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Table of Content

    25 November 2014, Volume 25 Issue 22
    Study on Tooth Surface Generation and Geometrical Characteristics of Novel Torus-involute Gears
    Cao Tao, Liu Lei
    2014, 25(22):  2983-2992. 
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    Novel torus-involute gears are unsensitive to installation errors and have a good meshing performance without tooth modification, which are easy to machine. According to the processing principles of torus-involute gears, the tooth surface equations of the working tooth surface, the fillet surface and the tooth root surface of the convex torus-involute gear and concave torus-involute gear were derived from the tooth surface equations of the virtul rack cutter. The complete and precise tooth surfaces of torus-involute gears were generated via three dimensional coordinates of points on the tooth surface in MATLAB and the solid models were established in Pro/E. Based on the mathematical model of tooth surface, the phenomena of tooth undercutting and tooth pointing of torus-involute gears were analyzed through numerical simulation. The limit curves of tooth undercutting, the beginning points of tooth pointing and the maximum tooth width of torus-involute gears were obtained. According to the generated tooth surface, the tooth contact analysis with installation errors were performed to demonstrate the advantages of insensitive to installation errors.

    Simple Modeling Method for Pipelines Characteristics of an Underwater Device's Hydraulic System
    Dong Chunfang, Feng Guohong, Meng Qingxin
    2014, 25(22):  2992-2996. 
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    For a hydraulic system with long pipelines of an underwater device, the system mathematical model with pipeline effect was established based on transmission pipeline dynamics. The pipeline impedance representation and its parameters were discussed. Referring to the mass-spring-damper model of pipeline, the original pipeline model was simplified by  applying frequency domain model reduction. The parameter calculation formulas of reduced model were obtained and the simulation analysis was done. It shows that the simplified model is very similar to the original one and convenient to  use in engineering applications.

    A New Type of Non-circular Gear Indexing Device
    Zheng Fangyan, Zhang Zhengyan, Chen Dingfang, Liu Youyuan
    2014, 25(22):  2997-3002. 
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    A new non-circular gear indexing device was designed combined with the principles of differential gear train, the non-circular gears and dividing device requirements. The mathematical model of the device was introduced. The transmission ratio of each gear was deduced in detail. On the basis of that, the design method of the non-circular gear was discussed. As an example, a set of design parameters, the 3D modeling and virtual simulation of the device were made. Finally, the device was manufactured, that verifies the feasibility of the device on the principle and design.

    Optimal Design of D-H Parameters of a 6R Robot for a Prescribed Workspace
    Gan Yi, Wang Junlei, Sun Fujia
    2014, 25(22):  3003-3007,3011. 
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    The related joints who affected the workspace of a 6R robot were analyzed and determined by using the analytical method. Then the workspace boundary curves of the 6R robot were acquired by using the graphic method, and a three-dimensional model of the workspace was established. In order to obtain a compact structure, based on a prescribed workspace, D-H parameters of the 6R robot were optimized by using the genetic algorithm, and the optimal solution was acquired. In the end, the optimal results were verified in the software of Pro/E.

    Chemical Mechanical Polishing of Soft-brittle CdZnTe Wafers Using a Developed Environment-friendly Solution
    Zhang Zhenyu, Song Yaxing, Xu, Chaoge
    2014, 25(22):  3008-3011. 
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    A strategy consisting of fixed-abrasive  lapping  and a developed environment-friendly solution was proposed for polishing cadmium zinc telluride(CdZnTe  or  CZT). This was to eliminate the disadvantages for conventional machining method including free abrasive lapping, polishing and chemical mechanical polishing on CZT wafers. Waterproof paper of alumina with mesh size of 3000 was employed as fixed-abrasive lapping pad. Lapping experiments were conducted at a pressure of 17kPa on CZT wafers. The rotation speeds for polishing plate and pad were as 80r/min respectively, and the duration was as 5min during lapping experiments. The developed environment-friendly solution consisted of peroxide, silica, and natural orange juice that was used for pH modulator. Chemical mechanical polishing was carried out at a pressure of 28kPa, rotation speeds of 60r/min for both of polishing pad and plate, and a duration of 30min. The experimental results show that ultra-smooth polished surfaces are achieved, where surface roughness Ra, root mean square(rms), and peak-to-valley(PV)  values are as 0.568nm, 0.724nm, and 6.061nm, respectively.

    Preliminary Exploration of Skid Steering of a Novel Wheeled Manned Lunar Rover
    Wang Chunyan, Duan Tingting, Zhao Wanzhong, Yu Leiyan, Lü Zewei
    2014, 25(22):  3012-3017. 
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    The steering system of manned lunar rover has a direct impact on its smoothness, path tracking and emergency obstacle avoidance capability. Herein, the skid-steer technology and manned lunar rover were integrated effectively. A new skid steer system of manned lunar rover was proposed, and the dynamics and kinematics modeling method were conducted. Based on the analyses of longitudinal driving characteristics, directional stability and steering characteristics of skid steering, an yaw angular velocity PID control method was proposed to achieve autonomous vehicle yaw rate tracking control. Simulation results show that the skid steer of manned lunar rover has a good pivot turn capability. In the steering process, it takes the steering agility into account at low speeds, and improves the vehicle's steering stability at high speeds effectively.

    Fitting Method of Tooth Profile Curve for Involute Cylindrical Gears Based on MLS
    Sun Yonghou, Xiao Wei, Huang Meifa, Hu Rukai
    2014, 25(22):  3017-3021. 
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    Aiming at the problem of low precision for fitting method of profile curve of involute gears, the MLS was used to fit tooth profile curve and was validated by an example about the calculation of pitch deviation. At the beginning, CMM was used to measure a gear and the measured data as well as the pitch deviation were exported after the test. And then, with the principle of MLS method and the measured data, the profile curve was obtained by MATLAB. At last, the MLS fitting method was used to fit  the profile curve. By contrasting with the fitting results of least square, MLS method used to fit profile curve can get higher precision and smaller error. The calculation results of tooth pitch deviation show that: both the individual circular pitch errors and the total cumulative pitch errors agree with the experimental ones, and the MLS  method has been proved to be accurate and efficient, which can provide a kind of beneficial reference for the calculation of tooth pitch deviation and fitting of tooth profile curves.

    Machining Stability and Process Parameters Planning for Helical Milling Operation
    Liu Changyi, Tang Zhi'an, Yang Sheng, Lu Yuandong
    2014, 25(22):  3022-3027,3065. 
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    Helical milling operations machining process parameters planning approach were proposed based on analytical time domain cutting forces models and time and frequency domain dynamics models of the operations. The cutting forces both on the side cutting edges and on the bottom cutting edges along the helical feed path were defined by considering the circumferential feed motion and the axial feed motion of the tool. The dual periodicity which was caused by the spindle rotation, as well as the period of the helical cutting fool feed was included. Both the critical axial cutting depth and the critical radial cutting depth were solved. The cutting force model and dynamics model allowed the planning of machining process parameters including axial cutting depth, radial cutting depth, circumferential feed rate, axial feed rate and spindle rotation velocity in the chatter free zone during helical milling. Experiments were also performed in order to verify the planned machining process parameters for helical milling. No chatter occurred during the experiments. The accuracy and precision of the machined surface, including surface roughness, roundness and cylindricity, are equivalent to the boring process.

    Concavity and Tooth Undercutting of High-order Deformed Eccentric Conjugate Non-circular Gears
    Chen Jianneng, Ye Jun, Zhao Huacheng, Xu Gaohuan, Wang Ying
    2014, 25(22):  3028-3033. 
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    A novel non-circular gear form named high-order deformed eccentric conjugate non-circular gears was proposed to meet the requirements of more asymmetric transmission ratio changing in a circle. And the pitch curve equations of high-order deformed eccentric conjugate non-circular gears were established. On the basis of the theory of differential geometry, the concavity distinguishing conditions referred to pitch curves of driving gear and driven gear were deduced. The relationship between the gear modulus and minimal radius of curvature in pitch curve was obtained without tooth undercutting in the process. The design and simulation software of high-order deformed eccentric conjugate non-circular gears was compiled based on VB, and was verified with the examples.

    Characterization and Optimization of Negative Pressure Relief Valve
    Zheng Xinhua, Xie Lili, Liu Lizhuo, Yang Liangpu
    2014, 25(22):  3033-3037. 
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    This paper introduced the functional components of cabin pressure regulating system CTY-xx. The structure and  working principles of NPRV were explained. The theory of plate was used to analyze the behavior of the diaphragm in NPRV, and it is conclused that the opening of the valve is proportional to the pressure difference. The calculation method of effective flow area was given and the needed conditions of acquiring maximum nominal flow area was deduced. In analyzing dynamic characterization of the valve, the requirements of system stability can not be met if only the external behavior is concerned.This paper took the material property of polymer into consideration in establishing dynamic equation of the diaphragm. On the basis of that, the requirements of system stability were analyzed and the ways to shorten response time were pointed out. The testing results show that the bigger the valve's radium, the quicker the relief process.

    Study on 5-Axis CNC System Cross-coupled Controller Based on Double NURBS Hybrid Parametric Interpolation  Algorithm
    Dong Bolin, Liu Yang, Wang Zhisen
    2014, 25(22):  3038-3044. 
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    Aiming at the demands of complex surface high speed and high precision CNC machining, the contour errors and the orientation errors in 5-axis system were analyzed and the real-time math models of them were set up, and arrived at the system tracking error real-time math model. A 5-axis cross-coupled controller based on the double NURBS hybrid parametric interpolation algorithm was proposed. Simulation results show the machining precision of parts in 5-axis systems is improved effectively.

    CAD Technique of Shoe Last Deformation Surface Reconstruction Based on Rotating Transformation
    Hu Xiaochun, Zhao Bao, Zhang Qingqing, Dong Liang
    2014, 25(22):  3044-3049. 
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    A surface reconstruction method of shoe last deformation was proposed and implemented to promote the rapidness, personalization and diversity of shoe last design. The shoe last toe spring, heel height and wedge angle were transformed into the required values of personalization design by rotating transformation based on the two transform sections of interaction selected processing; the homogenization processing was conducted to the transformed shoe last to realize the smooth transition of the shoe last surface in the two transformation sections; the waist region of the shoe last matched with the transformed shoe last was designed by the fine adjustment of the axle wire of the shoe last bottom waist region and mapping to the shoe last model. The proposed surface reconstruction process can realize the parameterized and visual interactive methods to carry on the CAD module of last design on MATLAB software platform, and the interface is simple and convenient to operation and easy to real-time editing. The reconstructed shoe last model was proved well keeping the original shoe last fit and surface fairing through the analyses of volume and Gauss curvature of the surface of the original and reconstructed shoe last.

    Calculation of Large Rigid Body Pose and Multi-axis Synchronous Coordinating Control
    Qu Wentai, Ying Beihua, Dong Fenglian
    2014, 25(22):  3050-3055. 
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    Calculation of large rigid body pose and its high precision control was studied herein. Aiming at the 6-DOF large rigid  body pose alignment system, a fast calculation approach to the pose and a high precision multi-axis coordinating control system was presented. Firstly, mathematic models of large rigid body pose calculation were established respectively on a global frame which was found on the basic platform and a body-fixed frame system which was found on the center of the large rigid body. By detecting the initial positions and the final positions of four marks on the large rigid body, the displacement increments of three coordinates of the four supports could be easily calculated. Then, a compensation of synchronization error integration technology was proposed for the large rigid body pose alignment system. By the technology, the precision and speed of large rigid pose alignment could be improved significantly. The simulation results show that the proposed approach is rapid and effective, the control algorithm has guiding significance for engineering applications of large rigid body pose alignment.

    Experimental Studies for High Speed Grinding of Titanium Alloy Ti6Al4V
    Tian Lin, Fu Yucan, Yang Lu, Zhao Jiayan
    2014, 25(22):  3056-3060. 
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    In order to search the efficiency way to grind the difficult to cut material titanium alloy, and to further improve the potentiality of high-speed grinding, the high speed grinding tests of titanium alloy Ti6Al4V were systematically conducted, the variation characteristics of the grinding forces, grinding specific energy and grinding temperature were analyzed when the undeformed chip thickness altered. The experimental results reveals that the characteristic curves of the grinding forces, grinding specific energy and grinding temperature are different under a variety of the maximum undeformed chips thickness agmax. It practically embodies that when the agmax is constant, the forces and specific energy decrease slightly while the grinding speed vs rises, whereas the grinding temperature increases, meanwhile the grinding force and specific energy for brazed CBN wheel is less than that for ceramic bond CBN wheel and electroplated CBN wheel. These phenomena indicate the brazed CBN grinding wheel is the best choice owing to regular distribution abrasives on its surface with adopting the reasonable agmax, it means that the grinding speed is increased in proportion to the increases of workpiece vw, thus it is benefit to improve the high speed grinding productivity of titanium alloy Ti6Al4V.

    Mathematical Modeling of Variable Cross-section Beam Bending in MEMS
    Sun Jianghong, Yi Yuanlin, Zhao Qiuling, Liu Xu
    2014, 25(22):  3061-3065. 
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    A variable cross-section beam was used to reduce stress concentration in MEMS structure. A mathematical model of the variable cross-section beam bending could provide reliable theoretical basis to MEMS device processing. As a prerequisite to increase the utilization of space and retain maximum angle and maximum deflection unchanged,the maximum angle dimension stiffness Kφ and the maximum deflection dimension stiffness KW expression were constructed individually. Compared with the dimension stiffness of the original design parameters, the relationship among the dimension stiffness, the beam length and the height of the end face was created clearly, then providing a theoretical support for the design of beam structures in MEMS.

    Assessment of Rolling Bearing Performance Degradation Using Gauss Mixture Model and Multi-domain Features
    Zhang Long, Huang Wenyi, Xiong Guoliang, Cao Qingsong
    2014, 25(22):  3066-3072. 
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    CBM can avoid the occurrence of insufficient and excessive repairing.For the purpose of quantitative identification of  bearing fault severity underlying CBM, a GMM based approach was formulated. The GMM was firstly trained by the multi-domain features including both time and frequency domain which were extracted from bearing fault-free tage. Subsequent feature vectors were then input  to the trained model to compare their similarity degrees to the feature vectors of normal conditions. Such similarity degree served as a fault severity index which  was  herein  termed MDLLP(multi-domain log likelihood probability). MDLLP had a upper limit of 1, which facilitated the determination of performance degradation levels in the field.Experimental results show that the proposed method and index are able to detect incipient bearing faults and can trend the fault progression well. It is implied that the selection of optimal feature subsets has a substantial impact on the effects of  the proposed MDLLP.

    A Calculation Method of Zwicker Time-varying Loudness
    Zhou Minggang, Dong Qifei, Liu Yang, Chen Yuan
    2014, 25(22):  3073-3076. 
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    According to the German standard DIN 45631/A1, the frequency domain and temporal masking effect were simulated on the basis of the model of Zwicker steady-state loudness, the algorithms of Zwicker time-varying loudness were designed and implemented based on MATLAB. A time constant was introduced to describe the dynamic behavior of loudness. The noise sample of a domestic car was chosen to calculate loudness during acceleration, the calculation results were compared with the calculation ones by B&K sound quality software. The comparison results show favorable consistency, thus the method of calculating loudness of the time-varying noise is validated.

    Damage Detection for a Plate Based on a Single-transmitter Multi-receiver PZT Array
    Tian Zhenhua, Xu Hong, Li Hongyuan, Chang Yuan
    2014, 25(22):  3077-3080,3087. 
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    Based on ultrasonic guided wave technique, the damage detection for plates was studied. The characteristics of Lamb wave propagation were discussed herein. With the help of finite element coupling field simulation, the wave propagation and wave interaction with crack damage of Lamb waves were simulated. From the simulation results, the affection of crack size on Lamb wave propagation was analyzed. In order to quantify the locations and sizes of the damages, a single-transmitter multi-receiver PZT array was employed. Combined with probability-based imaging method, the damage distribution of the plate could be obtained. The imaging results of this distribution can reflect the location and severity of the damage obviously.

    Dynamic Characteristics Analysis of Wheelhead Based on Bayesian OMA Approach
    Hu Yujia, Xu Linlin, Li Haolin
    2014, 25(22):  3081-3087. 
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    In order to study the wheelhead's intrinsic modes from natural environment and harmonic modes under working conditions, a modal parameter identification technology based on Bayesian theory and OMA-Bayesian OMA approach was adopted. It was applied to identify the wheelhead's modal property by ambient vibration tests using different setups. The dynamic characteristics obtained included the natural frequencies, mode shapes and damping ratios, which were compared with traditional experimental modal analysis results then to verify the feasible practical applications of Bayesian OMA approach. The estimation for the level of excitation,prediction error and signal-to-noise ratio also added to the approach's uniqueness. Furthermore, vibration tests were conducted for the wheelhead under operational situations. The contrast between identified results from natural environment and power spectral density(PSD) in actual working conditions helps to distinguish the wheelhead's intrinsic modes and harmonic modes caused by periodic excitation successfully.

    Dynamics Characteristics Analysis in Multi-cases of Connection Frame in Macro/micro Motion Platform
    Zhang Lufan, Long Zhili, Nian Longsheng, Fang Jiwen,
    2014, 25(22):  3088-3092,3108. 
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    In order to explore dynamics characteristics in multi-case of connection frame in macro/micro motion platform, a connection frame was investigated in multi-cases during motion process of the macro/micro motion platform. And then, static and dynamic analysis as well as calculation of the connection frame were studied in multi-cases. At last, some important conclusions were obtained. Stress and displacement distribution were disclosed, and the relevant change trends of the maximum static stress and displacement in multi-cases were investigated. At the same time, first six order natural frequencies and mode shapes were obtained. Vibration test results verify the validity of the simulation data by hammer method.

    Research on Tool Lay-out of Hydroforming Process with Multi-cavity Mould for Profiled Cross-section Components
    Lang Lihui, Zhang Fan, Cheng Pengzhi, Wang Tao
    2014, 25(22):  3093-3097. 
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    The multi-step hydroforming process of trailing arm which is one of the typical automotive chassis parts was optimized  by numerical simulation and experiments. In order to improve forming efficiency and quality consistency, a multi-cavity mould was used and the influences of tool lay-out on hydroforming process were studied. It is a reasonable tool lay-out that hydroforming tool has symmetrical distribution with two “C”  shapes compared to other ones. It can improve the stress condition of the tool and parts during hydroforming process and make the quality of the forming parts be guaranteed, as well as enhance the production efficiency.

    Effects of Process Parameters on FPE in Radial Forging Processes
    Luan Qiancong, Dong Xianghuai, Wu Yunjian
    2014, 25(22):  3098-3103. 
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    By projecting the hammer of the radial forging process to a unit cylindrical surface, constraint conditions should be fulfilled by the parameters: radial feed rate and the axial feed rate were obtained after analysis. The relationship among  the empirical triangle criterion and the processing parameters in radial forging process was derived, the effects of the parameters on FPE was analyzed. FEA software MSC.Marc/Mentat was used to simulate the radial FPE in radial forging process. Equivalent strain should be larger than the critical value and the axial compressive stress criterion were adopted in the simulation, and the simulation results were compared with the results of the empirical criterion of FPE prediction. The comparison shows that the empirical method is suitable for radial forging process design. Also, the calculation results of the process parameters are approximate accurate in estimating the FPE of radial forging process. 

    Fatigue Performance and Failure Analysis of Aluminum Resistance Spot Welds
    Shi Yandong, Guo Haiding
    2014, 25(22):  3104-3108. 
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    Fatigue performances of resistance spot welds of aluminum alloy 5754 and 6111-T4 were experimentally investigated. Fatigue data of various specimen geometries were generated. Fatigue failure modes of aluminum spot welds were studied and fatigue crack growth behaviors were explored. Fatigue results indicate that effects of base material on joint fatigue life are negligible. To some extent,fatigue life increases as cyclic load ratio decreases. Fatigue life of spot welded specimen highly depends on the nature of load types at spot weld. In product design and development phases, spot weld under pure peel load should be avoided properly.

    Sensitivity Analysis of Mounting Stiffness in Power-train Mounting System
    Liu Dabin, Jiang Shengqiang, Mao Jiang, Luo Yubao
    2014, 25(22):  3109-3113. 
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    For tackling the issue of severe vibration coupling in the power-train mounting system of a vehicle, a 6 DOF model for the mounting system was built. A sensitivity analysis for the principal stiffness parameters of mounting components was performed in the ADAMS/Insight. Taking a few sensitive parameters found by above analyses as design variables and combining with the theory of vibration decoupling, the goal of improving the decoupling rate and making the torque roll axis parallel with the elastic axis of power-train mounting system, optimization of mounting system parameters was conducted. The results show that the vibration isolation capability of optimized mounting system is enhanced, achieving obvious results. In addition, it is also indicated that reducing design  variables by sensitivity analysis on related parameters can improve the efficiency of optimization.

    Integrated Control of EPS and AFS to Reduce Steering Vibration Derived from Road Impact
    Zhou Bing, Fan Lu, Xu Meng, Hu Xiaolan
    2014, 25(22):  3114-3118. 
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    This paper proposed an integrated control strategy to reduce the steering vibration stemmed from road impact. Human-vehicle-road closed loop model was established considering the influences of driver's maneuver. The EPS subsystem was designed based on damping compensation control strategy and the AFS subsystem was built based on optimal control strategy. Simulation results demonstrate that the integrated system shows better overall capability to reduce the oscillation of steering torque, steering speed and yaw rate, compared with using EPS or AFS alone. Hence, the driving comfort, handling stability as well as driving safety are enhanced simultaneously.

    Research on Working Stress and Stiffness of Vehicle Suspension Coiled Spring
    Luo Zhenxing, Dong Mingming, Zeng Rongbing
    2014, 25(22):  3119-3123. 
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    According to the spiral line space curved beam theory, helical spring force analysis model was set up, and shear deformation, rotational inertia and helix angle were taken into account, so the formulas for calculating stiffness were obtained. By introduction to correction coefficient, accuracy of job stress and strength analysis was improved. Finally, FEA results for design and verification of suspension helical spring show that the above formulas are accurate.