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Table of Content

    10 May 2014, Volume 25 Issue 9
    Lateral Position Control of a Flexible Web with Periodic Lateral Disturbance in Winding  Process
    Xiong Tao, Xiong Youlun, Wang Yuhui
    2014, 25(9):  1137-1142. 
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    The lateral displacement of a web is one of the most common problems in roll-to-roll(R2R) systems, which results in positioning errors, telescoping in a wound roll, and degraded product quality. The roller eccentricity is the main periodic disturbance for the lateral position of the web in the winding process. A plug-in repetitive controller was presented to attenuate the lateral disturbance caused by the roller rotary eccentricity. The control scheme just added a repetitive control part in primary controller, with the benefits of following or attenuating a discretional periodic signals in high accuracy. The simulation of an offset pivot guide was carried out with a plug-in repetitive controller and a traditional PID controller. It is shown that the proposed control scheme performs well in the lateral periodic disturbance caused by roller eccentricity, and dramatically improves the system steady errors.

    Analysis of Mechanical Behavior for Double Helix Single Screw Pump Stator Lining
    Shi Changshuai, Yang Qiming, Zhu Xiaohua, Tong Hua
    2014, 25(9):  1143-1148,1152. 
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    In order to study the forced state and deformation regularity of an inner contour line of a double helix single screw pump stator lining, then analysing the internal pressure, pressure difference, material nonlinearity and Poisson's ratio of the rubber by FEM analysis software, the effects of the factors on stress and srain of a stator lining and deformation regularity of the inner contour line were analysed, and a displacement equation under uniformity internal pressure and maximum displacement formula under heterogeneous internal pressure of the inner contour line of a stator lining were fitted. The results show that the stress and strain of the stator lining vary periodically and the displacement is by sinusoidally varying of the stator lining inner contour line under uniform internal pressure, and displacement varying is linear relation as internal pressure varying. Under pressure difference, the maximum of stress and strain transfer to the location of pressure difference, and the deformation regularity is changed, moreover, the values and varying ranges of displacement increase together. A tiny change of Poisson's ratio of the rubber can cause great effect on the deformation of the stator lining. Therefore, the rubberizing and varying of Poisson's ratio must be payed close attention during production, so as to enhancing the mechanical property of rubber. The work herein establishes a theoretical foundation for the choice of interference fit and linetype optimization design, and it has significant purport in engineering for improving work efficiency and useful life of the double helix single screw pump.

    Research on Modal Analysis and Spectrum Analysis of Neutron Shielding Module for ITER
    Chen Ke, Xu Shucheng, Yin Lei
    2014, 25(9):  1149-1152. 
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    Single-point response spectrum analysis of neutron shielding module was done to check out structural design scheme under earthquake load. Modal analysis of neutrion shielding module of ITER vacuum vessel was built. By modal superposition with acceleration spectrum of ITER final location in France, security against earthquake load of this structure was analyzed. The results show the validity of this structural design of this neuton shielding of vacuum vessel.

    Research on Grinding Forces of Creep Feed Grinding Cemented Carbide Tool Helical Grooves
    Song Tiejun, Zhou Zhixiong, Li Wei, Ren Yinghui
    2014, 25(9):  1153-1158. 
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    The grinding forces of creep feed grinding cemented carbide tool helical groove were analyzed by grinding wheel discretization method that the grinding wheel was regarded as composion of different elementary discs. Based on the grinding forces and torques of creep feed grinding cemented carbide tool helical groove, a mathematical model of grinding force ratio was established to describe the blunting of the diamond grains. The accurate signals of the grinding forces and torques were achieved by setting up a measurement system. The grinding force ratio was analyzed based on the mathematical model and the experimental data. The results show that the grinding force ratio can be used for grinding process evaluation.

    Study on Critical Preload of Prestressed Composite Structure Hydraulic Press
    Dong Xiaochuan, Jin Miao
    2014, 25(9):  1158-1163. 
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    The prestressed composite structures are widely used in the body design of heavy hydraulic press. How to determine the appropriate preload is a crucial issue. A calculation model of critical preload of hydraulic press frame was built with consideration of preload, for the hydraulic forging presses, especially the hydraulic free forging presses, under eccentric loads, on the basis of existing analysis model. Taking the three-cylinder and double-spherical joints hydraulic press as an example, the formula of critical preload was derived. To verify the formula, the critical preloads of a body model were tested experimentally, which was designed and manufactured at a ratio of 1∶15 based on 120MN hydraulic press, under different loads and offsets (10mm and 30mm). The results show that critical preloads calculated by the method herein are consistent with experimental values.

    Research on Titanium Alloy TC4 Electrical-discharge Machining Characteristics Using Oil-in-water Emulsion
    Xue Rongyuan, Liu Zhidong, Wang Xiangzhi, Qiu Mingbo, Tian Zongjun
    2014, 25(9):  1164-1168. 
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    To solve the problems for TC4 EDM, such as lower machining efficiency in kerosene and bad surface quality in distilled water, the kerosene and emulsifier were added into distilled water and vibrated by ultrasound to form oil-in-water emulsion herein. To study the characteristics of three kind of dielectrics used in TC4 EDM, kerosene, oil-in-water emulsion and distilled water were used as working dielectrics to machine titanium alloy, they were compared in aspects of MRR, electrode wearing rate (EWR) and surface quality. Results show that: two times higher machining efficiency in oil-in-water emulsion can be obtained than in kerosene and the surface roughness is decreased 15%~20% than in distilled water. After machining in oil-in-water emulsion, there are less surface microcracks on the workpiece, and its surface smoothness is better than the others machined in kerosene and distilled water, but the EWR is higher.

    Research on New Fast Measurement Method and Identification of Rotation Axis Movement Errors for CNC Machine
    Lin Shuwen, Wu Chengting, Lin Qingfeng
    2014, 25(9):  1169-1174. 
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    An identification model of rotation axis basic geometric errors was derived based on the theory of homogeneous transformation, and then a new fast measurement method and identification of rotation axis basic geometric errors based on ball-bar were proposed herein. The measurement of ball-bar was adopted by one end of the ball-bar was fixed on the rotary table in three different positions respectively. By the linkage control the other end of the ball-bar in circular trajectory, the deviations of each position measurement point in the directions of X, Y and Z could be measured in each discrete position. And then the rotation axis six basic geometric errors could be identified according to the established identification model. As to guide the distribution of the measuring points and reduce the influence of measurement error, a method based on sensitivity analysis of the coefficient matrix was presented and the accuracy of error identification is improved.

    Pulse Electromagnetic Field-assisted Chemical Mechanical Polishing Utilizing Magnetic Composite Abrasives Slurry and Its Polishing Performance
    Huang Yishen, Zhao Bingshan, Huang Shuiquan, You Hongwu, Xu Xuefeng
    2014, 25(9):  1175-1179,1238. 
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    A polishing method assisted by an auxiliary pulse electromagnetic field was proposed, where the magnetic polymer microspheres/SiO2 composite abrasives were anchored on a smooth glass tool plate by the magnetic force, and the dependence between diameter of composite abrasives and morphology of tool plate was reduced. In polishing processes, the abrasives entered into the polishing area easily by mean of pulse electromagnetic force, and a high material removal rate was obtained. An electromagnet with contrapuntal structure was designed, and simulation calculations show that uniform distributions of magnetic flux density and electromagnetic force are achieved. Force analyses indicate that the electromagnetic force can help the magnetic polymer microspheres enter the polishing area from near-polishing area, and material is polished by magnetic composite abrasives in two-body abrasion wear mechanism. Owing to the pulse electromagnetic force, magnetic composite abrasives is deposited and entered into polishing area easily without the occurrence of magnetic abrasives aggregation. Experiments of polishing silica wafer, using a glass tool plate of Ra 1.1μm surface roughness and pulse electromagnetic field with a certain frequency and duty cycle, have shown the superior characteristics. The material removal rate is increased from 137nm/min to 288nm/min with the assistance of the electromagnetic field of 5Hz frequency and 50% duty cycle, and the surface roughness of wafer is decreased from Ra 405nm to Ra 0.641nm.

    Research on Anode Design of Jet-electrodeposition Based on COMSOL
    Wang Ying, Kang Min,
    2014, 25(9):  1180-1185. 
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    In order to shorten the preparation period of anode nozzle, a mathematical model of the liquid field in machining area was built according to liquid turbulent flow, and a mathematical model of secondary electrodeposition was built according to electrodeposition with moving geometry. The boundary conditions were chosen according to the parameters of the jet-electrodeposition experiments.Software, COMSOL Multiphysics was used to simulate the machining area. The influences of liquid field and electric field distribution on machining precision were analyzed, and the profile curves of cathode growth at different times were simulated. And then the nice solution of anode nozzle was determined. It is demonstrated that the bottom of an arc-shaped anode nozzle will be the better to machining. The simulation results are in agreement with that of the experiments.

    Three Dimensional Numerical Simulation of Fluid Flow and Heat Transfer in Tree-shaped Microchannels
    Xu Shanglong, Guo Zongkun, Qin Jie, Cai Qiyu, Hu Guangxin, Wang Weijie
    2014, 25(9):  1185-1188. 
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    The microstructures of several typical leaves were measured and analyzed to get the diameter, angle and diameter ratio for each levels of leaf vein. The CAD model and simulation of heat and flow in a two-layer dendritic microchannel network for chips cooling were conducted. The simulation results show that the temperature distribution is more uniform in the tree-like microchannel than that in the paralell microchannel. The temperature and pressure drop are lower in the tree-like microchannel with 7 level branches than that with 6 and 8 level branches.

    Improved Immune Genetic Algorithm for Mixed-model Scheduling Problem
    Tang Hongtao, Ding Binchu, Li Xiulin, Lu Jiansha
    2014, 25(9):  1189-1194,1201. 
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    A hybrid workshop scheduling mixed-model with the purpose of minimum makespan was proposed. Job shop scheduling problem and parallel assembly flow shop scheduling problem were both included in this model. To reduce the solving difficulty, an improved immune genetic algorithm mixed with the decomposition strategy was put forward. In this algorithm, the multi-agent negotiation mechanism and the simulated annealing algorithm were introduced. In the end, the validities of the model and algorithm were proved by the implement in an automobile shock absorber enterprise.

    Formalization Reasoning Method for Flexible Process Planning Network Generation Based on Polychromatic Sets
    Lü Shengping, Qiao Lihong
    2014, 25(9):  1195-1201. 
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    A formalization reasoning method for flexible process planning network generation based on polychromatic sets was proposed. The formalization reasoning mechanism included mainly four steps: building feature constraint relation matrix and the relation network of features; constructing feature clustering entity matrix and revising the relation network of features; establishing feature-machining method relation matrix and generating the sub-network of flexible process planning; constructing the operation-resource relation matrix. The instance of flexible process planning network generation for a gear shaft was given to illustrate the effectiveness of the proposed reasoning method.

    A Nodal Translational Tentative Packing Algorithm of Circular Tubes in Multi-pipe Intersecting Structures
    Huang Shiyou, Xu Lei, Luo Xun, Ren Qingchuan
    2014, 25(9):  1202-1207. 
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    The port section intersecting lines of circular tubes are always mutational and complicated space curves in multi-pipe intersecting structures. Aiming at solving the packing problem of circular tubes in multi-pipe intersecting structures, this paper introduced a nodal translational tentative packing algorithm after analyzing development drawing which was based on analytic geometry and the principle of numerical integration. It gave the best packing scheme by using multipoint subdivision which was independent variable and integral area of waste tubes in development drawing. The packing problem of circular tubes that have port section intersecting lines in arbitrary shape can be solved effectively. Through examples, it can be seen that the algorithm is universal and efficient.

    Reconfigurable Robot Modeling and Experiments Based on 5-axis Machining System for Complex Parts
    Xia Boxiong, Du Jun
    2014, 25(9):  1208-1213. 
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    The G-code was used for reconfigurable robot multi-axis machining systems for machining complex parts with freeform surfaces of light materials with lower tolerance. A five-axis vertical articulated robot for complex surface machining was considered as a specific configuration of the five-axis vertical milling machine (X, Y, Z, A, B) spindle-tilting type to have developed the prototype of robotic control system. This paper described the robot modeling approach in detail, involved solving of direct and inverse kinematics and analysis of the robot workspace for the cases of three-axis and five-axis machining. The programming, control and processing capacity of the prototype of developed robotic machining system was verified by the machining experiments of three work pieces of light materials.

    An Experimental Study of Tool Cutting Radius Size Effect in Micro Cutting Processes
    Zhao Meng, He Ning, Li Liang
    2014, 25(9):  1214-1218. 
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    A micro cutting experiment was carried out to study how much the cutting edge radius size effect influence the cutting force, surface quality and chip formation. It is finded out when depth of cut is much less than tool cutting edge radius, the cutting edge radius size effect has a significant influence on micro cutting process, which results in rapid growth of specific cutting energy, bad surface quality and difficulties on chip formation. The experimental conclusions show the minimum cutting parameters of micro cutting and can be used as a guide of micro cutting parameter selection.

    Reliability Assessment of Multi-stage Gears Transmission System of Wind Power Growth Gearbox Based on Dynamics
    Xu Fang, Zhou Zhigang, Li Yingchun, Qin Datong
    2014, 25(9):  1219-1224. 
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    Aiming at high failure rate problem of wind turbine gear transmission system in the varying wind speed conditions, a dynamics model of gear transmission system coupled with bearing of wind turbine was established on the basis of simulating real wind speed, and the external random wind load and internal excitations such as time-varying mesh stiffness of gear pair, time-varying stiffness of rolling bearing and integrated transmission errors were considered in the model. Numerical method was used to simulate the dynamics model, the dynamic meshing forces of each gear pair as well as dynamic bearing forces of each bearing were obtained, the utility coefficient of gear, the dynamic load coefficients of gears and bearing were calculated. Then, a reliability assessment model of wind turbine gear transmission system was established, the reliabilities of each part and the whole transmission system were obtained, and the reliability of wind turbine gear transmission system under random wind was comprehensively evaluated. The research results lay a foundation for reliability design and dynamic optimization of gear transmission system of wind turbines.

    Bolting and Go-around Performance Analysis of Carrier-based Aircraft
    Duan Pingping, Nie Hong, Wei Xiaohui
    2014, 25(9):  1225-1231. 
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     In view of the complexity and importance of a carrier-based aircraft's landing and recycling process, a systematic model during bolting, composed of six-degree-of-freedom mathematic model of the carrier-based aircraft, four-degree-of-freedom model of landing gears and six-degree-of-freedom mathematic model of carrier, was established in the MATLAB-simulink environment, damping function of landing gears and dynamic characteristics of tires being considered. Meanwhile, the air wake and ground effect were numerically simulated in the model. The bolting trajectory of aircraft was calculated via algorithm for variable step-size Runge-Kuta. The effects of carrier movements, air wake and ground effect on bolting performance of aircraft were illustrated in details. From the calculation results, three important conclusions are obtained: the rolling and yawing movements of carrier threaten the lateral bolting performance, and the lateral displacement of sliding is up to 5m; air wake antedates the touchdown and induces elevation of longitudinal bolting trajectory, and the height of aircraft while flying off the carrier is increased by about 14m when the deck wind is 23.1m/s(45kn); ground effect is not beneficial to bolting performance.

    Decomposition Coordination Method of Product Family Model with One Leader and Multi-followers Structure
    Chen Mo, Du Gang, Zhang Ruchuan
    2014, 25(9):  1232-1238. 
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    The existence of a class of product family design problems with leader-follower structure was demonstrated. A general formulation of product family model with one leader and multi-followers was established. Aiming at the coupling decision variable among multi-followers, a decomposition coordination method was given. Through adding deviation on the objective, the variables of multi-followers become independent. The relationship between the Pareto solution of original problem and the feasible solution of decomposition coordination problem was discussed. At last, the method was validated by the case study of universal motor family.

    Neural Network Adaptive Optimal Control Strategy of Servo Motor Driven Hydraulic System
    Ma Yu, Gu Lichen
    2014, 25(9):  1239-1243. 
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    In view of the high energy consumption and low response of the traditional hydraulic system, a permanent magnet synchronous motor driven constant pump hydraulic system was designed instead of common motor, which was easy to realize closed-loop feedback control. Because of the serious random interference, multi-variable, nonlinear, strong coupling, it was difficult to establish precise mathematical model of hydraulic system. General PID was difficult to meet high precision control requirements, in this respect a forward neural network PID controller based on PSO-BP hybrid optimization algorithms for adaptive control of hydraulic system was proposed to realize precise control of flow under complex conditions. The control parameters of PID controller were adjusted adaptively by neural network, the weights of neural network were optimized by the mixed learning methods. An optimized non-linear combined control rule of P, I, and D was built by the self-learning ability of neural network and to strengthen the ability of changes in working condition. Simulation and experimental results show that: the controller has fast tracking ability, small overshoot and strong robustness. A new method is provided for the high-precision flow control of hydraulic system.

    Analysis on Arresting Performance of Carrier-based Arresting Device
    Liu Gang, Nie Hong, Ren Zhiyong, Jia Jin, Ren Guoxian
    2014, 25(9):  1244-1249,1255. 
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    To obtain the performance and design method of carrier-based arresting device, the components and the function of carrier-based arresting device were analyzed. A dynamic model of carrier-based arresting device was established and the aircraft arresting force was deduced. A set of curves about constant runout control valve area with different aircraft masses were calculated under  the constant runout conditions, also the longitudinal dynamic performances of aircraft were obtained. The results show that different mass aircrafts can be stopped in the limited distance by changing the area of constant runout control valve of carrier-cased arresting device, the overload and arresting distance are satisfied with the requirements of American military standard.

    A New Type Cold Rotary Forging Method for Hypoid Gear and Its Numerical Simulation
    Dang Yugong, Deng Xiaozhong, Wang Bin, Gao Zhenshan
    2014, 25(9):  1250-1255. 
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    At present, the cold rotary forging technology of hypoid gears existed problems such as very complex die structure and bigger rotary forging force, therefor the authors put forward a new type cold rotary forging technology. The method simplified the die structure, adopted the local line contact continuous plastic forming. Based on the basic theory of rigid-plastic finite element(FE) method, a three-dimensional dynamic FE simulation model of the whole process of hypoid gear cold rotary forming was analyzed by means of a common three-dimensional finite element software Deform-3D V6.0. The distribution and variation laws of velocity field, contact zone and die stress were investigated. The results of this research reveal the deformation mechanism of cold rotary forging for hypoid gears.

    Study on Hot Deformation Behavior and Flow Stress Constitutive Model of 22MnB5 at High Temperature
    Cao Shufen, Zhang Liqiang, Guo Pengcheng, Li Luoxing
    2014, 25(9):  1256-1261. 
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    Hot tensile tests of 22MnB5 were carried out with Gleeble-1500 at the temperatures varying from 500℃ to 950℃ and at the strain rates of 0.01s-1, 0.1s-1, 1s-1 to study its hot deformation behavior at high temperature. Afterwards, microstructure analysis of the cross sections of specimens was conducted to clarify the relationship between microstructure and hot deformation of boron steel under different conditions. The results show that the mechanism of hot deformation of 22MnB5 belongs to dynamic recovery and that the flow stress decreases with the increase of temperature and with the reduction of strain rate. In addition, the influence of temperature is more obvious than it of strain rate. However, the flow stress at the temperature of 500℃ and at the strain rate of 0.01s-1 is higher and the result seems a little different to the above law. Finally, constitutive model was established to represent the behavior of hot deformation of boron steel at high temperature.

    Research on Simulation Method of Blasting Test of Airbag Based on Cold Gas
    Bai Zhonghao, Long Yao, Wang Yulong
    2014, 25(9):  1261-1267. 
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    Aiming at the fact that the blasting test of airbag is depended on real inflators, according to the test regulations of airbag, a method of compressing cold gas to replace the pyrotechnic inflators was used to develop a test device to simulate the blasting test of airbag. The deployment device used for airbag was designed, and the strength and gas tightness of this device was also analyzed by ANSYS. Meanwhile, the Fluent software was used to analyze the effect of the tank shape of the calibration device on the p-t curve. A measurement and control system was developed based on the virtual instrument. Finally, two group airbags with different types were used to simulate the blasting test, the test results demonstrate that this test device can inflate the airbag rapidly and accurately, and the effectiveness and accuracy of the method were also validated.

    Performance Simulation of Engine Supplementary Brake
    Gong Jinke, Yan Sheng, Huang Zhangwei, Jia Guohai
    2014, 25(9):  1268-1272. 
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    A mathematical model of the engine supplementary brake was set up through discussing the working processes of engine supplementary brake. According to reference parameters of the supplementary brake (including the exhaust valve lash, engine speed, exhaust back pressure, etc.), the engine supplementary brake was analyzed with univariate and multivariate conditions by the method of numerical simulations and experimental tests. The results show that the cylinder pressure increases with speed and the peak pressure phase is more near the top dead center(TDC) under the higher speed conditions. The brake torque increases with the engine speed increase. The de-compressure brake has a maximum brake torque while the engine brake has the minimum brake torque. When the engine speed is constant, the bleeding brake and the de-compressure brake have a corresponding optimal exhaust valve lash, respectively. The higher the speed is, the bigger the exhaust valve lash is. The higher the exhaust back pressure is, the more the brake torque is.

    Design of an Electromagnetic Drive Active Headrest
    Zhang Panpan, Yin Xiaoqin, Wang Mingxia, Zhu Xihang
    2014, 25(9):  1273-1277. 
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    An electromagnetic driving active headrest was designed, which combined mechanics and electricity to achieve the fast forward displacement of the headrest with the link mechanism. The displacement law of driving slider was designed and the control voltage of electromagnetic actuator was derived in order to make the headrest with good performance of movement and dynamics. The theoretical values of the key points in the voltage curve were obtained by using the energy conservation method in every time and displacement partition. The test values of voltage were obtained through experiments. Compared with the theoretical values, the change rule of them is the same.