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Table of Content

    25 October 2007, Volume 18 Issue 20
    Study on Symmetrical Machining Method and Its Realization Mechanism
    Zhu Linsen, Tang Yangping, Bin Hongzan, Xiong Caihua
    2007, 18(20):  2395-2398. 
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    In order to enhance the machining efficiency of a large symmetrical freeform surface, this paper put forward a new concept of symmetrical machining (SM), analyzed the characteristics of SM. Taking a 4-axis SM machine as an example, this paper introduced the design of SM machine, and investigated the realization mechanism of SM. Based on the above research work,a 4-axis SM machine has been developed in China, and its efficiency on machining ship model surface is 85% higher than that of the traditional 4-axis single-cutter machine. More over, the design of SM machine save one set of servo driving system, and thus reduce the machine cost. 

    Research on the Grinding Force Based on the Probability Statistics
    Zhang Jianhua, Ge Peiqi, Zhang Lei
    2007, 18(20):  2399-2402. 
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    The abrasive gain of the grinding zone was analyzed by using the method of the statistical probability,the forecasting model of grinding force was established on the basis of single abrasive gain’s analysis, theoretical analysis was verified by the experiments.The experimental results coincide with the theoretical prediction and the model can accurately predict grinding force.

    Fault Diagnosis of Suction Fan Based on the Synthetically Relational Analysis
    Fu Mingfu, Xie Mingxiang, Rao Hong, Yang Guotai
    2007, 18(20):  2403-2405. 
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    Based on the theory and method of gray relational analysis, the similar coefficient was introduced to reduce the influent of relational degree affected by the maximum value or the minimum value in data and relational coefficient. The suction fan faults were diagnosed according to the synthetical relational degree composed by the relational degree and the similar coefficient.It is indicated that the method is available for the fault diagnosis of suction fan and has the characteristics of simplicity, low computation and high reliability.

    Static and Dynamic Shape Optimization of Continuum Structures Based on Efficient Difference Sensitivity Analysis
    Long Kai, Zuo Zhengxing
    2007, 18(20):  2406-2410. 
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    Some sensitivity analysis methods in continuum shape optimization were summarized. To overcome difficulty of high computational cost in difference sensitivity analysis, efficient derivatives were obtained using ‘approximate-difference’ strategy based on combined approximation method for static and mode analysis and accurate sensitivity was ensured under small disturbance.Virtual displacements of control points were selected as design variables, static and dynamic shape optimization model of continuum structure were constructed. Numerical examples were shown to demonstrate the feasibility and generality of the method and model proposed.

    Realization of Multi-cutting in WEDM-HS
    Liu Zhidong, Yu Rongheng
    2007, 18(20):  2410-2413. 
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    The analyses about multi-cutting conditions in WEDM-HS were given and some methods to assure steady multi-cutting were also discussed.One kind of commercial WEDM-HS was successfully designed and launched on market through improving the structure of machine,innovating the control system and using composite cooling liquid which has powerful washing ability.The first steady cutting efficiency has reached more than 200mm2/min and through the fourth cutting the surface roughness has reached Ra<0.8μm in more than 50mm 2/min average cutting efficiency.

    Research on Inverse Kinematics Algorithm with High Accuracy for a General [STHZ]6R Robot
    Liu Songguo, Zhu Shiqiang, Cheng Yonglun
    2007, 18(20):  2414-2418. 
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    In order to solve the problem of inverse kinematics for general 6R robots,an algorithm with high accuracy based on symbolic preprocessing and matrix decomposition was proposed.Symbolic preprocessing was performed to obtain the coefficient matrixes of the inverse kinematics equations and avoid the accumulative errors of floating point computations.Singular value decomposition was adopted to ensure the rank stability of coefficient matrixes, eigendecompostion of matrixes and the method of selecting elements with the highest magnitude were applied to minimize the influence of accumulative errors on solving stability and accuracy.All these ensure that the algorithm can get 16 real solutions at most with any required accuracy.Experiments on general 6R robots and PUMA560 robots with small configuration perturbations verify the validity of the proposed algorithm.

    Contact Characteristics of a Wire Race Ball Bearing with a Large Diameter
    Shan Xiaobiao, Xie Tao, Liu Junkao, Chen Weishan
    2007, 18(20):  2429-2432. 
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    The contact problem between balls and wire races in the wire race ball bearing with a large diameter was treated as a non-conformal contact problem.The contact nonlinearity was investigated by employing the Hertz theory.The result reveals that the geometrical size has no obvious effect on the contact characteristics,while the geometric nonlinearity is contributed by the rigidity and tensile strength of the contact solids.The measurements of contact deformation for contact of both steel ball-steel wire race and Si3N4 ceramic ball-steel wire race were performed on an inductance micrometer dial MDS-LVDT.It is found that the analytical contact stiffness is slightly higher than the experimentalone,and the contact stiffness of hybrid contact is higher than that of the steel-steel contact.It is mainly attributed to two aspects. One is that the Coulomb friction is ignored in the basic Hertz’s assumption.The other one is that the plastic deformation often occurs following with elastic deformation.The theoretical and experimental results show that the material nonlinearity of the contact bodies has a significant influence on the contact problem.The present study offers theoretical support for the preload and engineering application of wire race ball bearings with large diameter.

    Optimal Neural Network Internal Model Control for Hydraulic Bending Roll System
    Zhang Xiuling
    2007, 18(20):  2419-2421. 
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    The internal model control using neural network was introduced in allusion to mill hydraulic bending roll system’s nonlinear,time-varying performance.Author proposed means for using optimal neural network to train identificator and internal model controller off-line,improved adaptive BP algorithms’ learning law on-line.The simulation results have demonstrated that this kind of controller improves dynamic response speed and tracing accuracy.The hydraulic bending roll system possesses rapid response and strong robustness,the control effect is ideal.

    Study on the Motion Control of Mold Polishing Robot System
    Wang Ping, Yang Yanping, Deng Xiao
    2007, 18(20):  2422-2425. 
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    The paper introduced the structure and operational principles of a mold polishing robot system,we constituted a model of the robot for polishing free-form surfaces,then an efficient solution of inverse kinematics equations was also applied.Without limiting the scope of robot movement in the foundation,we solved the problem of catastrophe of robot joint value with the application of the arithmetic of numerical value comparison,that caused by the multiple solutions for robot joints.It is demonstrated that the arithmetic are accurate and effectual by the online experiments,so that it can provide theoretical foundation for enhancing the speed of controlling the robot system and optimizing the robot motion.

    Research on Calculation Method of the Static and Dynamic Characteristics of Magnetic Bearing Based on the Basic Solutions
    Yang Jing, Yu Lie
    2007, 18(20):  2425-2428. 
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    This paper investigated the calculation method of the static and dynamic characteristics of magnetic bearing.The general calculation method based on the basic solutions was put forward first.The basic solutions were defined based on local coordinate system, and then the coordinate transform relation between the static and dynamic characteristics of magnetic bearing with arbitrary structure and the basic solutions were deduced. Finally, the method of calculating the static and dynamic characteristics of magnetic bearing with arbitrary structure was provided. The calculation processes are quick, and a general and standardized method is also provided to calculate the static and dynamic characteristics of the magnetic bearing.

    Customer Group Preference’s Configuration Features Merging for Configurable Product Design
    Su Yan, Liao Wenhe, Guo Yu, Shi Huibin
    2007, 18(20):  2439-2443. 
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    In order to make configurable product design to meet customer
    group’s requirements, customer group’s configuration preference was studied.
    Configuration feature,configuration feature set,configuration feature vector,
    and preference factor vector were defined and relevant concepts were described.Asymmetry-distance with preference factor was defined and related theorems were proposed.Then a configuration features merging algorithm based on minimum asymmetry-distance with preference factor was established.Finally,bicycle’s hang-fork was taken as an instance and polynomial fitting method was adopted to verify the feasibility of the proposed merging method.

    Study on Hybrid Production Scheduling Based on TOC
    Chen Jie, Chen Dong, Ma Yizhong
    2007, 18(20):  2433-2439. 
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    An improved DBR scheduling method and its steps based on discrete event simulation system was proposed.By means of simulation model and its running,the constraint can be identified more correctly in order to locate the buffers.Taking use of annealing algorithm embodied in the simulation and optimization software,the optimized parameters,including the time buffer coefficient,tranportation lot-size,can be determined,and then the task time-table on constraints and non-constraints resources can be determined.A production scheduling example is given,which proves the validation and usability of the proposed method. 

    Optimization of Scheduling Based on Simulation and Orthogonal Test
    Wang Guoxin, Ning Ruxin, Wang Aimin
    2007, 18(20):  2444-2448. 
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    On the problem of production system coordinating scheduling in multi-decision positions,an optimum scheduling approach based on simulation and orthogonal was presented. In order to validate scheduling plan rapidly under dynamic production environment,considering modeling and simulation logic respectively,adopting the object-oriented method a rapid simulation modeling
    was accomplished based on modular control logic.Taking simulation model as target solution function and decision parameter as input variables for the simulation model,simulation test was optimized with orthogonal test.
    The optimum combination parameters were used to schedule and control production system.The validity and feasibility of the optimum approach has been proved by its application in a numerical control workshop in a research institution.

    A Cooperative Coevolutionary Algorithm for Job Shop Scheduling Problem
    Zhou Hong, Wang Jian, Shangguan Chunxia, Shi Ruifeng
    2007, 18(20):  2449-2455. 
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    An improved cooperative coevolutionary algorithm was proposed to solve job shop scheduling problem. According to the number of machines, the whole population was naturally divided into some subpopulation whose individuals encoded the preference list of jobs on the corresponding machine.The steady-state reproduction was introduced to genetic operators. The proposed algorithm combined
    three types of cooperative partners from every other subpopulation with the evaluated individuals to form the whole solutions and adopted the improved preference-list-based G&T algorithm to decode them to evaluate. Finally an updating technology and dynamic substitution with some new individuals at some other generations was adopted to speed up the convergence. Numerical experiments have been made to solve some job shop benchmark problems. The optimization results show the proposed algorithm have outperformed traditional genetic algorithms.

    A Framework of Performance Measurement System for Networked Manufacturing Agile Enterprise
    Zhang Chuncheng, Xue Hengxin, Yang Jianhua
    2007, 18(20):  2455-2459. 
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    Adapting the changing needs of the customers
    and linking with enterprise competitive strategy,a model of framework of performance measurement system for the networked manufacturing oriented agile enterprise
    was established based on the enterprise modeling architecture. And the design process of performance measurement system for the networked manufacturing oriented agile
    enterprise was modeled by using
    QFD chain approach on the basis of the enterprise strategy and the stakeholder.
    Implementation guidance of performance measurement system for the networked manufacturing oriented agile enterprise was discussed to direct the enterprise to integrate the performance measurement into the enterprise information system.

    Type Synthesis of 3T-2R Parallel Mechanism
    Tang, Ma Lüzhong, Shi Qiduan, Yu Yufeng
    2007, 18(20):  2460-2463. 
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    Based on the theory of single opened-chain(SOC) forming the structure of a parallel mechanism,some new types of 3T-2R 5-DOF SOC which are formed by a serial binary links or formed by the serial binary links with loops was put forward.The design principle and methodology about topological structure were invoked to make an exhaustive synthesis of 3T-2R parallel mechanism.All the mechanisms meet the design requirements of placing all the actuators on the base,
    which makes the electrical control easily.The fundamental characteristics about the mechanisms such as the attribution of the actuators and the coupling degree
    were analyzed.The research results are listed in the table. All the mechanisms have great potential in practical use.They provide a vital reference to the optimal selection of 3T-2R 5-DOF parallel mechanism.

    Assessment of Microscopic Morphology and Investigation of Tribological Characteristics of Surfaces Finished by Abrasive Jet with Grinding Wheel as Restraint
    Li Changhe, Hou Yali, Cai Guangqi, Liu Feng
    2007, 18(20):  2464-2468. 
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    The machined surface morphology was studied using SEM and microscope and microcosmic geometry parameters were measured with TALYSURF5 instrument.According to the metrical results, the surface topographical characteristics were evaluated with correlation of random process about machined surface before and after finishing.The results show that longitudinal geometric parametrical values of finishing surface are diminished comparison with ground surface,and the mean ripple distance is decreased and,ripple and peak density are increased.Furthermore,the finished surface has little comparability compared to ground surface.The isotropy surface and uniformity veins at parallel and perpendicular machining direction are attained by abrasive jet precision finishing with grinding wheel as restraint.The tribological characteristics of finished surface were also investigated with pin on disk wear tester of MG-2000.The experimental results show that the friction coefficient and wear amounts of finishing surface are obviously decreased compared with ground surface.As a result, life and precision consistency of finished workpiece are improved.

    Study on Pulsed Waveform with Backward Median Phase for Pulsed MAG Welding
    Wu Kaiyuan, Huang Shisheng , Li Xinglin, Ke Litao
    2007, 18(20):  2468-2471. 
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    For the one droplet per pulse transfer of pulsed metal active gas(MAG) welding,a novel pulsed waveform with backward median phase was presented. The effect of backward median current and backward median time on the welding process was studied. The optimum backward median current and backward median time were found by experiment when welding steel.The experimental results demonstrate that when the backward median current is in an optimum value range, the welding effect is satisfactory, and when the backward median current is small or large,the welding effect is similar to normal pulsed MAG welding process,the sense of backward median current is not obvious.On the basis of defining the backward median current as an optimum value,the welding effect is satisfactory when the backward median time is in an optimum value range.The instantaneous short circuit occurs when the backward median current is small or large. By adjusting the backward median current and backward median time, it can enhance the controllability of droplet transfer and get one droplet per pulse transfer,and the weld seam formation will be pretty good.

    Structure Design for a Multi-axis Force Sensor Used in Underwater Robot
    .Hefei University of Technology, Hefei,  .Hefei Institute of Intelligent Instrument, Chinese Academy of Science, Hefei,
    2007, 18(20):  2481-2485. 
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    In design of multi-axis force sensor used in underwater robot,the problem how to balance hydraulic pressure must be resolved firstly.Through the analyses of the stress and strain of some kinds of typical multi-axis force sensor structure used in robot, which was forced hydraulic pressure,characteristics of these structure and conditions to be applicable were obtained.The solid cylinder could bear hydraulic pressure in deep water,but the opening cylinder was not suitable to be used as elastic body because of the corrosion effect of seawater. The rigid closed thin wall full of oil or air could not bear the hydraulic pressure in deep water and the thin cylindrical structure applied with compensated film can bear the hydraulic pressure only in shallow water.The structure encapsulated with soft sac can bear hydraulic pressure and can be kept in good condition while its volume was changed large enough,but this structure was easy to be broken, also its shape and center of mass were not fixed. An idea to design an adaptive structure of multi-axis force sensor used in underwater robot was presented.The structure has the merits of open structure and closed one.The prototype has been trail-manufactured according to this idea.

    Modified Morlet Wavelet-based Adaptive Modal Parameter Identification
    He Qiyuan, Tang Baoping, Cheng Fabin
    2007, 18(20):  2476-2480. 
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    A novel adaptive modal parameter identification method based on modified Morlet continuous wavelet transform(MCWT) was proposed to improve the modal parameter identification precision. In MCWT,a modified operator was applied to adjust the band wide of the mother wavelet to improve the resolution in frequency domain. The proposed principle of maximum-energy (PME),and the principle of maximum-distance(PMD)/minimum-relativity (PMR) of continuous wavelet decomposition of the close scales were adopted to ascertain optimal decomposed scale of wavelet.Simultaneously, different anti-repeat operators were applied into target function to eliminate the coupling of the decomposed signals at the most extends.A simulation and an experiment were carried out on a simple supported beam,the results validate the proposed method.

    Movement Analysis of Micro-fluid in Digital Valveless Micro-pump
    Sha Jingjie, Hou Liya, Zhang Weiyi
    2007, 18(20):  2472-2476. 
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    This paper presented the movement analysis of micro-fluid in digital valveless micro-pump,which was based on the digital micro fluidic technology. The steady state between the border flow and the mid-flow of the micro-fluid in the valveless micro-pump was breaked off by the periodical disturbance that lead the velocity difference. The viscous force and the inertia force were interacted alternately,which drived micro-fluid flow, thus the mid-flow sprayed out.This paper gave the mid-flow movement expressions and figured that the mid-flow lags behind the border flow from the analysis on dynamics. Fluid from this micropump can make up a pulsating flow or continuous flow by adjusting the harass cycle length.

    Elastic-platic Dynamics Explicit Analysis of Cold Ring Rolling Process 
    Zhang Xuebin, Li Zhigang, Liu Yuqi
    2007, 18(20):  2486-2489. 
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    A elastic-plastic dynamics finite element method code RingForm was developed to analyze cold ring rolling process. The central difference method was introduced to solve dynamics explicit finite element equations. Strain state was estimated by the value of yield function of the last and the present time step. To reduce the accumulative difference caused by elastic-plastic constitutive relations,the radial return algorithm was employed.With comparison to the experimental results and the results obtained from ABAQUS,the cold ring rolling process of a ring part with rectangular section has been simulated to verify the accuracy and stability of the system solver.RingForm can correctly analyze the forming process for cold ring rolling, and can predict the parameters,such as axial width spread and end face flatness,of open cold ring rolling.

    Research on Deformation and Mechnics Properties of Tube-sheet Single Sided Resistance Spot Welding
    Yang Honggang, Zhang Yansong, Chen Guanlong, Lai Xinmin
    2007, 18(20):  2490-2492. 
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    In the tube-sheet single sided spot welding (SSSW) process, welding quality is affected by welding deformation significantly. The deformation of tube-sheet SSSW was analyzed through electrode displacement and the influence of welding parameters on the deformation and mechanics properties of the SSSW joint was investigated. Then the effect of changing electrode force on the welding quality of SSSW was studied using characteristics of electrode force of servo gun. The experimental results show that the deformation is linear with electrode force and welding energy. However, when high electrode force or welding current applied, the tensile strength is decreased. In the welding or holding stage, diminishing electrode force can reduce the deformation and increase tensile strength, which helps to improve welding quality of SSSW.

    FE Simulation of Influence of Height-diameter Ratio on Powder Metallurgic Product Properties
    Wang Deguang, Jiao Minghua, Yu Jianwei, Xie Ting, Wu Yucheng
    2007, 18(20):  2493-2497. 
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    The process of the metal powder warm compaction process was simulated by the finite element analysis(FEA) software, MSC/MARC. The simulation applied thermal mechanically coupled analysis,which was based on the updated Lagrangian Method to study the influence rules of different height-diameter ratio on the properties (relative density, equivalent stress) of green. The results indicate that the influence of two factors i. e. initially loose height and green diameter on the relative density distribution is not large with the same side pressing parameter, and the rules of its distribution are basically the same.With the increasing of side pressing parameter, the distribution of green relative density is not gradually uniformity,deviation value is gradually large, and area of low density gradually widen. The study of distribution of green equivalent stress was made, the distribution presents ‘X’ shape,which is same as the deformation of upset forging. Equivalent stress in the hollow area of ‘X’ is relatively lower and this is ‘friction dying area’, equivalent stress in the area of ‘X’ lines is relatively larger and is ‘easily deformable area’.With increasing of side pressing parameter,‘friction dying area’ gradually widen.And equivalent stress of green increases with increasing of initially loose height.

    Analysis of Performance and Microstructure of A105 Steel Welded Joint under Vibratory Weld Conditioning
    Lu Qinghua, Chen Ligong, Ni Chunzhen
    2007, 18(20):  2497-2501. 
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    The contrast tests of vibratory submerged-arc welding and normal SAW(submerged arc welding) on the valve steel A105 was carried out.The welding deformation and residual stress are decreased evidently.The dimensional stability and service security of the welding structure are increased obviously.The impact absorbing energy of weld is improved by 21% under vibratory weld conditioning. And the effect of mechanical vibration on the impact absorbing energy of weld is greater than that of HAZ(heat affected zone).The results also indicate that the microstructure of the weld and HAZ are refined distinctly. The fusion area and overheated zone are narrowed. And the dimension of Widmanstaten structure minishes or disappeares.

    A Road Surface Disturbance Elimination Method for Vehicle Detection
    Guo Lei, Luo Quanxu, Wang Jianqiang, Li Keqiang
    2007, 18(20):  2502-2505. 
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    A vehicle detection method with zero-height hypothesis validation was proposed to eliminate the disturbance caused by shadows and traffic signs on road surface. The principle was to assume that the initial detected targets were all 2D objects on road surface, the hypothesis was validated by the target movement during tracking process, and the targets which passed the validation were road surface disturbance. Feature-based method was applied on the image captured by monocular vision and the lidar data for the initial vehicle detection.The targets which failed to the hypothesis validation will be tracked, while the ones which passed the validation will be deleted. Experiments show that the proposed method can detect vehicles under various road conditions and can lower the false detection rate with the existence of road surface disturbance.

    Automobile Part Model Reconstruction Based on Geometric Constraints in Reverse Engineering
    Zheng Yeqin, Yang Wenyu
    2007, 18(20):  2506-2509. 
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    This paper comes from a project of precision measurement and digital modeling of automobile engine and transmission system. The underlying constraint relationship among the features of mated parts was taken into account in reconstruction process, and a new optimization reconstruction method was presented based on geometric constraints,which were expressed by geometric constraint graphs.Adding constraints to constraint graphs by priority, considering degree of freedom to obtain a consistent constraint system and finally the complicated constraint problems were decomposed into sub-problems to be solved.The approach was demonstrated by the practical parts from an automobile transmission system.The obtained geometric models are conformed to original design intents in geometric features and ensure assembly precision.

    Design and Analysis of Curve-type Assistance Characteristics of Electric Power Steering System
    He Ren, Geng Guoqing, Miao Lidong, Wang Cuiping
    2007, 18(20):  2515-2518. 
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    A method of segmeted parabola-type assistance characteristic was brought out to realize the curve-type assistance characteristics of the electric power steering system,and a single chip-microcomputer-based controller was designed to carry out the task.The mathematical model of single chip microcomputer control system was constructed,and Z transform was used to analyse the stability of the system.The test result shows that single chip microcomputer control system can realize the curve-type assistance characteristics.

    Research and Development on the Vehicle Roadway Test System Based on a New Six-component Wheel Force Transducer
    Zhou Yaoqun, Zhang Weigong, Liu Guangfu, Li Zhongguo
    2007, 18(20):  2510-2514. 
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    The aim of this paper is to propose a new method for designing a six-component WFT employing wireless data transmission and thus constructing a smart data acquisition and analysis system for roadway test.It was able to measure real-time
    six-direction wheel loads and other important parameters when the vehicle was running, and provided the experimentalist with friendly graphical users’interface, so that the evaluation and diagnosis of vehicle performance under different road conditions can be achieved.The mechanical design of the six-component WFT and the complete system,revalent data processing and actual experiments were discussed in detail.Experimental results indicate that the whole system is effective and ideal.