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Table of Content

    10 July 2013, Volume 24 Issue 13
    Development of a Rotary Test Apparatus for Liquid-solid Two Phase Flow Erosion Wear
    OU Guo-Fu, XIE Jian, ZHANG Li-Te, RAO Jie, JIN Gao-Zhe
    2013, 24(13):  1705-1709. 
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    A rotary test apparatus was developed herein, which was used for liquid-solid two phase flow erosion wear testing. The apparatus had significant advantages over commonly used rotary test apparatus: impact angle could be permitted within rang of 0°~90°, and uniform slurry density was obtained in different impact velocities, which used mixing blades and diversion trenches. In addition, the apparatus is simple in operation and provides continuous adjustable impact velocity between 0~28.5m/s, it meets that 8 specimens can be tested in different impact angles simultaneously. The errors of test data were within 6.8% obtained by experiments of mild steel in different impact velocities and angles, the relation between erosion rate and influence parameters is in line with classical conclusions. This test apparatus has promising applications in optimization design and lifetime prediction for equipment eroded by slurry erosion.

    Improvement for Kriging Method in Applications of Blade Measurement
    LI Bin-1, LI Feng-1, CHEN Fu-Ying-2, FU Zhi-Feng-2
    2013, 24(13):  1709-1714. 
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    Some unknown points should be estimated to solve blind measurement area aroused by blade overlap in the process of propeller blade measurement,and the estimation results had an important effect on the later processing of blades.By means of the basic idea of Kriging interpolation algorithm, a improved Kriging interpolation algorithm based on mixture data (measurement data and design data) was put forward.This new model employed spline method as the regression function,and whose subject was made up of measurement data.Besides,the characteristics of propeller section curve were considered adequately and the extension trend of the curve in the blind measurement area would be come up with design data.The experimental results show that the approach is of operation efficiency and the estimation results will satisfy application requirements of the enterprises.

    Design on Macro/Micro Strain Sensor Based on Grating
    XU Cong-Yu, FANG Wen-Qiong, SUN Ya-Qiong, YUAN Hang-Zhou, LUO Xiang
    2013, 24(13):  1715-1719. 
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    To meet the requirements of millimeter range and nanometer resolution of strain measurement for bridges and deep-sea equipment, a novel macro/micro strain sensor based on grating moiré fringe was designed. The sensor consisted of two sliders connected face to face by spring instead of guide connection so as to prevent the transverse deformation of measured object from sensor mechanism and installation condition. To analyze the additional deformation of support mechanism of sensor caused by spring force, the theoretical calculation and finite element simulation were well conducted. The theoretical analysis and experimental results show that, in the ±2mm range, the measurement resolution of sensor is less than 5nm and the maximum additional deformation aroused by support mechanism is less than 20nm.

    Spectrum Segmentation of Multi-mode Vibration Signals Based on Spectral Clustering
    WANG Dan-Dan, ZHOU Yu, XIE Qiang-Wei, WANG Xiao-Dong
    2013, 24(13):  1719-1723. 
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    The modal peak in frequency domain was interfered strongly under the strong noise, causing the inaccurate modal parameters, as well as producing modal frequency miscalculation. According to this situation, this paper adopted spectrum clustering algorithms to cluster the vibration spectrum, and come up with a new method for spectrum segmentation. First, according to the concept of wave spectrum, the vibration signal spectrum was divided into pack of waves. For each wave as a sample of clustering, this paper used spectrum clustering to cluster these waves. The wave similarity function, Laplace matrix and clustering algorithm were constructed, and this algorithm was used to cluster automatically.  Finally, the clustering result is that a big peak in macroscopic. By the experimental results of simulation signals, this spectrum clustering algorithms can accord with the macroscopic observation of modal separation efficiency,and it is stronger to the noise resistance than that of the existing k-means algorithms. According to the test of a cable, the stability and accuracy of this algorithm is demonstrated again. 

    Robust Controller of Hydraulic Robot Joint Based on Quantitative Feedback Theory
    WANG Yan-1, QIN Yu-Fu-1, GUO Sheng-Rong-2
    2013, 24(13):  1724-1727. 
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    Single joint performance of hydraulic robot directly affected the overall performance of the robot control. The uncertainty and time-varying of hydraulic system parameters decreased the control precision and response speed of single joint, which requested the single joint controller had robustness. A mathematic model of servo valve controlling swaying hydraulic cylinder was established and the system parameter uncertainty was analyzed. Based on quantitative feedback theory(QFT), a single joint robust controller was designed. Simulation shows that the controller has strong robustness against the slope interference and sine interference. Experimental results verify the correctness of the robust controller.

    Loop-Analysis-Based Automatic Creation Method for Bottom Finish Machining Region of Pocket Feature in Aircraft Structural Parts
    ZHANG Dan-Lei, LI Ying-Guang, LIU Chang-Jing, LIU Xu
    2013, 24(13):  1728-1733. 
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    A loop-analysis-based method was proposed to address the problem concerning the variety of curve-clipping types, the complexity of accepting or deserting the clipped curves and the error-prone characteristics of creating bottom finishing region of pocket feature in aircraft structural parts. In this method, the boundary of exterior loop of the generalized sides and generalized bottoms of the part were projected to the bottom. Then these curves were discretized to a set of lines. After that,
    the lines were tailored with the calculation of all the intersections. Ultimately, using the line-rotating method to analyze the loop and the optimized bottom finish machining region was obtained. This method can improve the efficiency of NC programming for bottom finish machining effectively, and bottom finish machining region of all kinds of pocket feature can be created using this method. Based on the above research, a feature-based bottom NC programming system was developed, which is applied in a large aviation manufacturing enterprise successfully.

    Research on Accurate Information Acquisition of Straightness Errors with Time-domain Three-point Method
    WANG Feng, TU Xiao-Fen, MENG Fan-Liang, LIU Yuan-Yuan
    2013, 24(13):  1733-1737. 
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    In the field of straightness measurement, the zero errors and random errors would increase quickly within a few iterations if conventional time-domain three-point method was used.As a result,the reconstruction of the straightness curve was distorted, thus the correct straightness error can not be obtained.A error-equivalent-averaging method based on comparing-then-elimination approach was proposed herein, and its effectiveness and practicality were also proved by simulations and experiments. Accordingly time-domain three-point method was optimized,thus it is possible to obtain  straightness information accurately.

    Finite Element Simulation of Small-hole on Titanium Alloy Drilled by EDM
    WANG Xu-Ti, HU Hui, LIANG Yan-De, XU Wen-Ji
    2013, 24(13):  1738-1742,1748. 
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    In order to predict volume removal rate of small-hole on titanium alloy drilled by EDM efficiently, a mathematical model of single-pulse on drilling small-hole on titanium alloy was developed with the application of finite element simulation. The model utilized several important parameters such as Gaussian heat source model,percentage distribution of the heat input among workpiece, spark radius with the discharge time and latent heat of melting . The picture of removed volume was simulated with the method of elements with birth and death. Then the volume removal rate was calculated finally. An experiment of drilling small-hole on titanium was carried out on K1C high-speed machining, time was recorded. Weighing method was applied to get the weigh before and after EDM. Then, the volume removal rate by single-pulse was calculated. Compared simulation and experimental results, the error is less than 10%. The model has the preferable prediction precision on volume removal rate by EDM. Consultation is provided to guide small-hole on titanium alloy drilled by EDM.

    Design and Experimental Study of Variable Freedom Bolt Clamping Mechanism
    WANG Cai-Dong-1, WANG Li-Quan-2, DIAO Dong-Yan-3, MENG Qiang-Xin-2
    2013, 24(13):  1743-1748. 
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    A variable freedom bolt clamping mechanism was designed by the configuration design method of variable freedom mechanism, which could solve the problems of 20 bolt clamping positions for flange connection tool of underwater petroleum pipeline. The various functional structures in different working stages were analyzed, and the clamping mechanism had the function that clamping and release of the bolt group. The bolt clamping mechanism system's multi-body dynamics model was built by the software of ADAMS. By analysis of the operating process dynamics simulation, the stress curves of bolt were gained. The simulation results show that the group bolt forces uniform to meet the bolt clamping and positioning needs. The test of bolt clamping mechanism test prototype was carried on herein. The results indicate that the clamping mechanism has clamping and release function of the bolts, which will ensure the bolt positioning accuracy. The group bolts can lead-in the nuts successfully, which verifies that the design of the bolt clamping mechanism is rationality.

    Fast Automatic Fundus Images Registration and Mosaic Based on CUDA
    WANG Yu-Liang-1, CHEN Jian-Xin-1, LIAO Wen-He-1, ZHANG Yun-Hai-2
    2013, 24(13):  1749-1754. 
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    In order to overcome the characteristics of low contrast, non-uniform illumination, limited field of view (FOV), and the geometric distortion between different FOV of the fundus images, a fast automatic fundus image registration and mosaic algorithm was presented based on CUDA. Fundus images were enhanced by homomorphism filtering and the SIFT features in effective FOV were extracted and matched between images with CUDA speeded up. With CUDA application, point pairs were purified using RANSAC algorithm employed perspective model, transformation matrixes were computed according to the matching point pairs of surrounding FOV images to the central, image registration and image fusion was implemented to get fundus panoramic image finally. The automatic registration and mosaic results of multiple FOV images obtained by fundus camera show that the algorithm is robust and stability with registration accuracy is up to pixel level, the algorithm speed upgrades 10 to 30 times, high-precision automatic fundus image mosaic can be achieved.

    Application of Hilbert-Huang Transform Analyzer in Feature Extraction for Mechanical Faults
    CHEN Ren-Xiang, SHANG Bao-Beng, SU Jie-Jiang
    2013, 24(13):  1755-1760. 
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    In order to improve the portability and efficiency of feature extraction for mechanical faults based on HHT, a HHT analyzer was developed on the Visual C++ 6.0 platform. And, the efficiency and precision of the different interpolation methods,end extending methods and stopping criterion were compared, and merits and faults of the algorithms in HHT were obtained. Then, the strategy of choosing different HHT algorithms was proposed. A comparison was made between this analyzer and the HHT algorithm of DataDemon from DynaDx Corporation, and the correctness of the algorithm was verified for the analyzer. At last, the signals of outside circle fault for rolling bearing and rotor running across were analyzed by the analyzer, and the fault characteristics are extracted effectively.

    Design and Optimum of Novel Mechanical CVT
    CENG Wen, WANG Yu-Xin, JIA Gong-Mei, QING Yan-Mei
    2013, 24(13):  1760-1764. 
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    Based on the principle of variable speed transmission and characteristics of double crank mechanism and ratchet wheel mechanism, we came up with a new type of continuous non-frictional mechanical CVT. The kinematic law was studied through methods of analytic geometry and mechanism synthesis, and the function of transmission ratio and mechanism parameters were established. Maximal transmission ratio was the objective of the mechanism; to reach this target means to obtain optimum parameters, the structural size, double crank's formation and limit of transmission angle were as constraints. A computer program was worked out successfully to determine these optimum parameters.

    Analysis of Dynamic and Static Properties of Fluid-structure Interaction for Wires of #br# WDPSS-8 Robotic System in Streamline Flow Field of Low-speed Wind Tunnels
    ZHENG E-Jing, JIAO Shao-Ni, YANG Yong-Bai
    2013, 24(13):  1765-1772. 
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    The flexibility of wires in a wire-driven parallel suspension system for low-speed wind tunnels at the static experiments of the vehicle model will lead to the coupled behavior of wind-induced vibrations of wires which will make the posture of the end-effector deviate the desired values. In order to implement real-time compensation of the deviations of the postures, in terms of the WDPSS-8 system, dynamic and static properties of two-way coupled fluid-structure interaction for wires in the streamline flow with the wind speed of 35 meters per second were investigated on the basis of ANSYS/CFX software. The investigations were finished when the attitude angles of the vehicle model were changed one by one, under the assumption that wires were satisfied with the theory of linear elasticity and subjected to axial tensions. The results show that it is expectable that there exists much less aerodynamic interference of wires compared with that of traditional strut support; however the changeable values of the postures of the end-effecor should be calibrated by real-time compensation owing to 3-dimensional complicated vibrations of wires with the bending along the wind.In addition the vibration suppression of wires as well as flow control of the connections between the vehicle model and wires should be given; at the same time, since the axial stress of wires will change as well, the acquirement of aerodynamic forces/torques by measuring the tension of wires is not feasible.

    Pulsed Eddy Current Signal Detection and Analysis
    YANG Li-Jian, LI Chun-Hua, FEI Lei
    2013, 24(13):  1773-1776,1782. 
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    In order to detect the defects on thicker steel plate, a high-current pulse was needed, which was generated by chopping the low-voltage high power supply. Moreover, cylindrical probe was designed to detect surface defects of steel plate by slow discharging of exciting coil; rectangular probe was also designed to detect sub-surface defects of steel plate by instant discharging of exciting coil. Then the transient induced voltage signal of pulsed eddy current was processed by the wavelet filtering and amplitude normalization. Experimental results show that the wavelet filtering can improve detecting accuracy and the signals amplitude normalized can reflect the relationship of the defect curves at different depths defects more directly. It is concluded that amplitude of high pulsed eddy current signal excited by high-current can reflect the depths of defects on surface and sub-surface of thicker steel plate effectively.

    Fundamental Study of Forming by Controllable Spark-induced Combustion and EDM Finishing
    CHEN Wen-An, LIU Zhi-Dong, WANG Xiang-Zhi, WANG Fu-Zhi
    2013, 24(13):  1777-1782. 
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    A new method called forming by spark-induced controllable combustion and EDM finishing was proposed. It could gain the purpose of efficient removal rate and lower relative electrode wear rate, where the high-pressure oxygen was reacted with the melting metal, and pushed the products out from working region. In addition, the normal EDM which was carried out in oxygen off stage was finishing the surface to insure the accuracy and surface quality. The experiments were carried out by four methods: EDM in kerosene, EDM in water, continuous combustion and intermittent combustion. The results show that the material removal rate of intermittent combustion is increased 4.28 times than that of EDM in kerosene, and relative electrode wear rate is reduced 72%. This paper analyzed the machining mechanism of intermittent combustion by machining wave form, and also analyzed the processing characteristics of intermittent combustion by electrode couple surface micro-morphology and composition.

    Varying Load Incentive Dynamics Model and Response Characteristic of Planetary Gear System of Wind Turbine
    YANG Jun, ZHANG Li-Ping
    2013, 24(13):  1783-1788,1795. 
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    According to the characteristics of varying load and varying speed of the planetary gear system of a wind turbine, the dynamics model of the planetary gear system under varying load was proposed and the differential equation of system motion was obtained by analyzing the forces of components with rigid body or elastic body and applying theory of the composite motion. On the basis of these, the mechanism of influence of the internal and external incentive on dynamic load and dynamic factor of planetary gear system was analyzed. Taking a typical MW planetary gear system of wind turbine as an example, the dynamic response characteristics were simulated and analyzed, the results show that the time-varying mesh stiffness of gear pairs and the time-varying stiffness of bearing affect the size of response frequency, the low frequency components are found in response frequencies and energy allocation of various order frequencies is also influenced because of the external loads. The research results lay a foundation for dynamic optimization design and life analysis of wind turbine gearbox.

    A Compound Fault Diagnosis Method for Gearbox Based on Morphological Component Analysis and Energy Operator Demodulating
    LI Rong, XU De-Ge, CHEN Xiang-Min
    2013, 24(13):  1789-1795. 
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    Aiming at the problem of separating fault characteristics from vibration signals of a gearbox with compound faults, a compound fault diagnosis method for gearbox was proposed based on MCA and energy operator demodulating. According to the morphological difference of each component, different sparse dictionaries were built by MCA to separate each component from the vibration signals of a gearbox. By using MCA, the vibration signals of a gearbox with compound fault can be decomposed into harmonic component containing fault information of the gear, impulse component containing fault information of the bearing and random noise component. The harmonic component and the impulse component were analyzed respectively by the energy operator demodulating, and the compound fault diagnosis was carried out according to the demodulation spectrum. The simulation and application examples show that the proposed method can separate the fault characteristics from the vibration signals of a gearbox with compound faults effectively.

    Research on Influence of Electric-Feeder-Termination-Discharge on Contact Resistance in EDM of Silicon
    SONG Jia-Jie, QIU Meng-Bei, LIU Zhi-Dong, TIAN Zong-Jun
    2013, 24(13):  1796-1799. 
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    In order to improve EDM machinability of high resistivity silicon, a new method aimed at reducing the contact barrier was raised by EDM sweeping on the surface of metal film on the electric feeder termination, named electric-feeder-termination-discharge (EFTD). First, a copper film was deposited on the surface of silicon (2.1Ω·cm). Then, electrical discharge happened between a copper brush and the copper film. Finally, a heavily doped layer between the silicon and copper film was formed by the action of high temperature. The formation mechanism of heavy doped layer was analyzed. The test specimen (silicon) was prepared, and the I-U characteristic curve was measured. The results show the reduction of contact resistance. In the end, an EDM experiment on silicon ingot with the resistivity of 2.1Ω·cm and the diameter of 100mm was conducted. The EDM efficiency is as 30mm2/min.

    Active Vibration Analysis of a Liquid Hydrostatic Slide under Force Load
    DIAO Jian-Hua-1, 2, GAO Dian-Rong-1, 2
    2013, 24(13):  1800-1805. 
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    Based on hydrostatic slide under the force load, the active vibration models of the open type and the closed type hydrostatic slide were established, and then the oil film stiffness and the damping coefficient of the hydrostatic slide were derived. Imposing harmonic and anharmonic periodical load to the slide, the natural frequency, the amplitude and the phase angle of the slide system were calculated separately, and the influence of the design parameters of the slide system on the natural frequency and the amplitude was analyzed theoretically. Taking the closed type liquid hydrostatic slide as example, the natural frequency and the amplitude amplifying coefficient were analyzed. The results show that the natural frequency can be regulated by changing the pressure of the oil pocket and the thickness of the oil film, and then under the force load the pressure of the oil pocket makes no impact on the amplitude, but the thickness of the oil film, the oil temperature and the frequency of the load do. The proposed research analyzes the active vibration of a liquid hydrostatic slide system under force load, and provides a basis for reducing the vibration of the hydrostatic slide and improves the machining accuracy in the practical engineering.

    Robust Bilevel Optimization Model for Product Family Architecture Design
    LI Yan-1, 2, DU Gang-1, LIU Bei-1, 2
    2013, 24(13):  1805-1808,1816. 
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    A bilevel multi-follower programming model with uncertain coefficients was established herein for the product family architecture design to reflect the leader-follower relation among the platform parameters and non-platform parameters,and the global-local relation  among  the product family and each product of
    the product family in the uncertain circumstance.A hybrid genetic algorithm was put forward for the deterministic bilevel programming with no shared variables among followers transformed by robust optimization method.Finally,the robust bilevel optimization model
    was proved by a truss family architecture design.

    Modeling and Simulation Analysis on Impactor Hydraulic System of Water-powered Pile Driver
    WEN Ze-Jun-1, WANG Jin-1, YANG Shu-Yi-1, LUO Chun-Zhi-2, GUO Guang-Meng-2
    2013, 24(13):  1809-1816. 
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    Based on power-bond theory, a graph bond model of the hydraulic system was built, with the impactor function analyses of a water-powered piler. By using of the AMESim software, a simulation model of the impactor hydraulic system was developed. Setting the parameters, the motion curves of the impact pistol and valve were obtained by running the simulation model. The motion charateristics of the piston and valve were discovered by analyzing curves of the displacement, the velocity and the acceleration. Furthermore, the influences on its performance were studied by adjusting the parameters separately such as flowrate, relief valve pressure, pistol mass, the underlap length of front chamber and middle chamber etc. The results show that increase of flowrate can not improve the impact performance of water-powered pile drive if it meets the rated value of the hydraulic system; higher relief valve pressure can utilize the input engergy fully and improve its proformance obvisouly; increase of the pistol mass will lower its performance; extending the underlap length of the front chamber can improve its proformance; however, extending the underlap length of middle chamer will lower its proformance. It provides the theoretical basis for optimization and design of water-powered pile driver impactor.

    Control of Welding Residual Deformation and Hot Crack of LD10 Thin Plate by Welding with Impacting Rotation Compression
    ZHANG Yong, QI Xiu-Ling
    2013, 24(13):  1817-1821. 
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    Large welding residual deformation and hot cracks can be easily found during LD10 thin plate welding. The motion, welding with impacting rotation compression, was utilized to generate a force. The force acted on the weld bead and near weld zone to produce plastic extension. In order to know the effects of the welding with impact rotation compression on the microstructure and mechanical properties of the weldment, welding residual stress and deformation, metallographic observation, SEM of fracture, tensile experiment and hardness measurement of the weld joint were utilized. The experimental results show that the residual stress and deformation, hot crack can be reduced by the technology of welding with impacting rotation compression.

    Effect of Tangential Force on Contact Stability of Cellular Structure of High Temperature Sweating Lubricated Materials
    JIE Fang-1, 2, YAN Song-Shan-2, LIU Zuo-Min-2
    2013, 24(13):  1821-1825. 
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    Based on the contact mechanics model of high temperature sweating and self-lubricating thick-walled cell body, the orifice stress of the cell was analyzed under the tangential and normal forces, and the effects of tangential force on its contact stability were investigated using the finite element software of ANSYS. The results show that: tangential force has little effect on the contact strength and fracture behavior of thick-walled cell with single pore, however, it leads to the contact strength decrease of thick-walled cell with two and four pores, while the contact strength and fracture behavior of thick-walled cell with three pores depend on the value of the tangential force, and on its direction. Therefore, it is very important to control the structural morphology of the cell in the design and preparation of cellular materials.

    Influences of Particle Size and Combination on Forming Accuracy of SLS Silicon Carbide Preforms
    LIU Xiu-Mei-1, 2, XU Zhi-Feng-1, TU Huan-1
    2013, 24(13):  1826-1830. 
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    Laser sintered SiC ceramic powder with different combinations were fabricated by thermal-coating, and SiC ceramic preforms were produced by SLS. Influences of the particle size and combination on the forming accuracy of the preforms were discussed. The results of this investigation demonstrate that the size and combination of the particles have a significant impact on the forming accuracy of the laser sintered ceramic preforms. The warpage of the preforms decreases as the size of particle is inereased, while dimensional tolerance and surface roughness increase. Compared to single-size particles, the warpage of the preform which fabricated by the combination of dual-size particles is decreased by 11%~50%, surface roughness Ra is decreased by 12%~20%, dimensional tolerance is reduced by about 38%~79.6%.

    Effects of Additional Front-dome on Bulging-pressing Formability for Automobile Axle-housing
    CUI E-Beng, WANG Lian-Dong, YANG Li-Yun, LIU Chao
    2013, 24(13):  1831-1835. 
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    According to the bulging-pressing deforming new process,an initial seamless steel tube was made into automobile axle-housing blank with additional front-dome after diameter reducing, hydroforming and pressing, and the axle-housing can be gotten once the front-dome was removed. The additional front-dome affected the material utilization and the bulging-pressing formability. For a small axle-housing, three front-domes with different shapes and sizes were designed, the whole reducing, bulging and pressing deforming processes were simulated with software ANSYS, the reasonable size range for additional front-dome was given by analyzing the formability of dome part and ends buckling. The axle-housing blank was produced successfully with a common press, and the design method was proved to be reasonable comparing shape parameters with simulation results.

    Car Form Design Based on Subdivision and Deformation
    GUO Lei-1, 2, JI Xiao-Min-1, HU Gang-1, CHU Jian-Jie-3
    2013, 24(13):  1835-1840. 
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    A method for car form design based on subdivision and deformation technology was proposed herein.Firstly,the designer provided a basic simple mesh model of the car with multi-deformation channels and subdivided the car model.Then the detailed form was modified by the users according to the locally changeable models.Finally,the dseigner determined the final car form through statistic analysis of the feedbacks from the users.In this process,the redesign and the evaluation of the car form were carried out at same time.As a result,this method makes the users express personal expectations for car form,and enables the designer to obtain the direct data of the users' expected car form.This method is easy to conduct,and can obtain many car form solutions,which is able to promote the better communication and makes the design process more efficient.

    Optimization for Multi-link Suspension Hard-points Based on PDJI-MOPSO Algorithm
    FENG Jin-Zhi, CHEN Xin, ZHENG Song-Lin, HOU Cheng-Yu
    2013, 24(13):  1841-1845. 
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    Based on the rigid body kinematics theory, a mathematical model of a multi-link suspension was established, which was followed by the validation using the corresponding simulation model based on multi-body system dynamics theory. With perturbation method, multiple factors sensitivity analysis was researched about key hard-points of affecting suspension K&C characteristics, which were optimized by applying the PDJI-MOPSO algorithm, and the Pareto optimal solution set was obtained. The results show that the values of camber angle, toe angle and wheel travel track are reduced. The optimized suspension is more conducive to vehicle handling stability, and reduces tire wearing loss as well.