Table of Content

10 March 2011, Volume 22 Issue 5

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Forward Kinematics Analysis of 6-3 Stewart Parallel Mechanisms Based on Orthogonal Complement Method

CHENG Shi-Li, TUN Hong-Chao, WANG Chao-Qun, TAO Yu, SHU Jian-Yang

2011, 22(5):  505-509. 

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This paper presented a new analytical method to study the forward kinematics analysis of 6-3 Stewart parallel mechanisms. Analyzing the coupling relationships among the position and orientation variables of the moving platform, additional useful information was obtained, thus eleven compatible algebra equations used to solve this problem were obtained. The orthogonal complement method was used to eliminate the redundant variables, the forward kinematics of 6-3 Stewart parallel mechanisms can be expressed as an eight order equation in the end. Finally a specific example was introduced to verify the method offered herein. 

Virtual Reliability Test Method for Bearing Based on ADAMS

LI Chang, HAN Xin

2011, 22(5):  509-512. 

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Three-dimensional virtual test prototype of the bearings was set up in ADAMS firstly, Monte Carlo parameterization of the prototype was carried out in pseudo-random numbers subroutine. After times of virtual test on the parameterize prototype, analogizing different bearing parameter’s random errors with self-defining function, experimental data were got. Introducing VC++ program to read the data file automatically to compute the run-out reliability level of the bearing’s inner race, it presents a method of virtual reliability test for bearing, which can analyze the effects of different random errors on bearing dynamic behavior effectively. Lastly, it developed an universal bearing virtual reliability test program.

Application Standard Architecture of RFID in Automotive Manufacturing Enterprises

LI Wen-Chuan, WANG Xu, LUO Zhi-Yong

2011, 22(5):  513-518. 

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The role of application standard architecture was described

and the research status of RFID standard was discessed. Application requirements of RFID application standard architecture in automotive manufacturing enterprises were put forward from two points of view-enterprise internal and supply chain.The application standard architecture composed of basic standard, general standard, physical layer standard, collection layer standard, integration layer standard and application layer standard was constructed based on four-layer system structure of RFID system and detailed. The research can offer basic platform for RFID implementation in automotive manufacturing enterprises.

Research on Crankshaft Tangential Point Tracking Grinding Method Based on Three-axis

XU Zhi-Yang, HUANG Xin-Gong

2011, 22(5):  518-521. 

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By analyzing the deficiency of current crankshaft tangential point tracking grinding method based on two-axis, crankshaft tangential point tracking grinding method based on three-axis was proposed. The grinding wheel can move in X and Y axis direction. Their motion models were studied. The results show that this grinding method can achieve constant speed grinding. After experiments, the crankshaft pin can be machined with the cylindricity of 2μm and the surface roughness Ra of 0.4μm. And it provides an effective method to obtain high machining accuracy and surface quality of the crankshaft pin.

Reliability Model of Shield Machine Cutter Drive Multi-stage Planetary Transmission System Considering Failure Relevance

DIAO Yong, QIN Da-Tong, WU Wen-Hui

2011, 22(5):  522-527. 

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Multi-failure modes of each gear and multifactor relevance were existed in a planetary gear transmission. Based on the stress-strength interference theory, general reliability computation model for mechanical transmission system was presented under conditions of multi-failure modes and multifactor relevance, and applied to the reliability analysis for the multi-stage planetary transmission system used in shield machine cutter drive. Reliability models for each failure units like gears and bearings were established first. The reliability model of transmission system was obtained considering main failure modes and failure relevance of load and application factor, and Monte-Carlo method was used to simulate the result. The results demonstrate that the model can evaluate the reliability of shield machine cutter drive multi-stage planetary transmission system accurately. 

Grey Prediction of Interference Fit Force for Connecting Rod Small End Bushing

TUN Jiang, CHEN Liang, ZHOU Yi

2011, 22(5):  527-529. 

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In order to reveal the variation rule of interference fit force for connecting rod small end bushing, the influencing factors of fit force were analyzed, which show that the fit force is a random variables, it will change with the used time. On this basis, a grey prediction model of fit force was established according to grey theory, the accuracy of prediction mode was verified by experiments. The testing results show that the prediction results of interference fit force for connecting rod small end bushing has high precision, the grey prediction model can better reveal variation rule of fit force with used time.

Reuse of Virtual Prototyping for Complex Mechanical Products Based on Parametric Modeling

LI Wen-Wei, CHEN Na, YAN Guo-Dong

2011, 22(5):  530-535. 

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In order to reuse virtual prototyping for complex mechanical products, an automatic reconstruction approach of virtual prototyping was proposed through program drive to the size parameters of parameterized virtual prototyping. The modeling requirements for the basic virtual prototyping of complex mechanical products were described under the demands of parametric design. The parameter naming rule was presented. The mathematical model of parameter drive mechanism was described. The solving method of constraint matrix equation was demonstrated. On the basis of all above, we developed a series of parametric modeling program for complex mechanical products. This set of programs achieves the functions of automatic dimension parameterization of the basic virtual prototyping and the automatic reconstruction of the virtual prototyping based on parameter drive.

Analysis of Residual Stress for Autofrettaged Ultrahigh Pressure Vessels

YUAN Ge-Xia, LIU Hong-Zhao, FAN Cai-Xia, WANG Juan-Beng, WANG Qing

2011, 22(5):  536-540. 

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To analyze residual stress of autofrettaged pressure vessels, APDL language of ANSYS was used to model its parametric FE, which was used to emulated the loading and unloading of autofrettaged pressure vessels by using multiple load step of ANSYS. Effects of end conditions of the vessel and material parameters on the residual stress were studied. The results show that end conditions have few effects on hoop residual stress and radial residual stress, and have bigger effects on axial residual stress in near the bore; the location of the greatest hoop stress depends on unloading tangent modulus, big unloading tangent modulus can improve the residual stress of near the bore. The studies used ANSYS BKIN (bilinear kinematic hardening) model to simulate loading and unloading of material mechanical properties by defining two temperature profiles for the material, and improve the prediction precision of the residual stress.

Chatter Analysis on Non-linear Time and Frequency Domain in Finishing Milling Processes

FANG Chi-Feng, TONG Yong-Hai, TUN Chun-Qiao, ZHANG Qing-Wen, HONG Tong-Yue

2011, 22(5):  541-545. 

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To restrain the chatter in finishing milling processes,adopting many non-linear factors which are difficult to model in any closed-form mathematical model,a non-smooth non-linear variable coefficient differential equation in time and frequency domain was established and the numerical solution of the equation was obtained. The impact of the cutting parameters and helix angle on the chatter was proposed.The relationship between the radial cutting depth and the axial depth and the impact of the feed rate on the axial depth were obtained,which were validated by experiments. 

Micro-displacement Amplifying Mechanism Using Loading Revolute Joints and Flexible Hinges

LI Mo-Quan, GAO Chang-Yin, FENG De-Yun, XIAO Qi-Meng

2011, 22(5):  546-549. 

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A mechanism based on flexible hinges to amplify the displacement of stack-type piezoelectric ceramic actuator was designed. The mechanism was composed of semi-cylindrical revolute joints and flexible hinges.The performance of semi-cylindrical revolute joint was studied, and the models of stress and friction torque of semi-cylindrical revolute joint were performed. On the basis of analysis on maximum input displacement, elastic deformation, displacement loss of flexible hinges and the effect of revolute joint on loading, the displacement magnification mechanism was obtained. The results of the finite element analysis and theoretic analysis are in good agreement, which indicates the analytical methods are correct. 

Analysis and Optimization of Climbing-capability of Four-wheel-rhombus-arranged Mobility System

MA Chuan-Shuai, WEN Gui-Lin, ZHONG Zhi-Hua, JIN Qiu-Tan, CHENG Dong, ZHOU Jing-Yu

2011, 22(5):  550-556. 

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A newly developed four-wheel-rhombus-arranged mobility system for lunar rover was presented. To improve the climbing-capability, the independent active swing arms were integrated with the passive rotary link structure in the mobility system. In order to investigate the climbing-capability, the mechanical judging criterions were put forward based on quasi-static analysis method of the mobility system. The climbing capability of the mobility system was analyzed using the criterions. Due to the adjustment of the swing arms, the influences of swing arms on the climbing-capability were studied. Furthermore, the climbing capability was optimized based on the genetic algorithm method. The results indicate that the climbing capability can be greatly improved in the severe environment.

Normal Adjusting Algorithm of a 3-RPS Parallel Mechanism in Airplane Assembly

JU Ji-Hua, ZHOU Mo-Yong, HAN Xian-Guo

2011, 22(5):  557-560. 

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When the wall panels were flexibly assembled, drilled or rivetted, a typical 3-RPS parallel mechanism was used for self adjusting the position and orientation. And the end effector requested the aiguille working through the skin normal direction from the hole. For resolving the normal adjusting problem, the position and orientation modeling was firstly analyzed and described for the mobile platform of a 3-RPS parallel mechanism. And then the normal adjusting solution algorithm was brought forward. Finally, through an example the method is shown that it has the practical engineering application capability. And this normal adjusting algorithm can be extended to the further airplane digital manufacturing and assembly such as positioning and attitude regulation.

Coupling Vector Modeling of Floating Crane and Suspended Load

ZHANG Liang-Juan, SHU Chang-Meng, BAO Ji-Hu, ZHANG Feng

2011, 22(5):  561-565. 

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A 9-DOF nonlinear dynamics model was set up in the background of offshore turbine installation.The dynamics model incorporated ship motions coupled with nonlinear large payload swings. The ship and crane were treated as one rigid body and the model included arbitrary, bi-angular swings of the suspended load coupled with the 6-DOF of the ship, in addition to 3-DOF of the load in-plane and out-of-plane sway angles and elastic stretch of the hoisting cable. The model was described by matrix and vector, which is very general and applicable. The validity of the model was verified by comparion with existing models.

Research on SDG Model Automatic Construction Based on Functional Structure Tree

ZHOU Gong, ZUO Hong-Fu

2011, 22(5):  566-570,575. 

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To obtain the deep knowledge required for SDG modeling of a complex system, the analysis process of system working mechanism was discussed and a concept of FST was presented. FST is a kind of platform for constructing the SDG model, as it organizes diagnostic knowledge such as system function, behavior, failure. The approach of SDG modeling was introduced, which was to construct conjunction matrix based on FST, then transform it to graph. Compared with SDG structured manually, this approach saves time and efforts. It can be less error-prone and easy to maintain, It also meets the requirements of dynamic adjustment of SDG model due to changes in actual working conditions. Finally, the applicability of the approach was demonstrated with a case study of SDG modeling for A320 aircraft pneumatics system.

Study on Hysteresis Model of Giant Magnetostrictive Sensing Actuator Based on Neural Network

LIU Hui-Fang, GU Zhen-Yuan, WANG Fu-Ji

2011, 22(5):  571-575. 

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Based on the coupling relationship between Joule effect and Villari effect of the giant magnetostrictive materials, it proposed a giant magnetostrictive sensing actuator which used induced electromotive force generated by Villari effect and Faraday effect to drive giant magnetostrictive materials occurring Joule effect and generating strain. Its structure and working principle were presented herein. Meanwhile, in order to solve the hysteresis characteristics of the material in giant magnetostrictive sensing actuator, hysteresis loop under different pre-tightening force and maximum working current were measured. Moreover, it put forward establishing the magnetization hysteresis model of the giant magnetostrictive sensing actuator by BP neural networks. The calculation results show that the model can describe hysteresis characteristics under arbitrary pre-tightening force and maximum working current well. It provides evidence for hysteresis compensation of giant magnetostrictive sensing actuator.

Research on Application of a Hybrid Method of QFD and Orthogonal Experimental Method in Mass Customization

TUN Xin-Li, LI Ren-Wang, ZHANG Sai-Rong, XU Xin, LUO Hao

2011, 22(5):  576-579. 

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A new hybrid method of QFD and orthogonal experimental design for the design process of mass customization product was proposed herein, the purpose was to change the customers’ individual needs into design parameters accurately. First, the customization parts division was made according to the design process, selecting the sensitive parts which were affected by customers greatly, using the QFD method to analysis and design, then using the signal and noise analysis among the orthogonal design method to determine the associated relationship during the QFD analysis, the engineering technology parameter group was obtained,which corresponded with the customer requirements. Finally,the designed products with customer satisfaction and robust performance were made. And one bus company’s door design was taken as an example to explain in detail.

Research on Conversion Method from Customer Requirements to Technical Parameters for Green Design

GAO Xiang, LIU Zhi-Feng, HU Di, ZHANG Lei

2011, 22(5):  580-587. 

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In order to develop green products with good green performance and economic performance, the green performance and the constraints of function technical requirements were integrated into the transformation process from the customers’ requirements to the technical parameters.A method based on DEA and gray connection analysis (GCA) was presented. Through substituting the technical competitive analysis matrix with the relationship matrix between function technique and green performance, substituting the correlation matrix with the relationship matrix between function technique and the constraint of function technique, the structure of conventional house of quality (HOQ) was modified. The information fuzziness in HOQ was solved by using fuzzy mathematics. Then, the DEA model of modified HOQ were proposed to analyze the relative effectiveness of function technique requirements’ decision making units (DMU). Based on these, the direction of function technique needed to improve was determined through the sensitivity analysis used to analyze the key factors of DMU influencing technical efficiency based on GCA. Finally, the method was proved to be valid and meaningful through its applications in a dishwasher manufacturing enterprise of Guangzhou.

Research on Pectoral Fins Oscillating Asymmetrically in Time of a Cownose-like Robotic Fish

YANG Shao-Bei, HAN Xiao-Yun, QIU Jing, XIE Hai-Bin

2011, 22(5):  588-591,596. 

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Before the asymmetrical oscillation in time of Cownose-like robotic fish was discussed, the mechanic hint behind the swimming behavior was analysed. Firstly, a mathematic model of the fin rays oscillating asymmetrically in time was set up;secondly, the swimming experiments of the robotic fish with a series of asymmetric coefficients were made, and the results show that it exits a better range of asymmetric coefficients, and while asymmetric coefficients is 0.56, the robotic fish attains the best forward velocity. Finally, the hydrodynamic force of the robotic fish with these asymmetric coefficients was tested, and the relations among each other were discussed. These results will reveal that the attention of the swimming behavior of Cownose ray may improve the propulsive, especially in the case of oscillating with the 0.56 of asymmetric coefficient.

Optimization of Laser Marking Process Parameters on 2D Barcode in Part Surface

JIE Zhi-Feng, ZHANG Wei, LEI Lei, HE Wei-Beng

2011, 22(5):  592-596. 

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In allusion to the blindness in selecting process parameters of direct laser marking, this paper analyzed the influences of process parameters of laser marking and interactions on quality of 2D barcode through a large number of experiments. The process parameters included effective vector step, delay between the effective vector step, electric current and Q-switch frequency. The process parameters of laser marking on 2D barcode in the part surface were optimized and an optimization model was established. Also, a high quality of the 2D barcode which marked by laser can be guaranteed.

Modeling and Simulation of Abrasive Flow in Chemical Mechanical Polishing Using Discrete Element Method

TAN Huan-Jiang, ZHANG Gao, LI Meng-Jun

2011, 22(5):  597-603. 

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According to coupling computational fluid dynamics and computational granular media mechanics method, the motion of abrasive flow in CMP with composite particles was simulated using discrete element method. With PFC3D software, a two-phase flow model that predicted the kinematics and trajectory of the abrasive particles was built herein,two verification simulations were conducted to demonstrate the capability of the current method to solve nano-size two-phase flow problems. Finally, the CMP geometry simulations were conducted, some phenomenon observed in the experiments

were explained. 

Performance Parameter Calculation of Adjustable Speed Asynchronous Disk Magnetic Coupling

YANG Chao-Jun, ZHENG Wu, LI Zhi-Teng, LI Zhi-Bao, JIANG Sheng-Fa

2011, 22(5):  604-608. 

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A novel adjustable speed asynchronous disk magnetic coupling was proposed,of which conductor on driven plate adopted a deep slot teeth shape structure. While the length of air gap between drive and driven plate is changed, the strength of magnetic field is increased or reduced accordingly, then its run speed adjustment is available. It can be used in some high pulling torque and excess vibration of mechanical equipment to avoid vibration, or also realize the motor soft start when in load. Its configuration characteristics and main magnetic circuit characteristics were discussed herein and a deep slot asynchronous magnetic coupling with 9 pole-pairs and 16 slots was analyzed by three-dimensional FEM under static and transient state, the distribution of magnetic field and current were obtained. The performance parameters of the new coupling including torque, power loss and axial force were calculated, and their corresponding curves in the transient conditions were obtained.

Decomposition of Elastic and Plastic Deformation of Sheet to Tube Single-sided Resistance Spot Welding

YANG Hong-Gang

2011, 22(5):  608-610. 

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Combined with the function of weld indentation extraction of servo gun, the welding deformation of sheet to tube single-sided spot welding was studied by experiments,and decomposition of elastic and plastic deformation was realized. Research results show that elastic and plastic deformation will increase linearly with welding current. Under the same welding conditions, when the tube radius is decreased, elastic deformation gets smaller, and plastic deformation is increased, which make welding cracks easily occur. Research results can provide guidance for control of the welding deformation and crack of sheet to tube single-sided spot welding.

Simulation Analysis of Temperature Field in Induction-heating Warm Compaction Mold by Finite Element Method

YIN Yan-Guo, SHU Jian-Wei, WANG Yong-Guo, JIE Ting, TIAN Meng, SONG Beng

2011, 22(5):  611-615. 

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An induction heating model was built for warm compaction mold based on the induction heating theory. The temperature field in the warm compaction mold was analyzed by using electromagnetic-thermal coupling field of ANSYS software. The results show that the longitudinal temperature distribution along the inner wall of the mold is uniform and the temperature difference between the outer wall and inner wall of the mold is very small. The simulation results are in good agreement with the experimental results, which indicates that the temperature distribution in mold is very uniform by using the induction heating method and it is easy to control. The practical test proves that the advantages of induction heating method are very obvious.

Optimization of Structure Crashworthiness for a Passenger Car in High-speed Rear-end Impact

YANG Ji-Kuang, TANG Chao-Qun

2011, 22(5):  616-620. 

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A severe consequence could be resulted from an accident due to gas leakage from tank of passenger car in a high speed rear-end impact. This study aimed to improve the crashworthiness of the passenger car in rear-end impact and minimize the risk of gas leakage. Firstly a finite element model of a full-scale car was developed and validated for simulation of a high-speed rear-end impact according to the rules of new FMVSS301. The rear bumper and rail structure were optimized by using OED and comprehensive equilibrium methods. The effects of 4 parameters (thickness and type of material of rear rail and rear bumper) on integrity of fuel system of the car were considered as main design parameters. The main objective of optimization was the maximum effective strain of fuel tank. The secondary objectives were the energy-absorbing capability of rear rail and rear bumper and the deformation of tank structure around. The optimal parameters are as follows: material of rear rail is DP800 with thickness of 1.5mm, material of rear bumper is DP1000 with thickness of 2.0mm. In this configuration the maximum of the effective strain of fuel tank is reduced by 50.07%.The results show parameter optimization of main structure is very usable in improving the crashworthiness of passenger car in the rear-end impact.

Multi-objective Optimization for Ultra High Strength Steel B-pillar of Car Body Hot Forming Process Parameters

GAO Yun-Kai, DENG Wei-Zhi, CAO Wei

2011, 22(5):  621-624,629. 

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The ultra high strength steel B-pillar of car body hot forming process parameters, such as punch velocity, binder force，static friction, initial temperature of blank, initial temperature of tools etc. were analyzed based on orthogonal experimental design method and the comprehensive evaluation to maximum thinning rate and mean value of dangerous points’ principal strain was obtained by means of fuzzy mathematics. From this evaluation, the extent of overall influences on the process parameters was clarified. Through analyzing the factors resulted from the simulation results, the optimized B-pillar of car body hot forming process parameters scheme was obtained.

Optimization Design of Electric Vehicle Transmission Gear Ratio

HUANG Kang, LUO Shi-Shuai, WANG Fu-Lei

2011, 22(5):  625-629. 

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In connection with the problems to select the transmission number and ratio of pure electric vehicles,according to the requirements of road conditions in Chinese cities and in the case of parameters of electric drive motor and electric vehicle were set,taking the transmission ratio as a variable, the transmission ratio range which can meet the demands of power performance was defined preliminarily after the theoretical basis of the definition of transmission gear number was analyzed.Taking energy efficiency optimization as target, optimization of the transmission ratio of electric vehicles was studied and a visual optimization design method was established finally. Practical applications

show that the proposed method can design the number and the transmission gear ratio

for a pure electric vehicle which will meet the requests of road conditions and achieve

the optimal efficiency of energy utilization.