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    10 April 2009, Volume 20 Issue 07
    Dynamics Analysis of a 3-RRS Flexible Parallel Manipulator
    Liu Shanzeng,;Yu Yueqing;Si Guoning;Liu Qingbo;Yang Jianxin
    2009, 20(07):  0-762. 
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    The primary goal of this research is for dynamics analysis of a 3-RRS spatial parallel manipulator with flexible links. Firstly, a new model of spatial flexible beam element was proposed. Then, the dynamics equations of all serial sub-chains of the parallel manipulator were derived based on the finite element theory, kineto-elastodynamics (KED) analysis method and Lagrange equations. The dynamics model of the complete system was obtained through the applications of constraint conditions of the legs and the movable platform. Furthermore, Newmark numerical method was used to solve the dynamics equations. Finally, the dynamics responses of the movable platform were analyzed through a numerical simulation. The results can provide necessary information for dynamics performance analysis, dynamics simulation and control of the 3-RRS flexible parallel mechanism.

    Class Retrieval and Matching Model of Multi-hierarchy Case Based on Subspace Method
    Zhong Shisheng;Wang Tichun;Wang Wei
    2009, 20(07):  0-881. 
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    According to the structure of multi-hierarchy case, the subspace of multi-hierarchy case was presented and a subspace method was proposed for multi-hierarchy case retrieval, and an algorithm of multi-hierarchy case matching was presented based on grey relational analysis. Based on these, the class retrieval and matching model of multi-hierarchy case was put forward. The model can help designers search out the suited multi-hierarchy case classes for design problems quickly and accurately only by saving one eigenvector for every case class of each case space and calculating the subordinate degree of the two eigenvectors.By the corresponding case matching algorithm, the most similar case can be achieved from the suited multi-hierarchy case classes.Finally, an example of large-scale hydraulic scheme design was provided to validate and prove its efficiency and feasibility.

    Wear Mechanism of Sialon Ceramic Inserts in Turning of Inconel 718
    Song Xinyu;Zhao Jun;Jiang Junling
    2009, 20(07):  0-762. 
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    Sialon ceramic tool was used in turning of Inconel 718. The effects of cutting speed and feed rate on tool wear, surface roughness, and cutting forces were tested and analyzed at different cutting speeds and different feed rates. The modes and mechanism of tool wear of Sialon ceramic insert were analyzed. Tool life was given out in different conditions. Results show that the dominant wear patterns are rake face wear, flank wear, micro-chipping,delamination,notch wear, and breakage. The main wear mechanism is from adhesion, diffusion and abrasive. High temperature and high pressure play important roles in the cutting tool wear in high-speed turning of Inconel 718.

    Demodulation Analysis of Sliding Kurtosis Algorithm and Its Applications
    Yang Fuchun;Zhou Xiaojun;Yang Xianyong
    2009, 20(07):  0-881. 
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    A new demodulation method was proposed based on the local non-Gaussian characteristics of modulation signals. Using this method, a new kurtosis series was obtained firstly by computing the sliding local kurtosis of the original signals, then, FFT of the kurtosis series was done to demodulate the modulation information and carrier wave information. The analysis results of the simulation signals and the bearing and gear fault signals by the proposed method illustrate that the new method has good demodulation ability. 

    Research on Similitude Theory and Method for Complex System 
    with Multi-energy Domains Based on Bond Graph
    Wang Ailun;Liu Yun
    2009, 20(07):  0-762. 
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    The basic requirements for the similarity of these systems were advanced. The similarity analysis of bond graph was presented. The concepts of functional similarity and structural similarity for each hierarchy of the system were explored and the similarity requirements for the two different similarity categories of each hierarchy were derived by utilization of analysis of hierarchy based on the perspective of system theory. Thus, the similitude theory and method which can be applied to instruct the similarity research on complex system with multi-energy domains was established. Finally, the new method proposed herein was utilized in the similarity analysis of a temper mill system which is a typical complex system with multi-energy domains.

    Numerical Simulation of Three-dimensional Flow Field of Cathode of 
    NC-Electrochemical Machining in Machining Integral Impeller
    Wu Jianmin;Xu Jiawen 
    2009, 20(07):  0-881. 
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    In order to design the flow field of cathode for machining integral impeller in the NC-electrochemical machining (NC-ECM), a three-dimensional physical model of the flow passage was constructed according to the fluid flow’s movement characteristics,then three-dimensional flow field was simulated by the usage of the Reynolds time-averaged Navier-Stokes equations and the standard k-ε turbulence numerical model when the turbulence state in electrochemical machining had been determined. Pressure contours and velocity vectors on machined surface were showed when steady state was obtained in electrochemical machining. Improvement method was given according to numerical simulation results. Comparing the simulation results with the experimental ones, it is indicated that guiding the design of the cathode by computational fluid dynamics (CFD) simulation is accurate and practicable. 

    Inverse Dynamics Analysis of Parallel Mechanism of Hybrid Turning-milling Machine Tool
    Chen Chun,;Huang Yumei;Han Xuzhao
    2009, 20(07):  0-762. 
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    A closed inverse dynamics model of 2-DOF parallel mechanism of hybrid VC80 machine tool was established by Lagrange method and its correctness was verified based on ADAMS software. The required driving force of parallel mechanism under the condition of the given cutting path was calculated and analyzed.The results indicate that the moving platform and the rods’ gravity of the parallel mechanism of hybrid machine tool need the largest components of driving force under the condition of movable platform moving uniform, the cutting force and the inertial force require less, the joint driving force is affected by different velocity of the moving platform slightly.

    A Method for Calculating Dependency Degree between Coupled Tasks in Product Development
    Zhao Han;Wu Zhaoyun;Song Hui;Tai Lijun
    2009, 20(07):  0-881. 
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    In view of the disadvantages of calculating the dependency degree between coupled tasks in product development, the essential relation between changeability and sensibility (measure index of information dependency) was investigated deeply. The concepts of information correlation group and correlative degree were proposed. The correlative degree was measured by the methods of pair-wise comparison technique of FAHP(fuzzy analytic hierarchy process) and group decision making. The changeability matrix and sensibility matrix were constructed by the concept of correlative degree. Combined the index weight function, the computational method of information dependency was presented. The improved tearing rule and tearing algorithm flow were proposed. Finally, an applied case was given to show the efficiency and practicability of the improved tearing algorithm.

    Stiffness Analysis of Hollow Cylindrical Roller Bearings
    Li Weijian;Pan Cunyun;Wang Rongji
    2009, 20(07):  0-762. 
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    The paper at first studied the elastic deformation relationship between each roller of the hollow cylindrical roller bearing; and the equilibrium equation between the load of the individual rollers and external load was presented by static analysis; then according to the method of valid elastic modulus and Palmgren formula, the calculation formula between load and elastic deformation was determined. Through solving the three equations, the load distribution of hollow cylindrical roller bearings was calculated. Based on the values of load distribution, the stiffness formula of hollow cylindrical roller bearings had been deduced. The paper deeply analyzed the effects of hollow ratio of roller, external load, rotating speed and roller number on stiffness. The results show that the stiffness of hollow cylindrical roller bearings is minishing with the increasing of hollow ratio; it becomes bigger when the roller number grows; and as to external load and rotating speed, it reflects different rules according to different hollow ratio.

    Research on the Method of Profile Modification by Circular Curve for Involute Straight Bevel Gear
    Hua Lin;Huang Hailang;Han Xinghui;Feng Wei
    2009, 20(07):  0-881. 
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    The 3D precise geometrical model of a straight bevel gear was established by using UG with the sphere involutes. Tooth profile modification by circular curve was developed for involute bevel gear, and the method of how to determine the maximal profile modification quantum, the center of the circular curve and correlated parameter was given. The precise finite element model was obtained in ANSYS. An analysis was carried out on the results of non-linear contact FEA and simulation of the gear. The simulate data demonstrate that the method of profile modification is reasonable and the amplitude of the transmission error fluctuation and the maximal contact stress of the profile modification gear are reduced efficiently. The research results provide theoretical foundation for bevel gear modification by circular curve.

    Research on Micro-surface Formation Mechanism of Ultrasonic Elliptical Vibration Cutting
    Li Xun;Zhang Deyuan
    2009, 20(07):  0-762. 
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    Based on analysis of cutting process and 3D cutting model of the elliptical vibration cutting (EVC), the paper presents that the micro-surface formation mechanism of EVC is formed by the regular feed marks in feed direction and vibration ripples in cutting direction. The height of feed mark is affected by tool parameters, the shape and feed rate. The height of vibration ripple is determined by amplitude, frequency and speed coefficient, and influenced by tool rounded cutting edge radius. At the same time, the interval between vibration ripples is strictly proportional to the speed factor. With natural diamond and PCD tools for copper EVC experiments, the results of the experiments show that the above analyses are correct.

    Post-buckling Calculation and Structure Sensitivity Analysis of 
    Panels Subjected to Axial Compression Loads
    Sun Weimin;Tong Mingbo;Dong Dengke;Li Xinxiang
    2009, 20(07):  0-881. 
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    The nonlinear post-buckling loading process of 11 kinds of curved stiffened panels under axial compression loads was simulated by using the finite element (FE) method.The failure load and failure mode from FE results were obtained and agreed very well with the experimental results.Based on the FE results,the experimental design was applied for these panels and the dimensions sensitivity was computed by using the square response surface model.It is found that the thickness of the stringers has a larger effect,about 44.2% in total,on the critical damage load.Finally,response surface polynomial of the panel is given out to provide the basis for better design.

    New Measuring Method of Large Size Measurement Based on 
    Close Range Photogrammetry and 3D Optical Measurement
    Zhang Dehai;Liang Jin;Tang Zhengzong;Guo Cheng
    2009, 20(07):  0-762. 
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    To meet the requirements of accurate and convenient 3D measurement for some large parts,a new industrial optical measuring method was put forward, which was based on digital close-range industrial photogrammetry and 3D optical points dense cloud measurement.Based on photogrammetry theory , digital close-range industrial photogrammetry software named by XJTUDP software had been exploitured,it mought calculate un-coded points and coded-points fixed on the surface of large parts,it took a solid basement for the fusion of much pieces point cloud. On the basis of computer two-eye vision technology and heterodyne multiple frequency technology, 3D dense point cloud optical measurement software named by XJTUOM software had been developed,3D data of the object surface mought be acquired precisely by means of this way, According to the whole marked points come from XJTUDP,every pieces of point cloud mought be assembled automatically. Experimental studies show that the developed system possesses good accuracy,it can identify the fine structure on a large part,it is also portable and convenient for field measurement.

    Unconstrained Registration Algorithm for Multiple View 3D Scanned Data
    Cheng Xiaosheng;Cui Haihua;Liao Wenhe;Dai Ning
    2009, 20(07):  0-881. 
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    two-stage algorithm for registering 3D scans obtained from multi-view of an object was described. First step, two similar point clouds was selected from overlap regional. According to the principle of space coordinates transform, a new N-edge algorithm was used for pre-registration and acquire the transform matrix parameters of pre-registration. Then, the improved ICP(iterative closest point) algorithm was used to registration accurately for the initial positional sampling point clouds. This second step integrated the merits of traditional iterative closest point distance function, set multi-level thresholds for the termination of iterative and resample the corresponding point level by level. The two-stage technique has advantages in terms of accuracy, efficiency and global minimum convergence. Experiments show that this two-stage algorithm has the advantage of perfect performance and high precision, it is suitable for special 3D measurement registration field without coded points and no mechanical turntable.

    Research on Fault Diagnosis Methods for Centrifugal Pump Based 
    on Autoregressive and Hidden Markov Model
    Zhou Yunlong;Liu Changxin;Zhao Peng;Sun Bin;Hong Wenpeng
    2009, 20(07):  0-762. 
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    According to the characteristics of fault vibration signal, a new method for centrifugal pump based on autoregressive (AR) spectrum and hidden Markov model (HMM) was produced. The AR spectrum is not restricted by length of data, and AR spectrum parameters are sensitive for law of condition change. AR transformation was made to vibration signals, and then AR spectrum coefficients were got, which can be utilized as feature vectors of running state of centrifugal pump to train in each HMM, fault classification can be made according to the maximum-likelihood probability. The method was tested with the experimental data collected from the 2BA-6A centrifugal pump experimental system and the results demonstrate that the model is effective to classify classical faults.

    Research on Information Systems Based on Green Manufacturing 
    and Its Key Technologies for Automotive Manufacturing Enterprises
    Wang Yongjing;Liu Fei;Wang Qifeng,
    2009, 20(07):  0-881. 
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    How to construct the information system framework to support GM is vitally important to the automotive manufacturing enterprises. The paper proposed a five-layered information system framework model based on product life cycle engineering and its operation pattern. Two key technologies——data collection technology based on RFID and integration technology based on semantic Web services were then researched. The research fruits have been applied in a domestic automotive manufacturer and the feedback is encouraging.

    Design of Missile Inner-wall Grinding Robot and Its Trajectory Planning
    Sun Yilan;Liu Hongyi;Wang Pin,;Luo Zhong
    2009, 20(07):  0-762. 
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    Aiming at the grinding particularity of a class of missile inner-wall heat insulating layer with rotation ellipsoid structure, a four-axis simultaneous motion inner-wall grinding robot was developed. Moreover, referring to the pre-interpolation S-shape acceleration /deceleration and smooth transfer in CNC, the grinding robot trajectory planning was carried on. The trajectory planning was able to avoid impact, overshoot and oscillation in the start and stop processes of robot basic. And through the analysis of parametric relationship, the constraints of S-shape acceleration/deceleration were presented to simplify the solution. Moreover, the equal arc length time-sharing interpolation algorithm was applied to transform the displacement planned by S-shape acceleration/deceleration in every control time into corresponding coordinate of rotating ellipsoid grinding point. The simulation results prove the inner-wall grinding robot’s trajectory planning with high precision, speed and smoothness. All of these provide the necessary precondition for accuracy grinding of missile inner-wall grinding.

    Disk Low Cycle Fatigue Life Prediction Based on Multiaxial Fatigue Model
    Qian Wenxue;Yin Xiaowei;You Meiyan;He Xuehong;Xie Liyang
    2009, 20(07):  0-881. 
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    Alone with the increase of thrust weight ratio, low cycle fatigue failure is becoming a main failure mode of aeroengine compressor disk. There exist stress concentrations at the mortises of disk, and the local stress of every mortise is multiaxial stress. All the components of the local stresses are quite large. It is necessary to think about the influence of multiaxial stress to fatigue life.The multiaxial fatigue model was used to predict multiaxial low cycle fatigue life of disk. Also actual engineering instance was done with this model. The computational results show that it well consistent with the results of real disk test, and can satisfy the applications of practical engineering.

    Fatigue Crack Growth Rate of Hydraulic Turbine Blade Using Acoustic Emission Technique
    Wang Xianghong;Zhu Changming;Mao Hanling;Huang Zhenfeng 
    2009, 20(07):  0-762. 
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    The fatigue crack growth rate of hydraulic turbine blades was studied using acoustic emission (AE) technique in the laboratory. Through monitoring the crack growth process of the blade material in three point bending fatigue tests, the following results are obtained: the stress intensity factor (SIF) range of crack transited from the region with middle crack grown rate to the region with high crack grown rate is about 50MPa•m1/2; the amplitude of crack AE signals is mainly concentrated on 68~73dB; and the correlation of the energy and duration of events can qualitatively describe the fatigue state of blades. At the same time, the correlations among the AE count rate, energy rate, crack growth rate and SIF are obtained as well. The results provide reference for security evaluation and lifetime prediction of hydraulic runner using AE technique.

    A Condition-based Opportunistic Maintenance Strategies for 
    Multi-unit Series and Parallel System Based on Markov Chain
    Liu Fanmao,;Zhu Haiping;Shao Xinyu;Rao Yunqing;Gao Guibin
    2009, 20(07):  0-881. 
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    A new condition-based opportunistic maintenance strategies was presented for multi-unit series and parallel system. Under this policy, degradation model of equipment were modeled using continuous -time Markov chain and the deterioration process of equipment was divided three condition: new, minimal deterioration ,severe deterioration. With a consideration of maintenance economical relation of equipment, maintenance decisions were given based on deterioration states of the equipment. A eM-Plant model of cylinder production line was given on the background of car engine plant equipment maintenance optimization problem. The Monte Carlo simulation model of the equipment maintenance policy based on eM-Plant was also given in detail. By a numerical example,the average maintenance cost of cylinder production line in car engine plant in finite time zone was presented and best decision variants were given under this policy.

    Research on the Influence of Particle’s Friction Coefficient on Particles Flow Lubrication
    Wang Wei;Liu Kun;Jiao Minghua;Liu Xiaojun
    2009, 20(07):  0-762. 
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    Based on discontinuous mechanics, the non-fluidized particles flow lubrication model in tilting pad tribopairs was proposed by the discrete element method. The influence of particle’s friction coefficient was investigated mathematically. The results indicate that the peak of load profile and friction force profile are located in the entrance of tilting pad under particles flow lubrication which is different from fluid lubrication. Particles with lower friction coefficient can decrease the friction coefficient and increase the load capacity of tribosystem, which provides helpful guidance to engineering applications. The study of the micro characteristics that include the average contact force, body energy, contact friction energy and particle kinetic energy were carried out at the same time, which revealed the micro characteristics of particles flow lubrication. 

    An Off-chip Actuated Tensile Test Device for Microscale Mechanical Testing
    Zhang Duanqin;Chu Jinkui;Hong Zhiwu;Wang Liding
    2009, 20(07):  0-881. 
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    An off-chip actuated tensile test device was developed for the mechanical properties characterization of micromechanical structures. A load cell with a 0.25mN-precision level and a displacement sensor with 0.1μm-precision level were equipped. Elastic coefficient of the tensile tester was calibrated with force and displacement sensors in situ, and the deformation of gauge section was obtained using two-serial spring model. To improve precision and repeatability of the measurement, a simple alignment and gripping mechanism was presented using concave-convex slides to align specimens in axial and rosin-ethanol solution to conglutinate. The tensile tester is capable of measuring elastic modulus and fracture strength of specimens. The elastic modulus of single crystal silicon in 〈110〉 is 167±5GPa resulting from the testing results and the measurement errors were analyzed.

    Research on Mechanism of Metal Foil Forming Under Laser Driven Flyer
    Liu Huixia;Yang Kun;Wang Xiao;Wang Yun;Li Baochun;Gao Chuanyu;Zhou Ming
    2009, 20(07):  0-762. 
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    The mechanism of metal foil forming under laser driven flyer loading was analyzed herein.Combined with speed model for laser driven flyer and strain rate calculation formula under high speed impact, the forming strain rate under laser driven flyer loading were calculated and the results reached 106~107/s.The speed range of flyer loading was obtained according to high speed impact dynamics theory and provided a basis for selecting the laser parameters in forming. The forming characteristics under high pressure and high strain rate from the aspects were discussed including temperature rise, phase transition and dislocation density.The laser driven flyer forming technology can improve the formability of metal foil in theory.Forming experiments were designed and accomplished,10μm aluminum foil forming under laser driven flyer loading was achieved.

    Multi-directional Precision Forging for Casing
    Deng Lei;Xia Jucheng;Wang Xinyun;Hu Guoan
    2009, 20(07):  0-881. 
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    Based on the part structure and the characteristics of 7A04 aluminum alloy, multi-directional precision forging method was employed to increase material utilization ratio, efficiency and die life of casing manufactured by isothermal forming technology. The prompted method included roll forging baiting, multi-directional preforming and multi-directional final forming. Die with separable female die was designed. Thermal-force coupled finite element numerical simulation was carried out to get forming information. One stage multi-directional precision forging and two stages multi-directional precision forging were carried out. The experimental results indicate that one stage multi-directional precision forging technology can not obtain forgings meeting the specification; two stages multi-directional precision forging technology can obtain high-quality forgings, increase material utilization ratio to 85%, increase efficiency and die life significantly; the material flows steadily and fills the die cavity well during two stages multi-directional precision forging.

    Road Friction Coefficient Estimation Algorithm Based on Tire Force Observer
    Yang Cai;Li Liang;Song Jian;Li Hongzhi
    2009, 20(07):  0-762. 
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    A road friction coefficient estimation algorithm for dynamic stability control system was developed. Tire force was observed using tire force observer: the estimated brake wheel cylinder pressure was used to calculate brake force; the road force was calculated from wheel dynamics equation; vertical load of tire, the partition of used road friction coefficient and the slip ratio were calculated. All of them were used for road friction estimation and the verification experiment was done. Experimental results show that this algorithm can accurately estimate tire road friction coefficient and can be used for dynamic stability control system.

    Co-simulation of ABS for Vehicles under Turning Braking Based on ADAMS and Simlink
    Xu Zhongming;Yu Feng;Zhang Zhifei;Su Zhoucheng;He Yansong
    2009, 20(07):  0-881. 
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    Vehicle turning braking is a dangerous working condition. Vehicle dynamics model was established in ADAMS first, and simulation under turning braking without control was done, The results show that the vehicle obvious instability and swerve phenomenon was occurred. So a fuzzy ABS control system based on the slip rate was established under fuzzy control method in MATLAB/Simlink,combined with established vehicle dynamics model in ADAMS, co-simulation model was established in ADAMS and MATLAB/Simlink for turning braking. The results show that vehicle stability is greatly enhanced with fuzzy ABS control system.