China Mechanical Engineering

Modeling of Operating Characteristics of Ultrasonic Motor Using Equivalent Circuit 

HE Gong-Lin-1, 2, CENG Jin-Song-3, LONG Yu-Fan-1, LIU Wen-Guang-1

2011, 22(14): 1639-1644.

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To develop theoretical instructions for designing the dive of ultrasonic motor(USM),an equivalent electrical model for the USM was studied. Firstly,the vibration equation of the piezoelectric laminated piezoelectric beams excited by electricity was given, which resulted to a six-side equivalent circuit model for the beam's vibration. Then, taking into account the polarization configuration of the stator of the USM, a distributed parameter circuit network mode was derived for the free stator. Focusing on the stator's vibration in the frequency range near the motor's working modal frequency, with addtions, by modeling the dielectric loss and mechanical loss of the stator, a two-side equivalent circuit model was proposed for the stator. Finally, by taking into account the motor's pre-pressure, load and temperature which greatly influenced the characteristic of the

USM, a complete electrical equivalent model was established for the USM. Experiments

were made to validate the models. The results show that the experimental values agree

the simulations from the models well, which indicates that the models are available.

Nonlinear PID Synchro Control on Pattern Drawing Machine with Four Cylinders

NI Jing-1, BANG Li-Hui-2, CHEN Guo-Jin-1

2011, 22(14): 1645-1651.

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In view of the shortcomings on synchro motion of four cylinders in pattern drawing machine, an electro-hydraulic servo system with four cylinders was designed and its nonlinear dynamics model was presented. Then the theory of Taylor expansion to second order of output vector, optimal control and nonlinear disturbance observer design were introduced, and a nonlinear PID synchro controller for electro-hydraulic servo system with four cylinders was provided on the basis of tracking and synchronization index. The simulation and factual applications show that the proposed controller has better trscking and sychronization performance than that of conventional PID controller.

Polishing Contact Pressure Analysis Based on Bionic Stannum Polishing Pad

WANG Jun, GENG Xue-Ling, LV Yu-Shan, ZHANG Liao-Yuan

2011, 22(14): 1651-1655.

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In order to improve the uniformity of the contact pressure distribution of chemical mechanical polishing, based on the theory of Winkler foundation and phyllotaxis theory, a kind of stannum pad with bionic surface texture was designed, and the contact mechanism and ANSYS models were established. By the calculation of contact pressure distribution on polishing wafer, the contact pressure distribution

between the wafer and the pad, the effects of the geometrical and physical parameters on the contact pressure distributions were obtained. The results show that the horizontal effect of the polishing pad is very small, the uniformity of contact pressure distribution can be improved, and there are the phyllotactic parameters which make the contact pressure distribution more uniformity. 

Experimental Study on Vibration Signals of High-strength-steel Internal Thread Formed by Cold Extrusion

JIU Hong-1, 2, ZUO Dui-Wen-2, ZHANG Rui-Hong-1, WANG Shu-Hong-3

2011, 22(14): 1656-1658,1663.

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In order to reduce the effects of the forced vibration caused by inside and outside disturbing forces of machine tool on the quality of thread and the life of extrusion tap, this paper researched the vibration signals in the cold extrusion process of high-strength-steel internal thread under different extrusion conditions, and the change reason was also analyzed through the spectrum analysis. The results show that the variation trend of the vibration amplitude values is similar under different extrusion velocities,

and the master oscillation frequency changes in a random way.The amplitude value of vibration and the master oscillation frequency remain virtually unchanged under different lubrication patterns. While the viscosity number of lubricant exceedes 32mm2/s,the amplitude value of vibration and the master oscillation frequency can change dramatically,and high frequency vibration appears,then causing rupture of the extrusion tap. 

Experimental Research on Surface Quality of Marine Propeller in Belt Grinding

YANG Chun-Jiang-1, 2, HUANG Yun-1, 2, TUN Jian-Jiang-1, 2

2011, 22(14): 1659-1663.

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The effects of grinding parameters on surface roughness of marine propeller blade were studied by using orthogonal test. The influences of abrasive grain size, belt speed, contact roller's hardness, grinding depth and grinding feeding speed on surface roughness were discussed. The effects of abrasive grain size and grinding depth on residual stress were analyzed. The results show that the main effect factor on surface roughness is abrasive grain size. The optimum surface roughness can be obtained with the appropriate grinding parameters. The residual compressive stress can be formed because of the characteristics of belt elastic grinding. The residual compressive stress decreases with the abrasive grain size and increases with grinding depth. 

Simulation Prediction and Experimental Study on Exhaust Noise of Engine 

LIU Yong-Jiang, ZUO Cheng-Ji, LI Nie-Rong

2011, 22(14): 1664-1668.

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A simulation model of engine was established by using GT-Power software for predicting pure exhaust noise of engine,which was demarcated by engine tests. Simulation calculation and experimental study for the pure exhaust noise of engine were carried out under the same operating conditions. The research results show that the engine model established for pure exhaust noise prediction is accurate. The pike noise values of 1500r/min and 2500r/min are in 63Hz frequency and the pike noise value of 1500r/min is stronger than that of 2500r/min. With the engine speed increasing the pike value of noise transforms to the middle or high frequency and the middle to high frequency noise increases more rapidly than low frequency noise.

Analysis on Optimal Clearance of Piston Friction Pair and Its Influence Factors for Water Hydraulic Pump

HUANG Guo-Qi-1, HE Xiao-Feng-2, SHU Yu-Quan-2

2011, 22(14): 1668-1672.

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Based on the thermal balance principle, an optimal clearance formula of piston friction pair for water hydraulic pump was proposed. Simulation and experimental research were put forward on its influence factors, such as the structure size, couple material and environmental parameters. The results are as follows：a minimum thermal clearance exists in each piston friction pair, which must be smaller than its initial clearance, otherwise it will happen to death; there are some effective measures to reduce the minimum thermal balance clearance, such as decreasing the plunger diameter or swash-plate tilt angle, choosing the appropriate couple material, reducing friction coefficient and fully running-in, etc.

Design and Implementation of a Kinematic Measurement System to Torsional Deformation of a Shaft

DING Zhen-Gong, JI Xiao-Jun, LIU Ru-Hua

2011, 22(14): 1672-1675.

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This paper designed and achieved a kind of real time

kinematic measurement system to angel of torsion based on phase difference method with the core design of FPGA.This system's color code transducer used to measure speed and torque was composed of reflective laser probe and color code made on the revolving shaft. The outputs were in the form of impulse and phase difference while professional phase demodulation, period and pulse width measurement module focus on FPGA. Stimulating,field proving and actual testing show that the system measuring accuracy is superior to 0.5% full span within the measuring range of 0 to 2000N·m.

As a result,it can effectively solve kinematic measurement to angel of torsion, torque and power of high rolling shafts under tough circumstances. 

Study on Substrate Temperature Data Fusion in Large Area Diamond Coating Based on Optimal Weighting Algorithm

HONG Hong-Bei, LI Hong-Yuan

2011, 22(14): 1676-1679.

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The substrate temperature uniformity in large area diamond coating is important to obtain the film with high quality. To filter the measurement noises,multi thermocouples were used to measure the substrate's surface temperature from different points and the optimal weighting data fusion algorithm was

utilized for dealing with the measured temperature values at the same sampling moment. To further improve the temperature measurement precision, the least square, Bayes estimation and recursive least-square algorithms were adopted for the further data fusion. The considerable research results demonstrates that the temperature fusion results' precision is quite high by the combination algorithm of optimal weighting and least square, optimal weighting and Bayes estimation which are with good robustness when different disturbances occur, and the combination algorithm of optimal weighting and recursive least-square is with worse robustness and its temperature data fusion

results' precision is comparably less.

Multi-types AGVs Quantity Configuration Optimization Based on Simulation Optimization

ZHANG Yuan-Chun-1, FAN Xiu-Min-1, 2, JU Tian-Bang-Jiu-3

2011, 22(14): 1680-1685.

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To decide the best AGV quantity configuration,a mathematic model was set up using process,AGV path,dispatch rule as constraint,and making sure the outputs of workshop be largest.Due to the complexity of the problem,an optimal method based on simulation optimization was proposed,using simulation model to simulate the running of AGVs and the algorithm GA to determine the quantity of AGVs.At last,validity and feasibility of the method were proved by a case study of air-condition assembly workshop.

Study on Hierarchical Process Model Integrated Project Management and Workflow

XIONG Ben-Fan, TIAN Nian, LIU Qing-Hua, MO Li

2011, 22(14): 1685-1689.

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To deal with requirements in current product-development and limitations of project management and workflow,this paper proposed a hierarchical process model with a project breakdown structure and multi-level workflow space as a core.This solution monitored and tracked the product-development in all levels, and strengthened the practicability of the project management and workflow in PDM.It has been successfully applied in enterprises.

Production Line Simulation Based on Lightning

XU Zheng-1, CHAN Zhong-De-1, LI Zhou-1, Hans Peter Lentes2

2011, 22(14): 1690-1693.

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A novel VR system based on Lightning was presented,which facilitated the virtual equipment behaviours simulation and virtual control simulation of a production line. Multi-layer simulation method was also used in this system.With the real-time signals of the online equipment, the online equipment as well as the virtual process were quickly diagnosed.With rapidly responds of this VR system,design engineer has the chance to optimize or make forward-looking decision of the line by using the advantages of this VR system.

Research on Elimination of Inventory Errors in Production Control Systems

LIU Meng-Qi-1, CHAN Mi-Yuan-1, HONG Xiao-Jing-2

2011, 22(14): 1694-1698,1714.

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When there is error in estimating the production delay time, inventory level will drift from the target in the “automatic pipeline, inventory and order based production control system”(APIOBPCS) model. By adding a PI control in the inventory feedback loop,a PI-APIOBPCS model was proposed, which could eliminate the inventory errors, but productivity and inventory levels fluctuated significantly. And by adding the PD controller in the order rate policy, a PID-APIOBPCS model was proposed, which can effectively eliminate the inventory drifts, and smooth the productivity and inventory levels, and reach the steady state quickly.

Registration for Turbine Blade between Dense Cloud Data and CAD Model

HUANG Qing-Li, BO Hun, CHENG Yun-Yong, ZHOU Li-Min

2011, 22(14): 1699-1703.

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For the matching problem between dense cloud data and CAD model,a registration method based on curvatures calculation of simplified model was proposed. Feature surfaces were extracted based on the curvature of simplified and CAD model, three corresponding points were searched through feature surfaces, and the transformation matrix was computed.Then the obtained matrix was applied to original cloud data to achieve pre-registration.The last step was accurate registration that achieved

through SVD-ICP algorithm.Experimental results show that the method can realize registration between dense cloud data and CAD model, and demonstrate the efficiency and practicality of the method.

Numerical Simulation and Experimental Study on Strengthening of Main Cutting Edges for Solid Carbide Twist Drills

XIAO Sai-Lai-1, 2, ZHOU Zhi-Xiong-1, SUN Zhen-Mei-2, ZUO Xiao-Chen-2, SHANG Ai-Min-1, ZHOU Qin-Yuan-1

2011, 22(14): 1703-1707.

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Three dimensional modeling was conducted for twist drills with plane clearance face herein.The main cutting edges were designed with rounding or negative chamfering for strengthening purpose,and a computer simulation model with given grinding parameters was obtained. Emulation study of the thrust force and torque generated by the drill was performed by using FEM analysis software DEFORM 3D results show that the negative chamfering method is superior to the rounding method in reducing the thrust force and torque, and tests were carried out. The study is benefit to the reasonable selection of negative chamfer parameters.

Dynamic Modeling for Mechanical Product Collaborative Design Process Based on OPN and Decision Rules

GUO Yin-Zhang, CENG Jian-Chao

2011, 22(14): 1708-1714.

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A dynamic modeling method for mechanical product collaborative design process was proposed herein to solve dynamic modeling problem,where decision rule information and decision transition were introduced. Firstly, mechanical design process was described as multi-design-unit model based on collaborative design process and model of OPN was denoted based on decision rules. These models have invoking interface for input and output. Then the design unit interface for input and output

was bound down judging decision transitions for collaborative design process and a control net model of whole collaborative design process was built. This model can confirm the implementing flow of collaborative design process in dynamic manner using decision information stored in decision transition information database. Finally, a collaborative design modeling example of chain-transportation-driven equipment was presented, which shows efficient of this method.

Research on Correlation of Friction Signals and Surface Topography of PEEK

LI Chao, JIAO Yu, ZHANG Jing, DIAO Man

2011, 22(14): 1715-1719.

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In order to investigate the correlation of friction force and coefficient signals of PEEK/QT400 and initial surface topography of PEEK,friction and wear tests of PEEK/QT400 were carried out on an UMT-3MT wear tester with same velocity and different loads.The fractal behaviors of initial surfaces topography and friction signals were studied with fractal theory and the fractal dimension of them were calculated using structure function measurement method.Results show that the initial surface of PEEK and friction signals both have obvious fractal characteristics,under the same velocity and same initial surface,the value of fractal dimension increases with the increases of contact load,and under the same velocity and different loads,friction signals of preliminary

running-in stage and initial surfaces of PEEK are both positive correlations.

Dynamics Modeling and Simulation of Mass Terms for Pneumatic Muscle Actuators

TAO Bi-Chao, ZHOU Jie-De, AI Jing-Song, XU Qing-Nan

2011, 22(14): 1719-1722.

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This paper aimed to achieve the dynamics model of mass terms for PMAs. In the modeling, PMAs were considered as a system of particles which were distributed uniformly along a cylinder.A dynamics model of PMAs was built by using the Lagrangian formulation. In the simulation, PMA were meshed in ANSYS and a modal neutral file was generated.The dynamics simulation was conducted in ADAMS by using the modal neutral file. Simulation results verify the feasibility of the model.

Customized Product Material Image Decision-making Support Model 

SU Ke-1, 2, SUN Shou-Qian-1, CHAI Chun-Lei-1, SUN Ling-Yun-1, LIU Zheng-1

2011, 22(14): 1723-1728.

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Aiming at the needs for product customization,this paper presented a decision-making support model based on the kansei engineering and the FAHP.Factor analysis was utilized to differentiate products into several styles;evaluation criteria were constructed by image words. It adopted fuzzy consistent relations to realize fuzzy reasoning rule and presented fuzzy consistent matrix method to accomplish dynamic adaptation.The results of defuzzification and sequencing are close to the psychological kansei image of the consumers. Finally, implementation of the proposed model was demonstrated in details via a case of chair material design.

Mechanism Optimization Design for 3-DOF Motion Platform

LUO Wen-Bao-1, LI Wei-Jia-1, HONG Xiao-1, GAO Yan-2, TUN Jin-Bei-1

2011, 22(14): 1728-1731.

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Based on the analysis of the characteristics of the 3-DOF motion platform, the key factors, such as the range of the platform, the sizes of panels etc.,were concluded as constraint conditions, the optimal weighed value of the controllability and the structure size of the platform were chosen as the optimal objective functions,the algorithm parameters of the platform mechanism were optimized based on acceleration genetic algorithm.The optimization results were applied to the design

of a kind of the 3-DOF motion platform with anti-torque arm.It is shown that the results meet the design requirements of miniaturization platform which provides a good performance at the same time.

Order Tracting Analysis Based on Local Mean Decomposition and Its Applications to Gear Fault Diagnosis

ZHANG Gang, CHENG Jun-Ku, YANG Yu

2011, 22(14): 1732-1736.

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Gear fault vibration signals in speed up or speed down processes were of multi-component modulated signals and the fault characteristic frequency varied with rotating speed. A new gear fault diagnosis method combined LMD with order tracking analysis was proposed.Firstly, the vibration signals in time domain were transformed into angle domain stational signals by order resampling. Then, a set of product functions(PF) were obtained by decomposed the signals in angle domain with LMD. At last, each PF's instantaneous amplitude was analyzed by frequency spectrum to extracting the fault characteristics. The analysis results from the experimental fault vibration signals of gear crack demonstrate this method can extracted the gear fault charateristics effectively.

Influences of Welding Parameters on Weld Appearance of Friction Stir Welding

LI Hai-Li, GENG Li, TUN Hong-Yan

2011, 22(14): 1737-1741.

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The influences of welding parameters on the weld appearance of friction stir welding of LY12 aluminum alloy were researched.The results indicate that,by using the tool with left threaded column pin, the nugget formed during welding is not symmetrical about the centerline of the pin,and the transfering extent of the plasticized metal of the retreating side is bigger than that of the advancing side. With constant rotating speed and plung depth of the tool,the transfering extent of the plasticized metal of the retreating side, the width of the nugget and the distance of the centre of nugget leaning to the retreating side decrease when the welding speed increases. With the plunge depth of the shoulder increases,

the width of the nugget and the distance of the centre of nugget leaning to the retreating side all increase when rotating speed and plung depth of the tool keep the same, while the transfering extent of the plastic metal of the retreating side increases and then decreases.

Research on Axisymmetrical Deep Drawing Process Based on Radial Double Segmental Blank-holder Technique

QIN Si-Ji-1, 2, HUANG Xiao-Zhong-3, WANG Jing-4

2011, 22(14): 1741-1744.

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A radial segmental blank-holder technique was proposed herein for axisymmetrical deep drawing process to improve blank-holder effect and raise the forming limit. Deep drawing processes under single and segmental blank holder were analyzed theoretically,experimentally and by finite element method respectively.The results for forming process of cylindrical parts show that it can carry out blank holding for different radial deformation zones by radial segmental blank-holder technique.Also, the blank-holder effect is enhanced more effectively and the forming limit increases by radial double segmental blank-holder technique comparing with that by conventional one.

Mechanics Analysis of Granules or Powder Flexible Cavity Deep Drawing Technology for Cup Shell

JIA Dun-Ting, HUANG Qian-Ying, GU Yong-Fei, ZHANG Chun-Xiang, CHEN Yan-Nan

2011, 22(14): 1745-1747,1753.

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A new granules or powder soft cavity forming(GFCF) technology was presented herein and the mechanics analysis was finished. The stress and strain state of forming parts were analyzed and the values were calculated compared with common rigid die forming based on the fundamental assumption. The theoretic equations were obtained for calculating the values of stress and strain. The research results prove that the forming limit can be improved and defects can be prevented when parts are formed by granules or powder flexible cavity forming technology.

Optimization of Design Parameters of Side Airbags for Protection of Child and Adult Occupants

YANG Xing-Mei, YANG Ji-Kuang, LIN Li-Hai

2011, 22(14): 1748-1753.

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For the optimization of parameters of thorax side airbags that influence the injury risks of child and adult occupants under side impact conditions, the application of finite element modeling and multi-body system models were used in combination with the experimental design method. The material permeability, the inflator time and the airbag installation position were chosen as design variables, the head resultant acceleration of the child and the chest visco-index viscous criterion(VC) value of the adult were

as objective functions. A surrogate model was constructed. The multi-objective algorithm was used to obtain the optimal values based on the constructed surrogate models. The results indicate that the optimal values suggest by the model for the objective functions are smaller than those obtained from the initial model. The head resultant acceleration of the child and the chest VC value of the adult are reduced by about 18% and 50% respectively, when compared to the values from the initial models.The thorax side airbag can protect the adult and the child effectively after optimization.

Optimization of Fuzzy Control Strategy for Parallel Hybrid Electric Bus Based on Genetic-ant Colony Algorithm

YIN An-Dong, DIAO Han, ZHANG Hui

2011, 22(14): 1754-1759.

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For a kind of PHEB,a fuzzy controller was constructed by using the difference between the requested torque and optimal engine torque and taking the super capacitor state of charge as inputs, and the engine torque as the output. The membership functions and rules of fuzzy controller were optimized simultaneously by using genetic-ant colony algorithm. A simulation model of the fuzzy control strategy was established by MATLAB/Advisor. The performance of the optimized PHEB were simulated.The results show that the optimized fuzzy control strategy can meet the requirements of overall vehicle performance and the fuel consumption is reduced by 10.2% compared with the non- optimized PHEB.

Design and Instantiation of Increased Program Bus Power Train System

LI Chao-1, CHEN Meng-2

2011, 22(14): 1759-1763.

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Based on the characteristics analysis of city buses,a power train system for increase program city bus was designed,and the main components of power train system (increase mileage device,drive motor and battery) were selected and calculated.With increased program power train system characteristic we developed a city bus of increased program,and it used increase mileage device extended by increasing range.Under public transport working conditions for vehicle assemble and test, and through the analysis of the technical characteristics it is proved that increased program buses are fuel-saving and eco-friendly,can satisfy the characteristics of vehicle performance and fuel economy.

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