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Table of Content

    25 June 2015, Volume 26 Issue 12
    Design of Straight Teeth Gear Shaping Cutter without Theoretical Cutting Edge Profile Errors
    Li Jia, Li Xiaoqun, Wang Peng, Zou Yu
    2015, 26(12):  1563-1568. 
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    Aiming at improving the gear shaping machining precision,a design method  of  a  gear shaping cutter without  theoretical cutting edge profile errors was proposed. Based on the conjugation theory of curved surface,a  mathematical model of the conjugate surface of the tooth surface  was  built according to the tooth surface to be machined and the movement characteristics of gear shaping. The sphere surface was chosen as rake face, and the intersecting line of the conjugate surface and the rake face was get by secant method, and the mathematical model of the cutting edge  was built. Many similar cutting edges were  get from the point that the requirements  of without  theoretical cutting edge profile errors  could  be  met  after  grinding.The flank face was formed by these cutting edges, and its mathematical model was built.The gear shaping experiments show that the machining precision has  good consistency  using the cutter before and after grinding , and the correctness and feasibility of this design method is confirmed.

    A  Sequential  Iteration  Algorithm  for  Reliability  Analysis  with Random  and  Dependent  Interval  Variables
    Pan Baisong1;Xie Shaojun1;Du Xiaoping2;Liang Lihua1
    2015, 26(12):  1569-1575,1583. 
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    Focusing on  the  mixed conditions  of both random  variables and dependent interval variables,an efficient hybrid reliability analysis method was   proposed.Interval variables made the reliability analysis problem become  a  double-loop  optimization problem.In order to reduce the impacts  on the reliability analysis  efficiency by the double-loop optimization and dependent interval variables,
      an efficient  sequentially iterative strategy was  proposed,and   a   formula  to  transform the dependent interval variables modelled by  ellipsoid model  was  developed  into independent interval variables,and   the limit-state  function  was  approximated  during the inner loop in the second order form to make the optimization  problem become a more solvable quadratic programming problem.The results show that the proposed sequential iteration algorithm has good efficiency and   accuracy, and that the reliability analysis results are affected by the assumption of dependence between interval variables; results under the assumption of independence between interval variables
    can be  more conservative than that of  dependence.

    A Numerical  Simulation Method  for Force Analysis of an  Overconstrained  PM
    Zhao Yongsheng1,2;Liu Wenlan1;Xu Yundou1,2;Yao Jiantao1,2;Jin  Linru1,3
    2015, 26(12):  1576-1583. 
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    A numerical simulation method for force analysis of the overconstrained  PM was proposed,in view of the fact that very few literatures had  focused on the force simulation analysis of this type of mechanism at present.The rigid-flexible mixed  model of the overconstrained PM was established combining the  3D modeling software,the ADAMS software and ANSYS  software,which  was idendical with the theoretical one completely.The base,moving platform and kinematic joints  were  built as rigid bodies,while the links easy to produce  spatial composite elastic deformations were built as flexible bodies,and the virtual joints were adopted  to replace the actual joints with complex shape during modeling.Only the driving values  were needed  to  be  changed to obtain the actuated forces/torques and the reactions of the kinematic joints when the overconstrained PM was in arbitrary configuration,thus  avoiding rebuilding the simulation  model.Force analyses of three type of overconstrained PMs were  carried out using the proposed method.The results show the correctness and universality of the method, meanwhile show that the method provides a simple and effective way for force analysis of the overconstrained PMs instead of complex calculations.

    Class Ⅰ  Synthesis  of  Cam Mechanism with  Floating Flat Faced Pushrod
    Chang Yong;Lin Rongfu;Li Yanping
    2015, 26(12):  1584-1595. 
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    A  new solution  strategy  of  “preset  cam  axis O1+equidistant/grid/discretization+check+selection”  was proposed.By building “fixed  and  floating  coordinate  system” and  introducing  the  concepts  of:support  function,instantaneous area set and economic searching area,the method for solving the cam axis satisfying the following single or all conditions:ρ>0,α≤[α]∩α≤[α]r andρ>0  ∩α≤[α]∩α≤[α]r, the position area and the morphological characteristics  of cam axis  were  described.Furthermore,the method for searching the flat's working length and length were obtained.The results  show   that the the position area has some characteristics as following: it is like a isosceles triangle with contraction convergent; it exists ridge pointO*1,ridge line  {O*1},and a optimal ridge pointO**1.Lastly,the optimization(non  inferior) solution set of  cam axis and the optimal cam axis are achieved.The problem of class  Ⅰ  synthesis of cam mechanism with floating flat faced pushrod are solved successfully and satisfactory.

    Design and Analysis of a Multiple Output 3D Printing Redundant Parallel Manipulator
    Chang Dingyong;Fang Yuefa
    2015, 26(12):  1595-1602. 
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    A multiple output 3D printing robot was designed. The main configuration of this robot was Delta parallel manipulator, the Stewart parallel manipulator was served as an auxiliary configuration. In order to achieve multiple output ability, more extruders on the end effector of the robot were arranged. Based on the established kinematics model, the inverse kinematics of the proposed redundant parallel manipulator was analyzed and the velocity Jacobian matrix was obtained. Then, the velocity and acceleration of each actuated joint were solved.The motion coordination of the mechanism with a prescribed motion trajectory  was analyzed, which was based on the simulation model. In addition, dexterity and static stiffness of the mechanism were analyzed.

    A  New  Blast  Furnace Distributor and  Analyses  of  Its Movement and Stress
    Lin Wenqiang;Guo Aibo
    2015, 26(12):  1603-1606. 
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    A spatial-linkage-based  distributor was designed  since the complexity and large space occupation of  the bell-less  top  equipment.The authors   simplified the fabric construction and developed a mathematical  model,the governing equations of rotary cylinder was obtained after the specific  trajectory motion simulation using ADAMS  as  well  as the  nonlinear  fitting with MATLAB.The distributor discussed herein  was long subjected to cyclic impact load at 200~600℃,fatigue failure was the most common failure mode.Strength calculations of dangerous parts and fatigue assessments of their nodes were conducted using ANSYS,a software of  which was based on finite element analysis.Analysis shows that the largest fabric angle of this distributor is of  40°and the relative error is less than 0.05%,the structural strength can meet the requirements of an infinite fatigue life.

    Reliability   Modeling   and   Statistical Analysis  for  Series  Structural  Products
    Chen Xiaoping1,2;Chen Wenhua1;Xu Jiaqing2;Hu Rufu2
    2015, 26(12):  1607-1610. 
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    Due to  the small number of electrical connector, the contact reliability  life  could  not be described by the Weibull distribution model.This paper studied a new reliability modeling and statistical method, as well as the model parameter point estimation and Bootstrap interval estimation method for the reliability life analysis of any given  numbers  of  electrical connector.The results were verified by the experiments and show that  the real distribution may evaluate more accurately than Weibull distribution approximation model for the series structural products.

    Thermal Error Measurement and Rotation Accuracy Evaluation of  CNC  Lathe  Spindle
    Li Yan;Liang Liang;Li Yinghao;Gao Feng
    2015, 26(12):  1611-1615. 
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    Considering  that  various  types  of error components were contained in the thermal errors,the  orthogonal method was adopted  herein  to measure  the rotation errors of spindle including radial errors and axial errors  resulted from thermal deformation under various temperature fields.Based on complex vector principle of spindle rotation errors,error separation with  FFT  method was  used to separate the eccentric errors  of  the calibrated artifact and displacement caused by thermal deformation from sampled signals to obtain pure rotation error motion of the rotation axis successfully.So that,the rotation  accuracy of  spindle concerning thermal deformation was evaluated accurately,its analyzed results provide the experimental basis and reference data for the subsequent thermal error compensation.

     

    Machining  Technology  for  Elastic   Composite Cylindrical Rollers
    Yu Jianghong1;Yang Wen2;Li Chao1;Yao Qishui1
    2015, 26(12):  1616-1621. 
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    As the research object,NU318E  elastic composite  cylindrical roller bearing  was analysed and optmised.The processing dimensions were certified and the process  planning was  formulated.The  difficult points were  discussed  including  the  hard-to-guarantee concentricity,the high requirements  of the inner hole and deep hole surface roughness and the material filling processing difficulty,and they were dealt with experiments and adjustments in the   planning.The test results  show that the elastic composite cylindrical roller processed by the thecnology accords with the design requirements and the route is reasonable.

    Thermal  Characteristic Analysis  of a  Mining  Dump-truck  Engine   Compartment  and  Optimization
    Liu Shuichang1,2;Gu Zhengqi3;Zhang Yong1,3;Fan Zunjin1
    2015, 26(12):  1621-1625. 
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    The  engine  compartment  of   mining  dump-truck  is  semi-open  and  its  radiating  load  is  large.To  avoid  insufficient  cooling  and  local  heat  damage,heat  flow  field  thermal  property  in  engine compartment   was  analyzed by  combination  of  real vehicle  test  and  CFD  method.The  analyses  show  that,the reflux at the top edge of   fan's cover  and a  large amount of air flowing close to the deck generate the insufficient cooling of the upper heat sources,thus,a  group of deflectors are  added on the deck, and more the deflectors  layout optimization is carried out  based  on  Kriging  approximate model method.Then,the air flow in the compartment is  improved, the air flow volume towards the upper heat sources increases by 13.8%,the area where air temperature is higher than 370K is   reduced  significantly.

    Applications of Nonparametric Multivariate Rank Chart to Aircraft Engine Monitoring
    Kong Xiangfen;Zhang Bing
    2015, 26(12):  1626-1629,1683. 
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    Multiple monitoring of aircraft engine could solve the problems that the previous one-parameter monitoring detected so many parameters that the indicates will be distorted.TheT2 control chart and the rank chart were applied simultaneously to monitor low-pressure rotor vibration value and high-pressure rotor vibration value for their real-time monitoring,and the performances of the two charts in aircraft engine real-time monitoring were compared and analyzed.The results show that the performance of rank chart is better than the T2 control chart.

    Research   on Technologies   of  NURBS Curve  Fitting  and  Interpolation  in High  Speed  NC  Machining
    Yang Ping;Yang Mingtai;Zhang Yangyang
    2015, 26(12):  1630-1634. 
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    The  algorithm  of  NURBS  curve  fitting  was  put  forward  based  on  least  square  method,and the  NURBS  interpolation  technology  based  on  arc  length  parameter  compensation.By  the analyses  of  characteristics  of  the  free  surface  interpolation  algorithm  of  modern  CNC  system,NURBS  curve  fitted  with  least  square  method  could achieve  a  smooth  tool  path  and  reconstruct  designed  outline  curves  to  some  extents.The   NURBS  method  of  parameter  compensation,which  used  interpolation  parameters  to  be  temporary  interpolation  points  obtained  by  the  Taylor  expansion  method,was applied to  ensure  that the speed  rate  fluctuations  could  be  decreased  effectively,and  that  the speed was  controlled  within  the ideal  range,and that  the  process  precision was   further  improved,and  that  the  vibration  of  machine  was  reduced.The simulation  results  show   that  the  algorithm  is  simple  and  efficient,and  easy  to  be  implemented,which  can   satisfy the  demands   of  modern  CNC system.

    Experimental  Research  on  Boundary Slip  Affectted  by  Liquid Viscosity
    Gao Chenghui1;Du Hua1;Wang Weiqi2;Pan Ling1
    2015, 26(12):  1635-1638,1644. 
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    In order to  study  fluid  flow  characteristics  of  the micro-nano  gap,the  boundary  slip  in  micro-nano  gap  was  studied  using atomic force  microscope,mainly  from the standpoint of liquid viscosity.The  solid sample was SiO2,the  liquid  sample   was  pentarythriol  oleate  with  different  viscosity,their molecular formula are  C77H140O8,their  viscosity  were   32mm2/s  and  150mm2/s,respectively.Using  the  relative  velocity  method  processed  the  test  results,as the results shown,two different  types  of  pentaerythritol  oleate  on  the  face of  SiO2  both  have boundary slip,the boundary slip increases with increasing  of  liquid  viscosity.The  reason  is  shown  as  follow,with  the viscosity increasing,the shear force  which  will increase  between nearing the solid surface liquid molecules and contacting with  solid surface liquid  molecules,so  that solid-liquid  force is easy to overcome,easy  to  generate  boundary slip.

    Damage Identification Based on Multi-scale Transmissibility Function and Grey Moment Relative Entropy
    Yang Bin1;Liu Jibiao2;Cheng Junsheng1
    2015, 26(12):  1639-1644. 
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    To extract the damage sensitive features directly from the vibration response, a damage detection method was proposed based on the multi-scale transmissibility function and the grey moment relative entropy, without requirments for the exciting forces. The multi-scale transmissibility function was obtained by calculating the cross correlation function between vibration responses under different scales after decomposed by the wavelet decomposition, and then the grey moment vector was acquired as the damage indicator by calculating the grey moment of the multi-scale transmissibility matrix under different scale ranges, which was independent of the different loading conditions. And the damage pattern could be identified by the relative entropy among the grey moment vectors of the test data and the sample data. Experimental tests undertaken on a experiment structure validate the proposed method.

    On  Cutting  Mechanism  of  CBN-WC-10Co  Composite   Cutting   Tool  Material  with   WEDM
    Mao Cong1,2;Sun Xiaoli1,2;Lu Ji1,2;Zhang Jian1,2
    2015, 26(12):  1645-1651. 
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    Traditional machining was unsuitable for CBN-WC-10Co composite cutting tool material due to its  perfect toughness,high hardness and excellent abrasive resistance.WEDM  was   an  effective method for  the cutting tool material because of the unique advantages.Experiments on WEDM of CBN-WC-10Co  composite cutting tool material were carried out.The surface properties of WEDM specimens were analyzed by scanning electron microscopy(SEM).The material removal mechanism and thermal damage of CBN-WC-10Co were discussed.The study  indicates that the material removal mechanism with WEDM  is  mainly due to the extremely high temperature generated by the discharge channel which makes the local material melt or gasification,and  the products are thrown out under the action of discharge explosive  force.Meanwhile,the discharge explosive force  makes  part of  CBN  particles directly  fall off from the cemented carbide and forms  pits.Cobalt is easy to  over-removal for the good conductivity,low melting point and boiling point,and  then WC  particles  always  drop  from  the  surface  owing to the losing of the supporting structure.The shock wave generated in the discharge channel can also cause the appearance of the local crack at WC grains edge.

    A Step Identification Method of Mechanisim Parameters of 5-DOF Parallel Machine Tool
    Dang Pengfei;Fang Lijin
    2015, 26(12):  1652-1657. 
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    A step identification method of mechanisim parameters was proposed based on QPSO algorithm to improve the accuracy of 5-DOF parallel machine tool. Firstly, according to structural characteristics of 5-DOF parallel machine tool, the measurement configurations were  selected optimally. Then, the identification problem of mechanisim parameters was regarded as a nonlinear optimization problem, and solved through the two-step identification. The simulation results illustrate that the actual values of geometric errors of parallel robot can be identified accurately through the step identification method based on QPSO. Furthermore, the step identification method of mechanisim parameters is feasible for other limited-DOF parallel robots.

    Fault Diagnosis of Rolling Bearings Based on DEMD and Symmetric Difference Energy Operator Demodulation
    Meng Zong;Ji Yan
    2015, 26(12):  1658-1664. 
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    Aimed at the modulated characteristics of the mechanical fault vibration signals, in order to extract amplitude and frequency informations of multi-component amplitude modulation and frequency modulation signals, a method was put forward based on the DEMD combining with symmetric difference energy operator demodulation. First of all, the original vibration signals were decomposed by DEMD algorithm, getting a number of single component signal, and then symmetric difference of three energy operator demodulation was used for every single component signal, getting instantaneous amplitude and instantaneous frequency of each single component signal, and the spectral envelope was calculated, finally the method was applied to the simulation signals and the rolling bearing fault signals. The experimental results show that the method can accurately extract the fault features of mechanical fault signals and realize rotating machinery fault diagnosis effectively.

    Study  on  Torque  Converter  Blades  Parameters  by Sensitive  Parameter  Analysis
    Liu Zongqi1,2;Li Zhiyuan1;Liu Hailin2
    2015, 26(12):  1664-1669. 
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    In  automobile  and  engineering  vehicle  transmission system,the  blade  design  of  hydraulic torque converter  was  of   always difficulty.By the  use  of  DOE  technology,the blade import and export angle,deviation angle and loss  coefficient  were studied as the sensitive parameters  of  hydraulic torque converter.Their  influences   on  the peak efficiency,starting  torque ratio and  torque  coefficient  were  synthetically  considered.Finally,the  influence  trend among  these parameters was obtained,the specific domains  of the influencial factors were  confirmed.The influence trend was verified  by relevant  tests,based on the change of the import angle of the pump impeller.It  has important guiding significance on converter optimization.

    Mesh  Model  Restoration  for   Complex  Holes
    Yuan Tianran1;Cheng Xiaosheng2;Sun Quanping1
    2015, 26(12):  1669-1675. 
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    In order  to meet the practical engineering application needs  of  complex  hole restoration,this paper  proposed  a  robust mesh model restoration architecture with C0~C2  continuity based on zipper closure principle and thek  order  discrete Euler-Lagrange  equation  derived from minimizer of the surface energy functional.The  final experimental results show that the proposed hole restoration method can  deal with complex holes efficiently and correctly.

    Buckling   Optimization  of  Composite  Laminates  Based   on  Improved  Simulated Annealing  Algorithm
    Sun Shiping;Zeng Qinglong;Wu Jianjun
    2015, 26(12):  1676-1683. 
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    An improved direct search SA  algorithm  was presented to find globally stacking sequence design of symmetrically composite laminates with maximum buckling load.A new point generation mechanism was introduced into improved SA to enhance  the stability and efficiency of the algorithm,which the variational search area for generating new point was proposed to realize global and local search consistent.The design variable was as   discrete ply angle and buckling response of laminate was analyzed by Ritz method to consider the bend-twist coupling.A multiple-global optimal  problem known was explored to comparative investigate the performance of improved SA.Further,the numerical examples were conducted for different angle increments,layer  numbers,aspect ratio and load ratios,the results show that the presented algrothm is capable to optimize the stacking sequence of composite laminates.

    Preforming  Tube's  Design and Deformation  Analyses   of  Medium-sized  Truck Bulging-pressing Axle  Housing
    Wang Liandong;Pang Meng;Zhou Lifeng;Cui Yaping
    2015, 26(12):  1684-1689. 
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    This paper  proposed the preforming tube's  design criteria of medium-sized truck bulging-pressing axle housing  based  on  the  deformation analyses of round  tube  blank   pressed into  special section.For a truck axle housing with the load of  5t,the bulging-pressing deformation   technology was introduced and  30 groups of preforming   tubes with different front cover ratius and different rear cover ratius were designed.And the  whole forming process was simulated by using ABAQUS software.Through the formability analyses of  preforming tube's  bulging and pressing processes,the front cover scaling factorKm  and  the rear cover scaling factorKn  were determined.The reference body of  revolution and   a  typical non-symmetrical  preforming tube were selected for  bulging-pressing  tests.It  is found that the former's  rear cover  is  cracked in the forming process and the later successfully trial produces   sample with good forming,and the measured values generally align with  the simulated values of  wall  thickness  in  the  forming  process.

    Cooperative Control Strategy  of  Power  Following-speed Switching in  a  Range  Extender  Electric  Vehicle APU
    Shen Yongpeng1;Wang Yaonan1;Meng Bumin1;Yi Dihua2
    2015, 26(12):  1690-1696. 
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    To  solve  the  cooperative control problem of the engine and generator in APU system,the speed switching-power  following  APU  cooperative control strategy was proposed  herein.Firstly,the power-speed  switching table  of  the engine was designed  according to  the optimal brake specific fuel consumption(BSFC)  curve.Then,a  second order sliding mode controller of the engine speed was designed,which was based on the engine mean value model.Meanwhile,the PWM rectifier output power  controller  was  designed,which was based  on  the  direct  power  control  algorithm.Through the closed-loop control of the engine speed and PWM rectifier power,the proposed control strategy forced the engine to  run along the optimal BSFC curve.Finally,the joint simulation model   was  developed based on AVL Cruise and MATLAB/Simulink.The simulation results show that the proposed APU cooperative control strategy is excellent  in  aspects of power following and speed controlling accuracy,battery voltage,current  and state of charge(SOC) fluctuations,as well as the operating points distributions.

    A Study of Power Shift  Mechanical Transmission for Pure Electric Vehicle
    Zhao Kegang1;Yao Weihao1;Liu Yanwei2; Ye Jie1
    2015, 26(12):  1697-1703. 
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    A novel power shift mechanical transmission for pure electric vehicle was put forward,which was accomplished by single actuator.A mathematical model of this 2-speed transmission system was set up,both of the dynamics performance of torque phase and inertial phase during gear shift was  studied.Combined with the bench test results,it is shown that the transmission has the characteristics of power seamless during gear shift because of the power transmitted by high and low gears keeps  a linear and continuous change. Moreover, vehicles equipped with this 2-speed mechanical transmission were  also studied on power performance and economy, the results show that,compared to other transmissions,the vehicle performance and  cost issues are given consideration to through this transmission.