China Mechanical Engineering

Study on Effect of CNC Machine Motion Errors on Tooth Contract Analysis of Spiral Bevel Gears

TANG Jin-Yuan, LEI Guo-Wei

2010, 21(20): 2395-2401,2429.

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Researches of the effect of machine kinematics errors on tooth contact analysis of spiral bevel gears were made. Based on the multi-body error-modeling method and the theory of gear

engagement, the paper brought forward the spiral bevel gear tooth contact analysis including the machine tools’ kinematics errors.With an example of a pair of spiral bevel gear processed by spiral generated modified(SGM) method, here particularly introduced

the course of E-TCA establishment.The quantified relation between the spiral bevel gears tooth contact quality and the machine tools’ kinematics errors was found describing

in numbers.Analyzing the results of TCA and ETCA shows that the machine tools’ kinematics errors will influence the spiral bevel gears tooth contact quality. Different axis errors have different effects on tooth contact analysis, the results of the analysis give a theoretical reference to compensate machine geometric errors.

Thermomechanical Modeling and Simulation Analysis of Oblique Cutting

LI Bing-Lin, WANG Hua-Lin, HU Xu-Jin, LI Cheng-Gang

2010, 21(20): 2402-2408.

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A thermomechanical model for oblique cutting was proposed. Using equivalent plane approach, orthogonal cutting theory based on unequal division shear zone was extended and applied to oblique cutting. The orientation of the equivalent plane was determined by the equivalent plane angle. The geometrical parameters associated to oblique cutting were analyzed using the coordinate transformation approach. The governing equation of the shear velocity, shear strain, shear stress and temperature distribution in the shear zone were established. The flow stress was predicted from Johnson-cook material constitutive equation which considered the effects of strain hardening and thermal softening. At last, the cutting forces were calculated for different machining conditions, predicted results are in good accordance with oblique cutting test data from the available literature and found. The proposed model can be used to predict cutting force of end milling by the experimental validation.

Experimental Study on Exciting Torsional Guided Wave in Steel Pipe with Magnetostrictive Transducer

SHU Long-Xiang, WANG Yue-Min, LI Cheng-Hua, CHEN Li-Hua

2010, 21(20): 2408-2411.

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A configuration of magnetostrictive transducer to excite torsional guided wave in steel pipe was investigated.Several pieces of strips made of iron-cobalt alloy were attached to the steel pipe with the alignment angle 45° to the pipe axial direction. Through the magnetostrictive effect of the strips, torsional guided wave of T(0,1) mode was successfully excited in the steel pipe with high SNR. A intact steel pipe was tested in different excitation frequencies, the test singals were compared and the best excitation frequency was determined.

Numerical Analyses of Fatigue Life and Crack Growth Based on Damage Mechanics

DONG Bin, CA Gan-Wei, ZHENG Zhan-Guang, MAO Kun-Peng

2010, 21(20): 2412-2415.

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Based on the continuum damage mechanics, the fatigue damage behavior of a P355NL1 steel specimen with notch under cyclic load was discussed. A damage mechanics-additional load-finite element method was constructed by two ways, one was the fatigue damage coupling theory of strain equivalence, the other was the additional load method of damage mechanics, whose steps were measured by the length of cycle-index with a combining ekill technique. A subroutine to calculate damage and predict fatigue life on ANSYS platform was developed by APDL of ANSYS, the initiation and growth of cracks were simulated by damage developing, the crack propagation paths were given under the different cycles as long as the fatigue life has been obtained. At last, the comparison between fatigue test and calculation results indicates that this method is right, feasible and of high accuracy.

Research on Deflection Compensation of Ram of Super-heavy-duty CNC Floor Boring and Milling Machine

TUN Feng-He, WANG Shao-Wei, YANG Yo-Lin, WANG Ti-Hong

2010, 21(20): 2416-2420.

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A combined method of theoretical analysis, numerical calculation and experimental technique was proposed to solve the problem of deflection compensation of long stroke ram of super-heavy-duty CNC floor boring and milling machine. The laws of deflection of ram, and the relationship curve between deflection and stroke of ram were obtained through finite element analysis methodology. The preliminary calculation formula of compensation force was derived through theoretical analysis, and the relationship curve between compensation force and stroke of ram was obtained through finite element analysis methodology.Theoretical and experimental results show that, the method given

herein can exactly forecast the distribution of ram’s deflection, and it is feasible for deflection compensation of ram of super-heavy-duty CNC floor boring and milling machine.

Adaptive Backstepping Sliding Mode Control of Electro-Hydraulic System of Resonant Machine

ZHANG Beng-Jun, JIANG Xin-Hua

2010, 21(20): 2420-2423.

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With regard to the nonlinear, parameter uncertainties on the impact of running velocity control of the pavement component of resonant machine, an adaptive backstepping sliding mode control approach was proposed. The mathematical model of the velocity control based on proportional pump-control-motor system was set up, the adaptive backstepping sliding mode control algorithm was designed. The adaptive adjustable law of parameter uncertainties were given to ensure the asymptotic convergence of velocity output tracking errors based on Lyapunov stability theory. Results from simulations and experiments on vehicle show that this method has better velocity control performance and strong adaptability and robustness. 

Fuzzy Evaluation for Performance of On-machine Inspect System Using Normal Distribution Fuzzification Method

CHU Xiao-Cheng, XIE Wen-Hua, SHU Hui, GUAN Zhi-Gang

2010, 21(20): 2424-2429.

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A multi-level fuzzy comprehensive evaluation model and performance index system of on-line measurement system was established based on the theory of fuzzy.On the basis of test data, fuzzy evaluation matrix was obtained by using normal distribution fuzzification method, and the weight coefficient of each index was determined reasonably. Finally, the fuzzy theory was used to obtain evaluation results of all layers. Taking an on-line measurement system as instance,the feasibility of the evaluation method was demonstrated.Results show that the overall performance of this on-machine measurement system is good,with accuracy margin,and can be used to inspect parts on machine tools.

Research on Fretting Wear of Wind Turbine Slewing Bearings

WANG Sai-Meng, HU Meng-Heng

2010, 21(20): 2430-2433.

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Fretting damage form and fretting operation mode in raceways and teeth of wind turbine slewing bearing used on the wind turbine bearing were analyzed.In order to find difference of fretting wear at various contact angle and hardness, the composite fretting tests with GCr15/42CrMo ball-on-flat were carried out with grease at tilted angle of 45° and 60°,and at hardness of 58～60 HRC and 44～46 HRC respectively.The results show that the contact angle decreases at the high hardness, while the contact angle increases at the low hardness,the fretting wear damage of 42CrMo material

can be reduced,and the extent of fretting damage is related to mechanical properties of two material in contact with each other.

Research on Feature Extraction Method of High Pressure Water-jet Reflective Sound Signals

YANG Hong-Chao, WANG Cong-Dong, ZHANG Dong-Su, LI Meng, SUN Yu-Ling

2010, 21(20): 2434-2437,2467.

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In order to extract different eigenvalues of high pressure water-jet target effectively, the sound signal eigenvalues of target material and physical dimension were acquired by applying wavelet noise reduction and module maximum method. The basic principles were described in detail. The corresponding eigenvalues extracting software was programmed. The experimental facility collecting reflective sound signals was built by using mixed abradant water-jet equipment, mike and high-speed data acquisition equipment. The experiments detecting protecting arms mine, mud and stone by water-jet were done, and the data was acquired. The data was processed based on the software mentioned above. The wavelet parameters were well selected. The result shows that the sound signals of target reflection, water-jet and environment can be separated effectively by using wavelet noise reduction and the sound signal eigenvalues of different material target are obtained. The sound signal mutate spot eigenvalues of different physical dimension border are obtained effectively by using the module maximum method. These eigenvalues can be used to identify target material and physical dimension.

Envelopment-approach to Manufacturing of Spiral Bevel Gears Based on Computer Numerical Control Cutting Machine

ZHOU Kai-Gong, ZHOU Xiao-Yan

2010, 21(20): 2438-2444.

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A new method(envelope-approach theory) for generating the

meshing characteristic-oriented design of point-contact spiral bevel gears tooth surface was presented by application of the five-axis simultaneous CNC cutting machine. Differing from previous studies, the new method was derived from the idea of motion of moving trihedron along a predesigned path of contact on the predesigned (theoretical) tooth surface.The generated tooth surface provided by the new method has tangency of second order with the predesigned (theoretical) surface along the predesigned path of contact and the predesigned (least )warping in regions that differ from the path of contact.This means the new method can generate meshing characteristic-oriented design tooth surfaces.An example was given to prove that above-mentioned manufacture method is accurate and feasible.

Constrained Optimization Techniques for Job Shop Scheduling

YANG Hong-An, SUN Qi-Feng, GUO Jie

2010, 21(20): 2445-2450,2458.

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The job shop scheduling problem(JSSP) was formulated as constrained optimization problems(COP) herein,and a constrained optimization scheduling model was founded,which used a more realistic cost model that directly accounted for the tardiness costs, work-in-process inventory costs, and finished-goods inventory costs introduced by each job. For reducing complication of solving large-scale JSSP,

two-phase approach, which included bottleneck resource identification and single machine E/T sequencing, was put forward. In order to improve the search efficiency and reduce the frequency of thrashing phenomenon, consistency enforcing procedure was put forward to prune the search space by eliminating local inconsistencies that cannot participate in a global scheduling solution. By instantiating and satisfying bottleneck-resource and difficult variables first, the system moved to more constrained deadend states, this reduces the time the system wastes attempting to complete partial solutions that cannot be completed. The proposed approaches have been tested on a wide range of 80 scheduling problems and satisfactory results have been obtained.

Effectiveness Evaluation of Manufacturing Process Quality by Measurement of Extended Information Entropy

ZHANG Gen-Bao, CENG Hai-Feng, WANG Guo-Jiang, ZHANG Jia-Wei

2010, 21(20): 2451-2458.

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The complexity of manufacturing processes causes difficulties in process modeling, forecasting and control.From the information theory point of view, the information entropy of process is inversely related to their degree of order, therefore, process complexity can be described by information entropy to further analyze quality state and evolution direction of processes.To describe quantitatively the complexity in manufacturing processes,the information entropy theory was extended to establish a generalized information entropy model based on size, difficulty and state-diversity.Then complexity of manufacturing processes were divided into static and dynamic complexity based on their dependency on time.The extended information entropy model was used to study how to measure the complexity in manufacturing processes, and the method was applied in quality analyses and evaluation of manufacturing processes to measure quantitatively the effectiveness of process quality control by complexity. Finally, an example demonstrates validity of the proposed theory and methodology.

Order Allocation and Sequencing Research on Complete Vehicle Mixed-model Assembly

Line 

LI Su-Ke, LIU Cheng-Jiang, YU Dao-Yuan, ZHANG San-Jiang, SHI De-Song, HE Shi-Lin

2010, 21(20): 2459-2462.

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Through the analyses of the mixed-model assembly lines located

in different regions,this paper established the lowest cost to manufacture and load balanced allocation model for the target orders,and designed three sets of orders to reflect selling season, off-season and regular season orders. Besides this paper used

tabu-hierarchy genetic algorithm to solve the problems, and eventually gain a set of

Pareto,which indicates effectiveness of the model and algorithm.

Research and Application of Interactive Data Fusion Technology in Product Evolution Design

HUA Er-Tian, LIU Xie, NI Yang-Dan

2010, 21(20): 2463-2467.

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An interactive data fusion technology based on client demands

was presented herein and applied to product evolution designs. Through client-layer’s data fusion,the evaluation of different clients can be treated comprehensively and obtain the overall evaluation.Through data fusion among index sets of design variables,

a new index set of design variables can be built,which is consistent with client demands. At last, an application example was given.

Research on BOM Configuration Based on Product Design

CENG Fu-Hong, ZHOU Dan, GUO Gang

2010, 21(20): 2468-2474.

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In order to implement product development efficiently by being blended with autoconfiguration technology,a concept of KBOM was put forward.The reusable and sharable configuration models of products were established to represent domain-specific knowledge based on KBOM. then the configuration model was mapped to DCSP.

To solve the DSCP a graded traversal algorithm which was blended with backtracking algorithm and optimum seeking algorithm and similarity matching algorithm was designed and its inference process was provided.Finally, a configurable gear pump case was presented to verify

the effectiveness and feasibility of the presented approach.

Research on Extraction and Analysis Models for Job Shop’s Production Progress Information Based on Multi-information

WANG Dong-Jiang, YAN Ping, LIN Fan, LIU Fei

2010, 21(20): 2475-2481.

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Description and analysis of complex production progress information in job shop has been a difficult problem of the manufacturing execution system.

An analysis model for production progress information based on the multi-information of workshop operation state was proposed.After setting up the hierarchical relationship of various progress targets and establishing correlation matrix by analyzing the relevance of operation state’s multi-information,a model whose basic idea is guided by two information mainlines realized the analysis and processing of complicated production progress information through assessing with relevant feature attributes and index weights.

The results of practical applications show that, with accurate extraction and analysis of the complex production progress information, the balance problem of the workshop’s

progress and ability can be better solved,the management objective for a fast, efficient and low-cost modern job shop can be achieved, and the production management level and enterprise competitiveness of modern job shop can be improved.

Model of Partner Selection for Dynamic Virtual Enterprise with Extended QoS Constraints

ZHANG Si-Wen, NI Zhi-Wei, WANG Li, LI Zhi-Dong

2010, 21(20): 2482-2487.

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The present Web service architecture provides a good solution for the

integration of dynamic VE system,but it is still not good enough as to support the selection of dynamic VE partner with QoSextr constraints.So here an extended model(DVEPSEM) of dynamic VE partner selection was presented, By using QoS monitoring system, it extended the traditional QoS, monitoring and processing the enterprise QoSextr in a real time sense.Meanwhile,based on ontology semantics, it established the mapping between services category sets and domain ontology,thus the accuracy and efficiency in enterprise service discovery were achieved. An improved AGA partner selection algorithm based on DVEPSEM was proposed.The problem of partner selection with extended QoSextr constraints and in the large extended dynamic VE was resolved.Experimental

results show that IAGA algorithm can further reduce the evolution generation and improve the accuracy in partner selection.

Conflict Resolution Based on Hierarchical Knowledge Matching in Collaborative Product Creative Design

WANG Xiao-Lei, YANG Yo, YANG Ji, CENG Jiang, CHENG Bo

2010, 21(20): 2488-2495.

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In order to resolve the conflict in collaborative product creative design, a

conflict resolution method based on hierarchical knowledge matching was proposed. Conflict resolution process model of collaborative product creative design was established firstly, and hierarchical knowledge matching-based conflict resolution flow was analyzed. Then, the conflicts were reduced and conflicts’ importance weight were calculated by meams of rough set theory to identify the critical ones. Furthermore, in consideration of design iteration, to select the optimum in large number of feasible schemes generated by hierarchical knowledge matching, integrating the core idea of tabu search and elite recombinant in biological evolution, an improved tabu search algorithm was put forward to optimize product design scheme and coordinate conflict. Finally, the feasibility and effectiveness were verified by a motorcycle product collaborative design example. 

Molecular Dynamic Simulation on Mechanism of Ultrasonic Wire Bonding in Electronic Package

DING Yong, KONG Shu-Qing, JIN Zhang-Jiao, ZHENG Rong-Ti

2010, 21(20): 2496-2500.

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The microscopic mechanism of ultrasonic wire bonding was investigated by molecular dynamics simulation on the interfacial contact and adhesion. Considering that the real bonding area was in the state of plane strain, a two-dimensional atomic model was presented. Sutton-Chen potential was adopted for the interaction among gold atoms. Computational results indicate that after intimate contact between the wire and the bond pad, a strong adhesion generates at the interface, and the adhesion force will be the mechanism of ultrasonic wire bonding. Combining the real contact area from the finite element analysis before, the bonding strength of ultrasonic wire bonding was estimated, which was partially validated by experiments.

Study on Monitorability-based Design in Mechanical Equipment

ZHANG Ru-Lei, YAN Xin-Beng, YUAN Cheng-Qing, BAI Xiu-Qin

2010, 21(20): 2500-2504.

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The advantages of implementation of monitorability-based design were analyzed,implementation information flows of monitorability-based design were pointed out among different departments and the overall implementation framework of monitorability-based design was given during life cycle of mechanical equipment.A case of monitorability-based design was carried out during design,manufacturing by

using simulation tester of internal combustion engine.The excellent feasibility of example application has demonstrated that it provides a good attempt for application and extension of monitorability-based design on engineering.

On-line SOC Estimation of Li-ion Battery Using Luenberger Closed-loop States Observer

YUAN Hai-Chao, DIAO Yu-Lan, ZHONG Zai-Min

2010, 21(20): 2505-2509.

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A dynamic mathematical model of Li-ion battery used on fuel cell electric vehicle was constructed herein based on third order equivalent current model

firstly.A Luenberger closed-loop states observer was then designed to estimate battery SOC based on the dynamic model and feedback of battery voltage measured. Finally,the proposed algorithm was verified by cycle and field experiments.

Dynamics Analysis and Optimization of the Cab of a Heavy Commercial Vehicle

CHEN Guo-Dong, HAN Xu, LIU Gui-Ping, LEI Fei, JIANG Chao

2010, 21(20): 2509-2513.

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Dynamic characteristics of the cab of a heavy commercial vehicle were analyzed using finite element mode analysis theory; it was proved to be right by the corresponding modal test. Some assembly thicknesses were chosen as design variables

using sensitivity analysis, and the optimization problem was built with torsion stiffness constrained, and the first order mode as well as lightweight designed.The surrogate models of radial basis function and micro multi-objective genetic algorithm were adopted,then model manage technique was used to update and strictly control the error from surrogates.

At last, many non-dominated solutions with low errors were obtained, and many design schemes were offered. The first order mode is improved obviously and the weight is lighted.

Early Warning Research Using Information from Automotive Warranty Databases

CHU Hua-Gang, LIN Yan, TUN Wei-Cheng, JIN Beng

2010, 21(20): 2514-2518.

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Warranty databases of an enterprise can be used

for early detection of products reliability problems. It is of great significance for enterprises to improve customer satisfaction and reduce the warranty cost. On the analyses of

statistical properties of warranty data in the automobile industries,an early warning method with a synthetic control chart of incidents per thousand vehicles was created,and the

algorithm steps of the method were given, the control parameters were optimized,and finally a typical example of early warning application was given. The specific practice of enterprises applying the early warning system has demonstrated its effectiveness.

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