Table of Content

07 November 2018, Volume 29 Issue 21

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Design Method of Predecisional Remanufacturing Based on Component Structure Coupling Relationship

SONG Shouxu, WANG Wei, KE Qingdi, QIU Quan

2018, 29(21):  2521-2526,2538. 

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Aiming at the problems that a weak structure of optimization parts might lead to deterioration of the overall performance for parts in the design processes of remanufacturing, the coupling relationship between the structures of parts was studied. The concepts of structure function coupling system were proposed, the model of structure function coupling system was established, the structure coupling degree was expressed with structural influence factors. Then, the design method of predecisional remanufacturing was given in the part levels, and the overall performance of parts was improved in the whole life cycle, and the engine crankshaft was taken as an example to verify the method.

Green Degree Evaluation of High Efficiency Motor Schemes Based on Expected Goal

LI Fangyi, PENG Xin, WANG Liming, LI Long, WANG Geng, ZHANG Baocai

2018, 29(21):  2527-2532. 

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In order to improve the fuzzy judgments of green evaluation weight for product schemes, a green degree evaluation method of high efficiency motor was proposed based on expected goal and Larsen-type fuzzy inference. On the basis of decomposing characteristic information of product schemes in life cycle, a hierarchical model of green degree evaluation was established. According to the minimax clustering fuzzy (max-min) principle, three factors of products such as environment properties, energy attributes, and resource attributes were considered comprehensively. Moreover, the expected goal of project was set up by designers combining with the product standard, the production status of enterprise, and the environmental characteristics, which raised the objectivity and clarity of evaluation processes. The theoretical model was verified by the example of high efficiency low voltage three-phase asynchronous motor YE3 160L-4. The results show that the motor has a further optimization space on the consumptions of mineral resources, acid oxide emissions and so on.

Energy Consumptions Modeling and Simulation of Machine Tools Based on Vericut

XU Xingshuo, LI Fangyi, KONG Weisen, YU Wenkai, ZHOU Jinqiang, ZHOU Lirong

2018, 29(21):  2533-2538. 

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To realize the energy consumption predictions and simulations of CNC processing, the energy consumption model of machine tools was built by using the method of specific energy consumption based on Vericut Force module, and the CAD-CAM-ECS energy consumption simulation platforms of energy consumption were built by combining the UG CAM module and Vericut Force module, the energy consumption simulation of parts were realized in the machining processes. The results show that the energy consumption of machine tool model may effectively predict energy consumption of machine tools in the part processing based on IPW(in process workpiece) conditions. The CAD-CAM-ECS energy consumption simulation platform may accurately shine upon design characteristics of high energy consumption in machining process simulation, which may provide the basis for part design and processing optimization.

Transparent and Fair LCA  Method for Products

GU Fu, GU Xinjian, Zhang Wujie, Ni Yihua

2018, 29(21):  2539-2545. 

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To address the difficulties in acquiring, evaluating and maintaining LCA data, a transparent and fair LCA methodology was proposed herein. On the basis of state-of-the-art information technologies, automation, transparency and collaboration in acquistion, evaluation and maintainence of LCA data were achieved. On the basis of transparency, the contribution of related enterprises and individuals might be rewarded properly by the market, government and related enterprises. This mitigates the problems in acquiring, evaluating and maintaining LCA data, and propels the progress of green and sustainable manufacturing, as this topic requires further attention and support. Finally, the progresses of transparent and fair LCA methodology in China were analyzed, which indicates that this method develops rapidly and should be given great attentions and supports.

Life Cycle Assessment and Prediction of Proton Exchange Membrane Fuel Cell Vehicles for 2020

CHEN Yisong, DING Zhensen, LIU Jiahui, MA Jinqiu

2018, 29(21):  2546-2552,2564. 

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By modeling with GaBi software, the quantitative evaluation and predictive analysis were made for full life cycle energy saving and emission reduction of China's fuel cell vehicles in 2020 based on the development goal of China's fuel cell technology in 2020 and the U.S. DOE 2020 fuel cell vehicle technology plan. The results show that the average mineral resource depletion EADP(e), fossil energy consumption FADP(f) and environmental impact QGWP for fuel cell vehicles of China in full life cycle are as 0.609 kg(Sb-Eq.), 3.99×105 MJ and 2.99×104 kg(CO2-Eq.) respectively. The production of precious metals platinum, hydrogen production technology and fuel cell efficiency in raw material acquisition phase plays a key role in fuel cell vehicle life cycle EADP(e) and FADP(f), while QGWP mostly comes from the consumption of fossil fuel and electric energy in the processes of hydrogen production. The effective measures to reduce the impact of fuel cell vehicles on resources and environment are as below: accelerating the development of key materials and the efficient recycling strategies of platinum are used to reduce the consumption of precious metals gradually, improving hydrogen production technology which may change from fossil energy to renewable clean energy, gradually optimizing the power structure to effectively reduce the consumption of coal electricity in the hydrogen compression processes.

A Super Short-process Green Manufacturing Method and Energy Consumption Analysis of Micro Casting Forging and Milling for High Performance Parts

ZHANG Haiou, HUANG Cheng, LI Runsheng, ZHANG Hua, CHEN Junwen, FENG Kangtun, WANG Guilan

2018, 29(21):  2553-2558. 

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Firstly the idea of green design was introduced and applications in additive manufacturing were presented. Aiming at the bottlenecks of long process and high energy consumption of traditional manufacturing methods to make forgings parts with high performance, and a green manufacturing technology was proposed to make forging parts with ultra-short process hybrid micro casting forging and milling technology. Finally, taking an aero-engine forging part as an example, the calculation results show that the energy consumption of the traditional manufacturing method is 33.3 times of the energy consumption of micro casting forging and milling, and material consumption is 6.7 times of the micro casting forging and milling technology. Micro casting forging and milling provides a green material and energy saving manufacturing way with innovative ultra-short process to manufacture large complex forgings in China.

Regulation and Control Method for Tool Temperature in High-speed Dry Cutting Processes Based on Specific Cutting Energy

YANG Xiao, CAO Huajun, DU Yanbin, XU Lei, CHEN Yongpeng

2018, 29(21):  2559-2564. 

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The high cutting speed and the lack of cutting fluid during high-speed dry cutting made cutting processes heats accumulated on the cutting tools in a short time, which affectd the wear and service life of cutting tools seriously. The temperature rise control was an effective means to solve the tool thermal problems. The heat transfer characteristics of the cutting tools were analyzed during high-speed dry cutting processes. Temperature control model was established based on specific cutting energy and chip geometry. Then, a tool temperature control method was proposed with the minimum temperature rise as the target and the cutting speed, feed rate and tool cutting edge angle as variables. And, a case study on high-speed dry turning was conducted to verify the proposed tool temperature control method.

VARI Rapid Prototyping Processes for Battery Boxes of Composite Materials

ZHAO Xiaoyu, ZHANG Boming, LIAN Yilong, ZHANG Shuren

2018, 29(21):  2565-2570,2580. 

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The conventional manufacturing processes of several composite material parts were analyzed. According to the structure characteristics of battery boxes, the integrated VARI rapid prototyping processes of materials and structures were proposed, and the process programs and processing parameters were determined by using liquid molding simulation analysis software PAM-RTM. Compared with the resin transfer molding(RTM) processes of a traditional double-sided mold, VARI processes saved a lot of tooling equipment and processes, reduced the costs. In order to verify the feasibility of the process method, the samples were actually made, and the results show that the process method is fast, low energy consumption, and green and environment-friendly.

Multi-objective Optimization Model Faced to Demands of Energy Saving and High Efficiency for CNC Machining Systems

YAN Wei, ZHANG Hua, JIANG Zhigang, MA Feng,

2018, 29(21):  2571-2580. 

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Aiming at the complex multi-source and dynamic energy characteristics of CNC machining systems, a unit working state-based modeling and optimization method was proposed. Firstly, the CNC machining system energy consumption units and their energy characteristics in working states were studied, and dynamic energy models of time-varying and non-time-varying units were established. Secondly, an optimization model faced to energy saving and high efficiency was established, which took cutting speed and feed as the variables, and minimum energy consumption and machining time as the objectives, a solving method was proposed based on niche genetic algorithm. Finally, a machine tool center frame base processing case study was performed to verify the effectiveness of the proposed method and model, and the optimization results and the algorithm performance were also analyzed.

A Review of Key Fundamental Scientific Problems for Mechanical Equipment Remanufacturing

ZHANG Hongchao, LI Mingzheng, LIU Weiwei, YUAN Yingchun

2018, 29(21):  2581-2589. 

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The theoretical achievements and the technological perspectives achievements obtained through the national basic research program “Key Fundamental Scientific Problems on Mechanical Equipment Remanufacturing” were reviewed herein. The project used core parts of major mechanical equipment as the study objects, which were primarily the centrifugal compressors for the West to East Gas Transmission Project and heavy-duty engines. The major critical scientific issues were researched including the interdisciplinary of mechanical engineering, material engineering, mechanics, physics, chemistry and mathematics. The evaluation theories and atomic bonding between different materials were established for remanufacturability. An integrated remanufacturing system was established by proposing the competitive life analysis methodology, comprehensive evaluation methods and fundamental theories.

Green Additive Remanufacturing Technology

ZHU Sheng, ZHOU Chaoji, ZHOU Kebing

2018, 29(21):  2590-2593,2614. 

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The development of green additive remanufacturing technology was entered into a new stage in China, the technology was facing a great opportunity in the industrial markets and was supported greatly by the government. The concepts and characteristics of green additive remanufacturing technology were reviewed herein. The opportunities and challenges were listed, and the future research directions were proposed. According to the implementation of green additive remanufacturing technology and the construction of green additive remanufacturing technology system, this promising technology has the potential to realize the sustainable developments of resources and environment, further, the technology conforms to the strategic focus on green manufacturing presented by “Made in China 2025”.

Research on Remanufacturing Cost Prediction Model of Used Parts Considering Failure Features

ZHANG Xugang, AO Xiuyi, ZHANG Hua, JIANG Zhigang,

2018, 29(21):  2594-2599. 

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The impacts of failure features of used parts on remanufacturing cost were analyzed, and a predictive model for the remanufacturing cost for used parts considering failure features was established. The model combined with semi-supervised learning and LS-SVR algorithm, realized the prediction of remanufacturing costs of used parts under the conditions of only a few completed remanufactured parts and a large number of unknown remanufacturing cost parts. The algorithm incorporated a k-nearest neighbor (kNN) learner, supplemented by kNN, and the LS-SVR was used to evaluate the confidence level of untagged samples, adding the best unlabeled samples from each phase stepwise to the labeled ones. The gradual update of the prediction model might effectively reduce noise and improve model accuracy. Case verifications show that the proposed algorithm has good ability of regression prediction and generalization.

Experiments and Analyses of 3540Fe/CeO2 Coatings by Ultrasonic Vibration Assisted Laser Cladding

WANG Yuling, LIU Shanyong, ZHANG Xiangyu, LIU Yongwu, LI Rongchao

2018, 29(21):  2600-2605. 

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To study the optimization effects of ultrasonic vibration on laser cladding, the method of ultrasonic vibration applied to the cladding layer directly was introduced to prepare the high performance cladding layers of 3540Fe/CeO2, on the basis of determining the optimal processing parameters and the powder proportions. The influences of the applying method and the applying angles of the vibration on the macroscopic morphologies, microstructures, phase compositions and mechanics properties of the cladding layers were compared. The experimental results show that ultrasonic vibration improves the morphologies of the laser cladding layers obviously, when the applying angle is as 45°, the effect is optimal. The ultrasonic vibration may refine the organization and reduce the porosity without changing phase compositions, the coating tissues are transformed into equiaxed crystals and fine needle-like dendrites composed of the phases γ(Fe, Ni), Cr13Ni5Si2, Cr7C3 and so on. After the ultrasonic vibration is added, the average hardness of the cladding layers increases by 62% and reaches 1 148 HV. The friction coefficient decreases significantly, the abrasion loss decreases and the wear resistance improves. Through the scanning electron microscope （SEM） observation of the abrasions, the ultrasonic vibration may improve the wear form, the wear form of the specimen changes from adhesive wear mainly to regular abrasive wear, and the wear surfaces are smoother.

Optimization of Processing Parameters for Wear-resistant Cladding Coatings in Crankshaft Remanufacturing

HUANG Haihong, TANG Jie, QIAN Zhengchun,

2018, 29(21):  2606-2614. 

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In order to remanufacture and repair worn crankshafts by PTAW method, orthogonal experiments were designed to optimize the processing parameters of PTAW for wear-resistant cladding coatings. Ni60 wear-resistant cladding coatings were produced on the surfaces of 45 steel samples. The multi-factor effects of main arc current, travel speed and powder feed rate on microhardness and wear volume loss of the coatings were investigated. The performance of the cladding coatings produced with the optimal processing parameters was verified and characterized by the single factor tests. The optimal processing parameters were successfully applied to the remanufacturing of worn crankshafts. The results show that the powder feed rate is the significant factor which affects microhardness and wear volume loss of the cladding coatings within a certain range. With the increase of powder feed rate, the microstructure of cladding coatings is changed from columnar crystal to dendrite crystal and equiaxed crystal, and the microstructure properties, microhardness and wear-resistance are also significantly improved. The optimal processing parameters are given as below: main arc current is as 100 A, travel speed is as 70 mm/min, and powder feed rate is as 22 g/min. The surface quality of the remanufactured and repaired crankshaft main journals is good by using the optimal processing parameters.

Automotive Product Recycling: Material Efficiency and Key Technologies

CHEN Ming

2018, 29(21):  2615-2625. 

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Taking material efficiency as the main line, the concepts of material efficiency were understood and redefined. Taking the researches of automotive recycling of Shanghai Jiaotong University's Sustainable Design and Manufacturing Group as an example, the key issues were introduced in the processes of recycling automobile products. The scope involved the prediction of scrap volumes, dismantling plannings, remanufacturing, recycling of traction batteries, recycling of automotive shredding residues, life cycle assessments and other key contents.

Constraint State Graph Model Based on Phase Hinder and Its Disassembly Sequence

CHEN Jian, WANG Jianyong, HUANG Lin, LI Jinchun

2018, 29(21):  2626-2635. 

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In order to measure the sizes of the constraint direction interval of parts effectively in the disassembly processes, a constraint graph model was constructed herein based on phase hinder and the disassembly sequence generation method. First of all, according to the space constraint in the disessembly processes and hinder with each other relations, a concept of 3D phase hinder and calculation method were put forward, and a constraint state graph model was constructed based on phase hinder. Then, in order to describe the product state and the disassembly processes, the corresponding state matrixes and disassembly operator matrixes were constructed, and the disassembly processes were transformed into iterative operation processes of the disassembly operator matrixes and the state matrixes, and the disassembly rules and disassembly sequence planning algorithm were given based on the above researches. Finally, taking a plain vice as an example, the disassembly modeling and sequence planning were solved, the results show that the method is effective and feasible.

Review of Modeling Theory and Solution Method for Disassembly Line Balancing Problems for Remanufacturing

ZHANG Zeqiang, CAI Ning, ZENG Yanqing, LI Liuke, ZOU Binseng

2018, 29(21):  2636-2645. 

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The disassembly line balancing problem researches at home and abroad were summarized and combed. Firstly, the problems were described and two kinds of visual representation and classical mathematical model about disassembly were introduced. Secondly, the solution methods in literatures were analyzed and classified into exact methods, heuristic methods and meta-heuristic methods. Then, eight kinds of extended models and theories were summarized and analyzed related to the disassembly line balancing. Finally, the future research directions were discussed and prospected, and some suggestions for the next step were put forward.