Table of Content

25 November 2008, Volume 19 Issue 22

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Study on the Internal Gear Form Grinding and Wheel Dressing Technology

Ren Xiaozhong,;Deng Xiaozhong;Su Jianxin; Wei Bingyang

2008, 19(22):  0-2649. 

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Aiming at the machining status that internal gears with hard face were processed generally by nitriding after gear shaping or broaching, a form grinding method of internal gear and a dressing technology of form grinding wheel were studied. Based on the autonomous developed CNC internal gear form grinding machine,a grinding plan was proposed by which two flanks of a tooth could be ground by using one end of
the grinding wheel.Jumping division was used to control the pitch error.A kind of form wheel dresser was developed，and form wheel dressing program was prepared.Simulation
results show that the dressing program is feasible.

Ultrasound Aided Through-mask Electrochemical Micromachining of Micro-hole Array in Titanium

Hu Jianhua;Wang Wei

2008, 19(22):  0-2649. 

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Through-mask electrochemical micromachining of difficult-to-etch metals (e.g. titanium alloy) has a low cost and environmental impact compared with photochemical machining using toxic etchants based on hydrofluoric acid. The application of ultrasound to electrolytic photo etching was studied in an effort to solve the problem of non-uniform erosion due to the heat and hydrogen produced in the machining process. Experiments show ultrasound can increase mass transport, furthermore, it can reduce surface roughness and increase the etch rate of titanium (30μm/min) by properly selecting interelectrode distance, electricity parameters,sound field parameters as well.

Design of New Type High Performance Space Friction Pairs

Xiao Ke;Wang Jiaxu;Liu Wenji;Tang Feng

2008, 19(22):  0-2710. 

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By considering systematically the merits and drawbacks of driving devices with small tooth number difference,such as planetary reducer and harmonic reducer,combining effectively the new drive style with high precision and efficiency,a precise gear transmission and bearings were integrated as new friction pairs and their basic steady load, friction mechanism and friction moment were also studied herein. By optimizing the double objective function of basic steady load and friction moment,the structural parameters were determined.The material of every unit in the friction pairs was selected.Under this condition, we developed high accuracy, high reliability, long service life and high performance space friction pairs,which can reduce midst links in driving chain and make it a compact system with small volume, high drive efficiency, small friction-wear and low vibration noise.


Optimum Design of Controllable Linkage Mechanism under Given
Trajectory

Wang Rugui ;Cai Ganwei;Li Yanzhou

2008, 19(22):  0-2649. 

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A hybrid five-bar linkage mechanism system was investigated.
Based on the electromechanical coupling dynamic model of the system established by the finite element method,the effect on the dynamic response of structural parameters and electromagnetic parameters of the system was considered.And based on the dynamic response on condition that the output trajectory was circle,a parameter optimal model for the system was established by chaos-based particle swarm optimization
method.Then the dynamic characteristics of the system were optimized.This paper provides theoretical direction for the optimum control of such kind of multiple-degree-of-freedom linkage mechanism systems under given trajectory.

Machining Control for Complex Surfaces Based on Electrolytic In-process 
Dressing (ELID) Grinding and Magnetic Abrasive Finishing (MAF)

Chen Fengjun;Yin Shaohui;Wang Yu

2008, 19(22):  0-2714. 

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According to the high efficiency of
ELID grinding and flexible machining characteristics of MAF,a new synergistic process integrated ELID grinding and MAF was developed based on a platform of three-axis vertical machining center. A grinding tool for ELID and a finishing tool for MAF were designed. Processing path control of synergistic process for complex surfaces were analyzed. The tool wear and the form error of work-piece were studied, and the methods for compensation and interference avoidance were also presented. Finally, A control and compensation software
was developed and might be used to ELID grinding and MAF process for complex surface machining.

Movement Analysis and Control of Flexible Pneumatic 5-DOF Finger

Zhang Libin;Wang Zhiheng;Yang Qinghua;Bao Guanjun

2008, 19(22):  0-2649. 

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Based on flexible pneumatic actuator,a new kind of flexible pneumatic 5-DOF finger was proposed.The structure and operating principle of the 5-DOF finger was presented. The kinematics equation of the 5-DOF finger was built and the redundancy problem of the inverse kinematics solution was resolved by genetic algorithm. The BP neural network controller of the finger was designed and the experiments of the fingertip trajectory tracking were carried out. Experimental results show that the experimental
curve matches well with the theoretical curve,and genetic algorithm and neural network controller can control the 5-DOF finger exactly in real-time.

Analyses and Application of Whole-system Dynamic Error Modeling Theory

Jiang Minlan;Fei Yetai

2008, 19(22):  0-2714. 

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Invistigation of dynamic characteristics and accuracy theory about measuring system must build its mathematic model.Aimming at the limitations of traditional modeling methods, studying the whole-system dynamic error modeling theory was
established,which considered sufficiently the information of build-in units of the measurement system, so the built model can reflect the timevarying change of the transfer behavior of the system.The modeling theory can be applied widespread.The whole-error modeling of the hundredth meter was built using this theory, then experimental results validate
its correctness.

Selection of Wide Hot Strip Mills Configuration for Schedule Free Rolling

Shao Jian;He Anrui;Yang Quan;Shi Naian

2008, 19(22):  0-2649. 

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In order to improve the shape adjustment ability of
hot strip mills in schedule free rolling, this paper put forward a scheme of the wide hot strip mill type configuration. The characteristic of the new mill type was adopted linearly variable crown(LVC) work roll on upstream stands,taper work roll on downstream stands,and varying contact rolling technology on all the stands.The production data show that the new scheme can improve greatly the shape adjustment ability of wide hot strip mills and can meet the demand
for schedule free rolling.Now, the related technologies have been promoted on other wide hot strip mills. 

Dynamics Analysis and Simulation on Quadruped Robot in Passive Bound Gait

Ma Shiping;Yu Lianqing;Miao Guohua

2008, 19(22):  0-2714. 

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Based on the analysis model of quadruped robot in passive bound gait, the dynamics equations of quadruped in the phases of bound gait were derived with Lagrange method,and the transition equations between phases were presented.Then the Poincar map of bound gait was defined,and a fixed point of the map was figured out with Newton-Raphson method. Taking the fixed point as initial condition, the dynamics equations were integrated numerically with MATLAB,and the periodic motion curves were achieved.It is proved that quadruped robot can realize steady passive bound gait with a suitable initial condition.

Fitting and Application of the Integral Consant of Radial Force on Ball Bearing

Tian Rong

2008, 19(22):  0-2649. 

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Based on analysis of the complexity in calculation of radial deformation on ball bearings under radial load, a method which can simplify the calculation was given through fitting the integral consant of radial force.Four common fitting methods were introduced detailedly and the fitting precisions were compared under the same topmost power of primary founction.The fitting by rational function was proved the best.Using the fitting founction, the calculation of radial deformation was simplified, and the group of equations of radial deformation which were coupled each other and included a numerical integral function become simple.At last, an example was given to indicate that the result of new method is very anastomotic to that obtained from traditional method,the result from experiment is agree with that from calculation.

Neural Network Inverse Control of Bearingless Permanent Magnet-type Synchronous Motors

Zhang Shaoru,;Wu Aiguo;Wang Lijun;Han Yongdian

2008, 19(22):  0-2714. 

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The bearingless permanent magnet-type synchronous motor is a strong-coupled complicated nonlinear system.The linearization and decoupling control is a key to stable operation and practicability for this motor.Based on artificial neural networks,an inverse system decoupling control method for bearingless permanent magnet-type synchronous motors was proposed.This method combined approximation ability to nonlinear system,adaptability to parameter variations of artificial neural networks and decoupling characteristics of inverse system.Cascading the ANN inverse which consists of a static ANN and five integrators with the motor,the system was decoupled into two independent second-order linear subsystems and a first-order one,which were two displacement subsystems and a rotor speed one,so as to be easy to design the closed-loop linear regulator to control each of the subsystems.Simulation and experimental results show that strong robustness,good static and dynamic decoupling performance can be achieved by using the proposed method.

Inverse Kinematics Analysis for the Container Spray-painting Robot

Zhao Daxing,;Li Jiuling,;Zhao Zhiming;Zhou Xiaoming

2008, 19(22):  0-2649. 

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An opened-chain frame was adopted for the container spray-painting robot.Coordinate of the serial container spray-painting robot with 5 degrees of freedom was set up based on the Denavit-Hartenberg.With the analytic method,the inverse kinematics analysis of robot was
processed.Then,through the simulation of ADAMS,the displacement,velocity and acceleration curves of the end-effector could be obtained.The rationality of
robot mechanical structure was validated.It provides theory foundation for
the faster design and manufacture of the container spray-painting robot.

Application of V-shape Binder Surface to Design of Drawing Die for Auto Cover Panels

Wu Yumei;Yang Baiqiang;Zhou Jie;Yang Ming

2008, 19(22):  0-2714. 

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The drawing process of A pillar inner panel was performed using Dynaform which is a sheet forming simulation software.The reason of wrinkle was studied during blank-holding and forming process, and the generation trend of wrinkle was described by some graphs. It shows that the wrinkle is more serious with the greater height of binder surface. The new V-shape binder surface improving the flowing direction of material during blank holding was proposed to restrain the wrinkle effectively. Further,the new
spherical wall instead of the traditional wall was used to prevent crack of material in the arc edge of the part, and the maximal thinning rate decreases from 54.2% to 28.5%. The dies with optimized surface were machined and the qualified product was produced successfully.



Tool－Posture Optimization and Stiffness Index Analysis for Multi-axis NC Machine Tools 

Yan Rong;Peng Fangyu;Li Bin;Chen Jihong

2008, 19(22):  0-2649. 

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Based on the superposition principle of small deflections, general stiffness model for multi-axis series machine tool was established as physical constrains for tool posture optimization. On the sculptured surface to be machined, stiffness index of multi-axis machine tool was computed by general stiffness model. Then optimized stiffness index of multi-axis machine tool was used to determine tool posture in the available workspace. Tool posture optimization based on general stiffness model for multi-axis machine tool was discussed in detail, in which the characteristic of force ellipsoid in task space
was analyzed and machining-oriented stiffness index for multi-axis machine tool was originally developed for tool-posture planning.

Study on 3D Virtual Simulation Machining of Spiral Bevel Gear

Xu Yanwei;Zhang Lianhong;Liu Dequan;Wang Wei

2008, 19(22):  0-2714. 

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The equations of cutting edge and meshing were proposed with the theory of space meshing, a method to calculate the motion parameters of the NC spiral bevel gear machine was also proposed using the principle of graphics transformation based on the mechanism of the processing spiral bevel gear.The NC spiral bevel gear machine and the 3D virtual simulation machining model for processing spiral bevel gear
were modeled with VERICUT.The models of the NC spiral bevel gear machine and the 3D virtual simulation machining were verified by the virtual simulation machining on one pair of given spiral bevel gears with the NC processes calculated by MATLAB. Results of the virtual simulation machining indicate that the model of virtual simulation machining for processing the spiral bevel gear can reach the aims of design.

3D Milling Process Simulation of Aero-aluminum Alloy 7075-T7451 

Lu Dong;Li Jianfeng;Rong Yiming;Sun Jie

2008, 19(22):  0-2649. 

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A finite element model of milling Process of Al7075-T7451 was developed with AdvantEdge.The flow stress of Al7075-T7451 was taken as a function of strain, strain
rate and temperature in order to reflect realistic behavior in machining process.Cutting forces and cutting temperature were obtained in two milling cycles. And the chip formation process was simulated.The simulated chip morphology is similar with the experimented chip morphology.The simulated cutting forces are well agreed with the experimented cutting forces.

GA-BP Algorithm and Its Application in the Forecasting of Part Quality 

Xie Hongmei;Liao Xiaoping;Lu Yuhai

2008, 19(22):  0-2724. 

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In view of basic BP network lower convergence rate and easily
to sink into the partial minimum insufficiency,this article has made more comprehensive improvement on the basic BP network’s activation function, the momentum item,the study rate and so on,and adopted genetic algorithm to optimize the improved BP network.
After the basic BP network,the improved BP network were used separately,based on built-in genetic algorithm optimization a forecasting model of part qualitative indexes was
established.The model can forecast part qualitative indexes based on the modeling process parameter.The results indicate that the study efficiency of the genetic neural network surpasses other algorithms obviously.

Study on Influence of the Inertia Force and the Interfacial Slip 
on the Lubrication Properties of the Elastic-Metal-Plastic Journal Bearing

Fan Xun;Liu Xianwei

2008, 19(22):  0-2649. 

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Reynolds equation in cylindrical coordinates which included terms on the liquid inertia force and the interfacial slip was derived from continuous equation and Navier-Stokes equation. By the numerical computation,the influence of the liquid inertia force and the interfacial slip on the film pressure and the load capacity of the elastic-metal-plastic journal bearing was investigated.The results show that the water film pressure and the load capacity of the elastic-metal-plastic journal bearing are deteriorated after the interfacial slip is taken into account; the film pressure and the load capacity are improved by the liquid inertia force. The effect of the interfacial slip on the film pressure and the load capacity is more obvious with bigger eccentricity. 

Inverse Identification of Material Parameters Based on Crash Simulation and Genetic Algorithm

Gao Hui;Li Guangyao;Han Xu

2008, 19(22):  0-2724. 

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Based on crush test of the energy absorption box, an identification scheme for the determination of plastic parameters of blank sheet material was presented.The unknown parameters included the plastic harden and strain rate.The objective function was calculated using differences of the mean crush forces between the simulation and test results in different crash velocities. A genetic algorithm was employed to adjust the material parameters so that the calculated responses matched the measured ones in a least-square sense. An example shows that the accurate plastic parameters can be searched out by using this method. The crush tests of the energy absorption box are generally conducted in design of vehicle safety so no extra tests are needed in the inverse method. 

Intelligent Fault Diagnosis Based on Empirical Mode Decomposition and Support Vector Data Description

Li Qiang,;Wang Taiyong;Wang Zhengying;Huang Yi

2008, 19(22):  0-2649. 

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Aiming at the problem of multidimensional samples which classified by support vector data description(SVDD) might lead to unsatisfactory results,a novel method based on empirical mode decomposition and SVDD was proposed,and it was applied to fault diagnosis for rolling bearings.The results show that the presented method is efficient to extract the fault feature,reduce the dimension of the signals and improve the veracity of one-class classification in intelligent diagnosis significantly.

Study on Fuzzy Miner’s Rule Considering Load Sequence

Wang Xuliang;Nie Hong

2008, 19(22):  0-2724. 

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For the traditional Miner’s rule can not consider about the load sequence,fuzzy mathematics was used to analyze the fuzziness
of fatigue damage due to the stress beside the fatigue vague.The correctional fuzzy Miner’s rule can reflect the influence of load sequence on fatigue life.The result of calculations shows that the prediction error can reduce from 63% to 14.7%.Therefore,the method has better prediction precision and practicality value.

Structural Parameter Design and Accuracy Analysis of Binocular Vision Measuring System

Liu Qiong;Qin Xiansheng;Yin Shenshun;He Feng

2008, 19(22):  0-2649. 

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In order to improve the measurement precision for visual measuring system,the influence of binocular vision structure was investigated.A structural parameter model of binocular visual measuring system was investigated with the trigonometric method.Through analyzing the measuring accuracy of the measuring point in binocular visual measure system,the effect of the structural parameters and the error transfer rules on the visual measurement were probed.According to simulation results, optimal value range of structural parameters is supplied while the error is small.Enough theoretical research is offered for optimization design of binocular visual measure system.

Effect of Brazing Atmospheres on Wear Characteristics of Diamond

Chen Yan;Xu Hongjun;Su Honghua;Fu Yucan;Xu Jiuhua

2008, 19(22):  0-2724. 

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Applying furnace brazing in vacuum and argon gas respectively,the brazed diamond specimens with Ni-Cr brazing alloy were prepared, and the effect of brazing atmospheres on diamond wear characteristics were studied.The results show
that the wear characteristics of brazed diamond in different brazing atmospheres are varied under the same experimental conditions.Broken-up is the main mechanism for brazed diamond grits in vacuum;while wear flat and broken-up are the main mechanism for those in argon gas. Finally, the contrastive grinding tests show that the tool life and wear behavior of brazed diamond core drills in different brazing atmospheres are different.

A DBB-based Alignment Error Measurement Method for Rotary Axis of 5-Axis CNC Machine Tool

Zhang Dawei;Shang Peng;Tian Yanling;He Qiongyi

2008, 19(22):  0-2649. 

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A novel method was proposed to assess the main alignment errors of C axis of 5-axis CNC machine tool by using DBB.First, the measurement models were designed for 4 errors of C axis, during the measurement, several axes moved together in order to let the DBB run a circle and get the length changes of the bar. The errors were analyzed and calculated with the DBB’s length changes at their sensitive directions.The applicability and effectiveness of the proposed diagnosis method for 5-axis machining center were validated by comparing the calculated results of DBB method and the real errors set before.

Hydrostatic Pressure Calculation and Optimization of
Worktable for Heavy Duty CNC Vertical Turning Mill


Zhao Ming;Huang Zhengdong;Chen Liping

2008, 19(22):  0-2724. 

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A new method was proposed to predict the rigid displacement of the worktable and a novel correction-improvement method was presented to iteratively calculate hydrostatic pressures. Calculation results for two load cases were given to verify the effectiveness and stability of the proposed approach. Then, an optimization model was built to minimize the mass of the worktable under some constraints from structural and hydrostatic disciplines which were coupled bi-directionally. The optimization problem was solved using concurrent subspace design(CSD) method. After optimization, the worktable mass is
decreased significantly, which shows the effectiveness of CSD approach.

Study on Effects of Monocrystalline Silicon Anisotropy on Slicing Wafer Quality Using Fixed-abrasive Wire Saw 

Gao Yufei;Ge Peiqi;Zhao Huili;Zhang Lei

2008, 19(22):  0-2649. 

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The kerf shape formed during fixed-abrasive wire saw slicing monocrystalline silicon was considered as a semi-circular groove,and was visualized to regard as that formed by many discrete planes that parallel to the axial direction of the wire,so the model of wiresawing silicon wafers was founded.The effect of crystal anisotropy on the wafer quality sliced by wire saw was studied theoretically by choosing different wire approach directions (WAD) based on maintaining the symmetry in material removal rates on the two sides of the wire. Analytical results of slicing the most common(100),(110) and
(111) wafers are that any WAD can be chosen for slicing (100) and (110) crystals that will not influence surface finish,but for (111) wafer,there are six WADs [110],[110],[011],[011],[101] and [101] that can give the wafer a better flatness and less surface normal deviation effectively,hence improve silicon wafers quality.And
the analysis correctness was verified by experimental results.



Nonlinear Fatigue Damage Cumulative Model and the Analysis of 
Strength Degradation Based on the Double Parameter Fatigue Criterion

Zhu Shunpeng;Huang Hongzhong;Xie Liyang

2008, 19(22):  0-2724. 

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Damage degree as well as current applied stress level leads to fatigue failure in double parameter fatigue criterion. Proceeded from this argument,a nonlinear fatigue damage cumulative model which related with the current applied stress
was proposed after the definition of nonlinear damage.The fatigue limit,current applied stress level and the inseparable characteristics for the damage variables were considered by the proposed fatigue damage cumulative model,the fatigue damage evolution equation was derived under multilevel loading which can describe the fatigue damage evolution behavior well.The fatigue test data for two kinds of material were used to verify the model proposed.The results show that good agreement is achieved with this model to predict fatigue life.A nonlinear strength degradation model based on the double parameter fatigue criterion was presented from the view point that fatigue damage process is the process during which material static strength degrades constantly.The model was applied to predict fatigue lives for both two level cyclic loading and multiple amplitude program loading and verified by the experiments. It is shown that the estimation has good correlation with the experiments. 

Experimental Study on the Overall Structure of Titanium Alloy with High-effect Plunge Milling Process

Ren Junxue;Tian Weijun;Yao Changfeng;Jiang Zhennan

2008, 19(22):  0-2649. 

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The rough plunge milling and the traditional rough
side milling process were performed and compared from cutting force,cutting stability,temperature for the overall structure of the titanium alloy pieces. The experimental results show that in the same metal removal rate,the axial cutting force of plunge milling is slightly larger than that of side milling,while the active force in plunge milling is only 1/3 of that in side milling.With increasing of the depth of cut,the tool vibration of plunge milling is smaller than that of side milling, the cutting process is steadier, and the cutting temperature of plunge milling is lower than that of side milling. Finally, the experimental verification taking the passage slotting rough process of TC4 titanium alloy overall blisk as the example
was carried on and the results show that plunge milling’s efficiency increases more than one time,the entire cutting process is steady; its cost is only 13% of that of side milling. 

Research on Virtual Test System for CVT

2008, 19(22):  0-2724. 

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Based on the data of coasting performance test and engine bench test,the vehicle load model and the engine model were established. And the models were simulated dynamically by controlling the AC variable frequency motor.Through the simulation,a virtual test system for CVT was prepared. And a car equipped with CVT was tested by the system. The results show that the virtual test system is availability for CVT.

Research on the Hybrid System for the Series Hybrid Electric City Bus

Wu Sen;Cao Zhengce

2008, 19(22):  0-2771. 

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Through the drive test and vehicle working data acquisition
on a certain urban bus route, the driving data from the series hybrid city bus
WG6120HD was analyzed, and the hybrid system characteristics for the city were put forward.Based on this bus cycle,the control strategies that used the energy balancing for the city route and the engine dynamic power following were adopted to meet the total energy demand of the bus cycle and afford the transient power output of the
bus.The control system managed the energy and the power separately, which
harmonized the contradiction between the high power equipment and the lower average power demand for the city bus.The drive tests show that the hybrid system works reliably and the control strategies are reasonable and effective.