Table of Content

10 November 2008, Volume 19 Issue 21

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Experimental Study on Ultra-Precision Polishing by Nanoparticle Colloid Jet Machining

Song Xiaozong;Zhang Yong;Zhang Feihu;Luan Dianrong

2008, 19(21):  0-2524. 

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Studied the micro structure of work surface atoms, the high surface energy and intense adsorption of SiO2 nanoparticle.For producing ultra-precision surface, a nanoparticle colloid jet machining system was designed and manufactured where the reversible polymerize and decompose reaction was utilized to remove surface atoms. We employed the system to polish a K9 glass sample, some recent experiments prove that it is possible to fabricate ultra-precision in nanoparticle colloid jet machining. The microroughness of the work surface processed by nanoparticle colloid jet machining is under 1nm Ra.

Experimental Research on Super-smooth Polishing Process of Typical Silicon Carbide Materials

Kang Nianhui;Li Shengyi;Zheng Ziwen;Dai Yifan

2008, 19(21):  0-2645. 

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Super-smooth polishing experiments were carried out herein to study the polishing mechanisms and polishability of three types of silicon carbide materials: CVD SiC (chemical vapor deposition silicon carbide), HP SiC(hot-pressed silicon carbide) and RB SiC(reaction-bonded silicon carbide). A surface roughness of better than 2nm Rq (0.71mm×0.53mm) was achieved by analyzing the characteristic of each material and selecting processing parameters for each material. The experimental results indicate that during the lapping process, three types of silicon carbide materials are all removed by brittle fracture, and there exist surface cracks and pits caused by materials being pulled out on the surfaces. During the polishing process, CVD SiC is removed mostly by plastic scratches, thus the dominant factor of the surface roughness is the depth of the scratch on the polished surface; HP SiC is removed by plastic scratch and grains being pulled out at the same time, and the dominant factors of the surface roughness are the sizes of the SiC particles and the micropores between the particles; RB SiC is removed mostly by plastic scratches, and the dominant factor of the surface roughness is the height difference between the three components of RB SiC because of their different material removal rates.

Preparation of MoS₂/Zr Composite Coated Tool and Its Cutting Performance

Zhao Jinlong;Deng Jianxin;Yan Pei

2008, 19(21):  0-2524. 

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Medium-frequency magnetron sputtered coupled with multi-arc ion plated MoS₂/Zr coatings were deposited on M2 high speed steel (HSS) tools. The thickness, micro-hardness and coating-substrate adhesion strength of the composite coatings were studied. Surface morphologies of the as-deposited coatings as well as wear surface features after dry machining tests were investigated by scanning electron microscopy. The experimental results show that deposition of the MoS₂/Zr composite coatings onto M2 HSS twist drills causes significant enhancement in cutting performance. Coated tools exhibit improved flank wear resistance compared with that of M2 uncoated tools. The wear mechanism of the flank face and cheisel edge of the MoS₂/Zr coated tools is mainly delamination of the coating, and mild adhesion and abrasive wear.

Effects of Various Parameters on Material Removal Rate and the 
Footprint in Abrasive Jet Polishing Process

Li Zhaoze;Li Shengyi;Dai Yifan;Peng Xiaoqiang

2008, 19(21):  0-2645. 

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This paper firstly introduced the principles of abrasive jet polishing. Then some key influence parameters of jet polishing technology, such as incidence angle, jet speed, incidence distance, abrasive concentration and processing time were investigated based on experiments. The relationships among various parameters and polishing efficiency and the footprint in polishing region were analyzed. Optimized relation curve of every parameter was obtained. Based on these, a plane K9 optical sample was polished. The polishing rate is about 30nm/min, and the roughness of this polishing region is less than 2.5nm. The results lay an experimental foundation for the further research of abrasive jet polishing.

Experimental Investigation of Influence Factors for Thickness of Ground White Layer

Huang Xiangming;Zhou Zhixiong;Xia Qilong;Yang Jun

2008, 19(21):  0-2524. 

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Based on the tests of grinding GCr15 hardened bearing steel, the influences of grinding parameters such as wheel speed, workpiece speed, grinding depth and cooling condition on the thickness of white layer were studied. The experiments indicate rapid heating, rapid quenching and plastic flow result in white layers in grinding process. White layer depth varies with the different combinations of grinding parameters. Grinding depth has the most important impact on white layer depth, wheel speed follows, and workpiece speed at the last. The depth of white layer increases with the increase of grinding depth and wheel speed. The coolant, the reductions of wheel speed and grinding depth all tend to reduce the white layer formation and its thickness.And a statistical model is proposed for the prediction of the thickness of white layer in grinding.

A High Efficient Ultra-precision Synergistic Finishing Process for Optical Materials

Yin Shaohui;Ohmori Hitoshi;Lin Weimin;Uehara Yoshihiro;Chen Fengjun;Zhu Kejun

2008, 19(21):  0-2645. 

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An ultra-precision synergistic finishing process integrated to magneto-rheological finishing (MRF) and electrolytic in-process dressing (ELID) grinding was proposed for shortening total finishing time and improving finishing quality. A lot of nano-precision experiments were carried out to grind and finish some optical materials such as glass, silicon, silicon carbide, etc. ELID grinding, as pre-finishing,was employed to obtain high efficiency and high surface quality; and then, MRF, as the final finishing,was employed to improve further surface roughness and form accuracy. In general, form accuracy of ~λ/20(λ is a wavelenght unit,λ=632.8nm) peak-to-valley (P-V) and surface roughness less than 10 Angstrom unit are produced in high efficiency.

Discrete Element Method Simulation of Cracks in Monocrystalline Silicon Machining Process

Tan Yuanqiang;Yang Dongmin;Li Cai;Sheng Yong

2008, 19(21):  0-2524. 

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Discrete element model of monocrystalline silicon was constructed and calibrated. Based on the model, the dynamic process of micro-machining of silicon was simulated, and the effects of different cutting speeds, cutting depths and rank angles on the formation of surface cracks and debris were also analyzed. Results show that both of the surface crack number and maximum depth increases with increase of the cutting speed and cutting depth, while decreases as the rake angle increases; when the rake angle becomes positive from negative, the damage zone which is under and in front of the tool gradually increases; the damage level of silicon are remained without changes before the rank angle is changed to 0°, but the damage level becomes dramatically heavy when the rake angle reaches to -15°. 

Experimental Investigation on the Effect of Abrasive 
Grain Size on the Lapping Uniformity of Sapphire Wafer

Zhou Zhaozhong,;Wen Donghui;Zhang Kehua;Lu Congda;Yuan Julong

2008, 19(21):  0-2645. 

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Experiments were taken to investigate the effect of abrasive grain size on the lapping uniformity of sapphire wafer, macro and micro surface profiles were measured and compared by contact and contactless measurement methods. For W14 carbide boron abrasive lapping process, rolling and extruding effects are the main material removal process and leaves high density micro-crack on the lapped sapphire surface. On the other hand, W3.5 carbide boron abrasive grain performs a ductile cutting process for material remove process under the same operation parameters, only scratch on sapphire surface can be viewed by AFM. Experimental results show that abrasive grain size has a great effect on the surface integrity of the lapped sapphire, except the roughness to be achieved, the charging status of abrasive grain into the lapping plate and its effect on the surface integrity should be considered when choosing the abrasive grain size for precision lapping process. Lapping uniformity both for macro and micro level, roughness and flatness of sapphire wafer can be achieved by using W3.5 carbide boron abrasive grain and is acceptable by pre-polishing process.

Grinding Principle Error Analysis and Experimental Study of Spherical Mating Plate

Tong Fuqiang;Zhang Yong;Zhang Feihu Harbin Institute of Technology, Harbin,

2008, 19(21):  0-2524. 

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This paper described principles, requirements and motion law of generating method which was used to generate spherical surface. Spherical grinding error analysis is mainly about influence of geometric precision of machine on precision of graund parts, the influences of vertical, horizontal and angle on the spherical degree errors were researched respectively, and the specific calculation formulas were deduced. The homogeneity of grinding process was analyzed, the steering and speed ratio of the wheel and work piece are the main factor influencing grinding homogeneity. The experimental study used the workpiece material to do ELID(electrolytic in-process dressing) grinding expriment of the electrode. Preliminary result confirms that the experiment is an effective way of the carbide spherical ultra-precision grinding.

Speed Regulation System of Permanent Magnet Linear Synchronous Motor for Machine Tool Feeding Based on Improved ADRC

Zhou Zhenxiong,;Qu Yongyin;Yang Jiandong;Liu Dejun

2008, 19(21):  0-2645. 

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According to the nonlinear and variable coupling of AC permanent magnet linear synchronous motor(PMLSM) with unknown modeling dynamic state and uncertain destabilization,a improved first-order auto-disturbance rejection controller(ADRC) with its discrete model was proposed ,which could overcome the rough of non-linear function in nonlinear state error feedback of conventional ADRC.The inner disturbance and outside disturbance could be observed with the extend state observer of ADRC, and used it to offset the disturbance of system, and the real-time dynamic linearization of the non-linear speed regulation system of PMLSM was realized. The simulation result indicates the system based on this improved ADRC has better dynamic and static and robust characteristics. 

Study on Precision Grinding for Revolving Curved Surface Based on Uniform Surface Roughness

Kong Lingye;Yan Qiusheng;Song Junhui

2008, 19(21):  0-2524. 

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In order to improve the uneven surface roughness due to the different curvatures, the relationship among envelope height, feed rate, rotational speed and curvature of workpiece was analyzed based on equal-envelope-height grinding method. The results show that, low feed rate of grinding wheel and high rotational speed of workpiece are helpful to obtain smaller envelope height. And the smaller the radius of workpiece curvature, the more different the surface roughness. Besides, it is an effective method to solve this problem by changing the feed rate. The feed rate should be changed directly proportionally to radius of workpiece curvature. So, when grinding the revolving curved surface, diamond roller and various speeds at different radius of curvature are greatly helpful to the uniform surface roughness and surface quality.

Study on Path Planning Algorithm of 5-axis Laser Quenching for Free-form Surfaces

Xu Hongwei;Huang Yumei;Han Xuzhao;Li Yan

2008, 19(21):  0-2645. 

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In order to ensure the quenched quality of complicated surfaces, according to the factor that tool path planning of laser quenching for free-form surfaces is very important to the uniformity of surface hardness, based on analysis of characteristics of laser quenching, equal arc length method for determining the tool path of laser quenching for free-form surfaces was advanced. The optimized distance between tool paths of laser quenching was ascertained through experiments. In the end, an example computing the tool path using equal arc length method for B sample curve surface were applied to verify the feasibility of this method. 

Research on Stability of Regenerative Chatter with Double Elastic Body

Huang Qiang，;Zhang Genbao;Zhang Xinyu;Cao Dongfeng

2008, 19(21):  0-2524. 

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The processing stability of machine system was studied by combining theoretical analysis and test observations herein. From the viewpoint of the mass allocation and enough supply of energy to keep chatter, a result, which chatter should occur on tool system or workpiece one first, is concluded. Based on the points above, the recent model of regenerative chatter was expanded to one with double elastic bodies. Study results show: when the receptances of two elastic bodies have bigger difference in value, the one with bigger receptance should become the active body of chatter, and chatter frequency should be its natural frequency. This part should be the weak one of the system. When the receptances of two elastic bodies is close, the active body of chatter should be chosen according to the processing condition. Our testing results expose this course and result visually, of that the active body of chatter will be changed from one to another in increasing the cutting depth continuously.

A Resonant Accelerometer and Its Design

Guo Zhanshe;Fan Shangchun;Zhuang Haihan

2008, 19(21):  0-2645. 

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A resonant accelerometer was designed in order to overcome the low output precision characteristics of the sensors which were tested with analog signals. This accelerator has the advantages of good repeatability, high resolution and excellent stability. Relationship between the linear acceleration and the resonant frequency of the sensing unit was deduced and the finite element method was used to simulate the correctness of the theory. The theoretical result and simulation result are 722.2Hz and 720.87Hz respectively without acceleration is applied on this sensor. When 1g acceleration is applied on this sensor, the theoretical and simulation results are 727.3Hz and 726.28Hz and the relative errors are 0.18% and 0.14% respectively. Finally, the fabricated sensor was tested. The measured first order resonant frequency is 718.2Hz, which is very close to the theoretical and simulation result. The results indicate that this design is feasible. 

Experimental Study on EHL Friction under Big Slide-roll Ratio Conditions

Liu Kun;Bing Leigang;Liu Xiaojun;Wang Wei

2008, 19(21):  0-2524. 

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A series of EHL friction experiments under line contact and big slide-roll ratio conditions were conducted on a self-modified JPM-1 tribo-tester. Friction coefficients under various operation conditions were measured. A series of results which reflect the influence of working conditions on friction coefficient were obtained. The results show that when load is small, friction coefficient is sensitive to the load and the rolling speed; with increase of load, the sensitivity of friction coefficient to the load and the rolling speed reduces rapidly. Under big slide-roll ratio conditions, the variation amplitude of friction coefficient is small. As the load or rolling speed increases, the friction coefficient decreases, the rate of declination gradually slows down. 

Possibilistic Reliability Analysis for Complex Machinery Structure Based on Unascertained Information

Yang Ruigang，;Xu Gening;Lü Ming

2008, 19(21):  0-2645. 

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A new method based on mathematical theory possibilistic reliability was put forward to handle the load distribution. This method was used to meet the data needs of possibilistic reliability analysis, which used unascertained rational number to describe the load variables. Unascertained rational number was the most commonly used discrete unascertained number which was used for more precisely describing characterization of uncertainty data and avoided only a single real value omitting and distorting of information. Fuzzy complex structure system reliability which contained a number of possible failure modes was a difficult calculation. The reliability of steel structure system was determined by optimizing criteria method and incremental load method. The calculation results are closer to the actual true value by combination of unascertained mathematical theories and possibilistic reliability theories. A new kind of computation model and methods was explored for the complex structure of the system reliability analysis.

A Realization of Energy-saving Control System for Hydarulic Excavator

He Weixing;Chen Xiaoping;Lu Senlin;Pan Tianhong 

2008, 19(21):  0-2524. 

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There exist lots of energy losses in hydraulic excavator during its load frequently changing in various operation states. In order to reduce those energy losses and improve excavator performance, a control system for hydraulic excavator engine was designed. Taking advantages of the monitor ability and control ability of single chip computer, the control device took the hydraulic system pressure of the excavator as a criterion to make a stepper motor control the engine throttle to a proper position, so that without any changes in internal structure of the engine and the excavator hydraulic system, the energy was saved. The control system provides functions of idle speed control, dynamic model control, shot time overload control and overflow control etc. and realizes the need of getting system work stably, actuator moving steady, high control precision and saving energy efficiently.

Distributed Multi-level Collaborative Production-Distribution Planning
Model and Solution for Supply Chain

Li Ying;Yang Shanlin

2008, 19(21):  0-2645. 

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For a multi-echelon distributed supply chain consisted of a manufacturer, multi-warehouses and multi-detailers, with multi-productions, we developed a triple-level collaborative production-distribution planning model aimed to maximize the profit of each level. The problem included three sub-problems: the first-level problem, the second-level problem, and the third-level problem, which were decided by manufacturer, warehouses and retailers respectively. We also designed an interactive multi-level programming method based on fuzzy theory for solving the model. Finally, the model and algorithm were illustrated with a numerical example. In addition, it compared the interactive multi-level programming method with traditional fuzzy multi-objective programming method in respect of decision behavior and programming results.

Research on OWL-S Based Manufacturing Grid Service Discovery

Hu Yefa;Zhang Haijun;Tao Fei;Zhou Zude

2008, 19(21):  0-2524. 

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With semantic Web technology, the process of developing MGird services ontology was designed, as well as MGrid service description. A MGird service discovery model based on OWL-S was proposed. The service matching problem was transformed into ontology matching problem herein, and the algorithm for concept similarity measurement in ontology was improved. Experimental results show that the proposed model and algorithm are prior to the keywords based service discovery method in the aspects of veracity and perfectibility, effectively make up for the lower recall and precision of the keywords based service discovery and improve the quality of service discovery.

Tool-path Calculation for Shoe-last Machining Using Minimal Distance Method to Avoid Interference

Peng Fangyu;Ding Jidong;Chen Xubin;Li Bin

2008, 19(21):  0-2645. 

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Using the discrete points of a shoe-last and tool three-dimensional model and their coordinate transformation in space, the interference check in shoe-last NC machining was simplified to minimal distance check along the project vector, and the algorithm for tool-path planning without interference was proposed. Then, a method of quickly looking for the point with the shortest distance was designed according to the feature of shoe-last surface, in order to resolve the problem of huge quantities of computation. Through actual machining on shoe-last machine, the method was verified correctly and can improve the quality and efficiency.

Service-oriented Manufacturing: a New Product Mode and Manufacturing Paradigm

Sun Linyan;Gao Jie;Zhu Chunyan;Li Gang;He Zhe

2008, 19(21):  0-2524. 

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Product service system (PSS) could be categorized into product-oriented PSS，solution-oriented PSS，apply-oriented PSS and utility-oriented PSS. Then, the characteristics of each kind of PSS and the shift between them were discussed. Why producer service acts as the intermediate goods among different companies and why a company outsources its business processes were analyzed from the view of economics. Finally, service-oriented manufacturing was summarized from the perspectives of business model, industry insight and technology strength (BIT).

Simulation of Liquid Flowing over Surfaces with Micro-structure

Li Jian;Zhou Ming;Cai Lan;Ye Xia,;Wu Bo;Li Gang

2008, 19(21):  0-2645. 

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The flowing past a stripe surface was modeled based on the contact mode between liquid and solid surface. The Navier-Stokes Equation was dispersed using second-order center finite difference scheme and then solved. The boundary condition was of compound condition of no-slip and zero shear stress. The velocity distribution of our simulation is in partly agreement with the results of experiment and simulation.The difference between the pressure drops of liquid in the pipe composed of by smooth surface and by stripe surface implies that the stripe surface behaves well drag-reducing performance. Then the relationship of drag reduction to the scale of the microstructure and the ratio of grooves were obtained from the simulation results of surfaces with different structures.

Digital Phantom Modeling Method Based on Cone-beam CT Images

Huang Kuidong;Zhang Dinghua;Wang Kai;Zhang Shunli

2008, 19(21):  0-2524. 

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Ministry of Education,Northwestern Polytechnical University, Xi’an,710072
A notion of digital phantom was proposed, which can contain surface geometric information and inner material distribution information of an object simultaneously.Digital phantom modeling method based on cone-beam CT images was studied. In the aspect of digital phantom material modeling, an algorithm of computing material distribution was presented based on material identification. In the aspect of geometry modeling, a novel approach to reconstruct 3D object surface was put forward according to the characteristics of cone-beam CT images, which combined the local structures with the global topology. The experimental results show that the new modeling and realization techniques for measurement and reconstruction of inner structures and surface information of 3D object are feasible.

Investigation of Electrical Discharge Machining in Water Vapor

Gao Qing;Zhang Qinhe;Su Shupeng;Zhang Jianhua

2008, 19(21):  0-2645. 

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This paper investigated electrical discharge machining in water vapor. This technique took high pressure water vapor as the dielectric medium. Experimental results show EDM in water vapor exhibits advantage of lower tool wear, better machining stability. Generally, material removal rate (MRR) raises with the increase of discharge pulse duration time and discharge current , but decreases with the increase of pulse interval time. It is valuable that tool electrode wear is kept in a low level in most cases, but it is relatively higher at higher discharge current. 

Parametric Sensitivity in Reliability Analysis of Bevel Gear

Zhou Na;Zhang Yimin

2008, 19(21):  0-2524. 

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The reliability-based sensitivity computation and analysis of bevel gears was extensively discussed and a numerical method for reliability sensitivity computation and analysis was presented. The effect of basic normal distribution parameters on reliability of the bevel gears was studied. The respective programs can be used to obtain the reliability-based sensitivity information of the bevel gears accurately and quickly. The method presented herein provides the theoretical basis for reliability design of the bevel gears.

An L-M Method for Uncalibrated Visual Servo Control

Fu Qingshan;Zhang Zhisheng;Shi Jinfei

2008, 19(21):  0-2645. 

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Gauss-Newton method is most commonly used in uncalibrated visual servo control, but it may not be convergent or unable to converge to the expected value in large residual cases. So, a new uncalibrated visual servo control method using Levenberg-Marquardt method was proposed. The trust region strategy was used to insure that the model was a good simulation of the nonlinear function and the step was adjusted adaptively by the ratio between actual decrease of the function and the predicted decrease in this method. Besides, the Broyden’s method was used to estimate the image Jacobian online. The disadvantages of traditional method are avoided and it does not need to calibrate the camera and the robot by using this method. Simulation and experimental results demonstrate the success of the method.

Dynamics Analysis and Optimal Design of the Stator for a Rod-shape Ultrasomic Motor

Zhu Hua;Zeng Jingsong;Zhao Chunsheng

2008, 19(21):  0-2524. 

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The finite element method was used to derive the electromechanical coupled dynamics model of the stator of a rod-shape ultrasonic motor due to the complexity of its geometric shape.The dynamic behavior of the stator was analyzed via this model and the numerical result of the first bending mode frequency is 3.9% of error compared with the experimental result of the prototype stator. Both the structural design principles and the approaches to meet the modal requirements for the stator were proposed and a mathematical optimal model was established based on the pattern search algorithm to solve this multi-objective optimization problem. The numerical simulation results show that this efficient optimal model can quantify the structural parameters of the stator and also meet the stator’s design requirements for the modal frequency,the mode shape,the location of the piezoelectric ceramics and the interference mode at the same time. 

Analysis and Modeling of an Electromagnetic Levitation Micro-actuator

Chen Benyong;Pan Kerong;Yang Tao;Chen Jun;Jiang Weiguang;Guo Liang

2008, 19(21):  0-2645. 

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A novel electromagnetic levitation micro-actuator based on the synchronous tracking magnetic field was proposed. High precision micro-motion was available because it solved coupling of suspension force and lateral force. The mathematical model of suspension force of this micro-actuator was analyzed and established. The methods of vector potential, Fourier series and Maxwell stress tensor were applied to distinguish characteristic parameters of this micro-actuator. The relationship between suspension and air-gap, current was achieved after the influence of magnet materiel, size, current and air-gap on the suspension force was investigated. Experimental result shows the feasibility of this micro-actuator.

Application of Neural Network Trained by Chaos Particle Swarm Optimization to Fault Diagnosis for Rotating Machinery

Qiu Guoqing;Tang Xianlun;Zhuang Ling;Yang Zhilong

2008, 19(21):  0-2524. 

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A new particle swarm optimization algorithm with dynamically changing inertia weight based on chaos particle swarm optimization was proposed, in which the inertia weight of the particle was adjusted adaptively based on the premature convergence degree of the swarm and the fitness of the particle, the diversity of inertia weight made a compromise between the global convergence and convergence speed, so it can effectively alleviate the problem of premature convergence. The algorithm was applied to train neural network and a model of fault diagnosis for rotating machinery was established, compared with particle swarm optimization algorithm and genetic algorithm, the proposed algorithm can effectively improve the training efficiency of neural network and obtain good diagnosis results. 