, such as 2D/3D hydrofoils, venturi-type section, axisymmetric bodies with different headforms, and so on. But few of them pay attention to the differences of cavity shedding modality under different cavitation numbers in unsteady cavitating flows over the same object. In the present study, two kinds of shedding patterns are investigated experimentally. A high speed camera system is used to observe the cavitating flows over an axisymmetric blunt body and the velocity fields are measured by a particle image velocimetry (PIV) technique in a water tunnel for different cavitation conditions. The U-type cavitating vortex shedding is observed in unsteady cavitating flows. When the cavitation number is 0.7, there is a large scale cavity rolling up and shedding, which cause the instability and dramatic fluctuation of the flows, while at cavitation number of 0.6, the detached cavities can be conjunct with the attached part to induce the break-off behavior again at the tail of the attached cavity, as a result, the final shedding is in the form of small scale cavity and keeps a relatively steady flow field. It is also found that the interaction between the re-entrant flow and the attached cavity plays an important role in the unsteady cavity shedding modality. When the attached cavity scale is insufficient to overcome the re-entrant flow, it deserves the large cavity rolling up and shedding just as that at cavitation number of 0.7. Otherwise, the re-entrant flow is defeated by large enough cavity to induce the cavity-combined process and small scale cavity vortexes shedding just as that of the cavitation number of 0.6. This research shows the details of two different cavity shedding modalities which is worthful and meaningful for the further study of unsteady cavitation.
2015, 29(02).
doi: 10.3901/CJME.2015.0107.008
Abstract:
The mechanical properties of ceramic cutting tool materials can be modified by introducing proper content of nanoparticles or whiskers. However, the process of adding whiskers or nanoparticles has the disadvantages of high cost and health hazard as well as the agglomeration; although a new in-situ two-step sintering process can solve the above problems to some extent, yet the problems of low conversion ratio of the raw materials and the abnormal grain growth exist in this process. In this paper, an in-situ one-step synthesis technology is proposed, which means the growth of whiskers or nanoparticles and the sintering of the compact can be accomplished by one time in furnace. A kind of Ti(C, N)-based ceramic cutting tool material synergistically toughened by TiB2 particles and whiskers is fabricated with this new process. The phase compositions, relationships between microstructure and mechanical properties as well as the toughening mechanisms are analyzed by means of X-ray diffraction (XRD) and scanning electron microscopy (SEM). The composite which is sintered under a pressure of 32 MPa at a temperature of 1700℃ in vacuum holding for 60 min can get the optimal mechanical properties. Its flexural strength, fracture toughness and Vickers hardness are 540 MPa, 7.81 MPa • m1/2 and 20.42 GPa, respectively. The composite has relatively high density, and the in-situ synthesized TiB2 whiskers have good surface integrity, which is beneficial for the improvement of the fracture toughness. It is concluded that the main toughening mechanisms of the present composite are whiskers pulling-out and crack deflection induced by whiskers, crack bridging by whiskers/particles and multi-scale particles synergistically toughening. This study proposes an in-situ one-step synthesis technology which can be well used for fabricating particles and whiskers synergistically toughened ceramic tool materials.
The mechanical properties of ceramic cutting tool materials can be modified by introducing proper content of nanoparticles or whiskers. However, the process of adding whiskers or nanoparticles has the disadvantages of high cost and health hazard as well as the agglomeration; although a new in-situ two-step sintering process can solve the above problems to some extent, yet the problems of low conversion ratio of the raw materials and the abnormal grain growth exist in this process. In this paper, an in-situ one-step synthesis technology is proposed, which means the growth of whiskers or nanoparticles and the sintering of the compact can be accomplished by one time in furnace. A kind of Ti(C, N)-based ceramic cutting tool material synergistically toughened by TiB2 particles and whiskers is fabricated with this new process. The phase compositions, relationships between microstructure and mechanical properties as well as the toughening mechanisms are analyzed by means of X-ray diffraction (XRD) and scanning electron microscopy (SEM). The composite which is sintered under a pressure of 32 MPa at a temperature of 1700℃ in vacuum holding for 60 min can get the optimal mechanical properties. Its flexural strength, fracture toughness and Vickers hardness are 540 MPa, 7.81 MPa • m1/2 and 20.42 GPa, respectively. The composite has relatively high density, and the in-situ synthesized TiB2 whiskers have good surface integrity, which is beneficial for the improvement of the fracture toughness. It is concluded that the main toughening mechanisms of the present composite are whiskers pulling-out and crack deflection induced by whiskers, crack bridging by whiskers/particles and multi-scale particles synergistically toughening. This study proposes an in-situ one-step synthesis technology which can be well used for fabricating particles and whiskers synergistically toughened ceramic tool materials.
2015, 29(02).
doi: 10.3901/CJME.2015.0104.002
Abstract:
Fatigue fracture is one of the main failure modes of Ti-6Al-4V alloy, fracture toughness and crack closure have strong effects on the fatigue crack growth(FCG) rate of Ti-6Al-4V alloy. The FCG rate of Ti-6Al-4V is investigated by using experimental and analytical methods. The effects of stress ratio, crack closure and fracture toughness on the FCG rate are studied and discussed. A modified prediction model of the FCG rate is proposed, and the relationship between the fracture toughness and the stress intensity factor(SIF) range is redefined by introducing a correcting coefficient. Notched plate fatigue tests (including the fracture toughness test and the FCG rate test) are conducted to investigate the influence of affecting factors on the FCG rate. Comparisons between the predicted results of the proposed model, the Paris model, the Walker model, the Sadananda model, and the experimental data show that the proposed model gives the best agreement with the test data particularly in the near–threshold region and the Paris region, and the corresponding calculated fatigue life is also accurate in the same regions. By considering the effects of fracture toughness and crack closure, the novel FCG rate prediction model not only improves the estimating accuracy, but also extends the adaptability of the FCG rate prediction model in engineering.
Fatigue fracture is one of the main failure modes of Ti-6Al-4V alloy, fracture toughness and crack closure have strong effects on the fatigue crack growth(FCG) rate of Ti-6Al-4V alloy. The FCG rate of Ti-6Al-4V is investigated by using experimental and analytical methods. The effects of stress ratio, crack closure and fracture toughness on the FCG rate are studied and discussed. A modified prediction model of the FCG rate is proposed, and the relationship between the fracture toughness and the stress intensity factor(SIF) range is redefined by introducing a correcting coefficient. Notched plate fatigue tests (including the fracture toughness test and the FCG rate test) are conducted to investigate the influence of affecting factors on the FCG rate. Comparisons between the predicted results of the proposed model, the Paris model, the Walker model, the Sadananda model, and the experimental data show that the proposed model gives the best agreement with the test data particularly in the near–threshold region and the Paris region, and the corresponding calculated fatigue life is also accurate in the same regions. By considering the effects of fracture toughness and crack closure, the novel FCG rate prediction model not only improves the estimating accuracy, but also extends the adaptability of the FCG rate prediction model in engineering.
2015, 29(02).
doi: 10.3901/CJME.2014.1230.182
Abstract:
The complexity of the kinematics and dynamics of a manipulator makes it necessary to simplify the modeling process. However, the traditional representations cannot achieve this because of the absence of coordinate invariance. Therefore, the coordinate invariant method is an important research issue. First, the rigid-body acceleration, the time derivative of the twist, is proved to be a screw, and its physical meaning is explained. Based on the twist and the rigid-body acceleration, the acceleration of the end-effector is expressed as a linear-bilinear form, and the kinematics Hessian matrix of the manipulator(represented by Lie bracket) is deduced. Further, Newton-Euler’s equation is rewritten as a linear-bilinear form, from which the dynamics Hessian matrix of a rigid body is obtained. The formulae and the dynamics Hessian matrix are proved to be coordinate invariant. Referring to the principle of virtual work, the dynamics Hessian matrix of the parallel manipulator is gotten and the detailed dynamic model is derived. An index of dynamical coupling based on dynamics Hessian matrix is presented. In the end, a foldable parallel manipulator is taken as an example to validate the deduced kinematics and dynamics formulae. The screw theory based method can simplify the kinematics and dynamics of a manipulator, also the corresponding dynamics Hessian matrix can be used to evaluate the dynamical coupling of a manipulator.
The complexity of the kinematics and dynamics of a manipulator makes it necessary to simplify the modeling process. However, the traditional representations cannot achieve this because of the absence of coordinate invariance. Therefore, the coordinate invariant method is an important research issue. First, the rigid-body acceleration, the time derivative of the twist, is proved to be a screw, and its physical meaning is explained. Based on the twist and the rigid-body acceleration, the acceleration of the end-effector is expressed as a linear-bilinear form, and the kinematics Hessian matrix of the manipulator(represented by Lie bracket) is deduced. Further, Newton-Euler’s equation is rewritten as a linear-bilinear form, from which the dynamics Hessian matrix of a rigid body is obtained. The formulae and the dynamics Hessian matrix are proved to be coordinate invariant. Referring to the principle of virtual work, the dynamics Hessian matrix of the parallel manipulator is gotten and the detailed dynamic model is derived. An index of dynamical coupling based on dynamics Hessian matrix is presented. In the end, a foldable parallel manipulator is taken as an example to validate the deduced kinematics and dynamics formulae. The screw theory based method can simplify the kinematics and dynamics of a manipulator, also the corresponding dynamics Hessian matrix can be used to evaluate the dynamical coupling of a manipulator.
2015, 29(02).
doi: 10.3901/CJME.2015.0112.012
Abstract:
The reliability assessment for an automobile crankshaft provides an important understanding in dealing with the design life of the component in order to eliminate or reduce the likelihood of failure and safety risks. The failures of the crankshafts are considered as a catastrophic failure that leads towards a severe failure of the engine block and its other connecting subcomponents. The reliability of an automotive crankshaft under mixed mode loading using the Markov Chain Model is studied. The Markov Chain is modelled by using a two-state condition to represent the bending and torsion loads that would occur on the crankshaft. The automotive crankshaft represents a good case study of a component under mixed mode loading due to the rotating bending and torsion stresses. An estimation of the Weibull shape parameter is used to obtain the probability density function, cumulative distribution function, hazard and reliability rate functions, the bathtub curve and the mean time to failure. The various properties of the shape parameter is used to model the failure characteristic through the bathtub curve is shown. Likewise, an understanding of the patterns posed by the hazard rate onto the component can be used to improve the design and increase the life cycle based on the reliability and dependability of the component. The proposed reliability assessment provides an accurate, efficient, fast and cost effective reliability analysis in contrast to costly and lengthy experimental techniques.
The reliability assessment for an automobile crankshaft provides an important understanding in dealing with the design life of the component in order to eliminate or reduce the likelihood of failure and safety risks. The failures of the crankshafts are considered as a catastrophic failure that leads towards a severe failure of the engine block and its other connecting subcomponents. The reliability of an automotive crankshaft under mixed mode loading using the Markov Chain Model is studied. The Markov Chain is modelled by using a two-state condition to represent the bending and torsion loads that would occur on the crankshaft. The automotive crankshaft represents a good case study of a component under mixed mode loading due to the rotating bending and torsion stresses. An estimation of the Weibull shape parameter is used to obtain the probability density function, cumulative distribution function, hazard and reliability rate functions, the bathtub curve and the mean time to failure. The various properties of the shape parameter is used to model the failure characteristic through the bathtub curve is shown. Likewise, an understanding of the patterns posed by the hazard rate onto the component can be used to improve the design and increase the life cycle based on the reliability and dependability of the component. The proposed reliability assessment provides an accurate, efficient, fast and cost effective reliability analysis in contrast to costly and lengthy experimental techniques.
2015, 29(02).
doi: 10.3901/CJME.2015.0106.006
Abstract:
Because of the tire nonlinearity and vehicle’s parameters’ uncertainties, robust control methods based on the worst cases, such as H∞, μ synthesis, have been widely used in active front steering control, however, in order to guarantee the stability of active front steering system (AFS) controller, the robust control is at the cost of performance so that the robust controller is a little conservative and has low performance for AFS control. In this paper, a generalized internal model robust control (GIMC) that can overcome the contradiction between performance and stability is used in the AFS control. In GIMC, the Youla parameterization is used in an improved way. And GIMC controller includes two sections: a high performance controller designed for the nominal vehicle model and a robust controller compensating the vehicle parameters’ uncertainties and some external disturbances. Simulations of double lane change (DLC) maneuver and that of braking on split-μ road are conducted to compare the performance and stability of the GIMC control, the nominal performance PID controller and the H∞ controller. Simulation results show that the high nominal performance PID controller will be unstable under some extreme situations because of large vehicle’s parameters variations, H∞ controller is conservative so that the performance is a little low, and only the GIMC controller overcomes the contradiction between performance and robustness, which can both ensure the stability of the AFS controller and guarantee the high performance of the AFS controller. Therefore, the GIMC method proposed for AFS can overcome some disadvantages of control methods used by current AFS system, that is, can solve the instability of PID or LQP control methods and the low performance of the standard H∞ controller.
Because of the tire nonlinearity and vehicle’s parameters’ uncertainties, robust control methods based on the worst cases, such as H∞, μ synthesis, have been widely used in active front steering control, however, in order to guarantee the stability of active front steering system (AFS) controller, the robust control is at the cost of performance so that the robust controller is a little conservative and has low performance for AFS control. In this paper, a generalized internal model robust control (GIMC) that can overcome the contradiction between performance and stability is used in the AFS control. In GIMC, the Youla parameterization is used in an improved way. And GIMC controller includes two sections: a high performance controller designed for the nominal vehicle model and a robust controller compensating the vehicle parameters’ uncertainties and some external disturbances. Simulations of double lane change (DLC) maneuver and that of braking on split-μ road are conducted to compare the performance and stability of the GIMC control, the nominal performance PID controller and the H∞ controller. Simulation results show that the high nominal performance PID controller will be unstable under some extreme situations because of large vehicle’s parameters variations, H∞ controller is conservative so that the performance is a little low, and only the GIMC controller overcomes the contradiction between performance and robustness, which can both ensure the stability of the AFS controller and guarantee the high performance of the AFS controller. Therefore, the GIMC method proposed for AFS can overcome some disadvantages of control methods used by current AFS system, that is, can solve the instability of PID or LQP control methods and the low performance of the standard H∞ controller.
2015, 29(02).
doi: 10.3901/CJME.2015.0109.011
Abstract:
The understanding of the liquid fuel spray and flow field characteristics inside a combustor is crucial for designing a fuel efficient and low emission device. Characterisation of the flow field of a model gas turbine liquid swirl burner is performed by using a 2-D particle imaging velocimetry(PIV) system. The flow field pattern of an axial flow burner with a fixed swirl intensity is compared under confined and unconfined conditions, i.e., with and without the combustor wall. The effect of temperature on the main swirling air flow is investigated under open and non-reacting conditions. The result shows that axial and radial velocities increase as a result of decreased flow density and increased flow volume. The flow field of the main swirling flow with liquid fuel spray injection is compared to non-spray swirling flow. Introduction of liquid fuel spray changes the swirl air flow field at the burner outlet, where the radial velocity components increase for both open and confined environment. Under reacting condition, the enclosure generates a corner recirculation zone that intensifies the strength of radial velocity. The reverse flow and corner recirculation zone assists in stabilizing the flame by preheating the reactants. The flow field data can be used as validation target for swirl combustion modelling.
The understanding of the liquid fuel spray and flow field characteristics inside a combustor is crucial for designing a fuel efficient and low emission device. Characterisation of the flow field of a model gas turbine liquid swirl burner is performed by using a 2-D particle imaging velocimetry(PIV) system. The flow field pattern of an axial flow burner with a fixed swirl intensity is compared under confined and unconfined conditions, i.e., with and without the combustor wall. The effect of temperature on the main swirling air flow is investigated under open and non-reacting conditions. The result shows that axial and radial velocities increase as a result of decreased flow density and increased flow volume. The flow field of the main swirling flow with liquid fuel spray injection is compared to non-spray swirling flow. Introduction of liquid fuel spray changes the swirl air flow field at the burner outlet, where the radial velocity components increase for both open and confined environment. Under reacting condition, the enclosure generates a corner recirculation zone that intensifies the strength of radial velocity. The reverse flow and corner recirculation zone assists in stabilizing the flame by preheating the reactants. The flow field data can be used as validation target for swirl combustion modelling.
2015, 29(02).
doi: 10.3901/CJME.2014.1117.169
Abstract:
High-speed pick-and-place parallel robot is a system where the inertia imposed on the motor shafts is real-time changing with the system configurations. High quality of computer control with proper controller parameters is conducive to overcoming this problem and has a significant effect on reducing the robot’s tracking error. By taking Delta robot as an example, a method for parameter tuning of the fixed gain motion controller is presented. Having identifying the parameters of the servo system in the frequency domain by the sinusoidal excitation, the PD+feedforward control strategy is proposed to adapt to the varying inertia loads, allowing the controller parameters to be tuned by minimizing the mean square tracking error along a typical trajectory. A set of optimum parameters is obtained through computer simulations and the effectiveness of the proposed approach is validated by experiments on a real prototype machine. Let the traveling plate undergoes a specific trajectory and the results show that the tracking error can be reduced by at least 50% in comparison with the conventional auto-tuning and Z-N methods. The proposed approach is a whole workspace optimization and can be applied to the parameter tuning of fixed gain motion controllers.
High-speed pick-and-place parallel robot is a system where the inertia imposed on the motor shafts is real-time changing with the system configurations. High quality of computer control with proper controller parameters is conducive to overcoming this problem and has a significant effect on reducing the robot’s tracking error. By taking Delta robot as an example, a method for parameter tuning of the fixed gain motion controller is presented. Having identifying the parameters of the servo system in the frequency domain by the sinusoidal excitation, the PD+feedforward control strategy is proposed to adapt to the varying inertia loads, allowing the controller parameters to be tuned by minimizing the mean square tracking error along a typical trajectory. A set of optimum parameters is obtained through computer simulations and the effectiveness of the proposed approach is validated by experiments on a real prototype machine. Let the traveling plate undergoes a specific trajectory and the results show that the tracking error can be reduced by at least 50% in comparison with the conventional auto-tuning and Z-N methods. The proposed approach is a whole workspace optimization and can be applied to the parameter tuning of fixed gain motion controllers.
2015, 29(02).
doi: 10.3901/CJME.2015.0108.009
Abstract:
The friction drive elevators the influence of the braking distance has very high significance to meet certain safety regulations and comfort. During the emergency braking the delay for the system a frame and a cabin should be within the range from 0.2 to 9.81 m/s2. However, there are no specialist literatures regarding the issues connected with emergency braking of elevating devices either. The results of the own empirical research work are presented regarding the influence of design changes on the working parameters of the friction drive elevator gears. ASG100, KB160, PP16, PR2000UD and CHP2000 types of safety progressive gears are analyzed. ASG100, KB160, PP16, PR2000UD type progressive gears are already produced by European manufacturers. CHP2000 type gears are established as the alternative option for the already existing solutions. The unique cam system has been used in the CHP 2000 gears. The cam leverage gives the chance to unblock, in a very easy way, the clamed gears after braking. Thus, it is a key aspect to perform laboratory tests over the braking process of a newly created solution. The proper value of the braking distance has a significant influence on the value of delay in terms of binding standards. The influence of loading on the effective braking distance and the value of the falling elevator cabin speed are analyzed and the results are presented. The results presented are interesting from lift devices operation and a new model of CHP 2000 progressive gear point of view.
The friction drive elevators the influence of the braking distance has very high significance to meet certain safety regulations and comfort. During the emergency braking the delay for the system a frame and a cabin should be within the range from 0.2 to 9.81 m/s2. However, there are no specialist literatures regarding the issues connected with emergency braking of elevating devices either. The results of the own empirical research work are presented regarding the influence of design changes on the working parameters of the friction drive elevator gears. ASG100, KB160, PP16, PR2000UD and CHP2000 types of safety progressive gears are analyzed. ASG100, KB160, PP16, PR2000UD type progressive gears are already produced by European manufacturers. CHP2000 type gears are established as the alternative option for the already existing solutions. The unique cam system has been used in the CHP 2000 gears. The cam leverage gives the chance to unblock, in a very easy way, the clamed gears after braking. Thus, it is a key aspect to perform laboratory tests over the braking process of a newly created solution. The proper value of the braking distance has a significant influence on the value of delay in terms of binding standards. The influence of loading on the effective braking distance and the value of the falling elevator cabin speed are analyzed and the results are presented. The results presented are interesting from lift devices operation and a new model of CHP 2000 progressive gear point of view.
2015, 29(02).
doi: 10.3901/CJME.2015.0106.005
Abstract:
Recent studies on staggered labyrinth seals have focused on the effects of different parameters, such as the pressure ratio and rotational speed on the leakage flow rate. However, few investigations pay sufficient attention to flow details and the sealing mechanism, which would be of practical importance in designing seals having higher performance. This paper establishes a theoretical model to study the seal mechanism, thus revealing that leakage is determined by the pressure ratio and geometric structure. Numerical simulation is implemented to illustrate details of the flow field within the seal structure. Viscous dissipation is used to quantitatively investigate the contribution that each location makes to the seal performance, revealing that orifices and stagnation points are the most important positions in the seal structure, generating the most dissipation. The orifice is carefully studied by using the theoretical model. Experiments for different pressure ratios are conducted and the results match well with those of the theoretical model and numerical simulation, verifying the theoretical model and analysis of the seal mechanism. Three new designs, based on a good understanding of the seal mechanism, are presented, with one reducing leakage by 24.5%.
Recent studies on staggered labyrinth seals have focused on the effects of different parameters, such as the pressure ratio and rotational speed on the leakage flow rate. However, few investigations pay sufficient attention to flow details and the sealing mechanism, which would be of practical importance in designing seals having higher performance. This paper establishes a theoretical model to study the seal mechanism, thus revealing that leakage is determined by the pressure ratio and geometric structure. Numerical simulation is implemented to illustrate details of the flow field within the seal structure. Viscous dissipation is used to quantitatively investigate the contribution that each location makes to the seal performance, revealing that orifices and stagnation points are the most important positions in the seal structure, generating the most dissipation. The orifice is carefully studied by using the theoretical model. Experiments for different pressure ratios are conducted and the results match well with those of the theoretical model and numerical simulation, verifying the theoretical model and analysis of the seal mechanism. Three new designs, based on a good understanding of the seal mechanism, are presented, with one reducing leakage by 24.5%.
2015, 29(02).
doi: 10.3901/CJME.2014.1229.181
Abstract:
To develop a robot system for minimally invasive surgery is significant, however the existing minimally invasive surgery robots are not applicable in practical operations, due to their limited functioning and weaker perception. A novel wire feeder is proposed for minimally invasive vascular interventional surgery. It is used for assisting surgeons in delivering a guide wire, balloon and stenting into a specific lesion location. By contrasting those existing wire feeders, the motion methods for delivering and rotating the guide wire in blood vessel are described, and their mechanical realization is presented. A new resistant force detecting method is given in details. The change of the resistance force can help the operator feel the block or embolism existing in front of the guide wire. The driving torque for rotating the guide wire is developed at different positions. Using the CT reconstruction image and extracted vessel paths, the path equation of the blood vessel is obtained. Combining the shapes of the guide wire outside the blood vessel, the whole bending equation of the guide wire is obtained. That is a risk criterion in the delivering process. This process can make operations safer and man-machine interaction more reliable. A novel surgery robot for feeding guide wire is designed, and a risk criterion for the system is given.
To develop a robot system for minimally invasive surgery is significant, however the existing minimally invasive surgery robots are not applicable in practical operations, due to their limited functioning and weaker perception. A novel wire feeder is proposed for minimally invasive vascular interventional surgery. It is used for assisting surgeons in delivering a guide wire, balloon and stenting into a specific lesion location. By contrasting those existing wire feeders, the motion methods for delivering and rotating the guide wire in blood vessel are described, and their mechanical realization is presented. A new resistant force detecting method is given in details. The change of the resistance force can help the operator feel the block or embolism existing in front of the guide wire. The driving torque for rotating the guide wire is developed at different positions. Using the CT reconstruction image and extracted vessel paths, the path equation of the blood vessel is obtained. Combining the shapes of the guide wire outside the blood vessel, the whole bending equation of the guide wire is obtained. That is a risk criterion in the delivering process. This process can make operations safer and man-machine interaction more reliable. A novel surgery robot for feeding guide wire is designed, and a risk criterion for the system is given.
2015, 29(02).
doi: 10.3901/CJME.2015.0113.014
Abstract:
There has existed a great deal of theory researches in term of chip production and chip breaking characteristics under conventional cutting and high speed cutting conditions, however, there isn’t sufficient research on chip formation mechanism as well as its influence on cutting state regarding large workpieces under extreme load cutting. This paper presents a model of large saw-tooth chip through applying finite element simulation method, which gives a profound analysis about the characteristics of the extreme load cutting as well as morphology and removal of the large chip. In the meantime, a calculation formula that gives a quantitative description of the saw-tooth level regarding the large chip is established on the basis of cutting experiments on high temperature and high strength steel 2.25Cr-1Mo-0.25V. The cutting experiments are carried out by using the scanning electron microscope and super depth of field electron microscope to measure and calculate the large chip produced under different cutting parameters, which can verify the validity of the established model. The calculating results show that the large saw-toothed chip is produced under the squeezing action between workpiece and cutting tools. In the meanwhile, the chip develops a hardened layer where contacts the cutting tool and the saw-tooth of the chip tend to form in transverse direction. This research creates the theoretical model for large chip and performs the cutting experiments under the extreme load cutting condition, as well as analyzes the production mechanism of the large chip in the macro and micro conditions. Therefore, the proposed research could provide theoretical guidance and technical support in improving productivity and cutting technology research.
There has existed a great deal of theory researches in term of chip production and chip breaking characteristics under conventional cutting and high speed cutting conditions, however, there isn’t sufficient research on chip formation mechanism as well as its influence on cutting state regarding large workpieces under extreme load cutting. This paper presents a model of large saw-tooth chip through applying finite element simulation method, which gives a profound analysis about the characteristics of the extreme load cutting as well as morphology and removal of the large chip. In the meantime, a calculation formula that gives a quantitative description of the saw-tooth level regarding the large chip is established on the basis of cutting experiments on high temperature and high strength steel 2.25Cr-1Mo-0.25V. The cutting experiments are carried out by using the scanning electron microscope and super depth of field electron microscope to measure and calculate the large chip produced under different cutting parameters, which can verify the validity of the established model. The calculating results show that the large saw-toothed chip is produced under the squeezing action between workpiece and cutting tools. In the meanwhile, the chip develops a hardened layer where contacts the cutting tool and the saw-tooth of the chip tend to form in transverse direction. This research creates the theoretical model for large chip and performs the cutting experiments under the extreme load cutting condition, as well as analyzes the production mechanism of the large chip in the macro and micro conditions. Therefore, the proposed research could provide theoretical guidance and technical support in improving productivity and cutting technology research.
2015, 29(02).
doi: 10.3901/CJME.2014.1203.175
Abstract:
There are few relevant researches on coils by tempering, and the variations of microstructure and properties of steel coil during the tempering process also remain unclear. By using thermo-mechanical control process(TMCP) technology, Mn-Ti typical HSLA steel coils with yield strength of 920 MPa are produced on the 2250 hot rolling production line. Then, the samples are taken from the coils and tempered at the temperatures of 220 ℃, 350 ℃, and 620 ℃ respectively. After tempering the strength, ductility and toughness of samples are tested, and meanwhile microstructures are investigated. Precipitates initially emerge inside the ferrite laths and the density of the dislocation drops. Then, the lath-shaped ferrites begin to gather, and the retained austenite films start to decompose. Finally, the retained austenite films are completely decomposed into coarse and short rod-shape precipitates composed of C and Ti compounds. The yield strength increases with increasing tempering temperature due to the pinning effect of the precipitates, and the dislocation density decreases. The yield strength is highest when the steel is tempered at 220 ℃ because of pinning of the precipitates to dislocations. The total elongation increases in all samples because of the development of ferrites during tempering. The tensile strength and impact absorbed energy decline because the effect of impeding crack propagation weakens as the retained austenite films completely decompose and the precipitates coarsen. This paper clarifies the influence of different tempering temperatures on phase transformation characteristics and process of Mn-Ti typical multiphase steels, as well as its resulting performance variation rules.
There are few relevant researches on coils by tempering, and the variations of microstructure and properties of steel coil during the tempering process also remain unclear. By using thermo-mechanical control process(TMCP) technology, Mn-Ti typical HSLA steel coils with yield strength of 920 MPa are produced on the 2250 hot rolling production line. Then, the samples are taken from the coils and tempered at the temperatures of 220 ℃, 350 ℃, and 620 ℃ respectively. After tempering the strength, ductility and toughness of samples are tested, and meanwhile microstructures are investigated. Precipitates initially emerge inside the ferrite laths and the density of the dislocation drops. Then, the lath-shaped ferrites begin to gather, and the retained austenite films start to decompose. Finally, the retained austenite films are completely decomposed into coarse and short rod-shape precipitates composed of C and Ti compounds. The yield strength increases with increasing tempering temperature due to the pinning effect of the precipitates, and the dislocation density decreases. The yield strength is highest when the steel is tempered at 220 ℃ because of pinning of the precipitates to dislocations. The total elongation increases in all samples because of the development of ferrites during tempering. The tensile strength and impact absorbed energy decline because the effect of impeding crack propagation weakens as the retained austenite films completely decompose and the precipitates coarsen. This paper clarifies the influence of different tempering temperatures on phase transformation characteristics and process of Mn-Ti typical multiphase steels, as well as its resulting performance variation rules.
2015, 29(02).
doi: 10.3901/CJME.2015.0112.013
Abstract:
Before 1980s, the circular suspension spring in automobile subjected to torsion fatigue load, under the cyclic normal tensile stresses, the majority of fatigue fracture occurred was in normal tensile fracture mode(NTFM) and the fracture surface was under 45 diagonal. Because there exists the interaction between the residual stresses induced by shot peening and the applied cyclic normal tensile stresses in NTFM, which represents as “stress strengthening mechanism”, shot peening technology could be used for improving the fatigue fracture resistance(FFR) of springs. However, since 1990s up to date, in addition to regular NTFM, the fatigue fractures occurred of peened springs from time to time are in longitudinal shear fracture mode(LSFM) or transverse shear fracture mode(TSFM) with the increase of applied cyclic shear stresses, which leads to a remarkable decrease of FFR. However, LSFM/TSFM can be avoided effectively by means of shot peening treatment again on the peened springs. The phenomena have been rarely happened before. At present there are few literatures concerning this problem. Based upon the results of force analysis of a spring, there is no interaction between the residual stresses by shot peening and the applied cyclic shear stresses in shear fracture. This means that the effect of “stress strengthening mechanism” for improving the FFR of LSFM/TSFM is disappeared basically. During shot peening, however, both of residual stress and cyclic plastic deformed microstructure are induced synchronously like “twins” in the surface layer of a spring. It has been found for the first time by means of force analysis and experimental results that the modified microstructure in the “twins” as a “structure strengthening mechanism” can improve the FFR of LSFM/TSFM. At the same time, it is also shown that the optimum technology of shot peening strengthening must have both “stress strengthening mechanism” and “structure strengthening mechanism” simultaneously so that the FFR of both NTFM and LSFM/TSFM can be improved by shot peening.
Before 1980s, the circular suspension spring in automobile subjected to torsion fatigue load, under the cyclic normal tensile stresses, the majority of fatigue fracture occurred was in normal tensile fracture mode(NTFM) and the fracture surface was under 45 diagonal. Because there exists the interaction between the residual stresses induced by shot peening and the applied cyclic normal tensile stresses in NTFM, which represents as “stress strengthening mechanism”, shot peening technology could be used for improving the fatigue fracture resistance(FFR) of springs. However, since 1990s up to date, in addition to regular NTFM, the fatigue fractures occurred of peened springs from time to time are in longitudinal shear fracture mode(LSFM) or transverse shear fracture mode(TSFM) with the increase of applied cyclic shear stresses, which leads to a remarkable decrease of FFR. However, LSFM/TSFM can be avoided effectively by means of shot peening treatment again on the peened springs. The phenomena have been rarely happened before. At present there are few literatures concerning this problem. Based upon the results of force analysis of a spring, there is no interaction between the residual stresses by shot peening and the applied cyclic shear stresses in shear fracture. This means that the effect of “stress strengthening mechanism” for improving the FFR of LSFM/TSFM is disappeared basically. During shot peening, however, both of residual stress and cyclic plastic deformed microstructure are induced synchronously like “twins” in the surface layer of a spring. It has been found for the first time by means of force analysis and experimental results that the modified microstructure in the “twins” as a “structure strengthening mechanism” can improve the FFR of LSFM/TSFM. At the same time, it is also shown that the optimum technology of shot peening strengthening must have both “stress strengthening mechanism” and “structure strengthening mechanism” simultaneously so that the FFR of both NTFM and LSFM/TSFM can be improved by shot peening.
2015, 29(02).
doi: 10.3901/CJME.2015.0109.010
Abstract:
The rolling process is determined by the interaction of a number of different movements, during which the relative movement occurs between the vibrating roll system and the rolled piece, and the roll system’s vibration interacts with the strip’s deformation and rigid movement. So many parameters being involved leads to a complex mechanism of this coupling effect. Through testing and analyzing the vibration signals of the mill in the rolling process, the rolling mill’s coupled model is established with comprehensive consideration of the coupling interaction between the mill’s vertical vibration, its torsional vibration and the working roll’s horizontal vibration, and vibration characteristics of different forms of rolling mill’s vibration are analyzed under the coupling effect. With comprehensive attention to the relationship between the roll system, the moving strip and the rolling parameters’ dynamic properties, and also from the strip thickness control point of view, further research is done on the coupling mechanism between the roll system’s movement and the moving strip’s characteristics in the rolling process. As a result, the law of inertial coupling and the stiffness coupling effect caused by different forms of the roll system’s vibration is determined and the existence of nonlinear characteristics caused by the elastic deformation of moving strip is also found. Furthermore, a multi-parameter coupling-dynamic model is established which takes the tandem strip mill as its research object by making a detailed kinematics analysis of the roll system and using the principle of virtual work. The coupling-dynamic model proposes the instruction to describe the roll system’s movement, and analyzes its dynamic response and working stability, and provides a theoretical basis for the realization of the strip thickness’ dynamic control.
The rolling process is determined by the interaction of a number of different movements, during which the relative movement occurs between the vibrating roll system and the rolled piece, and the roll system’s vibration interacts with the strip’s deformation and rigid movement. So many parameters being involved leads to a complex mechanism of this coupling effect. Through testing and analyzing the vibration signals of the mill in the rolling process, the rolling mill’s coupled model is established with comprehensive consideration of the coupling interaction between the mill’s vertical vibration, its torsional vibration and the working roll’s horizontal vibration, and vibration characteristics of different forms of rolling mill’s vibration are analyzed under the coupling effect. With comprehensive attention to the relationship between the roll system, the moving strip and the rolling parameters’ dynamic properties, and also from the strip thickness control point of view, further research is done on the coupling mechanism between the roll system’s movement and the moving strip’s characteristics in the rolling process. As a result, the law of inertial coupling and the stiffness coupling effect caused by different forms of the roll system’s vibration is determined and the existence of nonlinear characteristics caused by the elastic deformation of moving strip is also found. Furthermore, a multi-parameter coupling-dynamic model is established which takes the tandem strip mill as its research object by making a detailed kinematics analysis of the roll system and using the principle of virtual work. The coupling-dynamic model proposes the instruction to describe the roll system’s movement, and analyzes its dynamic response and working stability, and provides a theoretical basis for the realization of the strip thickness’ dynamic control.
2015, 29(02).
doi: 10.3901/CJME.2014.0821.139
Abstract:
Due to its highly favorable physical and chemical properties, titanium and titanium alloy are widely used in a variety of industries. Because of the low output of a single batch, plate cold rolling without tension is the most common rolling production method for titanium alloy. This method is lack of on-line thickness closed-loop control, with carefully thickness setting models for precision. A set of high-precision thickness setting models are proposed to suit the production method. Because of frequent variations in rolling specification, a model structural for the combination of analytical models and statistical models is adopted to replace the traditional self-learning method. The deformation resistance and friction factor, the primary factors which affect model precision, are considered as the objectives of statistical modeling. Firstly, the coefficient fitting of deformation resistance analytical model based on over-determined equations set is adopted. Additionally, a support vector machine(SVM) is applied to the modeling of the deformation resistance and friction factor. The setting models are applied to a 1450 plate-coiling mill for titanium alloy plate rolling, and then thickness precision is found consistently to be within 3%, exceeding the precision of traditional setting models with a self-learning method based on a large number of stable rolling data. Excellent application performance is obtained. The proposed research provides a set of high-precision thickness setting models which are well adapted to the characteristics of titanium alloy plate cold rolling without tension.
Due to its highly favorable physical and chemical properties, titanium and titanium alloy are widely used in a variety of industries. Because of the low output of a single batch, plate cold rolling without tension is the most common rolling production method for titanium alloy. This method is lack of on-line thickness closed-loop control, with carefully thickness setting models for precision. A set of high-precision thickness setting models are proposed to suit the production method. Because of frequent variations in rolling specification, a model structural for the combination of analytical models and statistical models is adopted to replace the traditional self-learning method. The deformation resistance and friction factor, the primary factors which affect model precision, are considered as the objectives of statistical modeling. Firstly, the coefficient fitting of deformation resistance analytical model based on over-determined equations set is adopted. Additionally, a support vector machine(SVM) is applied to the modeling of the deformation resistance and friction factor. The setting models are applied to a 1450 plate-coiling mill for titanium alloy plate rolling, and then thickness precision is found consistently to be within 3%, exceeding the precision of traditional setting models with a self-learning method based on a large number of stable rolling data. Excellent application performance is obtained. The proposed research provides a set of high-precision thickness setting models which are well adapted to the characteristics of titanium alloy plate cold rolling without tension.
2015, 29(02).
doi: 10.3901/CJME.2014.1128.173
Abstract:
Researches on forging manipulator have enormous influence on the development of the forging industry and national economy. Clamp device and lifting mechanism are the core parts of forging manipulator, and have been studied for longer time. However, the optimization and mechanical accuracy reliability of them are less analyzed. Based on General Function(GF) set and parallel mechanism theory, proper configuration of 10t forging manipulator is selected firstly. A new type of forging manipulator driven by cylinders is proposed. After solved mechanical analysis of manipulator’s core mechanisms, expressions of force of cylinders are carried out. In order to achieve smaller force afforded by cylinders and better mechanical characteristics, some particular sizes of core mechanisms are optimized intuitively through the combined use of the genetic algorithms(GA) and GUI interface in MATLAB. Comparing with the original mechanisms, optimized clamp saves at least 8 percent efforts and optimized lifting mechanism 20 percent under maximum working condition. Finally, considering the existed manufacture error of components, mechanical accuracy reliability of optimized clamp, lifting mechanism and whole manipulator are demonstrated respectively based on fuzzy reliability theory. Obtained results show that the accuracy reliability of optimized clamp is bigger than 0.991 and that of optimized lifting mechanism is 0.995. To the whole manipulator under maximum working condition, that value exceeds 0.986 4, which means that optimized manipulator has high motion accuracy and is reliable. A new intuitive method is created to optimize forging manipulator sizes efficiently and more practical theory is utilized to analyze mechanical accuracy reliability of forging manipulator precisely.
Researches on forging manipulator have enormous influence on the development of the forging industry and national economy. Clamp device and lifting mechanism are the core parts of forging manipulator, and have been studied for longer time. However, the optimization and mechanical accuracy reliability of them are less analyzed. Based on General Function(GF) set and parallel mechanism theory, proper configuration of 10t forging manipulator is selected firstly. A new type of forging manipulator driven by cylinders is proposed. After solved mechanical analysis of manipulator’s core mechanisms, expressions of force of cylinders are carried out. In order to achieve smaller force afforded by cylinders and better mechanical characteristics, some particular sizes of core mechanisms are optimized intuitively through the combined use of the genetic algorithms(GA) and GUI interface in MATLAB. Comparing with the original mechanisms, optimized clamp saves at least 8 percent efforts and optimized lifting mechanism 20 percent under maximum working condition. Finally, considering the existed manufacture error of components, mechanical accuracy reliability of optimized clamp, lifting mechanism and whole manipulator are demonstrated respectively based on fuzzy reliability theory. Obtained results show that the accuracy reliability of optimized clamp is bigger than 0.991 and that of optimized lifting mechanism is 0.995. To the whole manipulator under maximum working condition, that value exceeds 0.986 4, which means that optimized manipulator has high motion accuracy and is reliable. A new intuitive method is created to optimize forging manipulator sizes efficiently and more practical theory is utilized to analyze mechanical accuracy reliability of forging manipulator precisely.
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