Table of Content

10 August 2011, Volume 22 Issue 15

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Modeling and Analysis on Stick-slip Friction Course of Spherical Micromanipulator

WANG Feng-Fei, GUO Wei, SUN Li-Ning

2011, 22(15):  1765-1769. 

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3-DOFs rotations of spherical micromanipulator were achieved by relative displacement and frictions between the ruby balls and the micro-ball on the top of piezoelectric tubes. The stick-slip effects existed in this friction movement. The two-mass-oscillator equivalent engineering model of the spherical micromanipulator was established under the condition of simplifying spherical higher pair joints. The stick-slip course was divided into four phases and the dynamics models of phases were set up based on equivalent engineering model and LuGre friction model. The parameter feature curves were analyzed by numerical simulation. The experiments were also done, and the validity of the analysis was further proved by the results.

Research on Intelligent Optimization Model for Constraint-driven Product Conceptual Design

WANG Wei-Wei, TU Duo-Fu, YANG Gang-Dun, YANG Yan-Pu

2011, 22(15):  1770-1775. 

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An intelligent optimization method and model in connection with constraint-driven product conceptual design was developed to make the design evolution and optimization phase more objective and scientific. Firstly, the paper analyzed the constraints of product conceptual design and the principles of constraint-driven. Then, the framework of a constraint-driven product conceptual design intelligent optimization model was established. And the paper studied the algorithm mechanism and the supporting technologies on this basis. Finally, the optimization process of a kind of airport main fire engine was employed to demonstrate and test the method.

Testability Distribution Method Based on Multi-objective Optimization

DAN Gong-Liang, ZHANG Qi, SHU Chun-Sheng, WANG Fei

2011, 22(15):  1775-1778. 

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In order to solve the testability distribution problem,a multi-objective optimization model was proposed.Based on the mathematics analyses,the model was used to optimize the system test expenses and testability level.After the multi-objective problem was transformed to single-objective problem,the model was solved by floating-coding genetic algorithm.The method can improve the result’s precision,be programmed to solve the model in the condition of many more distribution parameters,and meet different distribution needs through changing the weight of every objective function.In the end,the testability indexes of a construction machinery hydraulic system were distributed by the method. The results indicate that the method can trade off the system testability and test expenses effectively, and distribute testability indexes reasonably by the restriction of system and its subsystems (or units) testability.

Topology Optimization Design of Gearbox Housing under Multiple Loading Cases

ZHANG Chi-Qing-1, 2, XIANG Chang-Le-2, LIU Hui-2

2011, 22(15):  1779-1783. 

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Aimed at the multiple loading cases characteristics of gearbox system, a gearbox housing FEM model was taken up, then the static analysis and modal analysis were performed, the stress nephogram and displacement nephogram were obtained.Based on the platform, a topology optimization design was carried on, where the optimal object was the 1st mode frequency, constraint conditions was the global stress, displacement amplitude and volume fraction, then the gearbox housing was modified according to structure’s material density nephogram results. The weight of modified structure is reduced by 19kg, then structure reanalysis was carried out, the results indicate that the topology optimization design is feasible.

Factors Influencing Indentation Depth of a Particle into Wafer Surface in CMP

JIANG Jian-Zhong-1, YUAN Xiao-Lin-2, DIAO Yong-Wu-1

2011, 22(15):  1783-1787. 

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In accordance with hypothesis of the equivalent beam bending for a three body contact among pad/wafer/particles, a more precise and reasonable mathematical model about the indentation depth of a particle into wafer surface in CMP was developed. The model comprehensively considered the influences of most valuables in CPM process including pad elastic modulus, wafer surface hardness,particle diameter, particle density and particle concentration. Among these valuables, particle diameter and particle density were often omitted in former models,which will lead to theoretical deviation. Finally, after the experimental validation, it is found that the theoretical value predicted by the model agrees well with the result of the experiments. 

Numerical Calculation and Roller Pressure Analysis of Theoretical Logarithm Profile Equation

LI Wei-Wei, CHEN Xiao-Yang, CHEN Xue-Jin

2011, 22(15):  1788-1792. 

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A theoretical logarithm profile equation was resolved iteratively using compound trapezoidal integration through assuming pressure distribution along contact width direction was obedient to half-ellipse distribution, setting the ratio of contact length and width of ideal line contact condition as initial value ,and combining the method of influence coefficient. The accuracy of numerical results was qualified by comparing the numerical results when setting a/b=∞ with Lundberg logarithm profile results. It concludes by analyzing three profiles and relative pressure distribution and contact region that the difference between Lundberg logarithm profile and numerical result profile is gradually increased from the middle to end. With the ratio of contact length and width decreasing, the difference between Lundberg logarithm profile and numerical result profile is increased, the uneven phenomenon near the end of contact region is apparent little by little, and the end of contact region of Lundberg logarithm profile are gradually out of contact; the numerical result profile can improve the pressure distribution and get continuous curve. By comparison ,the magnitude of modification of engineering logarithm profile is too large, the effect length of roller decreases.

Research on Cooling Liquid Failure of WEDM-HS

LIU Lin-Yan, LIU Zhi-Dong, TIAN Zong-Jun, WEI Wei

2011, 22(15):  1793-1797. 

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The changes of cutting speed, surface roughness and surface topography were researched. Adopting cutting speed as characterization of cooling liquid failure is more intuitive and accurate. The relation among the variation of the conductivity, ablation product concentration, pH value, viscosity and cutting speed was compared and the reason of the change of conductivity was analyzed from the aspects of ablation products, concentration and electrochemistry angle. It is proposed iron ions generated by electrolysis play a leading role in increasing the conductivity of the cooling fluid. Conductivity has great relevance to cutting speed and it can be considered as the index of cooling liquid failure measurement. 

Deformation Mechanism in Primary Deformation Zone during Micro-cutting Processes

TUN Ji-Hua-1, WANG Wen-Kui-1, LIU Zhan-Jiang-2

2011, 22(15):  1797-1801. 

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The strain gradient plasticity theory was used as the constitutive equation to illustrate the material properties at micro scale. The present paper employed the FEM to determine the distribution of effective stresses and strains when machining an AISI 1045 steel. The effect of the ratio of the uncut chip thickness to cutting edge radius on the distribution of effective stress and strain was analyzed.Orthogonal micro-cutting experiments were performed to obtain the chip roots to measure micro-hardness and metallographic sections of the chip roots. Strain gradient in the primary deformation zone

is proven to exist,which validates the simulation results.

Research on Dynamic and Hydrostatic Lubrication Characteristics of Water Hydraulic Slipper Friciton Pairs

LIU Huan-Long, KE Jian, XU Lan-Yang

2011, 22(15):  1802-1805,1836. 

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Compared to the common slipper friction pairs,a designed multi-cavity individual bearing slipper of water hydraulic piston pump has better anti-turnover ability and lubrication characteristics. Based on this kind of slipper,a mixed one including the dynamic and the hydrostatic lubrication and the added radial leaking damp were used to improve the anti-turnover ability of the slipper. And, the new slipper stuctures including three-cavity individual bearing slippers with the shallow cavity and the radial leaking channel were designed. Moreover, the CFD simulation was performed to analyze the pressure distribution characteristics and the anti-turnover stiffness with the results that their anti-turnover ability are further improved.

Corrosion Failure Mode Analysis of Mechanical Equipment Based on Failure Rules

RAO Sai-Xian-1, WANG Yuan-1, MO Zhang-1, SONG Guang-Xiong-2, ZHONG Qun-Feng-3

2011, 22(15):  1806-1809. 

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Corrosion failure features of stress corrosion cricking(SCC) and CF were generalized through analysis and summarization on the mechanical equipment corrosion failure cases and the existing failure information,COM Wizard,data base technique, reliability engineering were applied to construct effective corrosion failure diagnosis expert system.CF modes of real cases were analysized in the expert system through the corrosion failure feature inputs and the results were listed by general certainty factor as the evaluation parameter.

Assembly Path Planning Method Based on Viewpoint Tracking and Collision Detection

TIAN Fu-Jun, TIAN Ti-Tian, GENG Dun-Gao, ZHANG Zhen-Meng

2011, 22(15):  1810-1814. 

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In order to improve the visual degree of assembly path planning & simulation, an assembly path planning method based on viewpoint tracking was proposed. The principles of the method were analyzed, in this method, the relative position between viewpoints and moving assembly unit was adjusted by model view matrix, the motion of assembly unit was controlled by the transform of pose matrix, and the assembly path was managed by the views. A multi-level dynamic path collision detection algorithm based on projection was adopted to verify the validity of the path. An assembly process planning & simulation system was developed, and the method was verified by a complicated airplane component, the results show that the method can improve the visualization of the assembly path planning & simulation. 

Numerical Simulation of Two-phase Flow Field on Outside Blasting of Tubing

WANG Jin-Dong, LV Zhi-Li, LI Xin-Wei, WANG Wei

2011, 22(15):  1815-1818. 

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 In order to confirm the technologic parameters on the outside blasting of tubing, a numerical simulation of solid-gas two-phase flow was performed under different operating conditions.A discrete particle model following the Eulerian-Lagrangian method was applied to the simulation. The Spalart-Allmaras turbulence model was applied to simulate the continuous phase flow field. The gas flow field characteristics were obtained. The particle-trajectory model was applied to compute the particle phase flow field. Then, the solid phase was injected in the gas flow field. The load cases of the particles can be calculated, the trajectory and velocity field of the particles will be obtained. The results show that, the velocity that the particle sprays on the tubing wall is biggest when the spray distance is 100mm and the particle diameter is between 0.5mm to 1.0mm. The whole outside wall of tubing can be sprayed under such condition, and thus the blasting performance may be the best. 

Finite Element Analysis of Large Diaphragm Pump Rubber Diaphragm

LING Hua-Qi-1, ZHANG Wei-2

2011, 22(15):  1819-1822. 

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In allusion to the work process for a diaphragm of diaphragm chamber, a simplified two-dimensional axisymmetric finite element model of membrane structure was established, and laid bare the implicit dynamics analysis, while a three-dimensional symmetrical structure whole finite element model of the diaphragm chamber and diaphragm was established and laid bare the analysis for fluid-solid coupling. At last,for two different methods and results began comparison in order to elicit a reasonable numerical simulation method which will be used to simulate the changes on stress and displacement of diaphragm movement, so as to guide reasonable diaphragm design. 

Management for Equipment Maintenance Status Based on Maintenance Status BOM

HU Gao-1, 2, JI Yang-Jian-1, QI Guo-Ning-1, CHEN Fei-1, JIA Hua-Wu-3

2011, 22(15):  1823-1827. 

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At present,the management for equipment maintenance history were devoid of administrative levels and systematic,it was difficult to found the specific maintenance records in lots of maintenance documents

as well as the equipment maintenance history records were missed. So the maintenance

 status items and maintenance status were put forward as meta-data to record equipment maintenance process,BOM for maintenance status was constituted as the signboard and administrative tools of equipment maintenance status,the equipment maintenance

status was recorded and administered via the evolvement table of maintenance status

for each maintenance status items in BOM for maintenance status,then systematic record and management for equipment maintenance history was achieved.At last,the example of management for equipment maintenance status of plastic blowing modeling equipment was adopted to set forth above-mentioned. 

Bending Property Analysis and Experimental Study of Orthodontic Wires

ZHANG Yong-De, JIANG Ji-Xiong

2011, 22(15):  1827-1831. 

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This paper analysed the bending properties of nickel steel wires,including domestic stainless steel wires,β-titanium alloy wires and Australia stainless steel wires. The finite analysis software MSC.Marc was used to model the process of orthodontic wires’ bending combined with actual experiments. Then the paper compared the results and analyzed the errors. The results indicate that rebound angle of the four kinds of orthodontic wires is reduced sequencely, furthermore, rebound angle increases as bending angles’ addition. The finite element analysis results are basically the same with the experimental ones. An orthodontic wires bending robot was used to bend wire based on orthodontic wires’ bending properties. The fitting curve obtained when the distance of the fixed fixture and mobile fixture is two millimeters is much better than the fitting curve obtained when the distance is ten millimeters. So the distance between the fixed fixture and mobile fixture should be as small as possible when using orthodontic wires to bend wires.

Research on Friction Resistance of Circular Shear Cell Filled with Steel Granule

ZHANG Ba-Beng, WANG Wei, LIU Kun

2011, 22(15):  1832-1836. 

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In order to study the movement and lubrication characteristics of granular flow in the tribo-pairs, a circularity shear cell was constructed to simulate the shear movement of infinite parallel plate and observe the dynamic behavior of granule in the tribo-pairs. The surface structure, speed, particle size and the number of particles were changed to study the movement characteristics of granule and its effects on the tribo-pairs. The results show that: boundary conditions and particle properties have great effects on the movement characteristics of granular flow, and the shear dilatancy phenomenon which may cause the vibration are strongly related to the particle arch and its inherent force chain.

Research on Dynamic Load Characteristics of Wind Power Generation Transmission System under Random Wind

YANG Jun-1, 2, QIN Da-Tong-1, CHEN Hui-Chao-1, ZHOU Zhi-Gang-1

2011, 22(15):  1837-1842. 

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A load model of wind turbine transmission system under random wind speed was established, based on simulation method of random wind speed, calculation method of aerodynamic load, vector control method of generator and electromechanical coupling model of wind turbine transmission system. Valid sample of random load of wind turbine transmission system was obtained by example calculation of the load model, and compared with the random wind speed sequence. The results indicate that random load sequence and random wind speed sequence have the same changing tendency, good correlation and similar spectrum characteristics. The results provide the basis for further research of load characteristic and compilation of load spectrum of wind turbine transmission system in complex working condition.

Precision Positioning Stage Using Rod Shape Rotary Ultrasonic Motors

ZHANG Jian-Tao-1, SHU Hua-2, DIAO Chun-Sheng-2

2011, 22(15):  1842-1846. 

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A rod shape rotary ultrasonic motor utilizing the first bending vibration mode was provided,which was composed of one stator and two rotors. The motor

was applied for the actuator of a precision positioning stage. A control system for the

 stage was designed based on computer and GO-400 motion controller. The motor was driven by an ultrasonic motor driver. When the applied voltage to one electric port was fixed at 15V, the motor speed without load was 206r/min and the maximum load torque was 0.273N·m. It is confirmed that the ultrasonic motor is suitable for achieving precise positioning of the stage with forward/reverse control and speed PID control. It is proved by experimental results that the positioning errors of the stage is less than 2μm and forward/reverse displacement resolutions of 1μm are achieved. The precision positioning stage driven by rotary type ultrasonic motors can use rotary optical encoders instead of expensive linear optical encoders. Thus, the price of precision positioning system can be significantly reduced. 

Probability Assignment of Dimension Variant Based on Bayesian and Its Applications in Variant Design

XU Xin-Qing-1, HE Xiao-Ke-2, LI Dan-1, YAN Tian-Hong-1, CHENG Xin-1

2011, 22(15):  1847-1853. 

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Dimension constraint satisfaction priority of different types of parts was defined based on the part classification in mass customization. The variant design strategy was put forward for enhancing part reuse level of variant products by transferring/postponing the dimension variant requirements of parts. And dimension constraint conflict forms resulting from part reuse were analyzed. Aiming at the issues of dimension variant transferring/postponing, a variant probability matrix among part’s dimensions was constructed. And a probability assignment model of dimension variant requirements based on Bayesian was proposed which can concentrate variant design requirements on few parts so as to realize reuse of other parts. Based on these, variant design process for products constituting of multi-type parts was presented based on dimension variant transferring/postponing. Finally, an example was given to verify these. It is shown that the part reuse level of customized products is increased effectively by transferring and postponing dimension conflicts, and assigning dimension variant probability dynamically according to part classification information. 

Application of Particle Filter in Blind Source Separation of Gearbox Fault under Complex Noise Environment

LIU Xiao-Beng-1, ZHENG Hai-Qi-1, CHU Tian-Yu-2

2011, 22(15):  1853-1857. 

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In gearbox fault diagnosis, the signals collected by sensors were suffered generally by the disturbance from various types of unknown noises. Under the complex noise environments, the blind source separation of the gearbox faults can not obtain perfect results of separation.In order to solve this problem, a new noisy blind source separation method of gearbox faults was proposed based on particle filter. A denoising process to the observation signals was implemented using Rao-blackwellised particle filter before the independent component analysis. The simulation and experimental results show that the proposed method is effective.

Finite Element Analysis of Two-dimensional Gear Contact-Impact Problem with Stribeck Friction Model

ZHOU Wei, TANG Jin-Yuan

2011, 22(15):  1858-1861,1879. 

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A mixed finite element algorithm for dynamics contact/impact problem was proposed, based on which program package dealing with gear transient contact/impact process was devised. A two dimensional single-tooth impact model with Stribeck friction model was studied by the designed program. The variation regularities of the nodal normal contact force, friction force and the resultant force as well as impact time under different initial impact velocities were investigated. Meanwhile, the results under Stribeck friction condition were compared with those from Coulomb friction case. The preliminary validation was performed through comparison of the resultant normal contact force by virtue of ABAQUS in Coulomb situation. The contrast proves the validity of the developed program.

Research on Electromagnetic Support for Supporting Mechanical System by Variable Stiffness

CHENG Min-1, BO Yong-2, LIU Bao-Guo-2, BAI Hui-Chao-3

2011, 22(15):  1862-1866. 

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Based on the principles of support stiffness parameter of electromagnetic support varying with exciting current, an support style with parallel electromagnetic and mechanical support was proposed to make the machine system with variable stiffness supporting. By studying on the theoretical model of the electromagnetic support, the linearized rule and the rule of the system total stiffness being positive were obtained,on the basis of that the basic structure and characteristics of electromagnetic support were described, and the eccentricity of frame and dynamic gap affecting the electromagnetic support characteristics were also analyzed.The electromagnetic support stiffness and additional damping parameters of the cantilever beam system with parallel electromagnetic and mechanical support were identified. The results show that the experimental values of additional damping parameter are always far smaller than the theoretical values and can

be ignored, but the experimental values of stiffness parameter are accurate near the static operating point, which provides facts for the realization of variable stiffness supporting.

Influence of Distribution Characteristics of Gear Honing Speed at the Contact-points on the Surface Quality of Gear Teeth

LV Meng, LIANG Guo-Xing, MA Lin, GAO Xiao-Xu

2011, 22(15):  1867-1871. 

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The distribution of gear honing speed on the contact-line was varied,so the quality of gear tooth profile surface was in the great differences,and the performance of workpiece would be reduced. In order to improve the quality of workpiece,a vector expression of cutting speed on the contact-points was obtained by the coordinate transformation herein.The relationship between the quality of workpiece profile and cutting speed had been obtained by way of the experiments. It is showed that the surface roughness value of same tooth has further increscent differences with the increasing honing speed, and the surface quality of tooth is in the same trend.

Forming Limit of Electrodeposited Nickel Coating Based on Actual Stress-strain Curves

ZHOU Li-Qun-1, 2, DENG Jing-1, ZHOU Kai-1, LI Yu-Beng-1

2011, 22(15):  1871-1874. 

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Hill localized instability theory was used to derive the stress-strain equations of nickel coating sheet during forming process. By using polynomial fitting for experimental data, actual stress-strain curves of the electrodeposited nickel coating sheet were obtained. The forming limit left region of the nickel coating sheet was calculated by solving a nonlinear equation, and compared with one by using strain hardening curves. The research results show that the forming limit of the nickel coating by polynomial fitting is higher in security than the one by strain hardening curves, and the substrate anisotropy, coating thickness and substrate thickness have little influences on the formed limit curves. The results may play a directive role on the electrodeposited nickel coating sheet preparation.

Improvement of Pure Copper Powder Cones Warm Processed by High-pressure Torsion

ZHANG Kai, LI Ping, XUE Ke-Min

2011, 22(15):  1875-1879. 

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HPT was used to forming thin-wall cone of pure Cu powder at 300℃. The rules of compactness, microstructure and microhardness were studied, and they were compared with the cone processed by warm compaction at the same condition. It is shown that the relative density of the warm HPT cone reaches 0.9605, and it increases 5.06% compared with the warm compaction cone. The grain refinement of the cone processed by HPT is from 52% to 66%, and it is higher than 36% which processed by compaction. The average microstructure at mouth part, middle part and cone part from the warm HPT cone is increased 223%, 9% and 6% respectively, which compares with the warm compaction cone. It indicates that the middle part and the cone part have the highest and lowest microhardness respectively in the warm compaction cone, and the microhardness of ektexine is higher than inwall at the same part. The microhardness increases form cone part to mouth part in the warm HPT cone, and the distribution rules at cone part are the same as the warm compaction cone, however the mouth part and the middle part are contrary.

Shift Strategy of AMT Vehicle Based on Speed and Torque Control

LI Yong-1, 2, CHANG Sai-Qi-1, WEI Yang-Dun-2

2011, 22(15):  1880-1885. 

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Limitation of traditional AMT shift control strategy was analyzed.

A double layer powertrain integrated control method of AMT was presented;the outer layer program calculated the target engine rotate speed, target torque and clutch target position, and the inner layer program sended torque request signals to ECU to accomplish shift control action.To validate the above-mentioned method,a simulation model of electric

AMT vehicle with integrated powertrain control system was set up with MATLAB/Simulink.Rapid control prototype(RCP) of transmission control unit(TCU) was set up based on dSPACE and tested in vehicle.The simulation and test results indicate that the shift quality

are improved observably with the application of double layer integrated powertrain control method.

Parameter Optimization of Continuously Variable Transmission System with Reflux Power Based on System Efficiency Maximum Control Strategy

YIN Yan-Chi, SUN Dong-Shu, QIN Da-Tong, LUO Yong, DENG Chao

2011, 22(15):  1885-1889. 

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The relation between the instantaneous fuel consumption and system efficiency of a vehicle was studied, a transmission system control strategy based on system efficiency maximum was established, the design parameters of transmission system were analyzed. The range of ratio and characteristic parameter of a planetary gear set has effects on system efficiency. Optimization design method of continuously variable transmission system with reflux power based on system efficiency maximum control strategy was put forward. Taking MATLAB/Simulink as the platform, optimization results were obtained.Finally, simulation of the design parameters before and after optimization was complemented, the simulation results indicate that fuel consumption is reduced by more than one point seven percent by adopting optimization design parameters.