Table of Content

10 February 2023, Volume 34 Issue 03

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Research Review of Error Compensation Technology for Ultra-precision Machining

CHEN Qidi, HU Xiaolong, LIN Min, SUN Xiaoxia, ZHANG Tao, ZHOU Zhixiong

2023, 34(03):  253-268.  DOI: 10.3969/j.issn.1004-132X.2023.03.001

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 Ultra-precision machining technology was a key technology in high-end manufacturing fields. At present, ultra-precision machining has entered the nano scale. Mastering the key technology of ultra-precision machining error control, ensuring and improving the machining accuracy of CNC machine tools, become a hot research point to improve the machining and manufacturing levels. This paper systematically summarized the research status and development trend of ultra-precision machining error compensation technology, and focused on the geometric errors, force induced errors, thermal induced errors and their compensation methods, which had the greatest impact on ultra-precision machining. Then, a series of problems of ultra-precision machining in geometric error separation, cutting force, thermal induced error measurement and compensation were deeply discussed, and it is further pointed out that the ultra-precision machining error compensation technology should also pay attention to the development direction of high efficiency, high precision, generalization, modularization, intelligence and flexibility.

Modelling and Analysis of Multiple-cross-springs Flexure Pivots with Arc Curved Beams

CHEN Xin, LIU Jiangnan, LONG Wangpeng, LYU Jianwen

2023, 34(03):  269-276，286.  DOI: 10.3969/j.issn.1004-132X.2023.03.002

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It was challenge to balance the large turning angle and low stiffness of multiple-cross-springs flexure pivots with straight beams. The multiple-cross-springs flexure pivots with arc curved beam springs was designed to reduce the maximum stress and rotational stiffness. The high rotation accuracy and large stroke were obtained under pure torque driving conditions. The calculation equation of deformation stress of the arc curved beam springs was deduced, and the large deformation mechanicals analysis model of the flexure pivots was established. The accuracy of the theoretical model was verified by the rotation stiffness experiments and the deformation stress simulation calculation. Moreover, the relationship among the driving torque and deformation stress of the flexure pivots and the design variables, radius coefficient, spring curvature and configuration angle was discussed by using the deformation model. Some design schemes to reduce the rotation stiffness and deformation stress concurrently were proposed. The appropriate variable combination for the flexure pivots to obtain zero stiffness characteristics and negative stiffness characteristics were determined. The designed flexure pivots and the rotation characteristics analysis results provide a reference for the design of a new type of large-stroke flexure pivots.

Tribological Properties and Anti-friction Electrostatic Properties of CF/PEEK Composites

PANG Xianjuan, YUE Shiwei, HUANG Suling, XIE Jinmeng, WANG Shuai, SONG Chenfei, YUE Yun, LIU Jian, LI Dong

2023, 34(03):  277-286.  DOI: 10.3969/j.issn.1004-132X.2023.03.003

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CF/PEEK composites were prepared by vacuum hot pressing sintering technology. The thermal properties of the materials were tested by thermal conductivity analyzer and TG tester. Multifunctional friction and wear testing machine, 3D morphology profilometer, scanning electron microscope and friction electrometer were used to analyze the friction and wear properties and anti-friction electrostatic properties of the materials. The results show that with the increase of the forming temperature, the friction coefficient and wear rate of the materials decrease gradually. With the increase of CF contents, the friction coefficient, wear rate and friction electrostatic voltage decrease first and then increase. When the CF content is as 20%, the friction coefficient, wear rate and friction electrostatic voltage reach the lowest values, which are as 0.247, 5.6×10-6 mm/(N·m) and 3.3 V, respectively. Friction and electrostatic data show that the CF/PEEK materials prepared by this method have better friction properties and anti-electrostatic properties than that of commercial composites. The wear mechanism of CF/PEEK composites is mainly adhesive wear, accompanied by slight abrasive wear.

Study on Elliptical Ultrasonic Assisted Machining Performance of Micro Texture Turning Tools

ZHANG Shuo, ZOU Ping, FANG Rui, ZHOU Liang

2023, 34(03):  287-291，299.  DOI: 10.3969/j.issn.1004-132X.2023.03.004

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In order to further improve the cutting performance, the micro texture tool was applied to the elliptical ultrasonic assisted cutting processes, and the influences on cutting force, tool wear and surface quality were analyzed. Then the influence laws of tool surface micro texture angle and size on tool wear were analyzed. The results show that the micro texture tool may further improve the cutting performance while retaining the excellent performance of elliptical ultrasonic assisted cutting, and according to the experimental results, the change of micro texture angle and size will affect the wear resistance of the tool, when the micro texture is parallel to the main cutting edge and the width is as 70 μm, spacing is as 70 μm, the tool bond wear is the smallest.

Multi-mode Coordination Control of a Novel Compound Electromagnetic Linear Actuator

FAN Xinyu, WANG Peng, YIN Jie, ZHU Yanbing

2023, 34(03):  292-299.  DOI: 10.3969/j.issn.1004-132X.2023.03.005

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Aiming at the low force density and the lack for lack of self-holding ability at the end of conventional moving-coil electromagnetic linear actuators, a novel compound electromagnetic linear actuator was proposed. According to the structural characteristics, the mathematical model was established; also the cooperative drive mode with high driving capability and the single drive mode with low energy consumption were analyzed. Combining the inverse system and the feed-forward + PI feedback algorithm, the multi-mode coordinated controller of the compound electromagnetic linear actuator was designed. A simulation model was established by MATLAB/Simulink, and a prototype test platform was built. The effectiveness of the coordinated control method was verified through simulation and experiments. The results show that the actuator has good dynamic characteristics under different driving modes, and the displacement control errors are less than ±0.02 mm. The self-holding force of actuator is as 229.3 N. In the cooperative driving mode, the driving force may reach 574.9 N, and the turn-on transition time is as 4.8 ms; the turn-on transition time under the single drive is as 6.9 ms.

Adaptive Subdivision-Importance Sampling Method for Solving Structural Reliability

WANG Xinyuan, ZHOU Jinyu, XIE Liyang, CHENG Jinxiang

2023, 34(03):  300-306，313.  DOI: 10.3969/j.issn.1004-132X.2023.03.006

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When dealing with the problems of non-normality, multi-variables, small failure probability, and nonlinear performance functions, it was difficult to pursue satisfactory accuracy with low cost by means of traditional structural reliability solution methods. In order to overcome the shortcomings of existing methods, an adaptive subdivision-importance sampling method for solving structural reliability was proposed by organically combining universal generating function, adaptive subdivision method and importance sampling. According to the adaptive subdivision theory, the critical region was subdivided to reduce the discrete interval length, and the random variables were subdivided nonuniformly and adaptively by the backward recursion operation to obtain the probability of the failure region and the subdivided critical region, and the structure universal generating function of the critical region might be obtained by means of combination operations. The failure probability of the critical region was mainly obtained by employing the important sampling for the hot focal elements. The sum of the failure probabilities of the failure region and the critical region were the estimate of the structural failure probability. The examples indicate that the errors of the new method are significantly less than that of traditional methods. Additionally, the computational efficiency is improved with the help of importance sampling.

Isotropy Design and Vibration Reduction of a Three-dimensional Dynamics Vibration Absorber Based on Parallel Mechanisms

DONG Chenglin, CAI Longqi, LI Yi, LU Tong, ZHANG Luke

2023, 34(03):  307-313.  DOI: 10.3969/j.issn.1004-132X.2023.03.007

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Aiming at the multi-dimensional line-spectra coupling vibration control of power machines, a novel three-dimensional DVA was presented based on parallel mechanisms. The novel DVA has the merits of good modularity and small additional mass. On the basis of the establishment of dynamics model in terms of a set of joint coordinates, the modal analytical solution for modal analysis of the DVA was derived, leading to the condition to achieve dynamics isotropic design, and thereby a three-dimensional DVA reducing the line spectra vibration at 50 Hz was obtained. In addition, the effectiveness and advantages of the novel DVA in the applications on line-spectra vibration suppression of power machines were investigated. The results show that the maximum attenuations of the line spectrum response at around 50 Hz along three mutual vertical directions are all above 7 dB after the installation of the three-dimensional DVA, while only the line spectrum response along the direction of freedom may be suppressed effectively after the installation of the unidirectional DVA.

Structural Parameter Identification for Articulated Arm Coordinate Measuring Machines Using Modified Teaching-learning-based Optimization Optimized by Simulated Annealing Algorithm

XIA Junyong, LIU Kejin, ZHONG Fei, SUN Ying

2023, 34(03):  314-323.  DOI: 10.3969/j.issn.1004-132X.2023.03.008

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To improve the accuracy and decease the movement uncertainty of AACMM, a hybrid optimization algorithm(mTLBO-SA) was proposed to calibrate the structural parameters of AACMM，furtherly compensating for the errors and increasing the precision. First, the advantages and disadvantages of TLBO algorithm were analysed and it was then correspondingly improved to obtain mTLBO; next, a transitional criterion for convergence prevision was put forward to combine mTLBO with SA algorithm, resulting in mTLBO-SA; then, the structural parameters of AACMM were calibrated based on this theory and error experiments using TLBO, SA and mTLBO-SA, respectively; at last, the error experiments of single point repeatability were conducted again respectively using the AACMM before calibration and after calibration and the related results were compared resulting in corresponding conclusions. The results show that the proposed algorithm is effective and efficient to calibrate the real parameters of AACMM, which extremely enhances the accuracy and decreases the movement uncertainty of AACMM.

Three-dimensional Deformed Multi-core Optical Fiber Reconstruction Technology for Skins of a Near-space AirshipLI Mohan

MENG Kuo, SUN Guangkai, ZHOU Kangpeng, HE Yanlin, ZHU Lianqing

2023, 34(03):  324-331.  DOI: 10.3969/j.issn.1004-132X.2023.03.009

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In order to solve the problems of real-time monitoring of the airbag shapes of a near space airship, three-dimensional（3D） deformation reconstruction method of airbag skins was proposed based on temperature self-decoupling multi-core optical fiber sensor. According to the 3D shape characteristics of the airship airbags, the layout of the multi-core optical fiber sensors were designed. The sensing structure of multi-core optical fiber was combined with the Frenet-Serret equation to establish a 3D deformation reconstruction algorithm of the airship airbags with temperature self-decoupling function. Using flexible composite skins of the airship airbag as the test subjects, the 3D deformation multi-core optical fiber reconstruction test system of the airship airbag was designed and integrated. The test analyzed the 3D deformation reconstruction accuracy of the multi-core optical fiber sensors under the temperature change environments and the surface of airship airbag skins under different bending degrees, and verified the effectiveness of the method. The research results show that the method of multi-core optical fiber sensor with temperature self-decoupling may accurately reconstruct the deformation of the airship airbag skins in a large range of temperature environment, and the average value of the reconstruction errors of the 3D surface of the airship airbag skins is less than 1.5%. The real-time monitoring of shapes has application prospects.

A New Transfer Learning Method with Residual Attention and Its Applications on Rolling Bearing Fault Diagnosis

ZHAO Jing, YANG Shaopu, LI Qiang, LIU Yongqiang,

2023, 34(03):  332-343.  DOI: 10.3969/j.issn.1004-132X.2023.03.010

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A transfer learning algorithm was proposed based on class-specific residual attention convolutional neural networks(CSRA-CNN) to improve the fault diagnosis accuracy of rolling bearings. Residual attention mechanism was added to the convolutional neural network model, which made the model pay more attention to fault feature extraction in the training, and also improves the migration accuracy effectively. To evaluate the performance of the proposed method, the results were compared with traditional convolutional neural network under different transfer learning strategies. The proposed algorithm was verified by fault diagnosis integrated test bench of power transmission system and high-speed train comprehensive test bench. The results show that the proposed method may complete the transfer learning of different health states of bearings under variable speed and variable speed and load, and the transfer effect is superior to that of the traditional convolutional neural network. 

Experimental Study on Water Jet Guided Laser Processing of CFRPs

ZHENG Zhilong, ZHAO Yugang, LIU Qian, WANG Ke, ZHOU Haian, SONG Zhuang, DAI Di, ZHANG Xiajunyu

2023, 34(03):  344-351.  DOI: 10.3969/j.issn.1004-132X.2023.03.011

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The purpose of this paper was to investigate the influences of key processing parameters of water jet guided laser processing on the groovess cross-sectional morphology and heat affected zones of CFRPs. Therefore, based on the water jet guided laser processing equipment, a single factor experiment was designed to explore the effects of multiple key processing parameters, including laser power, water jet pressure, feed speed and laser repetition frequency. On this grooving experiment, the morphology of the groove sections and the formation mechanism of the heat affected zones were also analyzed. The following experimental results show that: the laser power has the greatest influences on the groove ablation depths and heat affected zones; the water jet pressure has the greatest influences on the groove ablation width; feed speed and laser repetition frequency has little effects on the groove ablation depth and ablation width, but has great effects on the heat affected zones. In addition, it is found that the removal area of groove cross sections displays V shape, and the heat affected zones are in the shape of sawtooth. A better groove section morphology is obtained by single factor analysis, the ablation depth and ablation width are as 772.8 μm and 894.7 μm, respectively. The heat affected zones of the carbon fiber layers is as 326.5 μm for the direction of 90° and 102.4 μm for the direction of 0°.

Sintering and Mechanics Properties of C3N4 Based Ceramic Tool Materials

ZHANG Yan, HUANG Chuanzhen, LIU Hanlian

2023, 34(03):  352-358，368.  DOI: 10.3969/j.issn.1004-132X.2023.03.012

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 A new type of composite ceramic tool material was developed with C3N4 as matrix, Ti(C, N) as additive phase and Mo, Ni, Co as metal phase. By hot press sintering, C3N4 based ceramic tool materials were sintered. The fracture toughness, flexural strength and vickers hardness of the composites were measured and the microstructure was analyzed. The results show that the C3N4 based ceramic tool material containing 35% Ti(C, N) and 8% Ni-Co, which was sintered under the sintering temperature of 1600 ℃, duration time of 45 min and sintering pressure of 32 MPa, have the optimum mechanics properties. The appropriate content of Ti(C, N) may refine crystal grains of C3N4, increase sintering density, and improve mechanics properties. The microstructure may be fine and uniform with appropriate Ni-Co contents.

Radial Load Identification Method of APM Vehicle Tires Based on 1D CNN and BiGRU

ZENG Junwei, JI Yuanjin, REN Lihui, GE Fangshun, SUN Zeliang, HUANG Zhangxing

2023, 34(03):  359-368.  DOI: 10.3969/j.issn.1004-132X.2023.03.013

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 In view of the facts that direct tire load measurement was expensive and complex and the traditional load identification method had low accuracy and poor robustness, A method for radial load identification of rubber-tyred vehicles was proposed based on 1D CNN and BiGRU. Taking the prior information of tire radial load data into full consideration, the feature set was constructed based on multi-source information such as vehicle vibration response, body poses and running states. The effective feature subset was retained by feature selection, and multi-time-step input-single-time-step output samples were constructed for network training. The multi-dimensional spatial features of the signals were extracted by 1D CNN and input into BiGRU to capture the bidirectional temporal features. Finally, the load prediction results were output by the model. The theoretical model was modified by combining prediction accuracy, generalization performance and robust performance. Taking APM300 vehicle as an example for load identification, compared with the traditional algorithm, the proposed method may reduce the errors of load identification effectively, is suitable for different operating conditions, and may overcome different degrees of measurement noise, which has practical application values in the engineering fields.

Multivariate Coupled Statistics Monitoring of Wafer Manufacturing Overlay Errors Based on CopulaHAO Lanyu

ZHOU Di, LI Yanting, PAN Ershun

2023, 34(03):  369-377.  DOI: 10.3969/j.issn.1004-132X.2023.03.014

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At present, most of studies of wafer manufacturing focused on discrete data defect pattern recognition, while chip lithography manufacturing was a continuous stacking process, and wafer overlap error monitoring based on continuous data was challenging and necessary. The data interpretability was fully considered in the processes of data monitoring, and new penalty terms were added in combination with wafer data characteristics and physical significance. A robust and sparse principal component analysis technique with high flexibility was proposed on basis of the improved LTS-SPCA dimensionality reduction model. Considering the geometric characteristics of wafers, optimal multivariate coupled statistic based on Copula properties of reflection and permutation symmetry was established to monitor the stacking process anomalies of wafer manufacturing. The accuracy of proposed method may reach 91.75%, which has high engineering application values.