2015 Vol.28(03)
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2015, 29(03).
doi: 10.3901/CJME.2015.0301.021
Abstract:
The sampling auger used in lunar sampling and return mission is to transmit power and convey soil, and its performance is the key factor of the whole mission. However, there is currently a lack of the optimization research on soil conveying volume and power consumption models in auger structure design. To provide the drilled object, the simulation lunar soil, whose physical and mechanical property is the same as the real soil, is made by reducing soil void ratio. The models are formulated to analyze the influence of auger structure parameters on power consumption and soil conveying volume. To obtain the optimized structure parameters of auger, the multi-objective optimization functions of the maximum soil conveying volume and minimum power consumption are developed. To verify the correctness of the models, the performances of different augers drilling simulation soil are tested. The test results demonstrate that the power consumption of optimized auger is the lowest both in theory and test, and the experimental results of soil conveying volume are in agreement with theoretical analysis. Consequently, a new method for designing a lunar sampling auger is proposed which includes the models of soil conveying volume and transportation power consumption, the optimization of structure parameters and the comparison tests. This method provides a reference for sampling auger designing of the Chinese Lunar Sample Mission.
The sampling auger used in lunar sampling and return mission is to transmit power and convey soil, and its performance is the key factor of the whole mission. However, there is currently a lack of the optimization research on soil conveying volume and power consumption models in auger structure design. To provide the drilled object, the simulation lunar soil, whose physical and mechanical property is the same as the real soil, is made by reducing soil void ratio. The models are formulated to analyze the influence of auger structure parameters on power consumption and soil conveying volume. To obtain the optimized structure parameters of auger, the multi-objective optimization functions of the maximum soil conveying volume and minimum power consumption are developed. To verify the correctness of the models, the performances of different augers drilling simulation soil are tested. The test results demonstrate that the power consumption of optimized auger is the lowest both in theory and test, and the experimental results of soil conveying volume are in agreement with theoretical analysis. Consequently, a new method for designing a lunar sampling auger is proposed which includes the models of soil conveying volume and transportation power consumption, the optimization of structure parameters and the comparison tests. This method provides a reference for sampling auger designing of the Chinese Lunar Sample Mission.
2015, 29(03).
doi: 10.3901/CJME.2015.0310.027
Abstract:
How to control surface roughness of steel strip in a narrow range for a long time has become an important question because surface roughness would significantly influence the appearance of the products. However, there are few effective solutions to solve the problem currently. In this paper, considering both asperities of work roll pressing in and squeezing the steel strip, two asperity contact models including squeezing model and pressing in model in a two-stand temper mill rolling are established by using finite element method (FEM). The simulation investigates the influences of multiple process parameters, such as work roll surface roughness, roll radius and roll force on the surface roughness of steel strip. The simulation results indicate that work rolls surface roughness and roll force play important roles in the products; furthermore, the effect of roll force in the first stand is opposite to the second. According to the analysis, a control method for steel strip surface roughness in a narrow range for a long time is proposed, which applies higher work roll roughness in the first stand and lower roll roughness in the second to make the steel strip roughness in a required narrow range. In the later stage of the production, decreasing the roll force in the first stand and increasing the roll force in the second stand guarantee the steel strip roughness relatively stable in a long time. The following experimental measurements on the surface topography and roughness of the steel strips during the whole process are also conducted. The results validate the simulation conclusions and prove the effect of the control method. The application of the proposed method in the steel strip production shows excellent performance including long service life of work roll and high finished product rate.
How to control surface roughness of steel strip in a narrow range for a long time has become an important question because surface roughness would significantly influence the appearance of the products. However, there are few effective solutions to solve the problem currently. In this paper, considering both asperities of work roll pressing in and squeezing the steel strip, two asperity contact models including squeezing model and pressing in model in a two-stand temper mill rolling are established by using finite element method (FEM). The simulation investigates the influences of multiple process parameters, such as work roll surface roughness, roll radius and roll force on the surface roughness of steel strip. The simulation results indicate that work rolls surface roughness and roll force play important roles in the products; furthermore, the effect of roll force in the first stand is opposite to the second. According to the analysis, a control method for steel strip surface roughness in a narrow range for a long time is proposed, which applies higher work roll roughness in the first stand and lower roll roughness in the second to make the steel strip roughness in a required narrow range. In the later stage of the production, decreasing the roll force in the first stand and increasing the roll force in the second stand guarantee the steel strip roughness relatively stable in a long time. The following experimental measurements on the surface topography and roughness of the steel strips during the whole process are also conducted. The results validate the simulation conclusions and prove the effect of the control method. The application of the proposed method in the steel strip production shows excellent performance including long service life of work roll and high finished product rate.
2015, 29(03).
doi: 10.3901/CJME.2015.0311.028
Abstract:
The most important consequence of adiabatic shear phenomenon is formation of sawtooth chip. Lots of scholars focused on the formation mechanism of sawtooth, and the research often depended on experimental approach. For the present, the mechanism of sawtooth chip formation still remains some ambiguous aspects. This study develops a combined numerical and experimental approach to get deeper understanding of sawtooth chip formation mechanism for Polycrystalline Cubic Boron Nitride (PCBN) tools orthogonal cutting hard steel GCr15. By adopting the Johnson-Cook material constitutive equations, the FEM simulation model established in this research effectively overcomes serious element distortions and cell singularity in high strain domain caused by large material deformation, and the adiabatic shear phenomenon is simulated successfully. Both the formation mechanism and process of sawtooth are simulated. Also, the change features regarding the cutting force as well as its effects on temperature are studied. More specifically, the contact of sawtooth formation frequency with cutting force fluctuation frequency is established. The cutting force and effect of cutting temperature on mechanism of adiabatic shear are investigated. Furthermore, the effects of the cutting condition on sawtooth chip formation are researched. The researching results show that cutting feed has the most important effect on sawtooth chip formation compared with cutting depth and speed. This research contributes a better understanding of mechanism, feature of chip formation in hard turning process, and supplies theoretical basis for the optimization of hard cutting process parameters.
The most important consequence of adiabatic shear phenomenon is formation of sawtooth chip. Lots of scholars focused on the formation mechanism of sawtooth, and the research often depended on experimental approach. For the present, the mechanism of sawtooth chip formation still remains some ambiguous aspects. This study develops a combined numerical and experimental approach to get deeper understanding of sawtooth chip formation mechanism for Polycrystalline Cubic Boron Nitride (PCBN) tools orthogonal cutting hard steel GCr15. By adopting the Johnson-Cook material constitutive equations, the FEM simulation model established in this research effectively overcomes serious element distortions and cell singularity in high strain domain caused by large material deformation, and the adiabatic shear phenomenon is simulated successfully. Both the formation mechanism and process of sawtooth are simulated. Also, the change features regarding the cutting force as well as its effects on temperature are studied. More specifically, the contact of sawtooth formation frequency with cutting force fluctuation frequency is established. The cutting force and effect of cutting temperature on mechanism of adiabatic shear are investigated. Furthermore, the effects of the cutting condition on sawtooth chip formation are researched. The researching results show that cutting feed has the most important effect on sawtooth chip formation compared with cutting depth and speed. This research contributes a better understanding of mechanism, feature of chip formation in hard turning process, and supplies theoretical basis for the optimization of hard cutting process parameters.
2015, 29(03).
doi: 10.3901/CJME.2015.0302.022
Abstract:
In non-conforming rolling contact, the contact stress is highly concentrated in the contact area. However, there are some limitations of the special contact model and stress model used for the theoretical study of the phenomenon, and this has prevented in-depth analysis of the associated friction, wear, and failure. This paper is particularly aimed at investigating the area of rolling contact between a sphere and a cone, for which purpose the boundary is determined by the Hertz theory and the geometries of the non-conforming surfaces. The phenomenon of stick-slip contact is observed to occur in the contact area under the condition of no-full-slip (Q < μ • P). Using the two-dimensional rolling contact theory developed by CARTER, the relative positions of the stick and slip regions and the distribution of the tangential force over the contact area are analyzed. Furthermore, each stress component is calculated based on the McEwen theory and the idea of narrow band. The stress equations for the three-dimensional rolling contact between the sphere and the cone are obtained by the principle of superposition, and are used to perform some numerical simulations. The results show that the stress components have a large gradient along the boundary between the stick and slip regions, and that the maximum stress is inversely proportional to the contact coefficient and proportional to the friction coefficient. A new method for investigating the stress during non-classical three-dimensional rolling contact is proposed as a theoretical foundation for the analysis of the associated friction, wear, and failure.
In non-conforming rolling contact, the contact stress is highly concentrated in the contact area. However, there are some limitations of the special contact model and stress model used for the theoretical study of the phenomenon, and this has prevented in-depth analysis of the associated friction, wear, and failure. This paper is particularly aimed at investigating the area of rolling contact between a sphere and a cone, for which purpose the boundary is determined by the Hertz theory and the geometries of the non-conforming surfaces. The phenomenon of stick-slip contact is observed to occur in the contact area under the condition of no-full-slip (Q < μ • P). Using the two-dimensional rolling contact theory developed by CARTER, the relative positions of the stick and slip regions and the distribution of the tangential force over the contact area are analyzed. Furthermore, each stress component is calculated based on the McEwen theory and the idea of narrow band. The stress equations for the three-dimensional rolling contact between the sphere and the cone are obtained by the principle of superposition, and are used to perform some numerical simulations. The results show that the stress components have a large gradient along the boundary between the stick and slip regions, and that the maximum stress is inversely proportional to the contact coefficient and proportional to the friction coefficient. A new method for investigating the stress during non-classical three-dimensional rolling contact is proposed as a theoretical foundation for the analysis of the associated friction, wear, and failure.
2015, 29(03).
doi: 10.3901/CJME.2015.0313.030
Abstract:
Globe control valve is widely used in chemical, petroleum and hydraulic industries, and its throttling feature is achieved by the adopting of valve plug. However, very limited information is available in literature regarding the influence of valve plug on the internal and external features in globe control valves. Thus the effect of valve plug is studied by CFD and experiment in this paper. It is obtained from external features that the pressure drop between upstream and downstream pressure-sampling position increases exponentially with flow rate. And for small valve opening, the increment of pressure drop decreases with the increase of cone angle (β). However, with the increase of valve opening, the effect of cone angle diminishes significantly. It is also found that the cone angle has little effect on flow coefficient (Cv) when the valve opening is larger than 70%. But for the cases less than 70%, Cv curve varies from an arc to a straight line. The variation of valve performance is caused by the change of internal flow. The results of internal flow show that cone angle has negligible effect on flow properties for the cases of valve opening larger than 70%. However, when valve opening is smaller than 70%, the pressure drop of orifice decreases with the increase of β, making the reduction in value and scope of the high speed zone around the conical surface of valve plug, and then results in a decreasing intensity of adjacent downstream vortex. Meanwhile, it is concluded from the results that the increase of cone angle will be beneficial for the anti-cavitation and anti-erosion of globe control valve. This paper focuses on the internal and external features of globe control valve that caused by the variation of cone angle, arriving at some results beneficial for the design and usage of globe control valve.
Globe control valve is widely used in chemical, petroleum and hydraulic industries, and its throttling feature is achieved by the adopting of valve plug. However, very limited information is available in literature regarding the influence of valve plug on the internal and external features in globe control valves. Thus the effect of valve plug is studied by CFD and experiment in this paper. It is obtained from external features that the pressure drop between upstream and downstream pressure-sampling position increases exponentially with flow rate. And for small valve opening, the increment of pressure drop decreases with the increase of cone angle (β). However, with the increase of valve opening, the effect of cone angle diminishes significantly. It is also found that the cone angle has little effect on flow coefficient (Cv) when the valve opening is larger than 70%. But for the cases less than 70%, Cv curve varies from an arc to a straight line. The variation of valve performance is caused by the change of internal flow. The results of internal flow show that cone angle has negligible effect on flow properties for the cases of valve opening larger than 70%. However, when valve opening is smaller than 70%, the pressure drop of orifice decreases with the increase of β, making the reduction in value and scope of the high speed zone around the conical surface of valve plug, and then results in a decreasing intensity of adjacent downstream vortex. Meanwhile, it is concluded from the results that the increase of cone angle will be beneficial for the anti-cavitation and anti-erosion of globe control valve. This paper focuses on the internal and external features of globe control valve that caused by the variation of cone angle, arriving at some results beneficial for the design and usage of globe control valve.
2015, 29(03).
doi: 10.3901/CJME.2015.0121.017
Abstract:
Modal analysis is a fundamental and important task for modeling and control of the flexible manipulator. However, almost all of the traditional modal analysis methods view the flexible manipulator as a pure mechanical structure and neglect feedback action of joint controller. In order to study the effects of joint controller on the modal analysis of rotational flexible manipulator, a closed-loop analytical modal analysis method is proposed. Firstly, two exact boundary constraints, namely servo feedback constraint and bending moment constraint, are derived to solve the vibration partial differential equation. It is found that the stiffness and damping gains of joint controller are both included in the boundary conditions, which lead to an unconventional secular term. Secondly, analytical algorithm based on Ritz approach is developed by using Laplace transform and complex modal approach to obtain the natural frequencies and mode shapes. And then, the numerical simulations are performed and the computational results show that joint controller has pronounced influence on the modal parameters: joint controller stiffness reduces the natural frequency, while joint controller damping makes the shape phase non-zero. Furthermore, the validity of the presented conclusion is confirmed through experimental studies. These findings are expected to improve the performance of dynamics simulation systems and model-based controllers.
Modal analysis is a fundamental and important task for modeling and control of the flexible manipulator. However, almost all of the traditional modal analysis methods view the flexible manipulator as a pure mechanical structure and neglect feedback action of joint controller. In order to study the effects of joint controller on the modal analysis of rotational flexible manipulator, a closed-loop analytical modal analysis method is proposed. Firstly, two exact boundary constraints, namely servo feedback constraint and bending moment constraint, are derived to solve the vibration partial differential equation. It is found that the stiffness and damping gains of joint controller are both included in the boundary conditions, which lead to an unconventional secular term. Secondly, analytical algorithm based on Ritz approach is developed by using Laplace transform and complex modal approach to obtain the natural frequencies and mode shapes. And then, the numerical simulations are performed and the computational results show that joint controller has pronounced influence on the modal parameters: joint controller stiffness reduces the natural frequency, while joint controller damping makes the shape phase non-zero. Furthermore, the validity of the presented conclusion is confirmed through experimental studies. These findings are expected to improve the performance of dynamics simulation systems and model-based controllers.
2015, 29(03).
doi: 10.3901/CJME.2015.0309.026
Abstract:
The metal sealing performance of subsea X-tree wellhead connectors is crucial for the safety and reliability of subsea X-trees. In order to establish the theoretical relation between metal sealing ring’s contact stress and its structural parameters and working pressure, a mechanical analysis method for double-cone sealing of high pressure vessels is applied in analyzing the metal sealing ring under the condition of preload and operation. As a result, the formula of the unit sealing load for the metal sealing ring under operation with residual preload is shown in this paper, which ensures that the metal sealing ring has an excellent sealing effect and can prevent the metal sealing ring from yielding. Besides, while analyzing the sealing process of the metal sealing ring, the change rule of contact stress and working pressure is concluded here, putting forward that the structural parameters of the metal sealing ring are the major factors affecting the change rule. Finally, the analytical solution through theoretical analysis is compared with the simulation result through finite element analysis in a force feedback experiment, and both are consistent with each other, which fully verifies for the design and calculation theory on metal sealing ring’s contact stress and its structural parameters and working pressure deduced in this paper. The proposed research will be treated as an applicable theory guiding the design of metal seal for subsea X-tree wellhead connectors.
The metal sealing performance of subsea X-tree wellhead connectors is crucial for the safety and reliability of subsea X-trees. In order to establish the theoretical relation between metal sealing ring’s contact stress and its structural parameters and working pressure, a mechanical analysis method for double-cone sealing of high pressure vessels is applied in analyzing the metal sealing ring under the condition of preload and operation. As a result, the formula of the unit sealing load for the metal sealing ring under operation with residual preload is shown in this paper, which ensures that the metal sealing ring has an excellent sealing effect and can prevent the metal sealing ring from yielding. Besides, while analyzing the sealing process of the metal sealing ring, the change rule of contact stress and working pressure is concluded here, putting forward that the structural parameters of the metal sealing ring are the major factors affecting the change rule. Finally, the analytical solution through theoretical analysis is compared with the simulation result through finite element analysis in a force feedback experiment, and both are consistent with each other, which fully verifies for the design and calculation theory on metal sealing ring’s contact stress and its structural parameters and working pressure deduced in this paper. The proposed research will be treated as an applicable theory guiding the design of metal seal for subsea X-tree wellhead connectors.
2015, 29(03).
doi: 10.3901/CJME.2015.0403.037
Abstract:
Ultra-high speed machining technology enables high efficiency, high precision and high integrity of machined surface. Previous researches of hybrid bearing rarely consider influences of solid particles in lubricant and ultra-high speed of hybrid bearing, which cannot be ignored under the high speed and micro-space conditions of ultra-high speed water-lubricated hybrid bearing. Considering the impact of solid particles in lubricant, turbulence and temperature viscosity effects of lubricant, the influences of particles on pressure distribution, loading capacity and the temperature rise of the lubricant film with four-step-cavity ultra-high speed water-lubricated hybrid bearing are presented in the paper. The results show that loading capacity of the hybrid bearing can be affected by changing the viscosity of the lubricant, and large particles can improve the bearing loading capacity higher. The impact of water film temperature rise produced by solid particles in lubricant is related with particle diameter and minimum film thickness. Compared with the soft particles, hard particles cause the more increasing of water film temperature rise and loading capacity. When the speed of hybrid bearing increases, the impact of solid particles on hybrid bearing becomes increasingly apparent, especially for ultra-high speed water-lubricated hybrid bearing. This research presents influences of solid particles on the loading capacity and the temperature rise of water film in ultra-high speed hybrid bearings, the research conclusions provide a new method to evaluate the influence of solid particles in lubricant of ultra-high speed water-lubricated hybrid bearing, which is important to performance calculation of ultra-high speed hybrid bearings, design of filtration system, and safe operation of ultra-high speed hybrid bearings.
Ultra-high speed machining technology enables high efficiency, high precision and high integrity of machined surface. Previous researches of hybrid bearing rarely consider influences of solid particles in lubricant and ultra-high speed of hybrid bearing, which cannot be ignored under the high speed and micro-space conditions of ultra-high speed water-lubricated hybrid bearing. Considering the impact of solid particles in lubricant, turbulence and temperature viscosity effects of lubricant, the influences of particles on pressure distribution, loading capacity and the temperature rise of the lubricant film with four-step-cavity ultra-high speed water-lubricated hybrid bearing are presented in the paper. The results show that loading capacity of the hybrid bearing can be affected by changing the viscosity of the lubricant, and large particles can improve the bearing loading capacity higher. The impact of water film temperature rise produced by solid particles in lubricant is related with particle diameter and minimum film thickness. Compared with the soft particles, hard particles cause the more increasing of water film temperature rise and loading capacity. When the speed of hybrid bearing increases, the impact of solid particles on hybrid bearing becomes increasingly apparent, especially for ultra-high speed water-lubricated hybrid bearing. This research presents influences of solid particles on the loading capacity and the temperature rise of water film in ultra-high speed hybrid bearings, the research conclusions provide a new method to evaluate the influence of solid particles in lubricant of ultra-high speed water-lubricated hybrid bearing, which is important to performance calculation of ultra-high speed hybrid bearings, design of filtration system, and safe operation of ultra-high speed hybrid bearings.
2015, 29(03).
doi: 10.3901/CJME.2015.0312.029
Abstract:
The current design and optimization of the occupant restraint system (ORS) are based on numerous actual tests and mathematic simulations. These two methods are overly time-consuming and complex for the concept design phase of the ORS, though they’re quite effective and accurate. Therefore, a fast and directive method of the design and optimization is needed in the concept design phase of the ORS. Since the airbag system is a crucial part of the ORS, in this paper, a theoretical model for the vehicle airbag is established in order to clarify the interaction between occupants and airbags, and further a fast design and optimization method of airbags in the concept design phase is made based on the proposed theoretical model. First, the theoretical expression of the simplified mechanical relationship between the airbag’s design parameters and the occupant response is developed based on classical mechanics, then the momentum theorem and the ideal gas state equation are adopted to illustrate the relationship between airbag’s design parameters and occupant response. By using MATLAB software, the iterative algorithm method and discrete variables are applied to the solution of the proposed theoretical model with a random input in a certain scope. And validations by MADYMO software prove the validity and accuracy of this theoretical model in two principal design parameters, the inflated gas mass and vent diameter, within a regular range. This research contributes to a deeper comprehension of the relation between occupants and airbags, further a fast design and optimization method for airbags’ principal parameters in the concept design phase, and provides the range of the airbag’s initial design parameters for the subsequent CAE simulations and actual tests.
The current design and optimization of the occupant restraint system (ORS) are based on numerous actual tests and mathematic simulations. These two methods are overly time-consuming and complex for the concept design phase of the ORS, though they’re quite effective and accurate. Therefore, a fast and directive method of the design and optimization is needed in the concept design phase of the ORS. Since the airbag system is a crucial part of the ORS, in this paper, a theoretical model for the vehicle airbag is established in order to clarify the interaction between occupants and airbags, and further a fast design and optimization method of airbags in the concept design phase is made based on the proposed theoretical model. First, the theoretical expression of the simplified mechanical relationship between the airbag’s design parameters and the occupant response is developed based on classical mechanics, then the momentum theorem and the ideal gas state equation are adopted to illustrate the relationship between airbag’s design parameters and occupant response. By using MATLAB software, the iterative algorithm method and discrete variables are applied to the solution of the proposed theoretical model with a random input in a certain scope. And validations by MADYMO software prove the validity and accuracy of this theoretical model in two principal design parameters, the inflated gas mass and vent diameter, within a regular range. This research contributes to a deeper comprehension of the relation between occupants and airbags, further a fast design and optimization method for airbags’ principal parameters in the concept design phase, and provides the range of the airbag’s initial design parameters for the subsequent CAE simulations and actual tests.
2015, 29(03).
doi: 10.3901/CJME.2015.0409.039
Abstract:
The current researches on the tooth surface mathematical equations and the theory of gearing mainly pay attention to the ordinary type worm gear set (e.g., ZN, ZA, or ZK). The research of forming mechanism and three-dimensional modeling method for the double pitch worm gear set is not enough. So there are some difficulties in mathematical model deducing and geometry modeling of double pitch ZN-type worm gear set based on generation mechanism. In order to establish the mathematical model and the precise geometric model of double pitch ZN-type worm gear set, the structural characteristics and generation mechanism of the double pitch ZN-type worm gear set are investigated. Mathematical model of the ZN-type worm gear set is derived based on its generation mechanism and the theory of gearing. According to the mathematical model of the worm gear set which has been developed, a geometry modeling method of the double pitch ZN-type worm and worm gear is presented. Furthermore, a geometrical precision calculate method is proposed to evaluate the geometrical quality of the double pitch worm gear set. As a result, the maximum error is less than 610–4 mm in magnitude, thus the model of the double pitch ZN-type worm gear set is available to meet the requirements of finite element analysis and engineering application. The derived mathematical model and the proposed geometrical modeling method are helpful to guiding the design, manufacture and contact analysis of the worm gear set.
The current researches on the tooth surface mathematical equations and the theory of gearing mainly pay attention to the ordinary type worm gear set (e.g., ZN, ZA, or ZK). The research of forming mechanism and three-dimensional modeling method for the double pitch worm gear set is not enough. So there are some difficulties in mathematical model deducing and geometry modeling of double pitch ZN-type worm gear set based on generation mechanism. In order to establish the mathematical model and the precise geometric model of double pitch ZN-type worm gear set, the structural characteristics and generation mechanism of the double pitch ZN-type worm gear set are investigated. Mathematical model of the ZN-type worm gear set is derived based on its generation mechanism and the theory of gearing. According to the mathematical model of the worm gear set which has been developed, a geometry modeling method of the double pitch ZN-type worm and worm gear is presented. Furthermore, a geometrical precision calculate method is proposed to evaluate the geometrical quality of the double pitch worm gear set. As a result, the maximum error is less than 610–4 mm in magnitude, thus the model of the double pitch ZN-type worm gear set is available to meet the requirements of finite element analysis and engineering application. The derived mathematical model and the proposed geometrical modeling method are helpful to guiding the design, manufacture and contact analysis of the worm gear set.
2015, 29(03).
doi: 10.3901/CJME.2015.0122.018
Abstract:
Although the parallel mechanisms have the advantages of high accuracy, velocity, stiffness, and payload capacity, the shortcomings of the space utilization and workspace limit the applications in the confined space. A novel 3 degrees of freedom spatial parallel manipulator 3-PSR-O (prismatic-spherical-revolute) is proposed, which possesses a compact architecture and extended workspace while maintaining the inherent advantages of the parallel mechanisms. The direct-inverse position, singularity and workspace are investigated. The mapping method is adopted in the position analysis, and the closed form solution is derived in the form of a six order equation. The singularity analysis of the mechanism is also carried out based on the geometrical constraints, including six singularity boundaries. A feature boundary, which is independent of the prismatic joints’ stroke limit, is obtained by integrating the six singularity boundaries. According to the formation of the reachable workspace, a concept of basic workspace is also introduced and presented in the analytical way. By demarcating the basic workspace along the central height with the feature boundary, the reachable workspace can be derived and analyzed more efficiently. Finally, a comparative study on the space utilization between the 3-PSP parallel mechanism and the new mechanism is also presented. The area of feature boundary of the new mechanism is about 140% of the 3-PSP parallel mechanism, while its installation radius is only 1/2 of the 3-PSP parallel mechanism. The proposed parallel mechanism shows great space utilization, and is ideally suited for applications in confined space occasions such as immersion lithography, nano-imprint etc.
Although the parallel mechanisms have the advantages of high accuracy, velocity, stiffness, and payload capacity, the shortcomings of the space utilization and workspace limit the applications in the confined space. A novel 3 degrees of freedom spatial parallel manipulator 3-PSR-O (prismatic-spherical-revolute) is proposed, which possesses a compact architecture and extended workspace while maintaining the inherent advantages of the parallel mechanisms. The direct-inverse position, singularity and workspace are investigated. The mapping method is adopted in the position analysis, and the closed form solution is derived in the form of a six order equation. The singularity analysis of the mechanism is also carried out based on the geometrical constraints, including six singularity boundaries. A feature boundary, which is independent of the prismatic joints’ stroke limit, is obtained by integrating the six singularity boundaries. According to the formation of the reachable workspace, a concept of basic workspace is also introduced and presented in the analytical way. By demarcating the basic workspace along the central height with the feature boundary, the reachable workspace can be derived and analyzed more efficiently. Finally, a comparative study on the space utilization between the 3-PSP parallel mechanism and the new mechanism is also presented. The area of feature boundary of the new mechanism is about 140% of the 3-PSP parallel mechanism, while its installation radius is only 1/2 of the 3-PSP parallel mechanism. The proposed parallel mechanism shows great space utilization, and is ideally suited for applications in confined space occasions such as immersion lithography, nano-imprint etc.
2015, 29(03).
doi: 10.3901/CJME.2015.0317.032
Abstract:
Coasting in gear is a common driving mode for the conventional vehicle equipped with the internal combustion engine (ICE), and the assistant braking function of ICE is utilized to decelerate the vehicle in this mode. However, the electric vehicle (EV) does not have this feature in the coasting mode due to the relatively small inertia of the driving motor, so it will cause the driver cannot obtain the similar driving feeling to that of the conventional vehicle, and even a traffic accident may occur if the driver cannot immediately adapt to the changes. In this paper, the coasting control for EV is researched based on the driving feeling. A conventional vehicle equipped with continuously variable transmission (CVT) is taken as the reference vehicle, and the combined simulation model of EV is established based on AVL CRUISE and MATLAB/Simulink. The torque characteristic of the CVT output shaft is measured in coasting mode, and the data are smoothed and fitted to a polynomial curve. For the EV in coasting mode, if the state of charge (SOC) of the battery is below 95%, the polynomial curve is used as the control target for the torque characteristic of the driving motor, otherwise, the required torque is replaced by hydraulic braking torque to keep the same deceleration. The co-simulation of Matlab/Simulink/Stateflow and AVL CRUISE, as well as the hardware-in-loop experiment combined with dSPACE are carried out to verify the effectiveness and the real-time performance of the control algorithm. The results show that the EV with coasting braking control system has similar driving feeling to that of the reference vehicle, meanwhile, the battery SOC can be increased by 0.036% and 0.021% in the initial speed of 100 kmh and 50 kmh, respectively. The proposed control algorithm for EV is beneficial to improve the driving feeling in coasting mode, and it also makes the EV has the assistant braking function.
Coasting in gear is a common driving mode for the conventional vehicle equipped with the internal combustion engine (ICE), and the assistant braking function of ICE is utilized to decelerate the vehicle in this mode. However, the electric vehicle (EV) does not have this feature in the coasting mode due to the relatively small inertia of the driving motor, so it will cause the driver cannot obtain the similar driving feeling to that of the conventional vehicle, and even a traffic accident may occur if the driver cannot immediately adapt to the changes. In this paper, the coasting control for EV is researched based on the driving feeling. A conventional vehicle equipped with continuously variable transmission (CVT) is taken as the reference vehicle, and the combined simulation model of EV is established based on AVL CRUISE and MATLAB/Simulink. The torque characteristic of the CVT output shaft is measured in coasting mode, and the data are smoothed and fitted to a polynomial curve. For the EV in coasting mode, if the state of charge (SOC) of the battery is below 95%, the polynomial curve is used as the control target for the torque characteristic of the driving motor, otherwise, the required torque is replaced by hydraulic braking torque to keep the same deceleration. The co-simulation of Matlab/Simulink/Stateflow and AVL CRUISE, as well as the hardware-in-loop experiment combined with dSPACE are carried out to verify the effectiveness and the real-time performance of the control algorithm. The results show that the EV with coasting braking control system has similar driving feeling to that of the reference vehicle, meanwhile, the battery SOC can be increased by 0.036% and 0.021% in the initial speed of 100 kmh and 50 kmh, respectively. The proposed control algorithm for EV is beneficial to improve the driving feeling in coasting mode, and it also makes the EV has the assistant braking function.
2015, 29(03).
doi: 10.3901/CJME.2015.0316.031
Abstract:
C-276 nickel-based alloy is a difficult-to-cut material. In high-speed machining of Hastelloy C-276, notching is a prominent failure mode due to high mechanical properties of work piece, which results in the short tool life and low productivity. In this paper, a newly developed Ti(C7N3)-based cermet insert manufactured by a hot-pressing method is used to machine the C-276 nickel-based alloy, and its cutting performances are studied. Based on orthogonal experiment method, the influence of cutting parameters on tool life, material removal rates and surface roughness are investigated. Experimental research results indicate that the optimal cutting condition is a cutting speed of 50 mmin, depth of cut of 0.4 mm and feed rate of 0.15 mmr if the tool life and material removal rates are considered comprehensively. In this case, the tool life is 32 min and material removal rates are 3000 mm3min, which is appropriate to the rough machining. If the tool life and surface roughness are considered, the better cutting condition is a cutting speed of 75 mmin, depth of cut of 0.6 mm and feed rate of 0.1 mmr. In this case, the surface roughness is 0.59 m. Notch wear, flank wear, chipping at the tool nose, built-up edge(BUE) and micro-cracks are found when Ti(C7N3)-based cermet insert turned Hastelloy C-276. Oxidation, adhesive, abrasive and diffusion are the wear mechanisms, which can be investigated by the observations of scanning electron microscope and energy-dispersive spectroscopy. This research will help to guide studies on the evaluation of machining parameters to further advance the productivity of nickel based alloy Hastelloy C-276 machining.
C-276 nickel-based alloy is a difficult-to-cut material. In high-speed machining of Hastelloy C-276, notching is a prominent failure mode due to high mechanical properties of work piece, which results in the short tool life and low productivity. In this paper, a newly developed Ti(C7N3)-based cermet insert manufactured by a hot-pressing method is used to machine the C-276 nickel-based alloy, and its cutting performances are studied. Based on orthogonal experiment method, the influence of cutting parameters on tool life, material removal rates and surface roughness are investigated. Experimental research results indicate that the optimal cutting condition is a cutting speed of 50 mmin, depth of cut of 0.4 mm and feed rate of 0.15 mmr if the tool life and material removal rates are considered comprehensively. In this case, the tool life is 32 min and material removal rates are 3000 mm3min, which is appropriate to the rough machining. If the tool life and surface roughness are considered, the better cutting condition is a cutting speed of 75 mmin, depth of cut of 0.6 mm and feed rate of 0.1 mmr. In this case, the surface roughness is 0.59 m. Notch wear, flank wear, chipping at the tool nose, built-up edge(BUE) and micro-cracks are found when Ti(C7N3)-based cermet insert turned Hastelloy C-276. Oxidation, adhesive, abrasive and diffusion are the wear mechanisms, which can be investigated by the observations of scanning electron microscope and energy-dispersive spectroscopy. This research will help to guide studies on the evaluation of machining parameters to further advance the productivity of nickel based alloy Hastelloy C-276 machining.
2015, 29(03).
doi: 10.3901/CJME.2015.0330.036
Abstract:
Most references on hydropneumatic suspension analysis regard it as harden Duffing spring and take the white noise as the system input, which is quite different from real physical model. It will introduce considerable errors to the analytical result compared with the numerical simulation which makes it impossible to give a good depiction of the hydropneumatic suspension dynamics. In this paper, the dynamic response of the hydropneumatic suspension is worked out using statistical linearization based on 2 DOFs nonlinear suspension model. The damping of the suspension and the tire stiffness are both regarded as linear components and the real road roughness spectrum is used to work out the system input. The explicit analytical equivalent stiffness, dynamic mean value offset from statistic equilibrium position and the sprung acceleration varied with parameters of hydropneumatic spring, road roughness and vehicle velocity are worked out by substituting the nonlinear stiffness of hydropneumatic spring with its first three terms Tyler series at the static equilibrium position using James formula. The comparison of the numerical simulation and analytical result both on statistical parameters and distribution shows the validity of the analysis. The explicit form provides a concise and valid method on hydropneumatic suspension design and optimization.
Most references on hydropneumatic suspension analysis regard it as harden Duffing spring and take the white noise as the system input, which is quite different from real physical model. It will introduce considerable errors to the analytical result compared with the numerical simulation which makes it impossible to give a good depiction of the hydropneumatic suspension dynamics. In this paper, the dynamic response of the hydropneumatic suspension is worked out using statistical linearization based on 2 DOFs nonlinear suspension model. The damping of the suspension and the tire stiffness are both regarded as linear components and the real road roughness spectrum is used to work out the system input. The explicit analytical equivalent stiffness, dynamic mean value offset from statistic equilibrium position and the sprung acceleration varied with parameters of hydropneumatic spring, road roughness and vehicle velocity are worked out by substituting the nonlinear stiffness of hydropneumatic spring with its first three terms Tyler series at the static equilibrium position using James formula. The comparison of the numerical simulation and analytical result both on statistical parameters and distribution shows the validity of the analysis. The explicit form provides a concise and valid method on hydropneumatic suspension design and optimization.
2015, 29(03).
doi: 10.3901/CJME.2015.0318.033
Abstract:
Drive wheel systems combined with the in-wheel permanent magnet synchronous motor (I-PMSM) and the tire are highly electromechanical-coupled. However, the deformation dynamics of this system, which may influence the system performance, is neglected in most existing literatures. For this reason, a deformable tire and a detailed I-PMSM are modeled using Matlab/Simulink. Furthermore, the influence of tire/road contact interface is accurately described by the non-linear relaxation length-based model and magic formula pragmatic model. The drive wheel model used in this paper is closer to that of a real tire in contrast to the rigid tire model which is widely used. Based on the near-precise model mentioned above, the sensitivity of the dynamic tire and I-PMSM parameters to the relative error of slip ratio estimation is analyzed. Additionally, the torsional and longitudinal vibrations of the drive wheel are presented both in time and frequency domains when a quarter vehicle is started under conditions of a specific torque curve, which includes an abrupt torque change from 30 N • m to 200 N • m. The parameters sensitivity on drive wheel vibrations is also studied, and the parameters include the mass distribution ratio of tire, the tire torsional stiffness, the tire damping coefficient, and the hysteresis band of the PMSM current control algorithm. Finally, different target torque curves are compared in the simulation, which shows that the estimation error of the slip ratio gets violent, and the longitudinal force includes more fluctuation components with the increasing change rate of the torque. This paper analyzes the influence of the drive wheel deformation on the vehicle dynamic control, and provides useful information regarding the electric vehicle traction control.
Drive wheel systems combined with the in-wheel permanent magnet synchronous motor (I-PMSM) and the tire are highly electromechanical-coupled. However, the deformation dynamics of this system, which may influence the system performance, is neglected in most existing literatures. For this reason, a deformable tire and a detailed I-PMSM are modeled using Matlab/Simulink. Furthermore, the influence of tire/road contact interface is accurately described by the non-linear relaxation length-based model and magic formula pragmatic model. The drive wheel model used in this paper is closer to that of a real tire in contrast to the rigid tire model which is widely used. Based on the near-precise model mentioned above, the sensitivity of the dynamic tire and I-PMSM parameters to the relative error of slip ratio estimation is analyzed. Additionally, the torsional and longitudinal vibrations of the drive wheel are presented both in time and frequency domains when a quarter vehicle is started under conditions of a specific torque curve, which includes an abrupt torque change from 30 N • m to 200 N • m. The parameters sensitivity on drive wheel vibrations is also studied, and the parameters include the mass distribution ratio of tire, the tire torsional stiffness, the tire damping coefficient, and the hysteresis band of the PMSM current control algorithm. Finally, different target torque curves are compared in the simulation, which shows that the estimation error of the slip ratio gets violent, and the longitudinal force includes more fluctuation components with the increasing change rate of the torque. This paper analyzes the influence of the drive wheel deformation on the vehicle dynamic control, and provides useful information regarding the electric vehicle traction control.
2015, 29(03).
doi: 10.3901/CJME.2014.1210.177
Abstract:
As the traditional forging process has many problems such as low efficiency, high consumption of material and energy, large cylindrical shell rolling is introduced. Large cylindrical shell rolling is a typical rotary forming technology, and the upper and lower rolls have different radii and speeds. To quickly predict the three-dimensional stresses and eliminate fishtail defect, an improved strip layer method is developed, in which the asymmetry of the upper and lower rolls, non-uniform deformation and stress, as well as the asymmetrical spread on the end surface are considered. The deformation zone is divided into a certain number of layers and strips along the thickness and width, respectively. The transverse displacement model is constructed by polynomial function, in order to increase the computation speed greatly. From the metal plastic mechanics principle, the three-dimensional stress models are established. The genetic algorithm is used for optimization calculation in an industrial experiment example. The results show that the rolling pressure, the normal stresses, the upper and lower friction stress distributions are not similar with those of a general plate rolling. There are two relative maximum values in rolling pressure distribution. The upper and lower longitudinal friction stresses change direction nearby the upper and lower neutral points, respectively. The fishtail profile of spread on the end surface is predicted satisfactorily. The reduction could be helpful to eliminate fishtail defect. The large cylindrical shell rolling example illustrates the calculation results acquired rapidly are good agreements with the finite element simulation and experimental values of previous study. A highly effective and reliable three-dimensional simulation method is proposed for large cylindrical shell rolling and other asymmetrical rolling.
As the traditional forging process has many problems such as low efficiency, high consumption of material and energy, large cylindrical shell rolling is introduced. Large cylindrical shell rolling is a typical rotary forming technology, and the upper and lower rolls have different radii and speeds. To quickly predict the three-dimensional stresses and eliminate fishtail defect, an improved strip layer method is developed, in which the asymmetry of the upper and lower rolls, non-uniform deformation and stress, as well as the asymmetrical spread on the end surface are considered. The deformation zone is divided into a certain number of layers and strips along the thickness and width, respectively. The transverse displacement model is constructed by polynomial function, in order to increase the computation speed greatly. From the metal plastic mechanics principle, the three-dimensional stress models are established. The genetic algorithm is used for optimization calculation in an industrial experiment example. The results show that the rolling pressure, the normal stresses, the upper and lower friction stress distributions are not similar with those of a general plate rolling. There are two relative maximum values in rolling pressure distribution. The upper and lower longitudinal friction stresses change direction nearby the upper and lower neutral points, respectively. The fishtail profile of spread on the end surface is predicted satisfactorily. The reduction could be helpful to eliminate fishtail defect. The large cylindrical shell rolling example illustrates the calculation results acquired rapidly are good agreements with the finite element simulation and experimental values of previous study. A highly effective and reliable three-dimensional simulation method is proposed for large cylindrical shell rolling and other asymmetrical rolling.
2015, 29(03).
doi: 10.3901/CJME.2015.0116.016
Abstract:
Computational fluid dynamics (CFD) can give a lot of potentially very useful information for hydraulic optimization design of pumps, however, it cannot directly state what kind of modification should be made to improve such hydrodynamic performance. In this paper, a more convenient and effective approach is proposed by combined using of CFD, multi-objective genetic algorithm (MOGA) and artificial neural networks (ANN) for a double-channel pump’s impeller, with maximum head and efficiency set as optimization objectives, four key geometrical parameters including inlet diameter, outlet diameter, exit width and midline wrap angle chosen as optimization parameters. Firstly, a multi-fidelity fitness assignment system in which fitness of impellers serving as training and comparison samples for ANN is evaluated by CFD, meanwhile fitness of impellers generated by MOGA is evaluated by ANN, is established and dramatically reduces the computational expense. Then, a modified MOGA optimization process, in which selection is performed independently in two sub-populations according to two optimization objectives, crossover and mutation is performed afterword in the merged population, is developed to ensure the global optimal solution to be found. Finally, Pareto optimal frontier is found after 500 steps of iterations, and two optimal design schemes are chosen according to the design requirements. The preliminary and optimal design schemes are compared, and the comparing results show that hydraulic performances of both pumps 1 and 2 are improved, with the head and efficiency of pump 1 increased by 5.7% and 5.2%, respectively in the design working conditions, meanwhile shaft power decreased in all working conditions, the head and efficiency of pump 2 increased by 11.7% and 5.9%, respectively while shaft power increased by 5.5%. Inner flow field analyses also show that the backflow phenomenon significantly diminishes at the entrance of the optimal impellers 1 and 2, both the area of vortex and intensity of vortex decreases in the whole flow channel. This paper provides a promising tool to solve the hydraulic optimization problem of pumps’ impellers.
Computational fluid dynamics (CFD) can give a lot of potentially very useful information for hydraulic optimization design of pumps, however, it cannot directly state what kind of modification should be made to improve such hydrodynamic performance. In this paper, a more convenient and effective approach is proposed by combined using of CFD, multi-objective genetic algorithm (MOGA) and artificial neural networks (ANN) for a double-channel pump’s impeller, with maximum head and efficiency set as optimization objectives, four key geometrical parameters including inlet diameter, outlet diameter, exit width and midline wrap angle chosen as optimization parameters. Firstly, a multi-fidelity fitness assignment system in which fitness of impellers serving as training and comparison samples for ANN is evaluated by CFD, meanwhile fitness of impellers generated by MOGA is evaluated by ANN, is established and dramatically reduces the computational expense. Then, a modified MOGA optimization process, in which selection is performed independently in two sub-populations according to two optimization objectives, crossover and mutation is performed afterword in the merged population, is developed to ensure the global optimal solution to be found. Finally, Pareto optimal frontier is found after 500 steps of iterations, and two optimal design schemes are chosen according to the design requirements. The preliminary and optimal design schemes are compared, and the comparing results show that hydraulic performances of both pumps 1 and 2 are improved, with the head and efficiency of pump 1 increased by 5.7% and 5.2%, respectively in the design working conditions, meanwhile shaft power decreased in all working conditions, the head and efficiency of pump 2 increased by 11.7% and 5.9%, respectively while shaft power increased by 5.5%. Inner flow field analyses also show that the backflow phenomenon significantly diminishes at the entrance of the optimal impellers 1 and 2, both the area of vortex and intensity of vortex decreases in the whole flow channel. This paper provides a promising tool to solve the hydraulic optimization problem of pumps’ impellers.
2015, 29(03).
doi: 10.3901/CJME.2015.0305.023
Abstract:
In the process of rock breaking, the conical pick bears great cutting force and wear, as a result, high-pressure water jet technology is used to assist with cutting. However, the effect of the water jet position has not been studied for rock breaking using a pick. Therefore, the models of rock breaking with different configuration modes of the water jet are established based on SPH combined with FEM. The effect of the water jet pressure, distance between the jet and the pick bit, and cutting depth on the rock breaking performance as well as a comparison of the tension and compression stress are studied via simulation; the simulation results are verified by experiments. The numerical and experimental results indicate that the decrease in the rates of the pick force obviously increases from 25 MPa to 40 MPa, but slowly after 40 MPa, and the optimal distance between the jet and the pick bit is 2 mm under the JFP and JSP modes. The JCP mode is proved the best, followed by the modes of JRP and JFP, and the worst mode is JSP. The decrease in the rates of the pick force of the JCP, JRP, JFP, and JSP modes are up to 30.96%, 28.96%, 33.46%, 28.17%, and 25.42%, respectively, in experiment. Moreover, the JSP mode can be regarded as a special JFP model when the distance between the pick-tip and the jet impact point is 0 mm. This paper has a dominant capability in introducing new numerical and experimental method for the study of rock breaking assisted by water jet and electing the best water jet position from four different configuration modes.
In the process of rock breaking, the conical pick bears great cutting force and wear, as a result, high-pressure water jet technology is used to assist with cutting. However, the effect of the water jet position has not been studied for rock breaking using a pick. Therefore, the models of rock breaking with different configuration modes of the water jet are established based on SPH combined with FEM. The effect of the water jet pressure, distance between the jet and the pick bit, and cutting depth on the rock breaking performance as well as a comparison of the tension and compression stress are studied via simulation; the simulation results are verified by experiments. The numerical and experimental results indicate that the decrease in the rates of the pick force obviously increases from 25 MPa to 40 MPa, but slowly after 40 MPa, and the optimal distance between the jet and the pick bit is 2 mm under the JFP and JSP modes. The JCP mode is proved the best, followed by the modes of JRP and JFP, and the worst mode is JSP. The decrease in the rates of the pick force of the JCP, JRP, JFP, and JSP modes are up to 30.96%, 28.96%, 33.46%, 28.17%, and 25.42%, respectively, in experiment. Moreover, the JSP mode can be regarded as a special JFP model when the distance between the pick-tip and the jet impact point is 0 mm. This paper has a dominant capability in introducing new numerical and experimental method for the study of rock breaking assisted by water jet and electing the best water jet position from four different configuration modes.
2015, 29(03).
doi: 10.3901/CJME.2015.0408.038
Abstract:
Current high power load simulators are generally incapable of obtaining both high loading performance and high energy efficiency. Simulators with high energy efficiency are used to simulate static-state load, and those with high dynamic performance typically have low energy efficiency. In this paper, the variants of secondary control (VSC) with power recovery are developed to solve this problem for loading hydraulic driving devices that operate under variable pressure, unlike classical secondary control (CSC) that operates in constant pressure network. Hydrostatic secondary control units are used as the loading components, by which the absorbed mechanical power from the tested device is converted into hydraulic power and then fed back into the tested system through 4 types of feedback passages (FPs). The loading subsystem can operate in constant pressure network, controlled variable pressure network, or the same variable pressure network as that of the tested device by using different FPs. The 4 types of systems are defined, and their key techniques are analyzed, including work principle, simulating the work state of original tested device, static operation points, loading performance, energy efficiency, and control strategy, etc. The important technical merits of the 4 schemes are compared, and 3 of the schemes are selected, designed, simulated using AMESim and evaluated. The researching results show that the investigated systems can simulate the given loads effectively, realize the work conditions of the tested device, and furthermore attain a high power recovery efficiency that ranges from 0.54 to 0.85, even though the 3 schemes have different loading performances and energy efficiencies. This paper proposes several loading schemes that can achieve both high dynamic performance and high power recovery efficiency.
Current high power load simulators are generally incapable of obtaining both high loading performance and high energy efficiency. Simulators with high energy efficiency are used to simulate static-state load, and those with high dynamic performance typically have low energy efficiency. In this paper, the variants of secondary control (VSC) with power recovery are developed to solve this problem for loading hydraulic driving devices that operate under variable pressure, unlike classical secondary control (CSC) that operates in constant pressure network. Hydrostatic secondary control units are used as the loading components, by which the absorbed mechanical power from the tested device is converted into hydraulic power and then fed back into the tested system through 4 types of feedback passages (FPs). The loading subsystem can operate in constant pressure network, controlled variable pressure network, or the same variable pressure network as that of the tested device by using different FPs. The 4 types of systems are defined, and their key techniques are analyzed, including work principle, simulating the work state of original tested device, static operation points, loading performance, energy efficiency, and control strategy, etc. The important technical merits of the 4 schemes are compared, and 3 of the schemes are selected, designed, simulated using AMESim and evaluated. The researching results show that the investigated systems can simulate the given loads effectively, realize the work conditions of the tested device, and furthermore attain a high power recovery efficiency that ranges from 0.54 to 0.85, even though the 3 schemes have different loading performances and energy efficiencies. This paper proposes several loading schemes that can achieve both high dynamic performance and high power recovery efficiency.
2015, 29(03).
doi: 10.3901/CJME.2015.0114.015
Abstract:
Many high-quality forging productions require the large-sized hydraulic press machine (HPM) to have a desirable dynamic response. Since the forging process is complex under the low velocity, its response is difficult to estimate. And this often causes the desirable low-velocity forging condition difficult to obtain. So far little work has been found to estimate the dynamic response of the forging process under low velocity. In this paper, an approximate-model based estimation method is proposed to estimate the dynamic response of the forging process under low velocity. First, an approximate model is developed to represent the forging process of this complex HPM around the low-velocity working point. Under guaranteeing the modeling performance, the model may greatly ease the complexity of the subsequent estimation of the dynamic response because it has a good linear structure. On this basis, the dynamic response is estimated and the conditions for stability, vibration, and creep are derived according to the solution of the velocity. All these analytical results are further verified by both simulations and experiment. In the simulation verification for modeling, the original movement model and the derived approximate model always have the same dynamic responses with very small approximate error. The simulations and experiment finally demonstrate and test the effectiveness of the derived conditions for stability, vibration, and creep, and these conditions will benefit both the prediction of the dynamic response of the forging process and the design of the controller for the high-quality forging. The proposed method is an effective solution to achieve the desirable low-velocity forging condition.
Many high-quality forging productions require the large-sized hydraulic press machine (HPM) to have a desirable dynamic response. Since the forging process is complex under the low velocity, its response is difficult to estimate. And this often causes the desirable low-velocity forging condition difficult to obtain. So far little work has been found to estimate the dynamic response of the forging process under low velocity. In this paper, an approximate-model based estimation method is proposed to estimate the dynamic response of the forging process under low velocity. First, an approximate model is developed to represent the forging process of this complex HPM around the low-velocity working point. Under guaranteeing the modeling performance, the model may greatly ease the complexity of the subsequent estimation of the dynamic response because it has a good linear structure. On this basis, the dynamic response is estimated and the conditions for stability, vibration, and creep are derived according to the solution of the velocity. All these analytical results are further verified by both simulations and experiment. In the simulation verification for modeling, the original movement model and the derived approximate model always have the same dynamic responses with very small approximate error. The simulations and experiment finally demonstrate and test the effectiveness of the derived conditions for stability, vibration, and creep, and these conditions will benefit both the prediction of the dynamic response of the forging process and the design of the controller for the high-quality forging. The proposed method is an effective solution to achieve the desirable low-velocity forging condition.
2015, 29(03).
doi: 10.3901/CJME.2015.0319.034
Abstract:
The inner and outer oil film dynamic characteristic coefficients of floating ring bearings(FRBs) change due to the manufacturing tolerance of the floating ring, journal and intermediate, which leads to high-speed turbocharger’s vibration too large and even causes nonlinear vibration accident. However, the investigation of floating ring bearing manufacturing tolerance clearance on the rotordynamic characteristics is less at present. In order to study the influence law of inner and outer clearance on turbocharger vibration, the rotor dynamic motion equations of turbocharger supported in FRBs are derived by analyzing the size relations between floating ring, journal and intermediate for the inner and outer oil film clearances, the time transient response analysis for combination of FRBs clearance are developed. A realistic turbocharger is taken as a research object, the FE model of the turbocharger with FRBs is modeled. Under the conditions of four kinds of limit state bearing clearances for inner and outer oil film, the nonlinear transient analyses are performed based on the established FE dynamic models of the nonlinear rotor-FRBs system applied incentive combinations of gravity and unbalance force, respectively. From the waterfall, the simulation results show that the speed for the appearance of fractional frequency is not identical and the amplitude magnitude is different under the four kinds of bearing manufacturing tolerance limit clearances, and fractional frequency does not appear in the turbocharger and the amplitude is minimum under the ODMin/IDMax bearing manufacturing tolerance clearances. The turbocharger vibration is reduced by controlling the manufacturing tolerance clearance combinations of FRBs, which is helpful for the dynamic design and production-manufacturing of high-speed turbocharger.
The inner and outer oil film dynamic characteristic coefficients of floating ring bearings(FRBs) change due to the manufacturing tolerance of the floating ring, journal and intermediate, which leads to high-speed turbocharger’s vibration too large and even causes nonlinear vibration accident. However, the investigation of floating ring bearing manufacturing tolerance clearance on the rotordynamic characteristics is less at present. In order to study the influence law of inner and outer clearance on turbocharger vibration, the rotor dynamic motion equations of turbocharger supported in FRBs are derived by analyzing the size relations between floating ring, journal and intermediate for the inner and outer oil film clearances, the time transient response analysis for combination of FRBs clearance are developed. A realistic turbocharger is taken as a research object, the FE model of the turbocharger with FRBs is modeled. Under the conditions of four kinds of limit state bearing clearances for inner and outer oil film, the nonlinear transient analyses are performed based on the established FE dynamic models of the nonlinear rotor-FRBs system applied incentive combinations of gravity and unbalance force, respectively. From the waterfall, the simulation results show that the speed for the appearance of fractional frequency is not identical and the amplitude magnitude is different under the four kinds of bearing manufacturing tolerance limit clearances, and fractional frequency does not appear in the turbocharger and the amplitude is minimum under the ODMin/IDMax bearing manufacturing tolerance clearances. The turbocharger vibration is reduced by controlling the manufacturing tolerance clearance combinations of FRBs, which is helpful for the dynamic design and production-manufacturing of high-speed turbocharger.
2015, 29(03).
doi: 10.3901/CJME.2015.0217.019
Abstract:
High strength aluminum alloy plate has a low elongation at room temperature, which leads to the forming of its components need a high temperature. Liquid or gas is used as the pressure-transfer medium in the existing flexible mould forming process, the heat resistance of the medium and pressurizing device makes the application of aluminum alloy plate thermoforming restricted. To solve this problem, the existing medium is replaced by the heat-resisting solid granules and the general pressure equipments are applied. Based on the pressure-transfer performance test of the solid granules medium, the feasibility that the assumption of the extended Drucker-Prager linear model can be used in the finite element analysis is proved. The constitutive equation, the yield function and the theoretical forming limit diagram(FLD) of AA7075 sheet are established. Through the finite element numerical simulation of hot granules medium pressure forming(HGMF) process, not only the influence laws of the process parameters, such as forming temperature, the blank-holder gap and the diameter of the slab, on sheet metal forming performance are discussed, but also the broken area of the forming process is analyzed and predicted, which are coincided with the technological test. The conical part whose half cone angle is 15° and relative height H/d0 is 0.57, is formed in one process at 250℃. The HGMF process solves the problems of loading and seal in the existing flexible mould forming process and provides a novel technology for thermoforming of light alloy plate, such as magnesium alloy, aluminium alloy and titanium alloy.
High strength aluminum alloy plate has a low elongation at room temperature, which leads to the forming of its components need a high temperature. Liquid or gas is used as the pressure-transfer medium in the existing flexible mould forming process, the heat resistance of the medium and pressurizing device makes the application of aluminum alloy plate thermoforming restricted. To solve this problem, the existing medium is replaced by the heat-resisting solid granules and the general pressure equipments are applied. Based on the pressure-transfer performance test of the solid granules medium, the feasibility that the assumption of the extended Drucker-Prager linear model can be used in the finite element analysis is proved. The constitutive equation, the yield function and the theoretical forming limit diagram(FLD) of AA7075 sheet are established. Through the finite element numerical simulation of hot granules medium pressure forming(HGMF) process, not only the influence laws of the process parameters, such as forming temperature, the blank-holder gap and the diameter of the slab, on sheet metal forming performance are discussed, but also the broken area of the forming process is analyzed and predicted, which are coincided with the technological test. The conical part whose half cone angle is 15° and relative height H/d0 is 0.57, is formed in one process at 250℃. The HGMF process solves the problems of loading and seal in the existing flexible mould forming process and provides a novel technology for thermoforming of light alloy plate, such as magnesium alloy, aluminium alloy and titanium alloy.
2015, 29(03).
doi: 10.3901/CJME.2015.0228.020
Abstract:
To understand the engine main bearings’ working condition is important in order to improve the performance of engine. However, thermal effects and thermal effect deformations of engine main bearings are rarely considered simultaneously in most studies. A typical finite element model is selected and the effect of thermoelastohydrodynamic(TEHD) reaction on engine main bearings is investigated. The calculated method of main bearing’s thermal hydrodynamic reaction and journal misalignment effect is finite difference method, and its deformation reaction is calculated by using finite element method. The oil film pressure is solved numerically with Reynolds boundary conditions when various bearing characteristics are calculated. The whole model considers a temperature-pressure-viscosity relationship for the lubricant, surface roughness effect, and also an angular misalignment between the journal and the bearing. Numerical simulations of operation of a typical I6 diesel engine main bearing is conducted and importance of several contributing factors in mixed lubrication is discussed. The performance characteristics of journal misaligned main bearings under elastohydrodynamic(EHD) and TEHD loads of an I6 diesel engine are received, and then the journal center orbit movement, minimum oil film thickness and maximum oil film pressure of main bearings are estimated over a wide range of engine operation. The model is verified through the comparison with other present models. The TEHD performance of engine main bearings with various effects under the influences of journal misalignment is revealed, this is helpful to understand EHD and TEHD effect of misaligned engine main bearings.
To understand the engine main bearings’ working condition is important in order to improve the performance of engine. However, thermal effects and thermal effect deformations of engine main bearings are rarely considered simultaneously in most studies. A typical finite element model is selected and the effect of thermoelastohydrodynamic(TEHD) reaction on engine main bearings is investigated. The calculated method of main bearing’s thermal hydrodynamic reaction and journal misalignment effect is finite difference method, and its deformation reaction is calculated by using finite element method. The oil film pressure is solved numerically with Reynolds boundary conditions when various bearing characteristics are calculated. The whole model considers a temperature-pressure-viscosity relationship for the lubricant, surface roughness effect, and also an angular misalignment between the journal and the bearing. Numerical simulations of operation of a typical I6 diesel engine main bearing is conducted and importance of several contributing factors in mixed lubrication is discussed. The performance characteristics of journal misaligned main bearings under elastohydrodynamic(EHD) and TEHD loads of an I6 diesel engine are received, and then the journal center orbit movement, minimum oil film thickness and maximum oil film pressure of main bearings are estimated over a wide range of engine operation. The model is verified through the comparison with other present models. The TEHD performance of engine main bearings with various effects under the influences of journal misalignment is revealed, this is helpful to understand EHD and TEHD effect of misaligned engine main bearings.
2015, 29(03).
doi: 10.3901/CJME.2015.0306.024
Abstract:
The ride comfort experimental assessment of crawler off-road vehicle is relatively overlooked, and is expensive and difficult to execute with higher and higher ride comfort performance requirements. To trade off between precise and cost, an experimental method based on the similitude theory is proposed. Under the guidance of the similitude theory, a 1:5 crawler power chassis scale model equipped with a kind of variable stiffness suspension system is used. The power spectrum density(PSD), the root mean square(RMS) of weighed acceleration, peak factor, average absorbed power(AAP) and vibration dose value(VDV) are selected as ride comfort evaluation indexes, and tests results are transformed via similarity indexes to predict the performance of full-scale power chassis. PSD shows that the low-order natural frequency of the vertical natural frequency(z axis) is 1.1 Hz, and the RMS, AAP and VDV values indicate the ride comfort performance of this kind of power chassis is between the “A little uncomfortable” and “Rather uncomfortable”. From the results, low-order vertical natural frequency, obtained by PSD, validates that the similarity relationship between two models is satisfied, and 1:5 scale model used in experiment meets the similarity relationship with the full-scale model; consequently, the ride comfort prophase evaluation with the 1:5 scale model is feasible. The attempt of applying the similitude theory to crawler vehicle ride comfort test study decreases the cost and improves the test feasibility with sufficient test precise.
The ride comfort experimental assessment of crawler off-road vehicle is relatively overlooked, and is expensive and difficult to execute with higher and higher ride comfort performance requirements. To trade off between precise and cost, an experimental method based on the similitude theory is proposed. Under the guidance of the similitude theory, a 1:5 crawler power chassis scale model equipped with a kind of variable stiffness suspension system is used. The power spectrum density(PSD), the root mean square(RMS) of weighed acceleration, peak factor, average absorbed power(AAP) and vibration dose value(VDV) are selected as ride comfort evaluation indexes, and tests results are transformed via similarity indexes to predict the performance of full-scale power chassis. PSD shows that the low-order natural frequency of the vertical natural frequency(z axis) is 1.1 Hz, and the RMS, AAP and VDV values indicate the ride comfort performance of this kind of power chassis is between the “A little uncomfortable” and “Rather uncomfortable”. From the results, low-order vertical natural frequency, obtained by PSD, validates that the similarity relationship between two models is satisfied, and 1:5 scale model used in experiment meets the similarity relationship with the full-scale model; consequently, the ride comfort prophase evaluation with the 1:5 scale model is feasible. The attempt of applying the similitude theory to crawler vehicle ride comfort test study decreases the cost and improves the test feasibility with sufficient test precise.
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