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Table of Content

    10 March 2008, Volume 19 Issue 5
    Application of Solution of Unstressed Cable Length to Kinematics
    Study for a Wire Driven Parallel Mechanism
    Tang Aofei;Qiu Yuanying;Zhao Ze;Song Lei
    2008, 19(5):  0-605. 
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    The feed supporting system with passive control cables
    for a large radio telescope (LT) was introduced, and the direct and inverse kinematics models were done.The unstressed length of the cable was first solved based on the catenary finite element theory deduced by H.B.Jayaraman when the end tension force of a decline cable was given.The direct and inverse kinematics models were next solved using the solution of the unstressed length of the cable. Finally,the kinematics analysis of the cable-cabin system for LT500m was made by the direct and inverse kinematics models.The simulation result shows that the methods proposed for the direct and inverse models are stable and quickly convergent so that it lays the theoretic foundation for real time control of the kinematics of the large-pan wire driven parallel robot (WDPR) system.

    Stiffness Characteristics Research of Closed-chain Six-bar Mechanism with Flexible Joints Based on Influence Coefficient
    Zhao Yanzhi;Zhao Tieshi;Shi Liju
    2008, 19(5):  0-629. 
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    In order to investigate the stiffness characteristics of planar closed-chain six-bar mechanism with flexible joints, the paper solved Jacobian matrix and Hessian matrix of the closed-chain mechanism with the method of influence coefficient. Based on the principle of virtual work, the constraint equation of the mechanism was established, considering deformation of active and passive flexible joints, and the stiffness matrix was deduced. Combining Rayleigh quotient of the stiffness matrix, the paper defined the index K used to estimate the mechanism stiffness, and plotted spatial graph of the stiffness performance. In additional, the directional stiffness characteristics of the mechanism was discussed. So, a novel and general method are raised for analysing stiffness of closed-chain mechanism with flexible joints.

    Power-bond Graph Based Modeling of Thermodynamic and Mechanical Energy Domains
    Song Lijun;Hu Zheng;Yang Yongmin
    2008, 19(5):  0-605. 
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    Due to the physical coupling in thermodynamic and mechanical systems, a new modeling methodology was offered based on power-bond graph. Power-bond graph was ideally suitable for multiple energy domains. As a fact, there are three forms of energy exchange in thermodynamic system, such as mechanical work, heat transfer and mass flow. Accordingly, three power ports of thermal C-field were analyzed to find out the thermal bond graph model. Afterwards, the model of mechanical translation and rotation was also figured out similarly but comparatively easier. On principle of bond graph, the normal state equation was deduced, from the simulation model describing the whole working process. Based on the model and the structure parameters of an actual diesel engine, the sound simulation result is achieved, verifying the validity of the methodology.

    Experimental Research on Digging Resistance for Large Hydraulic Face-shovel
    Chen Jin;Li Weibo;Zhang Shiqiang;Zhong Chunjian
    2008, 19(5):  0-629. 
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    To study the digging resistance of a large hydraulic face-shovel, the working device’s attitude (angles) and working cylinders’ pressure of a 70t-level hydraulic face-shovel was tested synchronously. Moreover, software MATLAB was used in date processing to reduce errors and get general digging performance. Thereafter, by taking the working device’s angles and hydraulic oil cylinders’ thrusts as independent variables, and the tangential-normal digging resistances as unknowns, the mathematic model of the digging resistances was established based on the mechanism property of this type excavator. According to the experimental data and the mathematic model, a program code was made to calculate the tangential resistance, normal resistance and the total digging resistance for the actual digging process. The cutting angle influence on the digging resistance and the ratio of normal and tangential resistance during the actual digging process were studied. The testing and the calculating results provide a precious basic data base for the digging resistance research of the large hydraulic face-shovel and the approach used herein can also be used in the digging resistance research of the similar digging devices.

    Experimental Research on the Design and Performance of Single Screw Pump
    Sha Yi;Bai Xiaobang;Li Jinlei;Ma Xinhua;Wang Xiaoying
    2008, 19(5):  0-605. 
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    The single screw pump performance and the similarity theory application were studied. The pump performance variation principles were conducted by analyzing the influence of hydranlic structure coefficients κ1 and κ2, specific speed ns on performance curves. Computational formulae of screw diameter D, screw-pitch and eccentricity e were deduced. Based on the summary of excellent hydraulic models, numerical analyses were applied to fit out the formulae for coefficients κ1 and κ2, pump volume efficiency ηV,while the single screw design method was built. The example design cases prove that the design method proposed herein is of high accuracy and practice, and it can embody some measures to improve the screw pump performance.

    Parameter Optimization for Single-enveloping TI Worm Gearing Based on MAGA
    Duan Luqian;Sun Yuehai;Wang Shuren;Zhang Ce
    2008, 19(5):  0-629. 
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    Magnified Adaptive Genetic Algorithm (MAGA) was adopted to make a multiobjective optimum design for single-enveloping TI worm gearing. The helix angle, normal module and tooth width of worm gearing were selected as optimization variable. For better meshing performance, included angle between directions of relative velocity and contact line, and induced normal curvature were selected as optimization objects. The optimal results show that it is practicable and effective to apply MAGA to the parameter optimization for single-enveloping TI worm gearing. Compared with conventional optimum methods, the optimal result obtained from MAGA is more reasonable. 

    Research on a Micro-EDM System and Its Techniques
    Zhang Yong;Zhao Hang;Zhang Guangyu;Wang Zhenlong;Zhao Wansheng
    2008, 19(5):  0-589. 
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    A micro EDM system which can machine micro electrodes, micro holes and micro 3D structures was developed. On this micro EDM system, the processing parameters such as machining open voltage, machining capacitances, rotating speed of spindle or dielectrics that effected on machining efficiency as well as the relative electrode wear rate were presented. And the processing rules of micro EDM are obtained. The technology that applied rotation chamfered edge electrode to increase the machining efficiency of micro holes of high aspect ratio was also researched. Lots of machining experiments were done, and the micro electrode with minimum diameter 6μm and the micro hole with minimum diameter 10μm are machined. Complex micro 3D structures can be machined easily on this equipment by using a method of electrode wear compensation on-line. At last, micro 3D structures, a micro turbo wheel with 24 blades, 4mm in dimension of outer diameter and a micro 3D beam which is very popular in MEMS,are machined on this machine, which proves the wide applications of the micro EDM system.

    Research on On-line Probing Measure-point Layout for Blade Parts
    Li Bin;Sun Zhonglin;Peng Fangyu;Li Haizhou
    2008, 19(5):  0-629. 
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    The paper provided two methods of on-line probing measure-point layout for numerical control machining of blade parts. To fulfill blank matching well with the CAD model,according to the thought that proper measure-points can reflect the blades parts surface geometry information well,it offered an self-adapting way for the blade blank measure-point layout. And it also got the reference amounts of measure-point based on the tests. To meet the quality requirements,it provides a blade parts measure-point layout according to the standards and users’ requirements. 

    point amount

    Reliability Modling of Pipeline Considering Dependent Failure
    Hao Guangbo;Xie Liyang;He Xiuyun;Li Li
    2008, 19(5):  0-589. 
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    With continuous system like pipeline and wire cable reliability modeling as the background,a continuous system strength probability density function was educed by minimal order statistics,which was taken as a series system comprising of a number of virtual segments.Next,dependent failure reliability modeling of the series system was analyzed based on minimal sequence statistics model.Then,two influence factors of
    material strength of pipeline were discussed such as material inhomogeneity and material quality instability,the reliability model of continuous system like pipeline was established which could reflect the dependent failure among segments and was validated by Monte Carlo.Last,the principle of segment-partition was discussed and the failure probability of lone pipeline was computed, providing foundation for the reliability design and computation of pipeline or wire cables.

    Tool Wear Detection Based on PCNN
    Li Pengyang;Hao Chongyang;Zhu Shuangwu;Wang Yi
    2008, 19(5):  0-629. 
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    The pulse-couple neutral network(PCNN) in the bionics
    was introduced into the tool wear monitoring for the first time herein.
    According to gray intensity in the region of tool wear is higher than
    that of the tool body and background,using the spatial neighbor and similar cluster gray
    of pixel,the binary image of the tool wear was segmented,and the region of
    tool wear was detected.This algorithm and the validity of this method are proved
    by experimental results of the image segmentation of tool wear for the different stages in
    a turning process,and the tool wear can be effectively judged.

    Pulse Electroforming Process Based on the Use of Nano-La3O2
    Lei Weining;Zhu Di
    2008, 19(5):  0-589. 
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    The effects of electro-parameters on microstructure of electroforming nickel layers and its properties were studied by scanning electron microscopy (SEM) and X-ray diffraction (XRD), in the condition of high frequency pulse current and additive of the rare earth nano-La2O3.It has been found that the cathodic polarization of the electrodepositing process is increased due to occurrence of nano-La2O3 special adsorption on electrode surface, which can result in crystal refining and lighting of electroforming layer in high frequency pulse electrodeposition. The properties of electroforming layers such as the micro-hardness and wear resistance can be greatly improved specially at the on-time of 100 μs ,the off-time of 500 μs and average current densty of 3A/dm2.

    Numerical Simulation of Temperature Field in Large Size Hydrostatic Bearings
    Zhang Yanqin;Shao Junpeng;Ni Shiqian
    2008, 19(5):  0-629. 
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    To obtain more detailed and accurate temperature distribution inside large size hydrostatic bearing,a simulation method was present,combined with a given example of prevalent applied large size hydrostatic bearing in heavy equipment.
    It consisted of three dimensional numerical model and boundary condition of hydrostatic sliding way and hydrostatic sliding way inside 3-D flow.The model equations were solved by the Finite Volume Method and by selecting segregated solver of FLUENT according
    to CFD principle.The more accurate results of temperature rise distribution on periodic surface are obtained. The effect of partial important parameters on temperature distribution was analyzed. The results are helpful for the design of large size hydrostatic bearing and the reliability of workbench.

    Crankshaft Fatigue Test Adopting Oscillating Method
    Yu Zhenglin;Cao Guohua;Jiang Tao
    2008, 19(5):  0-589. 
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    Using oscillating method the endurance bending test of automotive engine was done. Discussing the principles of the method, the tester using the oscillating method was designed. The industrial control computer was used as main controller, the variable frequency speed adjusting technique was adopted, the rotation speed of motor can be changed to adjust the oscillating frequency and the experimental load, the experimental data were sampled by a high precision displacement sensor. The system has the function to memorize the experimental data automatically, to judge the fatigue flaw at the forepart, to stop the rotation of the motor and give an alarm. The method can be used in test of multiplicate crankshaft with different neck sizes.

    A New Model for Remote Measurement and Control System of Virtual Instrument
    Yao Jinbao;Tang Baoping;Zhao Jie
    2008, 19(5):  0-629. 
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    On the basis of research of the technology of virtual instrument and network, a B/S structure model of the remote measurement and control system of virtual instrument based on Applet and Servlet (AS-VIRMCS) was presented to implement remote measurement and control without network programming. Further, the UML"4+1" view model was used to design a set of system diagrams such as use-case diagram, logical diagram, concurrency diagram and deployment diagram, which discussed network interaction and information transmission in detail. The AS-VIRMCS system is characterized by no network programming and no reworking in the software of virtual instrument. Finally, it was proved that the system model can do well in remote measurement and control by an application.

    Failure Risk Based Determination of the Test Intervals for Condition Based Maintenance
    Zhang Yaohui;Guo Jinmao;Xu Zongchang;Tian Songbai
    2008, 19(5):  0-589. 
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    The concept of failure risk was put forward in allusion to the fact that the failure rate of mechanical equipment increases with working hours. The interval varying test model of condition based maintenance for new equipment was constructed based on equal failure risk. The model for maintained equipment was proposed also with age reduction factor to describe the effect of maintenance which made the failure rate decrease. And an example was analyzed. The approach suggested herein can be used to determine the test intervals of condition based maintenance for mechanical equipment with safety or mission failure consequence.

    Integrated Model of GBOM and BOP Based on Genetic Production Structure
    Xue Dongjuan;Liu Xiaobing;Bai Zhaoyang;Lü Qiang
    2008, 19(5):  0-629. 
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    In traditional MRPⅡ/ERP systems, some production activities such as material requirements, capacity requirements and production planning are out of joint because of the incomplete integration of the product structure data and the production process data. To solve this problem, a PPGBOMP model based on production plans was proposed. The static product structure data and dynamic production process data were united in PPGBOMP. GPS (generic production structure) was introduced to represent the material logical relationship between BOM(bill of material) and BOP(bill of process) in tracking component kitting process. GPS provides a genetic expression of variant products with different-level production structures, diversity parameters and values. Definition of decomposition rules and planning rules with the form of constrained parameter assigns all parameters to the lowest-level materials of product disassembly structure and simplifies the harmonization of different variables. The consistency between product variables and operation variables is guaranteed by the diversity parameters and their values.

    A Muscle Force Prediction Model for Ergonomics Simulation
    Wu Jianfeng;Sun Shouqian,;Xu Meng;Shi Yuanwu
    2008, 19(5):  0-589. 
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    A muscle force prediction model was proposed to overcome some limitations in computer-aided ergonomic simulation. Firstly, a modified muscle geometric model based on the anatomical technique was built using the Hill-type model. Secondly, the static and dynamic muscle force prediction models were discussed by the optimal control theory. And the optimal criterion was the minimum sum of total-muscle-force. At last, experimental results of the upper-limb muscles show the validity of these models.

    Experimental Analysis of Parametric Resonance for Supported Pipe Conveying Fluid
    Jin Jiduo;Liang Feng;Yang Xiaodong;Zhang Yufei
    2008, 19(5):  0-629. 
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    The parametric resonance of clamped-pinned pipes conveying fluid was investigated experimentally. The resonance with the first mode of order 1/2 was analyzed for some different values of mean flow velocity. Unstable regions of several pipes were obtained experimentally. The results show that the property of instability observed in the experiments is in good agreement qualitatively with that given by the theory.[JP2]The following phenomena are found from the experiments:for a given value of mean flow velocity, the first mode parametric resonance may occur under certain values of amplitude and frequency of pulsating fluid. When the amplitude of the pulsating fluid is less than a certain value, the resonance can not occur again;when the mean velocity of flow is decreased, the region of the parametric resonance moves towards the lefts side. This implies that as the value of mean flow velocity increases the parametric resonance may take place more easily with relatively lower frequency of the pulsating flow.
    Study on the Mechanism of Electro-discharge Truing of 
    Cast-iron-bonded Fine-grain Diamond Wheel
    Ren Chengzu;Gao Daxiao;Jin Xinmin
    2008, 19(5):  0-589. 
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    e influences of discharging states on electro-discharge truing process were analyzed. According to the variation of roundness during truing, the methods to improve truing precision and efficiency were described. The dielectrics in different truing processes were selected by analyzing their discharge characteristics. The results of pin electrode experiments show that the discharging area on the wheel surface is an arc, which determines the maximum discharging time (T). Based on the analysis of the pin electrode experiments the influence of pulse cycle on truing process was studied, and experiments prove that the roundness will increase when pulse cycle is longer than T. Discharge voltage, current and impulse duration have direct influence on material removal rate, but with the material removal rate rising the roundness is not always decreased. Finally, the influence of wheel speed on the roundness of wheel was analyzed, which shows that the truing efficiency and roundness can be improved with the wheel speed increasing when the speed value is within a certain range.0

    ]Wear Model of Ti-Al Alloys as Self-lubricating Materials at High-temperature
    Yang Liying,;Wang Yanjun;Liu Zuomin
    2008, 19(5):  0-629. 
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    Ti-48Al-2Nb-2Cr self-lubricating materials with addition of different weight contents of eutectic solid lubricant were fabricated by vacuum hot pressing technology. A wear mathematic model at high temperature was proposed and wear mechanism was analyzed. The self-lubricating materials with 10% solid lubricant exhibit higher wear properties. It is indicated that a glaze film on the wear surface of TANC composites by addition of BC solid lubricant are formed since fluoride particles are forced out of the reservoirs due to its high thermal expansion coefficient. Additions of (38%CaF2+62%BaF2)solid lubricant to Ti-Al matrix can greatly enhance the wear resistance and reduce the friction coefficient of the self-lubricating materials. 

    Study on the Machining Performance of Micro Abrasive Jet Machining
    Fan Jingming;Wang Chengyong;Wang Jun;Luo Guosheng
    2008, 19(5):  0-589. 
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    There are several parameters that have been claimed to have a significant effects on the micro abrasive jet machining(MAJM) process: air pressure, mass flow rate, nozzle distance to target material, machining time, impacting angle, nozzle shape and size, abrasive, etc.Based on the experimental study of MAJM for glass, the influences of these technical parameters on material erosion rate and the shape of the eroding dimple were investigated, and the basic technical laws of these effects on machining performance for MAJM were obtained. The results indicate that the nozzle distance to target material is the most prominent factor for material erosion rate and structure size of eroding dimple, there is an optimum distance to get maximum erosion rate and machining depth. The nozzle type and impacting angle are the key parameters for the dimple structure profile, directly changing the shape of machining dimples.
    Optimal Tolerance Design Based on the Quality Loss Function with Multi-correlated Characteristics
    Peng Heping, ;Jiang Xiangqian, ;Xu Zhengao;Liu Xiaojun
    2008, 19(5):  0-629. 
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    This paper presented a tolerance design method based on the quality loss function with multi-correlated characteristics. The discussions focused on the derivation of functional relationship between the quality loss of products with multi-correlated characteristics and dimension tolerances, and a comprehensive model for optimal tolerance design was established based on manufacturing cost-quality loss. The purpose of the model was to balance manufacturing cost and quality loss so that optimal tolerance design is achieved and quality improvement and product cost reduction is realized. An example involving optimal tolerance design for products with correlated characteristics was presented to demonstrate the effectiveness of the proposed method.

    A New Artificial Immunity Based Fuzzy Kernel Clustering Algorithm
    Jiang Quansheng,;Jia Minping;Hu Jianzhong;Xu Feiyun
    2008, 19(5):  0-589. 
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    Aiming at the flaws of the fuzzy c-means and kernel clustering
    algorithm which it is sensitive to the initialization and easy to fall into local optimum,
    a new algorithm of fuzzy kernel clustering based on artificial immunity (AI-FKCM)
    was proposed.The AI-FKCM can quickly obtain the global optimum by combining kernel based
    fuzzy clustering and artificial immune evolution algorithm, using for reference of mechanism of immunocyte clone and memory,affinity maturation in the natural immune system,
    and operating to antibody with clone,high frequency mutation and restraining
    in each generation.The experimental results with simulation data,IRIS data and compressor running data demonstrate the feasibility and effectiveness of the new algorithm.

    Optimization of 3D Laser-carving Path Based on Balanced Focusing Energy
    Fu Xingdou;Wang Pingjiang;Tang Xiaoqi;Chen Jihong
    2008, 19(5):  0-629. 
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    In laser carving system, the sequency of 3D points to be carved is relative to quality and efficiency.The paper brought forward a method to measure mutual covering level of 3D points in layers by projection and using some image processing methods, according to which the number of points in one part was enlarged. And it also supplies a flexible way to balance carving quality and efficiency.

    Study on the Bonding Properties and Mechanism of Copper-steel Dissimilar Metal Joint Deposited by Plasma Arc
    Li Guodong;Li Zhuoxin;Li Hongling;Zhang Li
    2008, 19(5):  0-589. 
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    The fine texture and microstructure of dissimilar metal joint was observed with microscope and shear strength of the joints was tested. The bonding mechanism was studied by mean of SEM.The optical macroscopic experimental results
    indicate that the interface of copper-steel joint deposited by plasma arc is smooth and there are not any welding defects such as gas porosity and crack.Therefore,a weld without penetration between dissimilar metal is achieved.The segregation and permeation of iron is not found in the copper adjacent to the joint interface.Hence, the phenomena of embitterment can not occur in the deposited joints that is 28μm away from the joint interface.Mechanical property experiments show that the shearing strength of weld is higher than that of deposited copper.The SEM tests indicate that diffusion from iron to copper is more obvious than that from copper to iron. In the transition region of deposited joint, the oversaturated α+ε solid solution are formed in room-temperature,which indicates
    the copper layer and the steel body are well joined metallurgy. 

    Characterizations of Thermal Damage by Magnetic Barkhausen Parameters
    Based on Fatigue Properties
    Wang Hong;Yi Xiaowei;Liu Xuefeng;Zhang Yue
    2008, 19(5):  0-629. 
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    To develop an effective and practical evaluation criterion for thermal damage in high strength steel that can correlate the resultant deterioration of the material properties, nondestructive magnetic Barkhausen noise (BN) evaluation and the rotating bending fatigue testing were carried on different laser-burnt specimens of high strength 4340M. The correlations have been established between the Barkhausen Noise Ratio (BNr , the ratio of the max BN value in the damaged region to the average BN value in the un-damaged region) and the reduction of fatigue properties. Analyses on the results show that the reduction factor of fatigue strength decreases linearly as the BNr (i.e. thermal damage degree) increases, suggesting that BNr is a valid and reliable engineering indicator for thermal damage and can be conveniently used to predict the reduction of fatigue strength caused by thermal damage in high strength steel. It is shown that the fatigue life of the thermally damaged specimens decreases sharply initially and then reaches a plateau with increasing BNr, especially in the region of lower stress amplitude levels. Relative to the fatigue results at high stress amplitude level, the thermal damage is also found to have more effect on the reduction of fatigue life at low stress amplitude level.

    Influence Factor Analysis for Impact Damage of Composite Laminates
    Cui Haipo;Wen Weidong
    2008, 19(5):  0-589. 
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    The 3D progressive damage theory and finite element method were used to analyze the impact process of composite laminates. The influence of impact tup, composite materials, and ply orientation angles on the impact damage of composite laminates were researched, which provides the guidance for the structural design resisted impact of composite laminates.

    Regenerative Braking Simulation Research for CVT Hybrid Electric Vehicle with ISG Based on Forward Modeling
    Qin Datong;Deng Tao;Yang Yang;Lin Zhihuang
    2008, 19(5):  0-629. 
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    The braking force distribution of CVT hybrid electric vehicle was analyzed, considering effects of the engine braking,the CVT speed ratio and clamping force control,battery quick charging characteristics and generating characteristic of motor with high efficiency during braking, a regenerative braking control strategy for hybrid electric vehicle was proposed. According to forward modeling idea, combined with numerical modeling and theoretical modeling, a forward simulation model for regenerative braking system of CVT hybrid electric vehicle was built. The models were simulated during four typical driving cycles such as EUDC,and the results show that the control strategy and the models are accurate and applicable.

    Research on Structure and Control Strategy of Parallel Hybrid System Applied to Hydraulic Excavator Using Capacitor as Accumulator
    Xiao Qing;Wang Qingfeng;Zhang Yanting
    2008, 19(5):  0-589. 
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    The structure of a parallel hybrid system, which was applied to hydraulic excavator and adopted a capacitor as the accumulator, was analyzed. Then, aimed at the working conditions of hydraulic excavator, a control strategy, which was used to optimize work points of the engine and SOC(state of charge) of the capacitor, was developed and researched in the built experimental system. The research results indicate that the distribution of engine work points is improved, the variation range of capacitor SOC is restrained and the response performance of the system is not affected when employing this control strategy.