Table of Content

25 June 2013, Volume 24 Issue 12

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Experimental Study of Temperature Measurement for Stacked Die Chip

CHOU Feng-Shen, HAN Lei

2013, 24(12):  1563-1567. 

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A MP/MB infrared radiation thermometer was used to measure the temperatures of the heat stage and the structural surface of the stacked die chip,and the results were analyzed and then modeled.Experimental results include  temperature difference of the cantilever and non-cantilever area of the stacked die chip;and the reason discussion.Through the curve fitting of the temperatures of the different
areas,it is found modified Logistic model can be used to understand the
stacked die chip structure thermometry data modeling and the temperature rise mechanism properly.The results will be helpful to further studies of
the cantilever bonding kinetic mechanism.

Experimental Investigation of Water Jet-Assisted Laser Etching on Al2O3 Ceramics

CHEN Xue-Hui-1, 2, YUAN Gen-Fu-2, ZHENG Wei-2

2013, 24(12):  1568-1571. 

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An experimental device of water jet-assisted laser etching was designed,laser etching technology was combined with a medium-jet erosion processing,and the influences of laser processing parameters and jet processing parameters on the etching capacity and cross section quality of material sample were studied.The results show that the laser processing parameters and jet processing parameters have a decisive impact on the quality of the workpiece,the compound processing technology can remove above 90% melting slags which are produced by the laser processing,and the surface roughness are reduced effectively.The blind holes of  the machined materials have a regular inverted triangle shape.

Experimental Study of Gear Bending Fatigue Strength under Random Load with Gaussian Normal Distribution

HU Jian-Jun-1, 2, HU Hong-Bin-2, JIE Shi-Hua-2, GAO Xiao-Wang-2

2013, 24(12):  1572-1576. 

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For the  bending fatigue under the random load conditions with normal distribution,an equivalent load was analyzed and limiting value of gear bending fatigue strength was computed based on equivalent fatigue damage.The effect of load spectrum distributed parameter on equivalent load was analyzed,and load spectrum was compiled for luffing amplitude fatigue experiments.Then experiments of gear bending fatigue strength were achieved under random load according to normal distribution on MTS electro-hydraulic servo material fatigue tester,where the group method was used.The R-S-N curve was acquired in a concrete coefficient of variation.The tests prove that bending fatigue strength of gear under random load  is less than that under constant load.By contrasting with the bending fatigue strength computed based on constant load,the theoretical results can agree with experimental ones.

Analysis on Mechanism and Nonlinear Characteristics of a Novel Hydraulic Shock Pulse Generator

WANG Gong-Xian-1, WANG Ming-Han-1, HUA Hong-Xing-2, HONG Yu-3

2013, 24(12):  1576-1580,1586. 

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Based on the concept of hydraulic dissipation of kinetic energy,a novel structure of a shock pulse generator with combination of throttling by cone-shape spool and orifice was presented herein.By virtue of gap and orifice combination-throttling,the proposed structure dissipated the kinetic energy of a moving mass and decelerated it to a stop to produce desired shock pulses.By establishing motion equations of each component and analyzing the internal fluid dynamic phenomenon of the structure,the shock pulse generator was demonstrated numerically with such mechanical properties as:being able to self-adapt to the external loads applied to it;with high efficient dissipation of kinetic energy instantly;prompt and easy adjustment of the width and amplitude of shock pulses by changing the equivalent flow area of the damping orifices,which made it be applicable to different impact tests.It is suitable to use in conditions with large momentum change,especially the cases where the braking process with heavy moving loads and high speed is required to be controlled in desired way.

Three Dimensional Tolerance Synthesis Simulation Based on Quasi Monte-Carlo Method

HU Ben-Qing-1, HUANG Mei-Fa-2, JING Hui-2, ZHONG Yan-Ru-2

2013, 24(12):  1581-1586. 

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To deal with the disadvantages of low convergence and unstable results of Monte-Carlo method in computer aided 3D tolerance synthesis,a simulation method for computer aided 3D tolerance synthesis was proposed based on quasi Monte-Carlo method.On the basis of 3D tolerance representation of  the  screw parameter and spinor matrix,a 3D tolerance synthesis simulation equation  was established using coordinate transform knowledge in robot kinematics of rigid body and the method of generalized inverse matrix.The procedure of generating normal distribution random number with  Halton sequence and the process of 3D tolerance synthesis simulation were given.Finally,an engineering example,gear pump, was introduced to test the proposed method.The results show that the quasi Monte-Carlo method has higher convergence rate and more stable evaluation results than those of  Monte-Carlo method.Therefore,the quasi Monte-Carlo can be applied efficiently to the computer aided 3D tolerance synthesis simulation.

Study on Edge-forming Mechanism for Aspheric Surface Compliant Polishing

DAN Jian-Meng, ZHANG Min-Qiang

2013, 24(12):  1587-1591. 

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When machining speed,feeding speed and imposed pressure did not change in the whole polishing process,the length of feeding trajectory in the edge of a workpiece of aspheric surface was half of the length of in other area,so the removed material should be less in the edge of a workpiece of aspheric surface in theory.But the experimental results were always exactly the opposite and new theory needed to be put forward to fit it.Based on the foundational dynamics and its state transition in the polishing process,this paper re-studied a compliant polishing and shows that, the cutting time is cut to a half in the edge,but the imposed pressure will be increased from its initialized value to an infinite one by the 2 power.Therefore,among all the factors which will influence the material removal in the edge,the imposed
pressure will be in a dominant position over the cutting time thus the material in the edge will  be removed more.

Analysis of a 7-DOF Automated Fiber Placement Robotic Manipulator's Self-Motion Manifolds

GE Xin-Feng

2013, 24(12):  1591-1595. 

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The position joint space manifold and posture joint space manifold of a redundant robotic manipulator were defined,whose position and posture were decoupled,the redundant robotic manipulator's self-motion manifold can be obtained by pairing these manifolds.A 7-DOF automated fiber placement robotic
manipulator was analyzed using the defined self-motion manifolds,
and  its self-motion manifolds were obtained.The results show that
the automated fiber placement robotic manipulator's
self-motion manifold is correct using this method by simulation,
and this method is also applicable in analyzing the self-motion manifold of
the redundant robotic manipulator which the position and posture are decoupled.

Failure Modeling of Helical Compression Spring for Automatic Brake Adjuster

LUO Zai, JIANG Wen-Song, LIU Yi, HU Xiao-Feng

2013, 24(12):  1596-1599. 

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Through analyzing the working principle of automatic brake adjuster,this paper used FTA  method to establish a
mathematic failure model of helical compression spring,which directly caused the disable of automatic brake adjuster's self-regulation.Both of  the model
and the data of separation force and backlash which were tested by a measurement system of automatic brake adjuster,were used to judge whether the
critical position of the function of automatic brake adjuster's self-regulation was failure.As well,through testing the value change of adjusted torque to check whether the failure model above was right.Through the experiments,this model can judge correctly whether the function of automatic brake adjuster's self-regulation is failure.

Optimal Control of Primary Resonance of Smart Structures of Cantilever Beams

LIU Can-Chang-1, 2, QIU Jin-Gao-1, SUN Hui-Yu-1, JI Hong-Li-1, LIU Lou-1, 2

2013, 24(12):  1600-1604,1670. 

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A piezoelectric optimal feedback control methodology was provided to mitigate the primary resonance of a cantilever beam.The regions of the feedback gains  were obtained by using the stability conditions of eigenvalue equation.Attenuation rate
 was used to evaluate the performance of vibration control by taking the proportion of peak amplitude of the vibration for the suspension system with and without control.
Taking the attenuation rate as objective function and the stable regions of the feedback
gain as constraint conditions,the control parameter of velocity feedback gain was worked
out by using optimal method.It is found that a big feedback gain can lead to a small attenuation rate and has a good  control performance.Taking the energy function as objective
function,the control parameter of displacement feedback gain can be calculated.
The controller was designed to control the amplitude of primary resonance of
smart structures.The optimal feedback gains were worked out by using the datum of
primary resonance experimental test.An experimental control system was designed and
control experiments were carried out.

Research on Capturing Mechanism of Functional Requirements for Conceptual Design

CHAN Hong-Bei, GE Bin, XU Hai-Yan, SUN Zhi-Hong, XU Fang

2013, 24(12):  1605-1610. 

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In order to effectively obtain satisfactory products,customers  demands were collected and estimated through entropy method.Then a relationship matrix between  customers needs and functional needs  was established based on system of domain experts.Aimed at seizing satisfactory  and easily made products with great market competition,a conversion mechanism of  customers requirements based on knowledge of product design was proposed.In the process of transforming customers requirements to product design parameter,the effects of companys research and development ability and resources were fully considered.Finally,a case study was provided to illustrate the feasibility of the proposed approach.

Local Retrieval for CAD Model Based on Region Feature Decomposition

DAO Song-Qiao-1, 2, HUANG Zheng-Dong-3, MA Lou-Jie-4

2013, 24(12):  1611-1615,1675. 

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A CAD model retrieval method based on region feature decomposition was presented herein in order to resolve low retrieval efficiency problem for complex models.First,according to the salient geometric features of the mechanical part,the surface boundary of a solid model was divided into local
convex,concave and planar regions with the minimal number.Then,a kind of region
codes was given to surface region and their links in CAD model.And the similarity between two models was measured by the comparison of their
region codes.Experimental results show that this method is able to support local retrieval and its efficiency meets the requirements of  practical applications.

Multi-objective Dynamic Scheduling of Manufacturing Resource to Cloud Manufacturing Services

TAI Li-Jun-1, HU Ru-Fu-1, DIAO Han-2, CHEN Cao-Wei-1

2013, 24(12):  1616-1622. 

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According to the characteristics and problems of manufacturing resource scheduling in cloud manufacturing environment,a multi-objective optimization mathematical model was provided,and a dynamic scheduling technology was put forward,according to the characteristics of the disturbance events can happen easily in cloud manufacturing environment.It was able to respond timely when an incident.
A manufacturing resource scheduling method was presented based on genetic ant
colony algorithm.In order to make up the lack of ant colony algorithm easy to fall into
local optimum and the slow rate of convergence,advantage of genetic algorithm search
 ability and fast convergence were used to make the whole operation
process converge quickly and accurately to the optimal solution. Finally the results of simulation indicate the validity of algorithm．

Interactive Fitting Technology of Free Curve Oriented to Optimization of Control Vertices

JIANG Shui-Xiu-1, CHAN Yan-2

2013, 24(12):  1623-1626. 

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To solve the defects of control vertices distribution which was one of the basic issues in CAD free curve fitting,a new interactive fitting technology of free curve fitting was presented. The density and distribution of the control vertices, which
decided the shape of free curves,were planned manually with interactive processes, so that the quality of the control vertices distribution was guaranteed.The position of control vertices was adjusted automatically and iteratively to satisfy the approximation criteria. Applications show that both efficiency and quality of the fitting operation were satisfied very well.

#br# Buliding and Application of General Model for Machine Tool Errors

HUANG Jiang, LI Jing-Feng

2013, 24(12):  1626-1630. 

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The characteristics and its commonness of topological structure on machine tools were analyzed firstly herein,based on the multi-body system theory and the homogeneous coordinate transformation principle,the general expression on relative position-pose,movement and error among the machine components  were provided,and a general error analysis model for machine tool was established by programming.Through interactive input method,error modeling and analyzing on different machine tools would be achieved high-efficiently.The analysis results of error sensitivity and error regularity can be used as important
basis for tolerance design,stiffness control,installation and adjustment on
machine tools.

Dynamics Analysis and Structural Optimization Design of an Ultrasonic Cutter

ZHOU Qing-Li, TAO Zhi-Yuan, SHA Jin

2013, 24(12):  1631-1635. 

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In order to analyze the influence of an ultrasonic cutter's structural factors on its longitudinal vibration mode qualitatively and optimize its structural design,a dynamics model was established firstly,and its first-order longitudinal vibration mode was obtained analytically.The analytical result of the vibration frequency (52.5kHz) accords with the ANSYS computing consequence (52.3kHz) and the
experimental result (53.5kHz).Then a mathematical model of the structural
optimization design of the ultrasonic cutter was built.At last a structural optimization
design program was devised,and a host controller interface was programed using
the GUIDE tool of MATLAB.After the structural optimization,the deviation between the location of the nodal plane and the position of the clamping center is within 1μm,the amplitude of the tool bit increases by about 27%.

Structural Analysis of Electrical Connector Contacts and Insertion-Extraction Test

BO Jun-1, JIN Fang-Jian-2, CHEN Wen-Hua-1, JIAN Ping-1

2013, 24(12):  1636-1641. 

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In order to improve contact reliability of electrical connector,the paper took electrical connector contacts as object,the structural analysis and research on contact performance were presented,and a computational iteration method for contact area was proposed.The parameterized finite element model of the contacts was constituted,and motion simulation was accomplished by ANSYS,which was used to research contact performance of electrical connector contacts.And then,the change curves of
contact force and mating and unmating force in insertion-extraction process
were obtained,similarly the stress distribution of  the contacts was obtained.According to parameterization for the model of the contacts,the sensitivity of each parameter on contact performance were researched,the key parameters impacting contact reliability were obtained as well.Finally,the feasibility of the proposed method was verified by theoretical analysis and the simulation carried out by insertion-extraction test.

Constraint Satisfaction Modeling and Solving Method for Single Machine Group Scheduling Problem

JIANG Dui-1, CHEN E-Rong-1, 2, GUAN Zai-Lin-2, ZHOU Hong-Meng-1

2013, 24(12):  1642-1649. 

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Mix-flow production based on group technology was adopted generally by enterprises to meet the demands of multi-variety and small batch,and a
group scheduling method was used to balance the conflict relation between setup time decreasion and delivery satisfaction.Based on the analysis of group characteristics of  setup time
and processing batch size,the paper constructed a constraint satisfaction model for
 single machine group scheduling with the objective of minimizing weighted flow time
and tardiness,and introduced a mix solving method with a variable and value heuristic search,and look-ahead constraint propagation.Typical empirical analysis shows the proposed method is of  strong modeling capabilities and good adaptability.

Experimental Study on EHL Film Shape of  Elliptical Contacts

WANG Hua-Feng-1, GUO Feng-2, HU Ru-Fu-1, CHANG Wei-Yan-1

2013, 24(12):  1650-1654,1660. 

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Using a multi-beam interferometry,the experimental measurements of EHL film shape of elliptical contacts were carried out in an optical EHL test rig.The effects of the included angle between the entrainment direction and the minor axis of the elliptical contact zone,the entrainment velocity and the applied load on the film shapes
were observed.The obtained results were listed as follows.Smaller included angle gives rise to the thicker film and
the narrower contact zone as well as the sharper film shape at the inlet.Under lower entrainment velocity,the effect of the included angle or the applied load on the film thickness
is tiny.The included angle influences remarkably on the overall film thickness under
high speed and light load conditions.It is hard to establish hydrodynamic lubricating
film under heavy load and larger included angle conditions.

Closed-Form Method for Relative Pose Parameters between Chaser and Target Spacecraft Based on Quaternion

FENG Chun, TUN Hong-Chao, CHEN Bai, JIAO Bing

2013, 24(12):  1655-1660. 

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By using five non-coplanar reference points and monocular vision,a closed-form method for relative pose parameters of spacecraft was proposed.Firstly,the measurement system and the configuration setting of points were introduced.Secondly,the five feature optical points were made into two groups,three symmetry structural points as one group.Two equation sets of relative pose parameters were obtained by quaternion, then a closed-form solution was derived,and correct terms were added to obtain more accurate estimations for the pose parameters.In the end,the solution was validated by using mathematical simulation,and simulation results show that the solution can satisfy with the demands for the accuracy of relative parameters between spacecrafts and the real-time computation.

Effect of Wall Thickness on Microstructure of Ductile Iron Using Lost Foam Casting with Vibration

XIAO Ba-Chao, FAN Zi-Tian, ZONG Xiao-Meng, LONG Wei, LIU Xin-Wang

2013, 24(12):  1661-1665. 

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A ladder specimen of ductile iron was made by LFC with vibration.Graphite morphology and matrix microstructure were observed by means of optical microscope,and the numbers of spheroidal graphite were
analyzed by image analysis software.Effect of wall thickness on the graphite morphology and matrix microstructure was investigated.The results show that the numbers of spheroidal graphite first decrease and then increase,and the matrix microstructure first becomes larger and then gets refiner in the thicker specimens than in thin ones.In addition,the number of spheroidal graphite in the 60mm thickness specimen increases by 69.5% compared with the 30mm thickness specimen.The main reason of  the
graphite morphology and matrix microstructure changing is that the cooling rate
of the specimen is lower and active time of vibration on the solidification microstructure
is prolonged with increasing of wall thickness.Besides,vibration force increases the
role of  “viscous shear” on crystallization structure.

Research on Mechanism and Suppression Method  of Axial Climbing in Radial-axial Ring Rolling

BANG E-E-1, SONG E-Dong-2, CENG Xu-Dong-1, JIAN Dong-Sheng-1

2013, 24(12):  1665-1670. 

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Radial-axial ring rolling process is complex dynamic deformation process with multi-movement coupled effects,which easily causes variable instability phenomenon,one of that is the ring climb along the axial direction in radial-pass.Firstly,the mechanics theory was used to analyze the stress state of  the  ring in rolling process,so as to reveal the mechanical mechanism of climbing;then,a suppressive method was proposed based on optimizing the guide rollers' shape and distribution;lastly,the method was verified  by  FE simulation and experiment.The results provide scientific guidance for resolving the axial climbing in practical manufacture.

A New Method for Body Structure Analysis Based on Stress Recovery of Submodel

ZHOU Ze, LI Guang-Yao, CHENG Ai-Guo, DIAO Min

2013, 24(12):  1671-1675. 

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This paper applied the submodel technique on a mini-van for vehicle strength analysis. We introduced stress recovery approach to obtain accurate submodel boundary conditions, and the comparison between the results of submodel analysis and vehicle model analysis shows the credibility of the submodel approach.Then mesh refinement process was done on the submodel to guarantee the calculation converges over mesh size.Convergence analysis results show that with the ability of obtaining the accurate solution for critical stress area, the submodel technique ensures computational efficiency and improves the simulation accuracy,which shows
the high significance on engineering guidance of the submodel technique.

Robust Optimization of Automotive Door Structure Based on Taguchi  Method

XIE Hui-1, LIU Hang-1, HONG Jian-Cheng-2

2013, 24(12):  1676-1681. 

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An application of Taguchi parameter design in automotive door structural optimization was presented herein.The orthogonal experiment,the signal-to-noise ratio experiment,and analysis of variance were employed to investigate the sensitive controlling factors to the automotive door sag stiffness and the
fundamental frequency,by taking automotive door panels' thickness as controlling
factors,material properties and load as error factors.Then,the optimal combination of
controlling factors was proposed.The example results show that the optimal
design proposed by parameter design can improve the robustness of automotive door structural performance,and reduce the weight.

Research on Impacts  of Dynamic Friction Characteristics of Wet Cluch on Torque Transfer

ZHANG Fei-Tie, ZHOU Yun-Shan, CA Yuan-Chun, XUE Dian-Lun

2013, 24(12):  1682-1686. 

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In order to study the characteristics of wet clutch
engagement,the paper analyzed the mechanical structure of CVT(continuously variable transmission) wet clutch,
established the mechanical mathematical model of wet clutch and used  the model to
study influence of different slopes of the dynamic friction coefficient on torque transfer.
The results show that,for the friction coefficient with positive slope,the torque transfer
is convergent and for the friction coefficient with negative slope,the torque transfer is divergent.This paper presents a theoretical base for researching the transfer feature of wet clutch.

Service Oriented Product Modular Design Method and Its  Prospects

LI Gao-1, QI Guo-Ning-2, JI Yang-Jian-2, GU Xin-Jian-2

2013, 24(12):  1687-1695. 

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Providing “physical product and/or services” integrated solutions to customers becomes a trend,which is the new stage for service-oriented modular
design.The paper analyzed the status of service-oriented modular design firstly,
and differentiated the traditional physical products with the integrated product and services mode (generalized product).Then the modular design methods of generalized
product was summarized and presented.Finally,the possible research directions for service-oriented modular design were discussed,including personalized design,eco-design and smarter design.

Key Technologies and Development Trend of Bearingless Induction Motors

YANG Ze-Bin, SUN Xiao-Dong, SHU Huang-Qiu, LIU Xian-Xin

2013, 24(12):  1695-1703. 

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The bearingless induction motors combined the advantages of magnetic bearings and induction motors, so they can produce the radial suspension forces simultaneously  to support the rotor, and the electromagnetic torque to drive the load. Therefore,it showed great scientific research and application values in special fields, such as high-speed machine tools, compressors, turbo-molecular pumps,computer disk drives,etc.The operational principle of bearingless induction motors was introduced herein firstly.Then,the representative motor topology structure,mathematical model, and control strategy of the bearingless induction motors were overviewed.Finally,according to the current issues of the bearingless induction motor technology, several possible development trends of the bearingless induction motor technology were discussed, in order to show the way for studying the bearingless induction motor technology further.