Table of Content

25 February 2009, Volume 20 Issue 04

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On Action Mechanism of Improving Generating Motion Accuracy on Hobber with Zero Transmission

Huang Qiang，;Zhang Genbao１;Liu Run’ai

2009, 20(04):  0-382. 

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By analyzing the effect factors of generating motion precision on general CNC hobber and their action laws systematically,it is exposed that the master factors debasing the generating motion precision still come from the mechanical transmission.This result shows that the potential to improve the generating motion precision is not enough in this transmission frame.By comparision,the mechanism to improve generating motion precision on CNC hobber by zero transmission is uncovered.The comparision result shows that the hobber with zero-transmission has inborn dominance on generating motion precision.

Analytical Synthesis for Single Closed-loop and one DOF Over-constrained Mechanism 

Guo Sheng;Fang Yuefa;Fu Gaoge;Yue Cong

2009, 20(04):  0-503. 

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Based on the calculation formula of the degree of freedom(DOF) for spatial mechanisms and screw theory, the relationship among the number of constraints,kinematic pairs and DOF of single closed-loop over-constrained mechanism with one DOF was analyzed.Then,by using virtual principle and analytical method,the constraint force and coupling with independent constraint number:one,two and three, respectively as well as synthesis condition with arbitrary combination were studied.Given specific constraint combination,the condition of satisfying non-instantaneous motion was analyzed,the number and arrangement of kinematic pairs and spatial geometrical assembly condition of
pairs’axis layout were presented,additionally,typical mechanisms were illustrated.

Structural Design and Dynamic Characteristics Analysis for a Magneto-rheological Gun Recoil Shock Absorber under Impact Load

Hu Hongsheng,;Li Yancheng;Wang Jiong

2009, 20(04):  0-382. 

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A full-scale mock-up for MR shock absorber characterized with multistage slotted and smoothness disposal under impact load
was firstly established.Considering the dynamic of MR shock absorber under impact load,an inertia factor was introduced to Herschel-Bulkley model,which led to two revised models,named as Herschel-Bulkley-Inertia model.And a suit of real-time measuring and controlling simulation experimental platform including hardware and software for dynamic response of MR gun recoil shock absorber under impact load was developed.The parameters in Bingham-Inertia model and Herschel-Bulkley-Inertia model were identificated by
using the testing data.Further,the testing results prove that the designed MR gun recoil long-stroke shock absorber’s dynamic performance under impact load can be well controlled by changing the applied current,and the dynamic response models for MR gun recoil shock absorber under impact load are proved.

Monitoring and Analysis of High Speed Dry Machining Process 

Wang Xi;Xiao Yi;Dong Hai;Gong Tingkai 

2009, 20(04):  0-503. 

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The temperature,acoustic emission(AE) and vibration signals in the process of high speed dry milling aluminum alloy were gathered by a signal gathering system based on LabVIEW environment.The temperature signals were processed by the wavelet transform and show that temperature decreases as the machining feed increases.And then the AE and vibration signals were processed by wavelet package transform,A characteristic vector was constructed by the energy of different frequency segment，which was calculated by using the coefficient of wavelet package transform of the AE and vibration signals.The vector shows that the energy of low frequency segment is of the majority of the total energy,the low frequency segment is regarded as a stable factor in machining．

Self-measurement Temperature Sensors of Coated Cutting Tools

Zhang Shijun,;Liu Zhanqiang

2009, 20(04):  0-382. 

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In order to monitor the temperature of coated cutting tools in manufacturing industries,a special self-measurement temperature sensor (SMTS) was designed. The SMTS was fabricated with coating and its substrate of a coated cutting tool as a thermocouple. The SMTS has almost no influence on heat conduction within the coated cutting tool in machining processes. In order to calibrate the developed sensor, a special instrument was fabricated. The working principle of the SMTS was deduced. Then, it is highlighted that the two terminal outputs of the SMTS should be used two pieces of the different material conductive wire. Finally the cutting experiments were carried out under different cutting conditions using the SMTS. The results show that the SMTS can measure cutting temperature of test point at the rake face of the tool in real time, which has much benefit to manufacturing industries. 

System Design and Structure of Snake Robot Driven by Single Motor 

Liu Yang;Li Shiqi;Xie Tao;Guo Ju

2009, 20(04):  0-503. 

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This paper presented the reasons for low ratio between load and gravity of a robot.We designed a robot modular by getting some advantages from other robots with one directional driven and the uni-driven robot with flexible shaft as main shaft.There were two joints in one robot modular.Every joint was perpendicular to each other and was controlled by clutches of the joint. Subsequently,the simulation model was built to verify the mechanism.We studied kinematics of the robot by simulating the trajectory of the end-effector which aligned a line by MATLAB software.Lastly,the prototype of snake robot with 6DOFs was set out.

Research on Thermal Error Modeling,Measurement and Compensation for the Two Turntable 5-Axis NC Machine Tools

Wang Xiushan;Yang Jianguo;Yu Yongchang;Zou Caihong

2009, 20(04):  0-388. 

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The research identified the temperature fields of a two turntable 5-axis machine tool by placing temperature sensors,and measured the spindle thermal errors in three directions by displacement sensors.The correlation analysis theory was used
to find the correlation between temperature data and thermal error,and multiple variable regression linear method was used for establishing thermal error model.The experiments proved that there is averagely a 40% decreases in machine tool errors.

Mechanical Analysis and Experimental Research on Adjusting 
Technology for Cellular Position and Attitude in Microinjection

Tian Guizhong;Hou Liya;Zhang Weiyi

2009, 20(04):  0-503. 

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In microinjection,the experimental result is greatly affected by the position and attitude of injected cell.Nowadays,the low precision and efficiency of cell position and attitude is caused by manual manipulation.Based on coupling control of mechanical motion and liquid flow,an automatable adjusting technology for cell position and attitude was proposed.With end-actuator of micro-holding pipette,the cell position and attitude adjusting system was developed.On microscale,the manipulation mechanism of adjusting technology for cell position and attitude was analyzed with the control medium of cell
culture.In three orthogonal planes,the 3-D attitude parameter of cell was controlled by rotating or revolving motion.In the microinjection experiment of mouse oocyte,the principle of cell position and attitude adjusting technology was tested.The adjusting technology of cell position and attitude meets the demands of automatic positioning.6 degree-of-freedom precise cell positioning is achieved.

Feature Investigation of Acoustic Emission Signals 
under a Simulative Environment of Grinding Burn

Guo Li;Yin Shaohui;Li Bo;Chen Xun

2009, 20(04):  0-388. 

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In order to find the AE signals of grinding burn from the AE sources,this paper presented an investigation of the AE features of the thermal expansion of several materials,including in nickel-based alloys and ceramics,induced by laser irradiation,which was designed to simulate grinding thermal behavior.By using short time Fourier transforms,AE features at the grinding burn temperature can successfully be extracted without other mechanical interferential factors.The bigger the temperature change of workpiece is,the stronger the AE signals are.

Rapid Process Planning System of Radar Based on the Mixed Construction of B/S and C/S 

Liu Xiaojun;Yi Hong;Ni Zhonghua;Xu Hongxiang

2009, 20(04):  0-503. 

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Based on the analysis of the characteristics of the radar structure,production,process planning and process planning system’s requirements,a four-tier architecture of the radar rapid computer aided process planning system was constructed,which was based on the mixed construction of B/S and C/S.The key technologies such as workflow and hardware deployment were studied.The two main tools of the system─process file editor and process planning manager’s function structure were analyzed in detail,and the key technologies such as the classification code system and similarity calculation of the process planning based on group technology were investigated.The process file editor was designed based on C/S architecture using the smart document technology,the process planning manager,based on the B/S architecture,was designed by ASP.NET.Finally,the validity of the system was proved combined with the practice of the enterprises.

Numerical Simulation of Nanostructured Agglomerated Powder Melting Process during Plasma Spraying

Wang Dongsheng;Tian Zongjun;Shen Lida;Liu Zhidong;Huang Yinhui

2009, 20(04):  0-388. 

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To optimize the processing parameters of nanostructured coating prepared by plasma spraying using agglomerated powders, according to the heat transfer characteristics of plasma spraying, a computing model for analyzing the melting process of plasma spraying agglomerated ZrO2-7%Y2O3 powders was established by using the employment of ANSYS parametric design language. The effects of the diameter of powers and spray distance on melting process of powders were also investigated. The obtained experimental results show that the microstructure of the plasma sprayed coating exhibits a bimodal distribution which consists of a certain percentage of the fully molted and partially melted nanostructured particles under the optimum processing parameters.

Mould-base Configuration Method by Integration of CBR and RBR

Sun Yi;Shan Jihong;Sun Zhongwei;Mao Yalang

2009, 20(04):  0-503. 

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In order to associate the information of engineer technology and knowledge inherence component of product design,a new configuration method was proposed by integration of CBR and RBR knowledge system.It is more convenient for providing cases maintenance and operation.And it also fits to form configuration rules for mould-base design by the developed system which improves some functions,such as knowledge is properly decomposed and configured according to many component important attributes of mould design and mechanics
property.The similarity of structure and mechanics property was also combined,which developed the mould-base configuration precision and efficiency of mould-base design and manufacture.A prototype system was put forward to configurate the mould-base on Web,which implemented the method that typical rules and cases studied in detail is made for the intelligent mould-base configuration to prove the correctness and effectiveness.Finally an effective mould-base configuration scheme was mentioned.

Research on the Equipment Fault Diagnosis on the Basis of Decision Level Information Fusion

Rao Hong;Fu Mingfu;Xie Mingxiang;Yang Guotai

2009, 20(04):  0-388. 

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Directing to the low precision of single fault diagnosis method,a decision-level information fusion diagnosis system model was proposed,in which,the method based on the BP neural network and the method based on synthetically relational analysis were applied to the fault diagnosis firstly,and then the Dempster-Shafer evidence theory was utilized to partial fusions in diagnostic results,which were acquired in different test-points at the same time.At last,the decision fusion was applied to different partial fusions and got the finally diagnostic result.The sauction fan fault diagnosis example shows the validity of the dicision-level fusion fault diagnosis model.

Blind Identification of Rotors’ Mixed Vibration Signals Based on Negative Entropy Arithmetic

Li Shunming;Lei Yanbin

2009, 20(04):  0-503. 

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The basic conception of blind source separation was introduced and the research of blind source separation technique based on negative entropy was
dealed with.The simulation was carried through successfully after the presentation of fast fixed-point calculation algorithms.It
is the first research on the separation of rotors’ vibration signals that include several mixed vibration sources.The rotors’ complex vibration signals were separated successfully.It is discovered that the independence characteristics of signals in time domain is not clear,but the satisfactory separated results can be obtained in frequency domain.It provides a new method for analysis of the complex vibration signals and fault diagnosis.

Research on Composite Fault Diagnosis Method Based on the Second Generation Wavelet

Cui Lingli;Gao Lixin;Yin Haichen;Xu Yonggang

2009, 20(04):  0-388. 

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Aiming at the composite/complex fault of the rotor failure and weak roller bearing fault,a fault diagnosis method,the second generation wavelet was proposed to separate the coupling features of composite fault and to extract the fault feature of the roller bearings.Firstly original signals were decomposed and reconstructed by using the second generation wavelet.Then the high-frequency modulated signals from the decomposition and restruction of original signal were analyzed by envelop demodulation based on the empirical mode decomposition(EMD),by which the modulated fault feature was extracted.Non-modulation low-frequency rotor feature was extracted by using FFT to the low-frequency signals from the decomposition and restruction of original signals.Research results of simulation signals, experimental signals and engineering signals indicate that the method can extract the fault feature of scathing roll bearings early.

Dynamics Analysis for Aircraft Arresting Based on Absorbing Aircraft Kinetic Energy 

Liu Gang;Nie Hong

2009, 20(04):  0-503. 

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Since importance of research on aircraft arrestment,arresting system dynamics performance was studied.A dynamics model of arresting system was built based on absorbing aircraft kinetic energy,considering the aircraft thrust.The relationship between aircraft arresting force and arresting cable force was analyzed;also the aircraft stop conditions were given.Initial aircraft arresting force was expressed by polynomial with aircraft displacement,and the mathematic functions of symmetrical arresting force were built via the parameter analysis in this theoretical model.The aircraft asymmetrical arresting force regularities were shown,and asymmetrical arresting force was derived.The results indicate that the aircraft can be arrested in a certain distance,and the models satisfy with aircraft overload and the arresting system capability;the abrupt change and peak of initial arresting cable force are solved in stimulations.

Fault Diagnosis for Rotor System Based on Volterra Series

Tang Hao; Qu Liangsheng;Wen Guangrui

2009, 20(04):  0-388. 

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Research on Performance of a New Electrohydraulic Vibration Exciter

Xu Zibin,;Ruan Jian

2009, 20(04):  0-503. 

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A scheme of electrohydraulic vibration exciter using a 2D valve to control a hydraulic actuator was proposed to enhance the working frequency to a large scale.In the 2D valve,the rotary and sliding motions were independently exploited to control the frequency and the magnitude of the vibration respectively.The frequency of vibration exciter was determined by the rotary speed and the number of grooves distributed on a spool land.The theoretical analysis and test were carried out under the conditions that the elastic force constituted the main part of the load.When the linear opening of the valve reaches or exceeds a critical point,there is a phenomenon of system pressure saturation in one of the cylinder chambers,at this time,during the two processes of system import increasing and decreasing linearly,the corresponding piston displacements is obviously different and weakens as the linear opening is reduced. 

Research on Personalized Form Design Based on Product Brand
Characteristics Family

Yang Ying;Zhang Yanhe, 

2009, 20(04):  0-382. 

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As for difficulty of applying brand characteristics to personalized product form design,personalized form design method(PFDM) based on product brand characteristics family(PBCF) was proposed.Firstly,the optimal match between product form characteristics and personalized image was obtained by regression tree method.Secondly,product form prototypes of different brands were fabricated by cluster analysis,and identifying intensity of product form characteristics was obtained by two cognitive experiments.Finally,personalized form schemes which satisfied the user’s emotional requirements were achieved,and similarity model was used to examine whether the schemes was coincidence with the expected brand characteristics or not.Series mobile phones of Nokia 6,Nokia N and Motorola W were taken as examples,and the results show that PFDM based on PBCF is reasonable and effective.

Actuating Characteristics of Pneumatic Muscle with Shape Memory Alloy Fiber Shell

Wang Binrui;Zhou Weiyi;Xu Hong 

2009, 20(04):  0-503. 

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Intelligent pneumatic muscle(IPM) with shape memory alloy(SMA) fiber shell was proposed.Mechanism and characteristics test bed were designed and described.The actuator force model was presented.Contraction ratio of SMA fiber was used in characteristics study.Static actuating characteristics computing expressions were derived including contraction ratio,contraction force per section,stiffness and stiffness density
variation.Simulations of characteristics were done and comparatively analyzed using MATLAB.The results demonstrate IPM has greater bias angle,contraction force and flexible stiffness variation.The main advance is that the characteristics of IPM can be adjusted by SMA deform, more similar to human biological muscle than common pneumatic muscle.
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Effects of Slider’s Surface Shape on Particle Flow Lubrication Characteristics
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Wang Wei;Liu Xiaojun;Hu Zhaowen;Liu Kun

2009, 20(04):  0-382. 

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A non-fluidized particle flow lubrication model was constructed based on discrete element method(DEM).Considering the variation of slider’s position and speed,the macro characteristics,including the load carrying profile and the friction coefficient,were investigated with different surface shapes of slider.At the same time, taking particle and contact point as object,the micro characteristics were studied,which included the average contact force,body energy,contact friction energy,particle kinetic energy of particle flow lubrication.The results show that the interfacial particles flow have both solid-alike and liquid-alike feature.The load carrying capacity and friction coefficient of incline slider are better than others.Rayleigh slider has the highest load carrying capacity and friction coefficient. 

Influence Factor Analysis of Warpage and Optimization of Process Parameters
in Plastic Injection Molding of Thin-wall Plastic Parts Based on Taguchi Optimization Method

Wang Guilong;Zhao Guoqun;Li Huiping;Guan Yanjin

2009, 20(04):  0-503. 

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The optimization method of Taguchi experimental design was used to optimize the processing parameters in order to minimize the warpage of the front panel of large LCD TV.Considering the injection processing parameters such as melt temperature,mold temperature,packing pressure,packing time,injection time,cooling time,a series of CAE simulation experiments were proceeded to exploit the warpage.The signal to noise ratio S/N was utilized to find out the optimum factor levels and the relative significance of each processing parameters on warpage was also acquired based on the standard ANOVA.Confirmation analysis test with the optimal levels of the processing parameters was also carried out.

FEM Analyses on Forming Mechanics of Inclusion Defects Inner Heavy Backup-Roll Forging

Huang Huagui;Du Fengshan;Zhang Fang

2009, 20(04):  0-382. 

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By analyzing the species and deformation characteristics of inclusions inner bulk ingot,the non-linear finite element model for forging process of ingot with central spherical plastic and hard inclusions was setup respectively to study the inclusion defects inner heavy Cr5 forged-steel backup-roll.Numerical simulation results show that the spherical plastic inclusion is forged to ellipsoid,plat and flake,deforms compatibly with
ingot.Based on the metal flow law,stress and strain distribution around the hard inclusion,the forming mechanics of inclusion crack was discussed，and a physical simulation experiment was carried out to verify the presented conclusions.The influence law of tool width ratio and angle of V-shaped anvil on inclusion defects was also presented herein.

Research on the Modification Coefficient Calculation of 
Conical Involute Planetary Gear with Few Tooth Difference

Wang Guangjian;Chu Zhigang

2009, 20(04):  0-503. 

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Aiming to the modification coefficient design and calculation difficulties and complexity of few-tooth-difference planetary transmission made up of
conical involute gear,whose interference possibility of the planetary gear pair and modification coefficient varied along the gear axis,a new universal method was proposed.Under the condition of expected contact ratio and tooth profile interference checking point,the minimum of angle of engagement in the middle of the gear was calculated by Newton’s iterative
method and the other modification coefficient of both sides of the gear can be determined.A smaller engagement angle is achieved with the calculation method under the two limited conditions of contact ratio and tooth profile interference.

Numerical Simulation on Precision Forging of Spiral Bevel Gears

Luo Shanming,;Fang Yuan

2009, 20(04):  0-382. 

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A precision forging technology, closed die forging and divided flow,of spiral bevel gears was developed based on the divided flow method.3D rigid-plastic FEM was used to simulate the forging process of the closed die forging and divided flow and the conventional closed die forging respectively.Some parameters, such as load of forging,stress,strain and temperature were compared for the two forging technologies.Results indicate that the closed die forging and divided flow technology has many advantages,such as small load,small stress and well-proportioned temperature,compared with the conventional closed die forging.

Numerical Analysis of Fatigue Damage in TiN Coatings

Zhao Hua;Zhu Yongzhan

2009, 20(04):  0-503. 

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The damage evolution was defined on the basis of the fracture criterion of energy release rate in damage mechanics.While a loaded body was sliding cyclically on the surface of TiN coating/substrate system,the plastic accumulation and fatigue damage of the system were simulated numerically.The equivalent plastic strain accumulation and fatigue damage on the interface are mainly contributed by the cyclic shear stress,which is a key factor to cause the contact fatigue fail of coating/substrate system.The external loads,frictional coefficient and coating thickness all have some obvious influence on the fatigue life of coating/substrate system.

Study on Styling Image of Vehicle Based on Form Feature Lines

Hu Weifeng;Zhao Jianghong;Zhao Danhua

2009, 20(04):  0-382. 

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The conception of form feature was introduced and the main form feature line E1 was selected as the research object in terms of styling image.Using the kansei engineering method and statistical method, the sensitive kansei image adjective (SKIA) of E1 was obtained. Then the quantitative relationship between SKIA and E1 was established. According to the relationship, the most befitting value of E1 was found, which could improve the success rate of automobile form design. Through one automobile form design case, the method was proved to be rational and feasible.

Design Optimization on Lightweight of Full 
Vehicle Based on Multi-objective Genetic Algorithm

Zhang Yong;Li Guangyao;Wang Jianhua

2009, 20(04):  0-503. 

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Sampling data of thickness and material of automobile’s body front key absorbing energy parts were obtained by the D-optimal experimental design
method.Meantime，in order to improve computing efficiency，high accuracy meta-model that can substitute the front impact process was introduced to optimize design of automobile lightweight,then,the meta-model was optimized by using the multi-objective genetic algorithm.As a result，thickness and material of automobile’s body front key absorbing energy parts achieve reasonable configuration,meanwhile，automobile’s weight and B pillar’s acceleration achieve optimization as far as possible.It lightens the weight of full vehicle to meet the requirements of regulation CMVDR294.