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Table of Content

    10 September 2015, Volume 26 Issue 17
    Intelligent  Manufacturing——Main  Direction  of "Made  in  China 2025"
    Zhou Ji
    2015, 26(17):  2273-2284. 
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    How to transform from a big nation in manufacturing  to  a  powerful one is a great subject of China's  economic development in the new era.This paper discussed  the guiding ideology,strategic deployment,basic policy and strategic measure of “made in China 2025” based on detailed analyses of current manufacturing situations  of China,and indicated  that “Internet+advanced manufacturing+modern service industry” will become a new engine of China's economic development.It  is pointed  out that digitization,networking and  intellectualization of manufacturing industries  are the core technologies of  a new round industrial revolution, and should be used as commanding point,breakthrough and main direction of  “made in China 2025”.An overall thorough interpretation of above points was put forward.

    Research on Lightweight Design for Disc Brake Caliper
    Tang Jinyuan, Zhao Guowei
    2015, 26(17):  2285-2290. 
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    Taking volume and fatigue life as lightweight design goal, an integrated computer-aided technology was used for disc brake caliper's lightweight design. First, through comparing the barking torque which got by FEA and experiments it is proved that FEA's steps and methods are correct and feasible. Then, combining the maximum principal stress which got by FEA with nominal stress method and Smith method was used to calculate the fatigue of caliper. Finally, Through ISIGHT integrating CATIA、ABAQUS and MATLAB, the lightweight of caliper was performed.

    Local Characteristic-scale Decomposition Method Based on Differential Operator and Its Applications
    Wu Zhantao, Cheng Junsheng, Li Baoqing, Zheng Jinde
    2015, 26(17):  2290-2296. 
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    A novel non-stationary signal method differential operator based LCD(DOLCD) was proposed for improving the LCD method, of which, when the target signal contained components with frequencies close to each other, the decomposition ability was decreased, mode mixing phenomenon would easily occur and the physical meaning of intrinsic scale components decomposed were lost. A differential operator was used to differentiate the target signal in time domain, then the differentiated target signal was decomposed with DOLCD, then in the certain frequency ratio, the decomposition ability was enhanced, and the mode mixing was inhibited. The paper firstly studied the theory of DOLCD, then simulation experiments were used to compare the decomposition ability of DOLCD with LCD. The results indicate that DOLCD is more efficient in improving the decomposition ability, and inhibiting the mode mixing than LCD. Finally, the proposed method was applied to diagnose the rotor with misalignment faults successfully which indicated the effectiveness of DOLCD.

    Identification of Constitutive Equation Parameters of 300M Steel Based on Improved Temperature Model
    Xing Wanqiang, Xiong Liangshan, Tang Qi
    2015, 26(17):  2297-2301. 
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    In order to improve the accuracy of material constitutive equation parameters obtained from cutting experiments, a method to calculate average temperature in primary shear zone was proposed by integrating the temperature distribution equitation based on the moving heat source theory along the shear plane length, combining with the equivalent strain and strain rate calculated from the unequal divided shear zone model. A solution model for material Johnson-Cook(J-C) constitutive equation parameters was established. Through the cutting force and chip thickness data obtained from cutting experiments and genetic algorithm, the parameters in J-C constitutive equation of 300M steel were identified. Compared with the default constitutive model of 300M steel in AdvantEdge FEM software, the accuracy of main cutting forces, thrust forces and chip thicknesses simulated by the new obtained J-C model parameters is improved significantly, which demonstrates the effectiveness of the proposed solution model for constitutive equation parameters.

    Sliding Mode Control  for  Speed Tracking Based  on Differential  Geometry  during  Clutch Engaging  Process
    Zhao Han, Qiu Mingming, Huang Kang
    2015, 26(17):  2302-2307,2335. 
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    Aimed  at  nonlinearity,external disturbances and  parameter uncertainty of the  clutch  control system,a  sliding mode control   was  put forward   based  on  differential geometry for speed tracking during clutch engaging process.Considering the  uncertainty of  system  parameters  and  external  disturbances and  other uncertain factors, a single clutch dynamic system model was  established,feedback linearization  was used based  on  differential  geometry  method,the control law  was obtained,and  then a sliding mode controller  was  designed  based on  reaching law control method for the clutch control system with disturbance.The stability of  the system was proved by using  Lyapunov theory.The simulation results  show  that the controller can  make the process of clutch engagement speed tracking accuracy and robustness.

    Time-domain Analysis of Wind-induced Fatigue Life for High-rising Column
    Wang Rui, Chen Xuedong, Fan Zhichao
    2015, 26(17):  2308-2314. 
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    The long-term wind-induced vibration would cause fatigue failure of high-rising columns in windy coastal areas. Therefore, a numerical method of wind-induced fatigue life calculation for high-rising columns was proposed, based on time-history simulation of random wind-induced stress responses, joint distribution model of wind speed and wind direction, rain-flow method and Miner fatigue cumulative damage rule. Then a typical example illustrated the method and indicates that serious fatigue damage or failure might will be induced by the long time empty conditions for this column, while the wind-induced fatigue life in the operating conditions can meet the design demand; cross-wind resonance is the decisive factor of wind-induced fatigue for this empty column, compared with the along-wind vibration producing the mainly fatigue damage in operating conditions caused by the strong wind. The difference of fatigue distribution curves that one with single peak and the other several peaks in the empty and operating conditions shows the along-wind fatigue damage is more concentrated than that of the cross-wind.

    Study on Electron Beam Welding of Thin Niobium Plates
    Zhang Hongyu, Li Zhongquan, Qu Huamin, Zhang Shiwei
    2015, 26(17):  2314-2317. 
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    Superconductivity niobium cavity is an important part of high energy accelerator,it can be made by electron beam welding. Proper welding parameters might be found through the niobium plate welding for the welding of superconductivity niobium cavity. This paper described the welding technology of electron beam welding. Under different welding requirements, reasonable welding parameters can be quickly found, by the way of changing focusing current and welding current. Then, using the parameters above,other experiments will be done to see whether the weld is good. This method can be used to get expected welds effectively.

    Design Method of Hat-section Beam under Axial Loading
    Mo Yimin, Su Dong, Wang Feng, Zhang Jie, Lin Zhigui, Jia Ligang
    2015, 26(17):  2318-2325. 
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    A WSFE was introduced herein on the basis of traditional super-folding element (SFE), which was used to analyze the crushing failure, such as tearing of welds and unprogressive crushing of the flange for hat-sections beams. Strategies were proposed to avoid the failures above, and experiments were carried out to verify the effectiveness. The results of the experiments indicate that the crushing failure of welded hat-sections can be eliminated by increasing SFE on the sections, increasing the flange width, adjusting the angles adjacent to the flange, the energy absorption capability can be improved as well.

    Research on Non-sinusoidal Oscillation of Slab Mold Driven by Two Spatial Noncircular Gear Sets Synchronously
    Liu Dawei, Ren Tingzhi, Jin Xin
    2015, 26(17):  2325-2329. 
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    Due to the disadvantages of the vast investment, complicated control and weak synchronization of hydraulic driven device of slab molds, a new non-sinusoidal system comprised of spatial noncircular gears was presented with two point joint and synchronous output. Its transmission principle was given that the non-sinusoidal oscillation velocity of molds was composited by that of a pair of spatial noncircular gears and the eccentric shaft mechanism. The closed conditions and the mathematical model of pitch curves of the undulating face gear set were built under given transmission ratio, with non-sinusoidal wave constructed. Finally, the process for designing non-sinusoidal driven system under given wave function was illustrated through simulations. With the advantages of good synchronism and low cost over other driving styles, the new system has wide promotional values.

    Trajectory Planning for an One-legged-hopper Robot
    Wang Shenjiang, Guo Zuhua
    2015, 26(17):  2330-2335. 
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    An one-legged-hopper robot was simplified into a three-linkage model herein. The joints' trajectory planning problem was studied during jumping motion. After summarizing the current trajectory planning methods of hopper robot, a parameteric optimization method was adopted in the research to minimize the control effort of robot joints. The jump motion was decomposed into four phases: starting phase, flight phase, stance phase and stopping phase. Joint trajectories of each segment were planned by optimization separately. Finally trajectories for all joints were obtained during the whole jumping motion that the robot moved from static stand upright state to next static stand state.

    Calculation and Optimization  of  Product  Carbon  Footprint  in  Its  Manufacturing Processes
    Liu Qiong, Tian Youquan, John W. Sutherland, Zhou Yingdong
    2015, 26(17):  2336-2343. 
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    In  order  to  accurately quantify  product  carbon  footprint  in its manufacturing  processes for  multi-varieties  manufacturing  companies  and  to  provide a more accurate calculating method of product carbon labelling,a calculating method of product carbon footprint in its manufacturing processes was proposed,which was based on mapping relations among  carbon emissions in manufacturing processes and products manufactured.In order to reduce the product carbon footprint  in its  manufacturing  processes  for  a  flexible  job-shop,a multi-objective model  aiming  at minimizing the total product carbon footprint in manufacturing processes,minimizing  complete  time and maximizing workshop equipment  utilization was proposed.NSGA-II(non-dominated  sorting  genetic  algorithm-II) was designed to solve the model.By  comparing with the traditional scheduling model,the proposed model can provide a result with much less total product carbon footprint in manufacturing processes but almost the same complete time and workshop equipment  utilization.Therefore,the effectiveness of the research was  verified by the case study.

    Research on Integrated Process Planning and Scheduling Problem with Consideration of Multi-objectives
    Li Yan, Ba Li, Cao Yuan, Liu Yong, Yang Mingshun
    2015, 26(17):  2344-2351,2373. 
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    Aiming at the shortage of IPPS problem in multi-objective optimization, multi-objective optimization was integrated into IPPS problem. The makespan, processing cost and maximum machine workload were the main targets which will be optimized. The model was built for multi-objective integrated process planning and scheduling problem. A non-dominated sorting genetic algorithm (NSGA-Ⅱ) was proposed for the problem. A multi-layer structure was used to represent solutions. Selection and genetic operators are designed in the algorithm. Finally, the model and algorithm were proved through an application case.

    Early Performance Degradation Assessment of Rolling Bearings Based on Comprehensive Evaluation Function Constructing by Wavelet Packet Energy Spectrum
    Yang Fan, Tang Baoping, Yin Aijun
    2015, 26(17):  2355-2368. 
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    The traditional time-frequency characteristics was not obvious in the early degradation extraction of the rolling bearings so this paper put forward a method based on wavelet packet energy spectrum in combination with principal component analysis for the early degradation extraction.First using normal signal data the wavelet packet energy spectrum was acquireal, then the principal component analysis was used to achieve dimension reduction for the high dimensional feature vector. Finally through the principal component analysis the comprehensive evaluation function was constructed,which was used to achieve the early degradation extraction of the rolling bearings.

    On-line Quality Intelligent Diagnosis for Multi-variety and Small-batch Dynamic Process Based on MSVM
    Liu Yumin, Zhou Haofei
    2015, 26(17):  2356-2363. 
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    An on-line quality intelligent diagnosis method was proposed based on MSVM. In off-line training, the feature data was extracted using wavelet reconstruction of quality patterns, the MSVM recognition model and estimation model then were trained and tested.In online diagnosis, the abnormal pattern and the parameter of data flow in “monitoring window” were recognized and estimated by the trained recognition model and estimation model, then the dynamic process was diagnosed by the construed diagnosis library. Finally, the proposed method is applied to online diagnosis the precision-axis machining process, and the results of application example show its effectiveness.

    Geometric Modeling Theory of Bent Wire Rope Based on Pro/E
    Guo Wei, Lu Zhengxiong, Zhang Wu
    2015, 26(17):  2363-2368. 
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    In order to establish the bent model of multi-strands wire rope more exactly, the geometry relations of the various steel wires were analyzed about the bent wire rope in pace. Based on the theory of space alternate coordinate, the original parametric equation of the center line was deduced to the various steel wires in the bent wire rope. Using the capabilities of parametric and surface modeling of Pro/E, the solid modeling of the 6×7IWS bent wire rope was completed. The mathematical model of spiral steel wire rope lays a theoretical foundation for any bending wire rope and provides a possibility about theoretical analysis of the mechanical properties for the bent wire rope.

    Performance Simulation and Structure Improvement of EGR Cooler
    Lu Lei, Zhang Zhendong, Yin Congbo
    2015, 26(17):  2369-2373. 
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    The poor working conditions of EGR cooler often is due to excessive thermal load and the emergence of structure crack problem, which influences seriously its actual performance. The fluid field, the temperature and thermal stress distribution of cooler were calculated by using computational fluid dynamics and finite element analysis software with fluid-solid coupling thermal analysis technique. The results of calculation well agree with test data and it is concluded that the cracks on EGR cooler are caused by high thermal stress. Accordingly the cooler structure was improved, the outer surface increased turbulence slots. The cooler with that configuration has obviously lower thermal stress and cracks no longer happen again, indicating fluid-solid coupling thermal analysis being an effective way for solving the crack problem of EGR cooler.

    Real-time Monitoring of Crack Propagation in Metals Based on Quantum Dots
    Zhao Ziming, Luan Weiling, Yin Shaofeng, Tu Shandong
    2015, 26(17):  2374-2377. 
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    This paper reported the real-time monitoring method of crack propagation in metals with quantum dots. Experimental results show that the crack of epoxy resin mixing with quantum dot exhibits a bright line at crack, and its fluorescence intensity in the crack area is much higher than that of non-crack parts. With the help of confocal microscopy, the crack width can be detected as low as 7μm, stating that the detection limitation is greatly improved comparing with other non-destructive testing methods.

    Analysis of Vertical Nonlinear Vibration Characteristics for Bolter System on Roadheader under Random Excitation
    Chen Hongyue, Liu Liebei, Ma Ying, Zhang Yu, Xie Miao,
    2015, 26(17):  2378-2384. 
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    By combining the virtual simulation method, the Bekker model and the Newmark-β method, the nonlinear vibration characteristics of a bolter system on roadheader was analyzed during the process of drilling the top bolting hole. The resistance load of the anchor bit was obtained by the virtual simulation with DYNA software, and the load was discretized to be the random working load by employing the sample theorem. The nonlinear relation between the roadheader track and the tunnel bottom floor was expressed by Bekker model, and the multi-degree nonlinear vibration equation of the bolter system on roadheader was established according to Newton kinematics law. The equation was resolved by Newmark-β method, and the vibration characteristics of the entire machine was analyzed. The results show that the vibration state of the entire machine is as chaos  state by the influence of the contact force between the roadheader track and the tunnel bottom floor, the vibration quantity is very small though the pitch vibration and the roll vibration exist simultaneously, and the vertical vibration of the entire machine is predominant. Field experiments were carried out about vibration characteristics of the roadheader. Amount of vibration of the roadheader were measured when drilling 10 set of bolt holes. The root mean square values in the measured results of 6 set of vibration are close to the simulation value(1.5mm). Experimental results show that non-linear model of the bolter system on roadheader can be seen as accurate to some extent.

    Fatigue Crack Detection Using Nonlinear Ultrasonic Modulation Method
    Li Zheng, Wu Weiliang, Qu Wenzhong, Xiao Li
    2015, 26(17):  2384-2388. 
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    Due to the influences of stress, impact and cyclic load, metal structure was likely to generate fatigue crack or other tiny damages. Conventional nonlinear modulation method could not detect fatigue crack when the boundary conditions were nonlinear. Herein, a nonlinear ultrasonic modulation method was developed to detect a fatigue crack on an aluminum beam,which recognized the modulation of tone burst and high-frequency ultrasonic wave. Intact beam and cracked beam were chosen as the subjects for the experiments, two PZTs were boned on the surface of the aluminum beams as the actuator and the sensor.The STFT was used for computing the spectrograms of the response which is acquired by the sensor. The modulations of tone burst and continuous sinusoidal excitation indicate the presence of fatigue crack.

    Numerical Simulation and Experiments of Vapor Core Pump
    Yu Dingpeng, Wang Bin, Deng Weihua, Ye Zhifeng
    2015, 26(17):  2389-2393. 
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    As a variant of centrifugal pump, fuel VCP shows good application prospects in aero engines. The vapor core generating in impeller region had great influences on operation status and performance of VCP. Unsteady numerical simulation of VCP was presented herein based on RNG (renormalization group) κ-ε turbulence model and vapor-liquid two-phase cavitation model. Effects of inlet throttle opening and outlet load on vapor core region were studied. In order to verify the reliability of numerical results, basic characteristics of a prototype pump were tested. Results show that fuel vaporization inside the pump occurs at the impeller inlet. The vapor core region gradually expands with the decreasing outlet pressure. When expanding to the blade region, liquid fuel flows into the volute from the pressure side of blade. Other conditions being unchanged, vapor core region rapidly expands when reducing the throttle opening. Efficiency of the VCP is less than 20% at 2mm throttle opening. The simulation and test errors are within 10%.

    Influence of Retarder on Brake Stability of Tractor-semitrailer
    Xu Hang, He Ren, Wu Xiaohui
    2015, 26(17):  2394-2399,2405. 
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    A 7-DOF model of  tractor-semitrailer was built with due considerations of the influence factors, such as longitudinal  load  transfer  and  nonlinear  tire  model. The model was  set up by the Simulink module of  MATLAB. The results of the simulation show that:if  road adhesion coefficient  is high,the tractor-semitrailer will has a good performance of brake stability when retarder is at the 1st to 3rd gear,and when retarder is at the top gear, the tractor-semitrailer has a tendency of unstability,but it does not lose control completely. But if  road  adhesion  is  low, the tractor  rear  axle  will lock up firstly  even  if  retarder is at  the 1st  gear,which  can  make tractor sideslipe, so that it will cause the tractor-semitrailer  jackknife, lose control completely.

    Design and Improvement  of a Passenger Vehicle Frontal Structure Based on 25% Small Overlap Frontal Crash
    Li Linfeng, Liu Weiguo, Zhang Junyuan, Zhang Le, Zhou Hao
    2015, 26(17):  2400-2405. 
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    Comparing with the full frontal crash and the 40% offset crash,the differences and similarities of the vehicle structure deformation in the 25% small overlap frontal crash were  analyzed.Based on the deformation characteristics of the vehicle structure in the small overlap frontal crash,the optimization measures of the vehicle front end structure were proposed,which included improving structures and strengthening materials.The optimized vehicle model was tested in the 25% small overlap crash virtual experiments.And the results show that the performance of the vehicle structure is improved significantly and the intrusion of the passenger compartment decreases obviously.Through verifying the deceleration pulses in the full frontal crash and the 40% offset frontal crash,the stiffness of the improved vehicle model is proved to be properly configured and has no effect on the match of the occupant restraint system.

    Optimization of Vehicle Crashworthiness Based on Shrinking Space Regression Method
    Lü Juncheng, Mo Yimin, Yuan Zhijun, Wang Feng, Zhang Jie, Huang Feng
    2015, 26(17):  2406-2413. 
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    The frontal crashworthiness of a vehicle was chosen to be optimized herein. Opt LHD method, RBF model and NSGA-Ⅱ multi-objective optimization method were combined to optimize design variables. To accelerate the convergences of objectives in the process and seek latent solutions out of the initial design space, the shrinking space regression method was introduced to refresh the design region dynamically. The convergence conditions were finally met after several rounds of iteration. An optimal solution was reached, which promoted the frontal crashworthiness shapely without any mass increased. The fast convergence and high accuracy of this method was proved by the comparison between predicted and FEA results.