Table of Content

10 November 2010, Volume 21 Issue 21

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Study on Nonlinear Dynamics of Seeker Servo Mechanism Structure

LUO Zi-Rong, FAN Da-Feng, CHANG Jian-Zhong, YANG Zheng

2010, 21(21):  2521-2526. 

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Smart Bearing Based on Embedded Multi-parameter Sensors

SHAO Yi-Min, CHU Wen-Bing, ZHOU Xiao-Jun, GE Liang

2010, 21(21):  2527-2531. 

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A new smart bearing based on the embedded multi-parameter sensors was proposed herein, which was the integration of two accelerometer sensors, two rotational speed sensors and two temperature sensors on the bearing. It can monitor the horizontal and vertical vibrations of the bearing, and also the speed and the temperature. A new conjunctive structure of the compound sensor and the bearing was developed, which integrated compound sensor into bearing by a groove manufactured on outer raceway of the bearing. The principle prototype of smart bearing test rig was also developed to test and verify the performance of the smart bearing, and the results show the performance advantage when using the smart bearing to do condition monitoring.

Application of Hertz Contact Theory in Analyzing Load Distribution of Mill Roller Bearing with Boundary Element Method

XIAO Hong, YANG Xia, CHEN Ze-Jun, WANG Jian

2010, 21(21):  2532-2535,2540. 

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A revises method was proposed herein,which was used to analyze mill roller bearing load with boundary element method. First, a contact width was supposed, then the Hertz contact theory was used to revise the contact width.By means of the iterative algorithm, the calculation prosess will stop until the D-value of supposed contact width and the revised contact width satisfy the convergence conditions, with which a more accurate result can be obtained. An example of a conical bearing system of one duo mill was given to show the effectiveness and high accuracy of the theory. 

Fuzzy Control of Magnetorheological Damper and Parallel Connection Vibration Depression System Based on Magnetic Levitation Device

ZHOU Jin, LIU Yong

2010, 21(21):  2536-2540. 

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Because of large mass, low stiffness and damping of a magnetic levitation system, the vibration control is unsatisfactory. Especially, when the excited vibration amplitude is very large, the effect on vibration reduction will not be good. In order to solve the problem, the magnetic levitation system and the MR damper were connected parallelly. Moreover, because of the nonlinear and hysteretic behavior of MR damper, which was controlled by fuzzy controller. Based on the TMS320LF2407A DSP, the software and hardware of the system were designed. Experiments show that the fuzzy control MR damper parallel connecting with magnetic levitation system can get better vibration depression affections, and the amplitude of vibration will be reduced from 0.48mm to 0.16mm.

Sub-pixel Corner Detection Algorithm of Chessboard Image Based on Improved SUSAN Operator

YANG Nie-Fang, HUANG Yu-Mei, LI Yan, GAO Feng

2010, 21(21):  2541-2545. 

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An improved SUSAN corner detection operator was proposed herein aiming at SUSAN operator’s deficiency revealed in detecting chessboard corners. On the basis of the limitation analysis about the SUSAN operator, the authors pointed out that one of the disadvantages of the SUSAN operator is that it just takes into account USAN’s size without considering USAN’s shape in detecting feature points and which may result in incorrect detecting results. Therefore, two ring-shaped masks were added within the SUSAN circular mask to overcome this defect. Moreover，in view of chessboard image has sharp brightness contrast, its shape is symmetric and its brightness distribution is symmetric, the authors utilized the center of the gravity of brightness to position chessboard corners in order to achieve sub-pixel precision. In practical operation, the USAN was separated into two regions, that is, the internal pixel region and the external pixel region and the algorithm performance was enhanced by restraining the noise of the internal pixel region by means of averaging the brightness of the internal pixel region. Experiments show that the proposed algorithm can implement effective detection of all chessboard corners and can achieve sub-pixel precision.

Contact Stress Analysis of Variable Curvature Arc Spherical Roller Bearings

LI Sai-Cheng, CHEN Xiao-Yang, MA Chun-Qing, CHEN Ai-Hua

2010, 21(21):  2545-2550. 

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Two methods to reduce the stress value were presented herein according to the problems of stress distribution of spherical roller bearing: first, optimize the ratio of osculation coefficient under different load conditions; second, divide the available length of the roller to several sections evenly, and the radius of the roller between every section is different. Based on Boussinesque plastic contact theory, a numerical method was used to develop a computer program to calculate the stress on the roller-race contact areas. Compared to Hertz theory, the contact stress and other data of the program are exact enough. The contact stress is reduced to a large extent by the crown profiled method, accordingly the life of the bearing increases significantly.

Study on Fuzzy PID Intelligent Control System for Hydraulic Press Blank-holder Force

CAO Chun-Beng, SUN Yu

2010, 21(21):  2551-2554. 

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Taking YJ28E-1000/1600Q hydraulic press as an object, an intelligentable fuzzy-PID control model was built to deal with the undesirable dynamic response and the low steady-state precision of the hydraulic control system. A look-up table for optimal control parameters was generated from MATLAB Toolbox. The simulation results of the system show that the dynamic response and steady-state precision are improved greatly by adopting this kind of fuzzy-PID controller. 

Analysis on Contact State of Abrasive Belt Polishing Process for Engine Valve Surface

YAN Qiu-Sheng, SONG E-Nan, GAO Wei-Jiang, KONG Hai-Peng

2010, 21(21):  2554-2558. 

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The transitional surfaces of a engine valve neck were processed with abrasive belt polishing method and the polishing characteristics of the transitional surfaces were analyzed, then the motion model and the contact state model were established. In the polishing process, the polishing linear velocity of the transitional surfaces changed drastically and the contact state between the abrasive belt wheel and the workpiece was variational, these will affect the processing stability and the machined surface quality. The contact state and the change rule between the engine valve transitional surface and the elastic belt wheel were studied, and the variation curve of the material removal in the polishing process was calculated theoretically, which is approximately in accordance with the experimental results.

Analysis of Special Two-phase Flow Coupling Field in Vertical Roller Mill Based on RSM

SUN Ye-Wang, ZE Xiang-Bo, BAO Wei, WANG Wei

2010, 21(21):  2559-2564. 

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Mixture multiphase flow model and the Reynolds stress equation eddy viscosity model (RSM) of the chamber were used to simulate numerically internal special multiphase flow of HRM4800 chamber to analyze the powder transportation. The results show that under influence of the rotation of table and rollers, there is special three dimensional rotation flow field in the powder transportation and visible turbulent flow in the chamber. The gas-solid turbulent multiphase flow field has active local asymmetry and the turbulent pulsation. Especially，there are visible turbulent eddies in the flow field between table and rollers. It indicates the relation between flow boundary and turbulence. The high-speed flow flied is formed in the reduction flow field between table and chamber and profits the powder transportation. In the special flow field there is wall turbulent flow which has linear average velocity characteristics consistent with the legal theory of wall turbulence.

Application Study on SJ-2/2 Remote Control Car Ropeway

LUO Cai-Yang, FENG Jian-Xiang, JING Lin

2010, 21(21):  2564-2568. 

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Because YP2.5-A type remote control car exists several problems: structure is complex, volume is large, weight is bulking, operating speed is low, area of application is narrow and costing is high. YP-2 remote control car was designed based on productive experiments. YP-2 type remote control car, the structure and performance parameter of JSD3-2 type winch were analyzed. Application condition of SJ-2/2 type remote control car in plantation logging clearing was presented from technical reliability and economic rationality. According to comparison with the traditional cable crane, the SJ-2/2 type remote control car ropeway has characteristics of simple ropeway system, convenient installation and teardown, simple operation as well as high degree of automatization, advanced technology and high production efficiency, low operating cost, remarkable economy benefit.

A Trajectory Planning Method for Cubic Uniform B-spline Curve

MAO Zheng-Yu, LIU Zhong-Jian

2010, 21(21):  2569-2572,2577. 

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 A new interpolation method was presented to satisfy the requirements of CNC machining for complicated curves. Firstly, the proposed method used cubic uniform B-spline segments based on a real-time overlapping combination algorithm to fit complicated curves, and then an adaptive algorithm was provided to calculate the interpolation step size through taking the chord error, velocity and acceleration into consideration, which can provide a good performance for improving the contour accuracy and reducing the impact on machine.At last, a trajectory planning strategy was put forward to guarantee the trajectory in the interpolation process meeting the smoothed constraints of velocity, acceleration and jerk. The simulation results of interpolation experiments show that the presented method can ensure high-speed and high-accuracy of machining complex curves, and has a good smooth feature of velocity, acceleration and jerk. This method feasibility has already been proved in real CNC system.

Research on Drilling Experiments of SiC Particle Reinforced Aluminum-matrix Composites with Ultrasonic Vibration

HU Nie-Xin, ZHANG Xiao-Hui, LIU Chuan-Chao, DIAO Bei

2010, 21(21):  2573-2577. 

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A method of ultrasonic vibration drilling was presented to the hole-making of metal matrix composites based on fundamental analysis of vibration machining. In virtue of the self-developed ultrasonic drilling equipment, experiments of common and ultrasonic vibration drilling were performed on SiC particle reinforced aluminum-matrix composites（SiCp/Al）

with different contents of SiC by using two types of tungsten carbide drill. Cutting characteristics of machining composites with ultrasonic vibration were analyzed from such respects as the composites crush, drilling force, drill wear and hole surface quality. Results show that, during the ultrasonic vibration drilling process, drilling locating precision and surface quality of holes can be enhanced, wear of the drill chisel edge can be effectively improved, and the drilling torque can be reduced about 30%.

Design and Implementation of Manufacturing Execution System for Aircraft Tools

DU Hui, XIE Wen-Hua, LOU Pei-Huang

2010, 21(21):  2578-2583. 

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In order to improve the level of informatization and manufacturing, a manufacturing excution system for aircraft tools(MES-AT) was presented. Baesd on the research of the system’s requirement analysis, system structure and main function modules, the key methods and techniques of MES-AT, such as production planning based on CBR and MRPⅡ,fuzzy scheduling based on immune genetic algorithm, were deeply researched.Its application in a aircraft tools enterprise shows that both production efficiency and quality are improved greatly.

Componentization in Rapid Design of Assembly Line

ZHANG Shun-Qi, QIN Xian-Sheng, DENG Rui-Jun, BAI Jing

2010, 21(21):  2584-2589. 

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In order to design and manufacture assembly line rapidly with low cost, a concept of component was led in based on modular design. Componentization methodology was proposed and used for rapid customized design and manufacture of assembly line. Component, component instance, componentization and configuration were defined respectively. Componentization method and procedure were presented. Componentization was realized by the steps of element identification, element cluster and element set abstraction, and then a component library was built. Configuration principles of rapid customized design for assembly line were put forward. Configuration outfit formulation was constructed and the processes of component instantiation were presented. It was applied to design and manufacture an assembly line. The application was tested to improve the development cycle and efficiency.

A Study of Competitive Product Family’s Planning Theory and Method

WANG Zhi-Liang, MA Yin-Zhong, GENG Feng

2010, 21(21):  2589-2594. 

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First, product’s "family competition" idea was forwarded and the corresponding argument was theoretically verified: more member variety of product family increases competitiveness of product family; optimizing customized attributes can minimize product’s customization deviation from market demands. Second, this paper proposed a CV model which aimed to create and sustain "family competition" advantage with product family planning and a extended QFD model based on "family competition". Then a concrete CV computing method for product family and offspring was given. Third, analyzing CV’s competitive gap among families can let enterprise identify competitive advantages or inferior ones, and decision making principles adjusting customized attributes’ value were introduced. An example was given to illustrate the validity and effectiveness of the proposed theory and method.

Two-Echelon Inventory Model with Service Level Constraint and Controllable Lead Time Sensitive to Order Quantity

CHOU Wen-E, CHAN Mi-Yuan, LI Guan

2010, 21(21):  2595-2602. 

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Two-echelon inventory problem with service level constraint and unknown distribution function was analyzed when controllable lead time was sensitive to order quantity. First the basic model of this problem was established and based on relevant analyses the original problem could be changed by Minimax method. Then the optimal order quantity and production quantity influenced by service level constraint were analyzed and range of optimal order quantity and production quantity were given. According to this range, an effective method and tactics were put forward to solve the changed problem. In case analysis, the optimal two-echelon inventory can be obtained and it was analyzed how service level constraint and safety factor influence the optimal two-echelon inventory. The case results show that with the service level constraint and safety factor, the optimal two-echelon inventory is constrained by the higher constraint between service level constraint and safety factor. 

Simulation Modeling of Dynamic & Flexible Scheduling about Large-sized Component Production Workshop Based on Cellular Automata

CHEN Yong, RUAN Nie-Cong, LU Jian-Sha

2010, 21(21):  2603-2609. 

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A simulation model of dynamic & flexible scheduling about a large-sized component production workshop was built by using the cellular automata according to the characteristics. The scheduling system can be divided into 4 parts: work station, buffer, work piece, and scheduling rules. Work station and buffer were viewed as fixed grid nodes, work piece as moving particles, scheduling rules as the local self-evolution rules which included station choosing rules, work piece sequencing rules and task activating rules. Their program graphs were designed, the evolution of the state attributes values were illustrated based on a numerical example. By simulation modeling the job scheduling of a certain generator component production factory workshop, a better scheduling scheme was compared with the present one. Finally, it is verified that simulation modeling based on cellular automata is an effective method dealing with the dynamic & flexible scheduling about large-sized component production workshop.

Coherence Analysis of Inputs Using Multiple Correlated Subsystem-inputs System Modeling

AN Mu-Jin, LI Shun-Ming, ZHANG Yuan-Yuan, LIU Jian-Ya

2010, 21(21):  2609-2613. 

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A subsystem-input/single-output system model was proposed，then the correlation among inputs was analyzed, which was in two correlated subsystem-inputs/single-output system, and the input relationship after average process was given. On the basis of above, the correlation among inputs was derived, which was in multi correlated subsystem-inputs/single-output system and a model after average process was proposed. A collective average method was used, which can make the order coherence turn into a no order one, hence an exact modeling was obtained, and this was prepared for the further analysis to know the contribution of subsystem-inputs. Finally, the results of an automobile vibration test data were given, the theoretical analysis was verified.

Study on Oil Quality Evaluation Method and Its Implementation Based on Multi-information Fusion

LIU Jian, TUN Xiong-Chi, JI Shi-Ming

2010, 21(21):  2614-2618. 

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An oil quality evaluation method based on multi-sensor information fusion technology was presented, and its two-integration models were established,and a neural network model for solving two-integration models was developed. With the advantages of multi-source information technology, a comprehensive assessment of oil quality was implemented. Examples and experiments for demonstrating neural network training process and its results were given. The examples and experiments show that four kinds of oil samples predict the results origined from the evaluation method based on multi- information fusion technology are consistent with the actual ones. The comparison between trend projections and actual tests also show the correctness of the oil quality evaluation model. The proposed multi-information fusion technology for oil product quality evaluation method improves the evaluation precision and reduces dependence of technical personnel experience.

Friction and Wear Properties of MoSi₂ at Elevated Temperature and Wear Rate Prediction

HU Xiao-Beng, HUANG Zhi-Chu, ZHANG Hou-An, YA Jian-Hui

2010, 21(21):  2619-2623. 

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Using the Al₂O₃ ceramic as friction pair，the effects of single influence factor(temperature, load or speed) on the friction factor of MoSi₂ material were studied by high temperature friction and wear testing machine. The wear rate predication of MoSi₂ material under interaction among temperature, load and speed were also studied. The adaptive learning rate and with additional secondary momentum BP neural networks prediction model were studied. The network training process was also given. Network prediction and the actual testing results show that the improved BP neural network has higher prediction accuracy and the prediction error was controlled less than 3%. Network prediction can meet the predicting needs of molybdenum disilicide under the complex conditions.

A Detailed Numerical Drawbead Model and Its Applications to Wrinkle Simulation

ZHANG Hua

2010, 21(21):  2624-2627. 

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A numerical drawbead model developed in sheet metal forming simulation was introduced. According to the similar effect between an equivalent drawbead model and a spring, a spring element was adopted to treat the drawbead process in the incremental dynamic explicit method. The treatment can consider the drawbead passive effect in real-time and synchronously to reflect the sheet metal flow law. The results of practical automobile panel show that the numerical drawbead model can simulate the development of local wrinkling in deep drawing with higher precision.

Parameter Identification of Hyperelastic Constitutive Model Based on Hybrid Algorithm Combining Ant Colony Algorithm and Genetic Algorithm

CHEN Shao-Wei, CHENG Ai-Guo, HU Chao-Hui, HE Zhi-Cheng

2010, 21(21):  2627-2631. 

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A new hybrid algorithm was introduced constructing the hyperelastic material constitutive model based on combination of genetic algorithm and ant colony algorithm optimization strategy to analyze the reverse problems. The least-square method was adopted to minimum the difference between the simulation values and target values. The new algorithm employs ACA features, GA crossover and mutation evolutionary strategy to improve features of the global search. At the same time the algorithm was compared with GA, showing a better accuracy. The final results of the example herein also show that the algorithm has certain practicality in real engineering applications.

Recent Advances and Future Perspectives in New Type Grinding Wheels

DENG Chao-Hui, WU Qiao-Beng, ZHANG Gao-Feng, ZHANG Bi

2010, 21(21):  2632-2638,2645. 

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Grinding process is an important machining technique,and it has a wide range of applications in precision machining and ultra-precision machining.The wheel is a widely using tool in the grinding process,but the conventional wheel exists high specific grinding energy and temperature rise,high ratio of normal to tangential grinding forces,and the abrasive can fall off by grinding forces in the process.Moreover,grinding wheel wear and loading problems becomes more sever when grinding sticky materials,which requires more frequent wheel truing and dressing.This paper discussed the state-of-the-art and the achievements of the grinding wheels,and analysed the features and shortages of some new types wheels,such as brazed monolayer wheels,fiber wheels,slotted grinding wheel,soft wheels,porous grinding wheels and grinding wheels with controlled distributing abrasive,and the future perspectives in grinding wheels were also

studied.

Progress on NDT Technologies for Micro-defects of Engineering Ceramics

TIAN Xin-Li, WANG Jian-Quan, DAN Wei, YANG Dun-Fei, GUO Fang, ZHANG Bao-Guo

2010, 21(21):  2639-2645. 

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The engineering ceramics have eminent comprehensive performances, and very small critical size of processing damages or intrinsic defects. Therefore,

it is a necessary action of carrying out NDT upon ceramic blanks and products in order to ensure their quality and reliability. Some surface/sub-surface defects and inner defects detection technologies of engineering ceramics were summarized according to their current situation of research and application.And several potential NDT technologies were elaborated and reviewed except conventional penetrant testing,ultrasonic testing and

radiographic testing.There are many appropriate NDT technologies for engineering ceramics.

However,high efficiency, reliability and intelligent detection methods are needed for current economic and technical conditions.