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Table of Content

    10 December 2011, Volume 22 Issue 23
    Finite Element Analysis of Whirlwind Cutter of NC Heavy Crankshaft Milling-turning Combined Machine Tool
    GAO Sai-Yu-1, FU Hong-E-1, NI Yan-2
    2011, 22(23):  2773-2778. 
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    According to the structure characteristics of whirlwind cutter of NC heavy crankshaft milling-turning combined machine tool, a 3D model of whirlwind cutter was established using UG; the oil film stiffness of constant flow delivery oil hydrostatic guideway of whirlwind cutter was calculated; then, finite element models of whirlwind cutter were built by means of software ANSYS and the static and modal analysis were done, through which the stress distribution figures, structural deformation figures, the first six natural frequencies and vibration modes were obtained. Consequences analyses were carried out and the results show that whirlwind cutter has good static and dynamic characteristics and can meet the design requirements. Besides, the structure weak links of whirlwind cutter were pointed out, which provides reference data for further optimization design.
    Discrete Optimization of Compound Gear Box Based on Mixed Nonlinear Programming
    ZHANG Zheng-Yan, CHEN Ding-Fang, CHEN Wen-Qing, HU Ji-Quan, JIN Sheng-Beng
    2011, 22(23):  2778-2783. 
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    Taking the engineering project (triple gear-box assembled with spiral-bevel and helical-spur gears ) as a research target, an optimization model was established, which included discrete variables(module),integer variables(teeth number)and continuous variables(tooth width, spiral angle, etc.), featuring a complex nonlinear programming problem. A new optimization solution algorithm was proposed to obtain the discrete solution of module and teeth number, thus the deficiency of treating discrete integer variables as continuous variables was offset in traditional optimization design of gear reducer. The optimization results manifest that this optimization scheme meets the needs of engineering design and has a critical practical significance in decreasing reducer volume and saving materials. Moreover, this discrete optimization algorithm has been applied successfully in the design of gear box of shanghai zhehua heavy Industry Co.,Ltd.(ZMPC) and compiled into important reference for relevant designs.
    Research on Variant Design Process of Mechanical Products Based on Activity Definition and Its Applications
    HUANG Tie-Qun, XU Xin-Qing
    2011, 22(23):  2784-2790. 
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    In order to reuse all kinds of part resources effectively during product variant design, process modeling of mechanical product variant design was proposed from the aspect of design activity, and the modeling framework of variant design process was also presented. Firstly, the variant modes of different types of parts were analyzed based on the part classification on the context of mass customization. The dimension constraint network among mating parts was constructed at the parameter level of part. And then, variant design activity was defined with triple elements. Based on these,a logical structure model of variant design activity was established. Secondly, the rules of product variant design process configuration were identified from the aspects of activity and part respectively. As a result, variant design process of different customized product can be derived with the goal of reusing different types of part resources. Finally, an example was given to verify these methods and principles mentioned above.

     
    Experimental Research on Damping Characteristics of an Adjustable Shock Absorber
    ZHANG Ying-1, SHU Sai-Hong-1, WANG Jia-Qing-2
    2011, 22(23):  2790-2793. 
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    An orifice-adjustable shock absorber was studied. The effect laws of orifice diameter of piston, number of rebound valve, limit valve outside diameter and bypass throttling orifice diameter on damping force were studied by experimental method. The results show that decreasing orifice diameter, increasing the number of the recovery valve and increasing the limit valve outside diameter all result in the increase of damping force. Of these three factors, orifice diameter and limit valve outside diameter have higher effect on the damping force. As the bypass orifice diameter increases from 0 to 4mm, the damping force decreasing. If the diameter is greater than 4mm, the damping force changes slightly. By-pass orifice diameter has little effect on the compression damping force. The results provide the basis for the design of the bypass orifice-adjustable shock absorber.
    An Algorithm of S-shape Acceleration and Deceleration Based on Anticipation Interpolation Time
    TANG Xiao-Qi-1, HE Wang-Yong-1, 2, LI Yong-Bei-2
    2011, 22(23):  2794-2797,2801. 
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    On the analysis of S-shaped acceleration and deceleration (acc/dec)curve model which consisted of seven sections, the paper put forward an algorithm which can satisfy the requirements of the displacement, velocity and acceleration being zero at the end of the interpolation. At the same time, under a limited acceleration and limited jerk,the details of the algorithm how to obtain anticipation interpolation time of every S-shaped acc/dec curve sections were explained. Finaly, the simulation testing shows that the algorithm has good efficiency. It suits pre-interpolation S-shaped acc/dec control.
    Research on Intelligent Controller of Vibratory Pile Drivers Based on Composite Synchronization Control Scheme and Fuzzy PID Control Aalgorithm
    SHANG Bing-Xin, WANG Xiao-Hu, MA Yue-Jun, WANG Xue-Qin, SHU Deng-Lin
    2011, 22(23):  2798-2801. 
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    To improve the efficiency of pile driving and achieve stepless frequency and torque online regulation, a scheme of synchronized control was used in the control of vibratory pile drivers. In view of nonlinear and time varying characteristics of the electro-hydraulic servo system, an intelligent synchronized control system with fuzzy PID parameters was developed, taking calculational advantages of single-chip microcomputer(SCM) and compromising composite synchronization control scheme and fuzzy control theories. Experimental results indicate that the fuzzy PID controller can improve the dynamic characteristics and its control effect is better than that of conventional PID controller.
    Secondary Source Modeling Based on Analogue Circuits of Electrical Mechanical and Acoustical Systems
    NIE Yong-Gong, CHENG Jun-Ku
    2011, 22(23):  2802-2805. 
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    A method of secondary source modeling based on analogue circuits of electrical, mechanical and acoustical systems was provided in order to reduce the mismatch of transfer function estimation of secondary path in simulation of an active noise control system. The convergence range and noise reduction performance of the system using Filtered-X LMS algorithm were investigated. The results show that such a secondary source model has different amplitudes and phases from the ideal model, which makes the noise reduction performance of control system be much worse than the one with ideal model. Meantime, the convergence range of the control system is increased at low frequencies while decreased at high frequencies. The proposed model can provide a new method of secondary source modeling for further research on the simulation of active noise control systems.
    Dynamic Analysis of a Rotor-ball Bearing Nonlinear System with Alford Force
    CHENG Mei-1, MENG Guang-2
    2011, 22(23):  2806-2812. 
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    Under the conditions of both the nonlinear ball bearing force and Alford force, a dynamic model of the rotor system was set up. Then nonlinear dynamic properties of rotor-ball bearing with Alford force were studied by means of numerical stimulation. The nominal contact angle of the ball bearing was introduced in the improved ball bearing method. And the result is in good agreement with the previous conclusions, so it is feasible using this method to predict the dynamic characteristics of a rotor system. By using the numerical value integral method, the influences of a series of factors on the nonlinear dynamic behaviors of the coupled system were studied. By changing the values of the rotation speeds, the ball bearing clearance and the rotor eccentricity, the bifurcation diagram was obtained respectively. Meanwhile the pictures of some typical Poincare maps and frequency spectra were also given. From the results of the numerical simulation, it is found that there are periodic motion, approximate-periodic motion and chaos motion under combined Alford force and ball bearing.
    Analysis of Mapping Connection between Cylinder Telescoping and Rotation of Boom in Mechanisms
    TENG Ru-Min, SHU He-Lou, ZHANG Zhi-Gang
    2011, 22(23):  2812-2816. 
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    Mechanisms with rotation of booms driven by telescopic cylinders have many applications in construction machinery. Kinematical relations between cylinder telescoping and rotation of booms in such a mechanism were studied herein, without any idealization of manufacturing,assembling and controlling conditions. The obtained results give an explanation of why some of harmful motions occurred, and their applications in engineering practice were illustrated by a real examples. 
    Reversing Heat Flow Intensity of Waist Rail Movable Upright Column Based on Thermal Network
    LIU Ri-Meng-1, HU Xu-Xiao-2, HE Wei-3, JIA An-Jin-3, WANG Li-Hui-3, MAO Lei-1
    2011, 22(23):  2817-2821,2882. 
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    A waist rail mobile column of MKL7120 CNC forming grinder made in Hangzhou Machine Tool Group Co., Ltd. was taken as research subject.A thermal network model was constructed according to the structural characteristics of the upright column. The thermal network model and the upright column’s temperature(through experiment) at special points measured on the thermal steady state was used into reversing the heat flow intensity.Then using the circuit simulation software Multisim11,and put the reversing results into the thermal network model which had already been established to solve all nodes’ temperature of the thermal network. Then comparing the nodes’ temperature data with those experimental data, the errors is less than 2%. That demonstrates the established model is correct and reasonable. This model used to analyse the characteristics of spindle speeds and the speeds of the grinding head slider provides important data for the further studies of transient temperature field and thermal deformation of the upright column.
    Research and Application on Dynamic Statistical Process Control of Key Process in Multi-varieties and Small-batch Machining Workshop
    CAO Jun, YIN Chao, LIU Fei, LI Jin-Cai, YIN Qing
    2011, 22(23):  2822-2827. 
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    According to the problems of quality data acquisition not in time, lacking of quality sample data in key process of multi-varieties and small-batch machining workshop, which lead to the difficulty for implementing dynamic SPC (statistical quality control) and early warning for quality status, a three-layer technical framework of dynamic SPC for key process in multi-varieties and small-batch machining workshop was proposed, which integrated real-time filed data acquisition, data transforming of small samples, quality status on-line controlling and early warning. Meanwhile, the key technologies for the framework were studied, including the dynamic quality data acquisition based on the multi-functional information interactive terminal, the multi-charts SPC method under condition of small samples, and the quality status early warning based on BP neural network. Finally, the method was applied in a machining workshop, and good results were obtained.
    Research on Manufacturing Resource Service Fuzzy Clustering for Customer Demands
    HUI Wen, LI Dong-Bei, TONG Yi-Fei
    2011, 22(23):  2828-2833. 
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    After analyzing customer demands and the grey relation degree of manufacturing resources, a fuzzy similarity matrix and fuzzy cluster tree were constructed. An optimization model of resource clustering evaluated by internal genus degree, external detached degree and satisfaction degree of customer demands was proposed, which was based on fuzzy clustering tree.Then, genetic algorithm was applied to optimize the clustering results. To prevent the premature convergence problem and improve the optimization capability, the adaptive crossover and mutation probabilities method and elitist selection were employed. The simulation results indicate the effectiveness of the proposed new algorithm.
    Research on Multi-objective Method on Main Assembly Material Delivery Based on JIT
    GE Mao-Gen, LIU Meng-Zhou, JIAN Fang, HU Jing, JIANG Ceng-Jiang, ZHANG Ming-Xin
    2011, 22(23):  2834-2838. 
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    To solving the real-time material delivery problems during the assembly process of mechanical products, a multi-objective real-time materials distribution model was proposed considering from optimization objectives, constraints and impact factors, which integrated materials transportation costs, materials transportation time and materials storage on-line as optimization target. The calculation method of optimization objectives was given, a hybrid particle swarm algorithm was designed and the detail realization process with this algorithm was presented. Then distribution bills were gained, which used to guide materials distribution, and the overall objective optimization will be achieved, the decision-makers choose the preferred solution of optimization objectives according to the facts. Finally, the validity of this model and algorithm was verified by a case of assembly plant materials distribution problem.
    Study on Extended Manufacturing Task Planning Method Based on Correlation
    AN Bei-1, LIAO Wen-He-1, GUO Yu-1, SUN Wei-Gong-2
    2011, 22(23):  2839-2844. 
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    According to extended manufacturing was a new networked manufacturing model, which was oriented to armament and another complex products, the methods of extended task planning based on tasks correlation were proposed. Firstly, through comparison of extended manufacturing and normal networked manufacturing, the necessity of extended tasks planning was analyzed. Secondly, The definition of extended tasks 2-dimensional correlation and its evaluation criterion oriented extended manufacturing were given, and the extended task correlation matrix was established, by which complicated correlation including material transferring and correlation degree of extended tasks was described; then extended tasks were decomposed using PSO algorithm, and sets of extended tasks were generated. At last, the application process of the extended task modeling and decomposition was discussed.
    Resource Dynamic Allocation of Complex Product Development for Multi-project Management
    SUN Qing-Chao-1, SUN Wei-1, GUO Gang-2
    2011, 22(23):  2844-2848,2852. 
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    A mathematical model of resource allocating among multi-projects was built, the matching relationship was divided into rough matching and detailed matching. Next, for analyzing the feasibility of resources demand in every period, a DCRA method was presented, and the dynamic resource allocating model based on DCRA was established. In addition, a improved genetic algorithm was brought forward, to optimize the detailed matching relationship. An example proves that the presented methodologies are effective.
    Research on PWM Control of Micro Hydraulic Power System
    HAN Jia-Wei, LIU Bai-Yan, MO Wen-Feng
    2011, 22(23):  2849-2852. 
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    PWM control of a micro hydraulic power system was used in an oil automatic vertical drilling tool, so as to achieve continuous adjustment to resistant inclination force in the vertical drilling. For the micro hydraulic power system’s features of little volume, little flow and single piston pump drived, a discontinuous PWM control method was proposed. Determination of reasonable PWM control cycle, duty cycle, and the beginning and ending time can achieve the continuous control of the executive mechanism’s output force in a certain range using a two-way solenoid valve. Simulated by software AMESim, then an experiment was completed to verify the control strategy.
    Dynamic Modeling for Time Grating CNC Rotary Table Based on Time Series
    CHEN Zi-Ran-1, BANG Dong-Lin-1, 2, LIU Xiao-Kang-2, ZHENG Yong-2, ZHENG Fang-Yan-2
    2011, 22(23):  2853-2857. 
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    In order to apply a novel displacement sensor named time grating to full closed-loop CNC rotary table as an angle detector, it is necessary to transform temporal information to spatial information with time-space transformation algorithm for time grating sensor. According to time series analysis theory, dynamic model of dynamic characteristics of time grating CNC rotary table can be established. Therefore, the next measurement value can be predicted based on past measurement values with the dynamic model. At a result, original absolute displacement signals sampled in equal time interval can be transformed to continuous incremental pulses required by full closed-loop CNC system. Furthermore, the principles of selection criteria for dynamic models, parameters estimation, model checking were presented. In addition, regarding error control, last predicted errors were always corrected by current measurement values in real time so as to eliminate accumulated errors for realizing precision measurement. Experimental results prove that dynamic measurement displacement errors are within ±3″ with the dynamic model. And precise full closed-loop angular displacement measurement is realized.
    A Multi-objective Stochastic Programming Model for Emergency Logistics Based on Fuzzy Goal Programming
    DAN Sha-Lei, LIU Na
    2011, 22(23):  2858-2862. 
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    This paper addressed the problem of emergency facilities location-relief allocation in multi-suppliers, multi-affected areas, and multi-relief emergency logistics networks. Considering the uncertainty of demands and allocation paths, a multi-objective stochastic programming model was proposed, whose features were: the availability of relief-allocation path was stochastic, and there were coverage limits for relief suppliers to cover affected areas. The uncertainty was disclosed by using two-stage stochastic programming with recourse. And fuzzy goal programming based on “weighted ordered method” was proposed to solve the multi-objective problem. Numerical results indicate the validity of the model and solution.
    Numerical Study on Heat-flow Coupling Field in Microchannel Heat Sink Structures for Electronic Chip Cooling
    XU Chang-Long, QIN Jie, HU An-Xin
    2011, 22(23):  2863-2866. 
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    This paper studied on four styles of microchannel structures: parallel structure, gridding structure, helix structure, and tree-shaped structure's flow and heat transfer under the same conditions of equal transfer areas and same loads. The microchannel topological structures' influence on electronic chips cooling were analysed in the following of getting the electronic chips' temperature distribution and liquid's velocity field of the different microchannel heat sink structures. The temperature of the electronic chip with parallel microchannel to dispel heat is below 80 and almost 81% area of the chip is below 60. The temperature of the chips with gridding and helix microchannels are above 90,they separately have 62% and 61% of the chips'area is between 20 and 60.But the temperature of the electronic chip with tree-shaped microchannel to dispel heat is below 70 and more than 94% area of the chip is below 60 and the temperature distribution is of uniform. Besides, microchannel system can take over more quantity of heat while liquid's average velocity of flow inside the electronics' microchannel is big. This conclusion provides an important foundation of theory and technology in electronic chips’ heat elimination which have high heat flux density.
    Full Hyperstatic Solutions of Spherical Parallel Mechanism 2-RRR+RRS
    LIU Chi-Beng, HOU Yu-Lei, QIU Xue-Song, ZHOU Yu-Lin
    2011, 22(23):  2867-2872. 
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    Based on dismantle-bar method, a set of hyperstatic equilibrium equations of the spherical parallel mechanism 2-RRR+RRS were establised, and the deformation compatibility equations of the mechanism were also set up with the consideration of the elasticity of the mechanism and the superposition principle of small deformation. Then, corresponding different input forces and torques, the relationship curves among the forces acted on the components of the mechanism and the pose of the mechanism were obtained using MAPLE software, and the infulence of the applied external forces or the external torques on the mechansim was clarified. The research contents herein provide the theoretical foundation for the engineering design and practical applications of the 2-RRR+RRS spherical parallel mechanism.
    Reversal Estimation Model of Mechanical Properties for X60 Pipeline Steel Plate during U-forming O-forming(mechanical) Expanding Processes
    GUO Bao-Feng, DIAO Dan-Yan, WANG Lin-Feng, JIN Miao
    2011, 22(23):  2873-2878. 
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    Taking X60 pipeline steel for example, bending deformation features for different specifications during UOE processes were analyzed using FEM, to achieve reversal calculation method of mechanical properties of steel plate determined by pipe, for mechanical property changes of longitudinally submerged arc welding(LSAW) large diameter linepipe in the process of UOE forming and specimens flattening. Bending specimens with the same equivalent strain were made through four point bending. Mechanical property change law of X60 pipeline steel plate after bending and flattening was investigated according to API standards regarding flattening test methods of mechanical properties for pipe body specimens, and reversal estimation model of yield strength for X60 pipeline steel plate in the equivalent strain range of 0.0104~0.0586 was presented.
    Influences of T6 Heat Treatment on High-speed-milling Machinability of SiCp/Al Composites
    GE Yang-Fei-1, XU Jiu-Hua-2, FU Yu-Can-2
    2011, 22(23):  2878-2882. 
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    PCD tool was used to investigate the influences of heat treatment on the machinability when high-speed milling of SiC-particle-reinforced aluminum matrix composites at the cutting speed of 1200m/min. The results show that the cutting forces and the cutting temperature of T6 composite are higher than that of no heat treated material. The saw-toothed chip form is more evident for the T6 material. The above facts indicate that the cutting process of T6 materials is more unstable and that the PCD tool suffers from more cutting impact, which induces excessive chipping, peeling, cracks on the cutting tool. Therefore, the tool life when high speed milling the T6 composites will be much lower than that of the no heat treated materials. The results also show that the machining induces defects such as pits, micro cracks, matrix tearing and smearing etc. are much less for the T6 materials, which results in low surface roughness value and shallow hardened layer.
    Research on Effects of Rear Suspension on Frontal Impact Vehicle Body Acceleration
    DIAO Min-1, ZHONG Zhi-Hua-1, DONG Li-Jiang-1, CHEN Chao-1, WANG Jing-Liang-2
    2011, 22(23):  2883-2886. 
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    For the situation of significantly different results of frontal impact tests of the same vehicle model with one luxurious car and one basal car, by applying the finite element simulation technology, crash performance was mapped after time decomposition, space decomposition and crash force decomposition. The dynamic analysis of the sub-system consisting of rear suspension assembly was carried out for the causation. The results show that for the vehicle model of front-mounted engine, rear-mounted drive, chassis has an important contribution of collision force transmission. The multi-link rear suspension of the luxurious car has a greater longitudinal stiffness than leaf spring rear suspension of the basal car, which causes a higher acceleration markedly. The corresponding solution is educed after the analysis.
    Simulation of Automobile EHB Hydraulic Control Based on Generalized Predictive Control
    WANG Ji-Dong-1, 2, HUANG He-1, CHEN Mo-Wei-1, LIU Xiang-Yu-1
    2011, 22(23):  2887-2892. 
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    In order to set up a hydraulic model of EHB system precisely, AMESim and Simulink were both used considering the dead zone and saturation properties of high-speed solenoid. Then a predictive model was developed by system identification.A hydraulic controller was designed based on GPC theory.The simulations of wheel cylinder pressure control test and anti-lock brake tests show that the GPC controller is feasible and effective even when the parameters of hydraulic system are time-varying.Compared to traditional PID controller,the designed controller can further improve the brake performance. 
    Research and Optimization of Ride Comfort for Rhombic Bus under Random Road
    ZHANG Xi, MO Xu-Hui, ZHONG Zhi-Hua, YAN Xiao-Lei
    2011, 22(23):  2892-2897. 
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    According to the unique chassis layout mode,a fifteen DOF model of rhombic bus was built,and the corresponding analyses and solve were done by MATLAB software.With weighted vertical root mean square values of each passenger’s acceleration as optimization objective,and with dynamic displacements of each suspension and relative dynamic loads as constraint conditions,the parameters of suspension were optimized by NSGA-Ⅱ.The optimized results indicate that the ride comfort ability of rhombic bus is improved greatly after optimization.The values of every design variable will have better reference significance to the engineering after optimization.