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Table of Content

    25 May 2008, Volume 19 Issue 10
    Temperature Control Algorithm for Optical Lithography Projection Lens
    Nie Hongfei;Li Xiaoping;Zhang Lingli
    2008, 19(10):  0-1139. 
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    A two-input two-output nonlinear PI algorithm was presented to improve the convergent speed and steady-state accuracy of the temperature control system for projection lens,which had the characteristics of big inertia,multi-time-delay and multi-perturbation.Control process was divided into five phases from start to stability according to the ideal dynamic response curve.Improved PI algorithm was applied to precise by adjust and intelligent decision realizes choice and switch of the multi-model.This
    algorithm is used in the temperature control system of projection lens of optical lithography and has achieved quick convergent speed and ±0.006℃ temperature stability.The contrast experimental results show that the algorithm has strong robust and self-adaptive.

    A Multi-objective Optimization Method Based on the 
    Trust Region Model Management Framework and Its Application
    Liu Guiping;Han Xu;Guan Fengjiao
    2008, 19(10):  0. 
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    A multi-objective optimization method based on the trust region model management framework was suggested to reduce the dependence on the approximations.In each optimization iteration,the approximation models were constructed by the quadratic response surface approximation technique with the samples obtained from the Latin hypercube design.And a Pareto optimal frontier predicted by the approximations was identified through the micro multi-objective genetic algorithm,and the trust region model management framework was employed to manage the approximations.Eventually, the present method is successfully applied in the thin-walled sections for structural crashworthiness.

    Establishing the Static Stiffness Matrix of Compliant Chain for a Fully 
    Compliant Parallel Robot Using D-H Transformation Method
    Yang Qizhi;Ma Lüzhong;Guo Zonghe;Yin Xiaoqin
    2008, 19(10):  0-1139. 
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    A new type asymmetrical spatial fully compliant 3-RRRP parallel robot was designed.Based on the static stiffness matrixes of the compliant joints and the compliant prismatic pairs, the model of a normal chain was established, then the theory and the static stiffness matrixes of the chain were obtained by using the coordinate matrix transformation method(D-H transformation). Finally, in order to justify the correctness of the theory, a simple compliant chain model was established. The actual values of the static stiffness matrix of the chain were calculated. Then the result was simulated using the ANSYS software. The simulation results show that the calculated values are similar to the simulated ones. It is convenient for getting the whole static stiffness matrix of the fully compliant robot and improving the precision and soon on.

    Development of Rapid Dynamics Modeling System of Machine Tool Based on PATRAN
    Mao Kuanmin;Ye Jun;Li Bin
    2008, 19(10):  0. 
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    Dynamics characteristics of joints in machine tool were studied,and the dynamics mathematical models of joints were created.A rapid dynamics modeling system of machine tool was constructed through PCL(PATRAN Command Language) on the basis of FEA software PATRAN,and the DMIG card was used to input the experimental data into the FEA software PATRAN.The theoretical model and experimental model of finite element were combined and the efficiency and precision of finite element model are advanced.

    Research on the Radial Magnetic Force of Axial Placement and
    Axial Magnetization Multiannul-shaped Permanent Magnetic Bearings
    Tian Lulin; Li Yan;Tian Qi;Li Zhihang;Yang Guoqing;Li Shujuan
    2008, 19(10):  0-1139. 
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    Aiming at small magnetic force and the complexity of magnetic force numeral calculation for previous research of radial magnetic force model on APAM(axial placement and axial magnetization) bi-annular-shaped PMB(permanent magnetic bearings),the new construction of APAM multi-annular -shaped PMB was designed,which can make good use of magnetic energy and have greater radial magnetic force. Based on analysis of the gap magnetic conductance of multi -annular-shaped PMB,connected with rare earth permanent material property and the principle of magnetic-flux equivalency in flux paths as well as linearity adding, this paper adopted the differential coefficient of magnetic energy to virtual displacement method to derive a magnetic force analytical calculation formula of APAM multi- annular-shaped PMB. This formula indicates that the radial magnetic force of APAM multi-annular-shaped PMB is in positive proportion to the second power of residual magnetism induction density,and that the radial magnetic force increases with an increment in the magnetic annular radial size, average radius,the number of permanent magnetic annular and total magnetic conductance of magnetic circuit,and that the radial magnetic force decreases with an increment in the axial and radial gap.Test validation employed experimental device refitted by triaxial vertical milling machine and triaxial ergometer,the model calculation values are basically in agreement with those actually-measured. 

    Stability Prediction for High-speed Milling Including Feed Rate in Low Radial Immersion
    Song Qinghua;Ai Xing;Wan Yi;Pan Yongzhi
    2008, 19(10):  0. 
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    Dynamics model for high-speed milling system in low radial immersion was developed,including regenerative effects, tool-workpiece loss-of-contact and feed effects.The linearization theory of periodic delay differential equation and semi-discretizated technique were used to approximate the finite dimensional Floquet transition matrix in order to determine the stability of milling process.The stability charts for several feed rate in low radial immersion were constructed.It is shown that stability limits are reduced evidently due to the effects of feed rate for low radial immersion in high-speed milling processes.

    Variance Analysis of Line Samplingbased Reliability Sensitivity
    He Hongni;Lü Zhenzhou
    2008, 19(10):  0-1139. 
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    In order to determine the convergence of the line samplingbased reliability sensitivity method,the variance and the variation coefficient were derived for the reliability sensitivity estimation based on the line sampling.The interval under the given confidence of the reliability sensitivity estimation based on line sampling was calculated approximately.Several examples were used to compare the variance and the variation coefficient of line samplingbased reliability sensitivity and those of MonteCarlobased reliability sensitivity.The results show that the line samplingbased reliability sensitivity method is more efficient than MonteCarlobased reliability sensitivity method with an acceptable precision.

    Design and Optimization on the Bonding Head with Parallel Structure in IC Die Bonder
    Li Ketian;Chen Xin;Liu Ji’an;Fan Yunmou
    2008, 19(10):  0. 
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    Bonding head is the key execute parts of the IC die bonder. The parallel bonding structure was proposed, and working principles and structure size optimization were discussed. Two driving motors of the bonding head were fixed in the rack and never move as the bonding head moves, so the weight of the executor is light. The bonding head standed as triangle style, so the rigidity of the structure is high. By controlling the two motors in the way of collaboration, the bonding head can fulfill the function of IC chip picking, transporting, and bonding, etc.

    GMA Hysteresis System Identification and Compensation Based on KP Model
    Wang Xiangjiang,;Wang Xingsong
    2008, 19(10):  0-1139. 
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    The improved Krasnosel’skii-Pokrovkii(KP) model was employed to build the frequency-independent hysteresis model for the the giant magnetostrictive actuator(GMA).Then a method for identifying the density function of KP model for the GMA was proposed. Also a compensating operator of KP model was built so as to mitigate the effect of the hysteresis. Based on the operator a variable structure control was proposed, and the adaptive control law for the variable structure control was deduced from the Lyapunov stability theorem. The simulation and experimental results confirm the accuracy of the electromechanical system model and the validity of the control strategy.

    Experimental Research on the Anti-loosing Friction Moment of Fe-based SMA Locknut
    Li Junliang;Du Yanliang;Sun Baochen
    2008, 19(10):  0. 
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    By experiments,three sources of the antilock friction moment and the static antilock friction performance on the Fe-based SMA locknut were tested separately,as a result the feasibility of the new-type nut was proved.The results show that the anti-loosing performance becomes better with the increasing of the recovering treatment temperature.When the recovering treatment temperament is 500℃,the friction moment in the radial direction reaches 33.66% to the general frictional moment,and the general anti-loosing frictional moment of the new-type nut has improved 80.37% than that of the normal one.The experimental result is close to the theoretical result.It is obvious that the new-type nut has better anti-loosing performance.The study results also show that the relation between the tightening moment and the loosing moment of the new-type theoretically accords with 0.8 times compared with the normal nut.

    Research on Approach of Prognostics Feature Information
    Extraction Based on Wavelet Correlation Feature Scale Entropy
    Zeng Qinghu;Liu Guanjun;Qiu Jing
    2008, 19(10):  0-1139. 
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    A prognostics feature information extraction approach was proposed based on wavelet correlation feature scale entropy

    WCFSE.The defining and computing way of WCFSE were presented based on integration of Shannon information entropy theory and wavelet transform correlation filter WCFSE. can quantitatively describe energy distribution of different scales which can response difference of equipment running states,the equipment running states were estimated by magnitude of the selected WCFSE which can mostly embody fault features.Several states of roller with normal state and different fault severity states were recognized by the proposed method.Experimental results show that the proposed method is effective and practicable,and a new approach is proposed for the feature information extraction of equipment degradation state recognition and fault prognostics.

    Dynamics Analysis and Experimental Study on a Metal Bellow
    Xiong Yonghua;Du Farong;Zhong Yuping
    2008, 19(10):  0. 
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    The finite element model of DN200 type metal bellow was set up,based on the finite element theory.The inherent property parameters were obtained from the modal analysis on the metal bellow model.Under the single-point excitation,the transient dynamic response curves in time domain and frequency-domain were calculated.The dynamic experiment of the bellow was carried out,and the inherent properties and mechanical impedances were measured.The test results accord with the impedance change rules of flexible parts.The simulation reliability is verified, compared with the experimental results.The numerical simulation and the experimental research methods have some directive significance on bellow design and product development.

    Research on Anti-segregation of Screw Minute 
    Material of Varied-diameter Complete Burying and the Low-speed Construction
    Li Ziguang;Zhu Qi;Cheng Zhanfeng
    2008, 19(10):  0-1139. 
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    The isolating reasons of partly buried and the high speed construction to the traditional screw minute material were analysed,and the aspect of mechanics characteristics and the tumbling mechanism in the transportation process were analysed.The new technologies for complete burying and the low-speed construction of varied-diameter screw minute material were proposed herein.The practical application of new technologies,from the aspects of road surface compactness and the temperature isolation were measured.The feasibility of the new technologies was proved by using this kind of new screw-minute material to carry out the complete burying and the low-speed construction.

    Optimization for Main Drive Mechanism of Gear Shaper with Quick-return Characteristics
    Yi Chuanyun;Zhong Ruiling;Cao Xiangao;Chen Jing
    2008, 19(10):  0. 
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    This paper presented an optimization method to the double crank slider six bar mechanism,which had quick-return characteristics,and was used in main drive of gear shaper.The stable velocity in working stroke is obtained,the working stroke is shortened,and the return velocity is raised,all of these can improve the main drive of gear shaper greatly,and raise cutting efficiency and surface quality of the gear shape.

    Experimental Studies on Notch Wear for High Speed Machining of Nickel-based Superalloy with Ceramic Tools
    Xiao Maohua;He Ning;Li Liang;Liu Haibin
    2008, 19(10):  0-1139. 
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    Based on the experiments of high speed machining of nickel-based superalloy with ceramic cutters,the impact frequencies of the saw-tooth-shaped chip edge on rake face and cutting edge in different speeds were calculated and the influence of chip edge on notch wear formation was analyzed.A new tool table was used to deburr in the experiments,and the height of burr on the working surface with the size of notch wear was compared in deburring cutting and normal cutting.The depth of cut zone(DOC-zone) was investigated by scanning electron microscope(SEM) equipped energy dispersive x-ray spectroscopy(EDS).The results show that the side cutting burr and saw-tooth-shaped chip edge are the ultimate cause of occurrence of notch wear and adhesion accelerates the development of notch wear.

    Simulation and Experimental Analyses of Synchronization Control for Shield Thrust System
    Hu Guoliang;Liu Leping;Gong Guofang;Yang Huayong
    2008, 19(10):  0. 
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    A thrust hydraulic system of shield tunnelling machine was introduced.Simulation analysis of synchronizing thrust for thrust hydraulic system was carried out using AMESim and MATLAB software.The synchronization PID control program of master-slave mode was developed using PLC software.Experimental analysis of synchronizing thrust was put up on a shield simulator test rig,and the experiments with two different loads were also compared.The simulation and experimental results show that there are good synchronizing effects by applying synchronization PID control with master-slave mode,and the synchronization precision can be controlled within ±3mm,which can meet the tunnelling requirements in different kinds of geologies.

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    Guo Yinbiao;Guo Jiang;Wang Zhenzhong
    2008, 19(10):  0-1139. 
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    In accordance with the requirements of axisymmetric aspheric measuring,three paths were put forward and estimated.The applicant situations of these three paths were analyzed.A data processing system with high precision was carried out.The Gauss-Newton method was adopted as the curve fitting algorithm for the axisymmetric aspheric surface.The monotonous and super-quadric equations of axisymmetric aspheric lenses were taken as the polynomial mathematics model to verify the accuracy of the nonlinear least square fitting method respectively.The experimental results indicate
    that the fitting residual errors are in the 1nm magnitude order,so the curve fitting algorithm can be used in the high-precision curve fitting exactly.

    Algorithm for Open Cutting and Its Applications in the Numerical
    Simulation of Sheet Metal Stamping
    Xie Shaohui;Liu Yuqi;Du Ting
    2008, 19(10):  0. 
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    An algorithm for open cutting was presented for mesh adaptive technique,and the template library based on mesh adaptive was built.Elements which were passed by trimming line were adjusted by using advancing inciting and adjustment method.The transmission of physical information was completed by a mapping method.This algorithm was integrated into the software FASTAMP which is based on dynamics explicit method.The simulation of a practical automobile body metal sheet was presented,in which the size,position and shape of the open cutting and the distance of the die were optimized when the open cutting was processed.This optimized plan was applied in the production,the precision of the numerical result and the practicability of the algorithm for open cutting were validated by this experimental result.

    Design and Analysis of Ion Beam Figuring Machine for Optics Components
    Jiao Changjun;Li Shengyi;Xie Xuhui;Zhou Lin
    2008, 19(10):  0-1139. 
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    The post-algorithm and error compensation were discussed. The direct kinetic algorithm of KDIFS-500 was set up based on DH method,and followed by the error model with respect to positioning errors and assemble errors of ion source and workpiece. The prominent influence of the deterministic assembly error of the ion source in the tangent plane would be canceled with an error compensation matrix.Thorough analysis of the error model with compensation matrix,it is indicated that the influence of the positioning error along the trajectory of the ion beam and that of the incidence angle error on the figuring process can be ignored with the constraints applied by satisfaction with the demand of the positioning error in the tangent plane.

    Control Strategy of a Five-bar Cobot Based on Velocity Constraints
    Lu Dunmin,;Zhang Lixun;Yang Xiangdong;Chen Ken
    2008, 19(10):  0. 
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    A control strategy based on velocity constraints was introduced.In order to implement virtual constraint control of Cobot(collaborative robot) endpoint the control strategy calculated the control values according to operation forces of operator,trajectory errors and current velocity of the Cobot endpoint.The simulation of Cobot following a straight line and a section of circle was completed.The simulation result shows that the control strategy fulfils the demands of trajectory virtual constraint control.

    Analysis on the Crack Arrest in Cr12 Cold Punch Cavity Die with 
    Half-embedding Spatial Crack by Using Electromagnetic Heating
    Fu Yuming;Zheng Lijuan;Liu Yu
    2008, 19(10):  0-1139. 
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    The crack arrest in Cr12 cold punch cavity die with half-embedding and half-ellipse crack on inside surface using electromagnetic heating was analyzed.A numerical simulation method was proposed for analyzing the coupled field in cavity die with spatial crack at the moment when the current was switched on.The distribution of temperature field was studied around the crack tips in cavity die with half-embedding and half-ellipse crack.The crack arrest experimental study in cut section of cavity die cut with cracks was conducted on pulse current generator (model ZL-2) developed by the authors. The research results show that the crack tip along the half-ellipse cracks will be melt and the small welded joints can be formed at a small sphere near the crack tips,and the super fine metal structure is gained,the mechanical capability of crack tip is improved.So, the goal of crack preventing can be reached.The thermal-electrical coupling theory was applied in numerical simulation,the material nonlinear,state nonlinear and geometry nonlinear problems were discussed in proceeding.The temperature field results of numerical simulation correspond to the experimental ones.

    Dynamics Modeling and Frequency Analysis of a 3-RRS Flexible Parallel Manipulator 
    Liu Shanzeng;Yu Yueqing;Su Liying;Yang Jianxin
    2008, 19(10):  0-1257. 
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    The primary goal of this research is dynamics modeling and frequency 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 application of constraint conditions of the legs and the movable platform.Based on the dynamics model,the relation of the natural frequencies and design parameters of this mechanism were studied through numerical simulation.From the simulation results,the natural frequencies are relatively sensitive to the sectional parameters,structure size and characteristic parameters of material on mechanisms.

    Experimental Studies of Pitching Vibration of Ultrasonic Bonder Transducer
    Guang Ming’an;Han Lei
    2008, 19(10):  0-1139. 
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    Pitching vibration of ultrasonic bonding transducer can affect the bonding quality of IC. We obtain the first three natural frequencies of structure of the ultrasonic bonding transducer through the experiments,and acquire the trends of these natural frequencies when fixing capillary. The results show that the ratio of the first three natural frequencies of ultrasonic bonding transducer accords approximately with the theoretic ratio of a cantilever beam. Conclusions can be drawn that energies of pitching vibration of the ultrasonic bonding transducer mostly focus on the first natural frequency,and that capillary can affect the natural frequencies and increase the energy dissipation of ultrasonic bonding transducer at the first natural frequency. 

    A Study of Necessity of Control Equation for General Functional Scroll Profiles
    Wang Licun,;Chen Jin
    2008, 19(10):  0-1257. 
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    In the study of general scroll profiles and its conjugation profiles for scroll compressor, the general scroll profiles equation based on functional analysis was given using the intrinsic equation of curvature radius and curve differential coefficient. The scroll profiles pitch line and controll equation were researched.The conjugation scroll profiles of orbiting and fixed scroll discs were deduced through scroll profile controll equation. The conclusion is that the scroll profile controll equation is the necessary condition to create the scroll profiles for the scroll compressor,not the sufficient condition. While the profiles are just the scroll profiles for scroll compressor, the controll equation can create the conjugation scroll profiles of the orbiting and fixed scroll discs. On the contrary, only knowing scroll profile controll equation,but the profiles do not belong to the scroll profiles for scroll compressor, the scroll profile controll equation can not create the scroll profiles for scroll compressor.

    Research on the Experimental Rig for the Property of Oil Film of the Frictional Pairs in Hydro-viscous Variable Speed Driver
    Huang Jiahai;Chen Ning;Qiu Minxiu;Jiang Jianyong
    2008, 19(10):  0-1139. 
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    In order to investigate the dynamics characteristics of flow field between frictional pairs in the hydro-viscous drive(HVD),an experimental rig was designed and manufactured, which was used for simulating the oil film flow field. The corresponding data acquisition system and the closed-loop control system for lubricant film thickness were also devised according to the experimental goal. The hydraulic control system, the variable-frequency electrical motor speed regulating system as well as revolving hydraulic cylinder actuator made the initiative friction disk rotational speed and lubricant film thickness adjustable,so as to conduct experimental research on the flow field under different rotational speeds and lubricant film thickness conditions.Finally the oil film flow field under certain condition was simulated by this experimental rig.And several pressure and temperature data of the flow field were collected.

    Fully Coupled Thermo-mechanical Model for Numerical Simulation of Friction Stir Welding Process
    Zhang Zhao;Bie Jun
    2008, 19(10):  0-1257. 
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    Fully coupled thermo-mechanical model of friction stir welding was proposed to simulate the temperature field and the material deformations in the welding process of AL6061-T6 aluminum alloy.The comparison with experiments shows the validity of the current model. Computational results show that the maximum temperature in friction stir welding is lower than the melting point of the work piece material.A region with lower plastic strain can be found behind the welding tool near the bottom surface,which is formed due to the special material flow patterns in friction stir welding.The distribution of the plastic strain on the top surfaces is similar to onion textures observed in the appearance of the friction stir weld.

    Research on the Dynamic Recrystallization Behavior of 20SiMn
    Dong Lanfeng;Zhong Yuexian;Ma Qingxian;Yuan Chaolong
    2008, 19(10):  0-1253. 
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    Based on the thermodynamics research, the flow stress curves of 20SiMn under the common production condition of heavy forging was investigated herein,and the optimized range of forging parameters was suggested with the order of refining the grains by dynamic recrystallization.Also,by nonlinear curve fitting and regression on the experimental data,the dynamic recrystallization model of 20SiMn was established.Finally,a method for measuring the volume fraction of dynamic recrystallization based on the flow stress curve in metallic material was proposed.Further experiments have showed the validity of the model and the measuring method.

    Viscoelastic Model to Calculate the Internal Stress of Injection Molded Polymers
    Zhao Zhenfeng;Wu Haihong,;Shen Changyu;Huang Ming
    2008, 19(10):  0-1183. 
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    Based on viscoelastic theory of the solidified polymer,creep experiments and the characteristics of injection processing,a four-element mechanical model in series was proposed to simulate the internal stresses in injection molded parts.The constitutive equation was deduced.And the formulas were derived to express the changes of elastic modulus and viscous factor of injection molded polymers.To verify the reliability of the model,the internal stresses in an injection molded plate were simulated.The simulated results were compared with experimental data.The results show that the model is accurate and reliable.Research conclusions can be interpreted well with the theory about the structure and mechanical properties of polymers.

    Testing Validation and Parameter Optimization in Occupant Restraint System Development
    Zhang Xuerong;Liu Xuejun;Su Qingzu
    2008, 19(10):  0-1249. 
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    Virtual testing or mathematical simulation using MADYMO becomes a vital tool for occupant restraint system development. To obtain predictive crash simulations, it is very important to validate a MADYMO model according to appropriate processes. Guidelines and considerations for frontal impact restraint system modeling and validation were described in detail herein. Based on the validated model, design of experiments (DOE), parameter sensitivity analysis, response surface model (RSM) and optimization were performed. The probability of serious injury decreases by 4.2%. In engineering applications, MADYMO simulation is efficient way to develop robust and reliable restraint systems.

    Design and Construction of Automotive Human-machine
    Interface Experimental Platform with Multi-parameter and Adjustable Function
    Yuan Quan;Liu Wenchao;Zhang Sen
    2008, 19(10):  0-1183. 
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    Based on the theory and technology of mechanical structure design,automotive inner decoration design,human-machine engineering and CAD,an automotive human-machine interface experimental platform was designed and developed,which can be used in the relevant experiments and researches of the automotive ergonomics.This experimental platform were composed of real seat,steering wheel,dashboard,display and operation device,and virtual road display device,with multi-parameter and adjustable function.Through an ergonomics performance evaluation system of automotive cab,the platform can be applied in the experiments through the real human-machine interface and the simulation of the virtual road information.