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Table of Content

    10 June 2009, Volume 20 Issue 11
    Test and Simulation on Energy Saving of the New Variable Displacement of Double Action Vane Pump
    Chen Lei;Zhang Pan
    2009, 20(11):  0-1269. 
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    With respect to the serious energy cost of present hydraulic power steering system, this paper discussed the configuration and the action principle of a new variable displacement of double-action vane pump, which consisted of a floating block. Then the mathematical and simulation model for hydraulic power steering of automobile were established. The pump was produced and the test was performed. The results show that the pump with the floating block can reduce the energy efficiently and prosperous utilization is expected.

    Kinematic Method for Machining Setting Parameters Transformation from
    Cradle Grinding Machine to Free-form Grinding Machine
    Zhou Kaihong,;Tang Jinyuan;Yan Hongzhi
    2009, 20(11):  0-1269. 
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    Based on keeping the relative position between the cutter and work piece unchanged, the problem how to substitute Free-form CNC grinding machine for cutter-tilt cradle machine tools to generate bevel and hypoid gears was studied. The transformation formulas of the machining setting parameters from grinding machines to Free-form grinding machine in explicit form were derived by means of analyzing the higher order spatial acceleration at the reference point, An example was given to verify the algorithm, and from the TCA results it is proved that the transformation based on the reference point is accurate and efficient enough to meet the requirements of real-time interpolation of
    the CNC system.

    Dynamic Model and Parametrical Control Based on the 
    Genuine Length of Wire for Short-circuit CO2 Arc Welding
    Li Chuntian;Luo Yi;Du Changhua;Chen Fang
    2009, 20(11):  0-1292. 
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    Based on the comprehensive analysis of welding circuit for CO2 arc power, a system model through power, cable, wire, molten droplet and arc,was created, and according to distributed temperature function about a variable of genuine length of wire, a wire-voltage function was developed. Then, a dynamic and multicycle molten droplet- voltage mathematic model was also found by the time weight coefficient for the equivalent length of short-circuit transferring molten droplet and by the transform of wire volume from a solid to a liquid state. Besides these, a arc-voltage function involving the welding current, the genuine length of wire and the height of welding torch, was established logically and especially. Meanwhile, the correlative parameters were simultaneously analyzed. At last, the acute comparison was made between simulation and experimental oscillograms of voltage and current herein.

    Analysis of Performance Variation of a Tuning Fork Vibratory MEMS Gyroscope
    Wang Anlin;Wen Yongpeng;Jiang Tao;Liu Zhao;Liu Guangjun
    2009, 20(11):  0-1385. 
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    This paper focused on a tuning fork vibratory micromachined gyroscope which was fabricated through silicon bulk microprocessing technology. From the view of the parametric design, we analysed the effects of the key parameters on performance variation caused by fabrication errors for final detection capacitance. The equations of natural frequency and total detection capacitance were obtained by the dynamical analysis for this gyroscope. Two key parameters which affect the performance greatly are achieved with the analysis of the amplitude frequency response of opposite-and inphase-direction-detection capacitance and useful recommendations for the design and the fabrication are consequently suggested. The experimental results have good agreement with the simulation ones.The symmetry of the left and right structure of the gyroscope is very important for the performance of the gyroscope. The work herein presents the effects of key parameters variation caused by fabrication errors on performance of the gyroscope, and has an important reference theoretical basis for further performance improvement of the gyroscope.

    An Intelligent Method Based on Small Sample for Wear Life’s Failure Distribution of Bearings
    Lü Defeng;Zuo Hongfu;Cai Jing;Wang Ye
    2009, 20(11):  0-1292. 
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    A method of parameter optimized least square support vector machine was given out to predict more data based on the small sample data obtained from experiments,and the parameter’ optimization made use of the immunity-particle swarm algorithm, so the sample’s number of bearing’s wear life was expanded. The parameters of four kinds of possible life distributions were estimated using the failure data from prediction, and the actual life distribution of the bearings was confirmed by distribution tests. Finally, an example was analyzed in detail for the method and the results show that the bearing failure rate is Weibull distribution. Comparision among three ways shows that the method given out herein is excellent.

    Kinematics Analysis of a 3-Dof 3-PC(RR)N Spherical Parallel Manipulator
    Li Qinchuan;Chen Huanhuan;Li Yi;Hu Xudong
    2009, 20(11):  0-1385. 
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    This paper addressed the kinematics analysis of a 3-DOF (degrees of freedom) 3-PC(RR)N spherical parallel manipulator, which had three sub-chains. The only two structural parameters of the manipulator were illustrated and the inverse displacement analysis as well as Jacobian matrix was proposed using analytical method. Based on the inverse displacement the reachable workspace and dexterous workspace were obtained by numerical solution. Further, the constraint and kinematic singularity of the mechanism was presented. Finally the prototype was analyzed.

    Sliding Mode Control with Parameters’ Direct Self-tuning for Electro-hydraulic Servo System
    Zhang Xizheng,;Wang Yaonan
    2009, 20(11):  0-1292. 
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    new robust tracking controller for electro-hydraulic servo system based on adaptive sliding mode control was presented. The Sigmoid function with parameters’ tuning was adopted instead of sign function to reduce the high frequency chattering of inputs and to obtain less tracking errors. Without the boundaries of the uncertainties, the controller and the self-tuning laws for controller parameters were designed by using Lyapunov stability argument. The state trajectories can reach the sliding mode and the tracking error can convergence to zero within finite time while control input chattering does not exits any more. Simulation and experimental results was presented to verify the feasibility effectivenesss.

    Single Crystal Diamond Tool Wear Mechanism during 
    Ultra-precision Turning of SiCp/2024Al Metal Matrix Composites
    Ge Yingfei;Xu Jiuhua;Yang Hui;Luo Songbao
    2009, 20(11):  0-1385. 
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    The wear pattern and its mechanism of single crystal diamond(SCD) tools were investigated during ultra-precision turning of SiC particle-reinforced 2024 aluminum matrix composite. The results show that the stress alternates due to the tool cutting the soft aluminum alloy matrix and the hard reinforcement particle alternately,and the high frequency impact of the SiC particles on the tool edge causes the chipping and peeling. The high temperature and pressure, and the micro cutting effect of the reinforcement results in the abrasive wear of SCD tools.The results of XRD(X-ray diffraction) analysis on the machined surface and Raman analysis on the flank face show that the combined effect of abrasive wear of SiC particles and catalysis of copper in the aluminum matrix leads to the sever graphitization of diamond tools.

    Application of Grey GM(X,N) Model on CNC Machine Thermal Error Modeling
    Yan Jiayu;Yang Jianguo 
    2009, 20(11):  0-1292. 
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    Based on the grey system theory,GM(1,4) model and GM(0,4) model were constructed for machine tool thermal error compensation.All of them could map the dynamic relationship between the thermal error and the temperature of several associated thermal points as well as reveal the
    trend of the thermal error by means of differential equations.Real cutting experimental data of a CNC turning machine was used to establish and verify the models.The results show that the new methods perform better than that of the traditional GM(1,1) model;that the calculation procedure is simpler and timesaving comparing with artificial neural network(ANN) models and modified ANN models which are widely used in recent years. So that the models are more suitable for the industrial applications.

    Fibre Bragg Grating Based Magnetic Force Online Measurement System for Magnetic Bearings  
    Ding Guoping;Zhou Zude;Hu Yefa
    2009, 20(11):  0-1385. 
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    To solve magnetic bearings’ magnetic force online measurement problem, a fiber bragg grating (FBG) strain sensing mechanism was appied in magnetic force measurement. A FBG magnetic force sensing device was designed and fabricated, and the relationship between magnetic force and FBG wavelength shift was derived. A FBG-based magnetic force online measurement system was established, through which magnetic force was measured under different air gap, rotating speed and coil current conditions, and the feasibility of FBG-based magnetic force online measurement was verified.

    Energy Saving Pneumatic Piston Vacuum Generator
    Pan Xiaobin;Li Xiaoning;Xu Youxiong
    2009, 20(11):  0-1292. 
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    Currently used jet vacuum ejector has a defect of large air consumption due to its requirement of continuous air supply. Focusing on this problem, a new type of piston vacuum generator was researched based on the principle of vacuum generation by volume expansion. Besides the maximum vacuum, the response time and air consumption were the most concerning performances. Therefore, in order to improve these performances, two pistons with unequal diameters were adopted,a directional valve was used to control air flow in vacuum cavity, and supply flow rate was adjusted during vacuum holding. Experimental results show that the maximum vacuum of piston vacuum generator prototype is about 93kPa, the response time is about 3.70s and the air consumption is reduced about 71.3% compared to the comparative vacuum ejector within 60 seconds. 

    Dynamics Analysis and Control of Wire-driven Rehabilitative Robot
    Liu Pan;Zhang Lixun;Wang Keyi;Zhang Jinyu
    2009, 20(11):  0-1385. 
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    During the course of rehabilitative training, a wire-driven parallel robot was designed to coordinate and control the trainer pelvis movement. Based on the idea of force/position hybrid control, using the Newton-Euler, the dynamics equation was established. The relations between the pulling force and the torque calculation formulation of driving motors were deduced. In view of the characteristics of nonlinearity, strong coupling and MIMO(multi-input multi-output) of the system, a fuzzy sliding mode control algorithm was utilized to realize the pelvis trajectory tracking. The results of theoretical analysis and simulation experiments show that the tracking accuracy is much better and the control system has strong robustness. 

    Research on Data Management Under Collaborative Simulation 
    Environment for Complex Mechanical Products
    He Zhaoxia;Liu Geng;Han Bing;Wang Haiwei 
    2009, 20(11):  0-1292. 
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    According to the characteristics and types of simulation data, a management method was presented. New database system was designed by combining relational database and content repository. And the content repository for simulation data was stablished and designed by using user defined node type. In the repository, simulation metadata was stored as node properties. Furthermore, simulation data files can be stored in node what made it easy to be uploaded or downloaded. And simulation flow data can be stored in relational database. An engineering application was used to demonstrate the feasibility and practicability of the data management system.

    Reconstruction of Sharp Feature on CAD Mesh Model
    Shen Jianguo;Zhang Sanyuan;Chen Zhiyang;Ye Xiuzi 
    2009, 20(11):  0-1385. 
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    A fast sharp feature reconstruction algorithm for CAD mesh was proposed herein. Depending on the user inputs, the algorithm detected mesh feature to be reconstructed, and then incrementally calculated the new face normals of the feature region according to the ones of the non-feature region. Finally, the vertex positions were adjusted based on those new normals. It can deal with the chamfered or blended sharp features on the mesh, and the common features with noise. The experimental results demonstrate that the algorithm can fast construct sharp edges and sharp vertices on the CAD mesh, and has broad practical value.

    Efficient Process Parameter Optimization of RHCM
    Technology Using Response Surface Methodology and Genetic Algorithm
    Liu Donglei;Xin Yong
    2009, 20(11):  0-1292. 
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    By integrating Taguchi method, response surface methodology (RSM), genetic algorithm (GA) and data processing technology, an efficient optimization of process parameters in RHCM was investigated. The main process parameters which influenced on high-gloss surface part quality efficiently were determined firstly. Then a predictive response surface model for comprehensive quality index of part was created using RSM. In order to eliminate the abnormal matrix during the regressing analysis stage, and ensure the high fitness of estimated model as well, the conception of average matrix base was introduced for the first time during the experimental data processing phase. The response surface (RS) model was interfaced with an effective developed GA to find the optimum process parameter values. And a front panel of LCD television was considered as a high-gloss part example which was manufactured by RHCM technology. The case results show that it is feasible and effective.

    Study on Modeling of Numerical Simulation Milling Deformation 
    for Aerospace Frame Monolithic Components
    Wu Hongbing;Jia Zhixin;Zhang Xuechang;Liu Gang
    2009, 20(11):  0-1385. 
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    Aiming at the the cutting deformation of aerospace monolithic components in milling process, a numerical simulation method for the milling process was approached. The key technologies of simulation were investigated. The factors including initial residual stress, cutting loads, cutting sequence and tool path were synthetically considered. The experiments were carried out under the same conditions. The results of simulation agree with the experimental ones well. The results show that the milling process simulation is an effective method to predict the machining deformation correctly.

    Structural Topology Optimization Based on the Level Set Method and FreeFEM
    Zhan Yanglie;Zhuang Chungang;Xiong Zhenhua;Ding Han
    2009, 20(11):  0-1292. 
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    This paper presented a new procedure which can implement the structural topology optimization in a short time. This method was based on implicit representation of material boundary and employed the FreeFEM to realize the finite element analysis during the topology optimization process. The triangle mesh model was adopted for the elastic analysis and the node displacement was delivered to the MATLAB software by using interface function. Then the velocity field of optimization was computed in the MATLAB environment. The topology optimization of elasticity was obtained by iteration of finite element analysis and the boundary propagation. The numerical examples illustrate that the proposed algorithm can improve the computational efficiency and the numerical accuracy of structural topology optimization.

    Study on the Removed Quantity of Difficult-to-machine Materials in Laser-chemical Combined Etching
    Chen Yuanlong;Xu Bichao;Yuan Genfu;Bi Baoqing
    2009, 20(11):  0-1385. 
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    The mechanism of laser-chemical combined etching was introduced.Based on technical experiments,it was studied systematically how the laser technological parameters and corrosive parameters to affect eclipsed quantity of difficult-to-machine materials in laser-chemical combined etching.Higher efficiency and better surface quality can be acquired in combined machining than in laser milling. 

    Topology Optimization of Steady-state Heat Conduction 
    Problems with Design-dependent Heat Loads
    Zhang Hui;Liu Shutian;Zhang Xiong
    2009, 20(11):  0-1292. 
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    Topology optimization of steady-state heat conduction problems with topology-dependent heat sources was studied herein.The nodal temperature variance in the design region was proposed as the objective function to estimate the extent of the uniformity of temperature distribution and the total volume of high heat conductive material was used as the constraint.The design-dependent heat loads derived from the heat source density were taken into consideration in the optimization.The regularized Heaviside function was adopted to relate the material density to the material heat property and the discrete 0/1 design was obtained.Several numerical examples demonstrate the validity of the proposed objective function and the optimization method.

    Decision Model and Practical Method of Energy-saving in NC Machine Tool
    Shi Jinliang,;Liu Fei;Xu Dijian;Chen Guorong
    2009, 20(11):  0-1385. 
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    A decision-making model for energy-saving by a NC machine tool’s break between processing steps was set up according to the power equation of a NC machine tool. It is difficult to directly solve the model. A method for calculating the key parameters of the model by establishing the testing data table and curve fitting was proposed so that the model can be applied in practice. 

    Godunov-type Solutions with Second Order in Time and Space for
    Fluid Structure Interaction Model of Liquid-filled Pipeline
    Chen Ming;Pu Jianing
    2009, 20(11):  0-1292. 
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    Based on finite volume method, discrete scheme of fluid structure interaction model was formulated. Numerical fluxes at cell interfaces were calculated by MUSCL-Hancock method possessing second order precision in time and space. Slope limiter was introduced to obtain high resolution TVD scheme. When cells at the boundary were calculated, it was proposed that virtual cells should be established to obtain second order solutions in the whole computational domain. The instance verifications show that the proposed scheme has several desirable advantages, such as high precision, without fake numerical oscillation, low sensitivity to Courant number and good stability.

    Numerical Simulation Analysis of Random Vibrations on Contact Nonlinear Structure
    Lin Lihong;Chen Xiao’an;Miao Yingyun
    2009, 20(11):  0-1385. 
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    With harmony superposition method,which helps to get the excitation sample in the time domain obtained from stationary Gaussian random process,and the contact nonlinear prestressed structure discretized spatially by finite element method,then the dynamic characteristics of the structure under excitation sample in the time domain,such as the structural strength,contact status and main frequency of vibration,were acquired by central difference method.This numerical simulation analysis method of random vibration can simulate all contact nonlinear questions with high efficiency and precision,which is different from traditional linear mode superposition method.Dynamic characteristics of the contact nonlinear prestressed structure under random loads were analyzed by instance.Finally,the key technologies existing in simulation analysis were further discussed.

    Study on the Effect of Wall Slip on the Micro-scale Flow Considering Melt Elasticity
    Tang Jun;Yu Tongmin;Xu Bin
    2009, 20(11):  0-1292. 
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    Based on the theoretical analysis of Uhland wall slip model, a wall slip model was developed with model revision method,which took into account the role of melt elasticity in polymer melt filling micro channel. With the model, the numerical simulation was carried out by using PS material. The results indicate that the wall slip can promote the reduction of flow resistance and the increase of flow velocity. The experimental results of capillary flow show that the trend of the melt pressure drop in dies and the trend of various velocity comply with the numerical simulations which consider the elasticity of polymer melt. In view of this, the conclusion is that the effects of melt elasticity on the behavior of filling flow in micro channels can not be ignored.

    Simulation and Experimental Study on Rolling Worm Shaft in Cross Wedge Rolling and Cross Rolling
    Yan Huajun;Liu Jinping;Hu Zhenghuan
    2009, 20(11):  0-1385. 
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    The combinational rolling approach of cross wedge rolling and rolling worm shaft at the two ends of rough steps and spiral tooth was put forward. Worm shaft blank forming process was simulated by use of DEFORM-3D finite element software under different conditions, through researching changes of rolled piece heart failure stress.The results about processing parameters influence largely on forming quality of workpieces are obtained. By rolling worm shafts in H630 cross wedge rolling mill, rolling effect obtained are basically the same as the software simulation results. The results show that if process parameters are proper, worm shaft can be rolled successfully using the technique of cross wedge rolling and cross rolling.

    Effect of Material Properties on Springback of High Strength Steel Parts
    Wu Lei;Jiang Haomin;Wang Chen;Li Guangyao
    2009, 20(11):  0-1292. 
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    The paper focused on parts’ springback influenced by variational material properties, yield stress, friction coefficient, n value and thickness were studied by experiments and simulation analysis on a representative model. Reasonable design of experiment was carried out to determine influence of major factors on springback. The results indicate that variation of yield stress has more influence on springback and variation of thickness has less infulence on springback.

    Finite Element Simulation of High-speed Cutting Material MTMoCr
    Ruan Jingkui;Gong Aihong;Zhou Xueliang 
    2009, 20(11):  0-1385. 
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    To study high-speed machining process of auto panel dies, a finite element model (FEM) was built. Under conditions of high-speed cutting, high strain rate, high temperature and high strain were happened in the work piece material. High-speed compress experiments were done to achieve material mechanical properties. Other key technologies such as the interface friction model and the heat conduction equation between tool rake face and chip flow were studied. High-speed milling experiments were completed and cutting forces result from FEM and experiments were compared. The distribution of machining temperature and stress was studied, and the chip shaping process was analyzed. It is shown that the finite element model can reflect the real process of high speed machining auto panel dies and the model can be used to select optimal machining parameters and tools.

    Investigation of Control Strategy for Regenerative Braking of HEV Based on Efficiency Optimization
    Yang Yang;Qin Datong;Hu Minghui;Deng Tao
    2009, 20(11):  0-1292. 
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    Based on the CVT(continuously variable transmission) hybrid electric vehicle,the motor/battery united efficiency model according to Ni-MH
    battery pack and the ISG motor performance test was set up, and the optimal working line
    in which the motor and battery working at the highest efficiency level was obtained.A regenerative braking control strategy was put forward,which can realize optimal matching of
    CVT,motor and battery, at the same time, and the optimal system efficiency of system can be achieved.The computing results show that the ISG motor/battery can achieve efficient operation and the recovery of braking energy can be improved obviously with the help of the regenerative braking control strategy under the safe braking conditions.

    Study on Navigation of Intelligent Vehicles Based on Multi-sensor Fusion
    Wang Tanbin;Chen Wuwei;Jiao Jun;Wang Minglei
    2009, 20(11):  0-1385. 
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    Aiming at the insufficiency of information acquired by a single sensor, a method of fusing the information acquired by camera and ultrasonic sensors was proposed for navigation. A method for segmenting the navigation path and identifying obstacle through the information of vision was put forward. D-S evidential theory and the method of fuzzy logic were used to fuse the information of the environment obtained by image processing and multiple ultrasonic sensors. Methods of information fusion, modeling of the ultrasonic sensors, image segmentation and mathematical morphology were included herein. The simulation and experiments indicate that the navigation path can be segmented efficiently and this method of information processing can identify obstacles efficiently and makes satisfactory results of navigation and obstacle avoidance.