Table of Content

25 March 2023, Volume 34 Issue 06

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Tooth Surface Generation and Meshing Characteristics Analysis of Low-angle Face Gear Drives

ZHOU Ruchuan, WU Wenmin, FENG Manman, GUO Hui, LIN Yanhu

2023, 34(06):  631-640.  DOI: 10.3969/j.issn.1004-132X.2023.06.001

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 Gear geometry and meshing properties of the low-angle face gear drives were investigated in order to enhance meshing capabilities of the gear drives with small shaft angle in helicopter transmission systems. The applied coordinate systems for generation of the low-angle face gear drive were established and the equation of the tooth surface of the small cone angel face gear was derived based on gear meshing theory. The tooth surface equation of a double-crowned cylindrical involute pinion was deduced by application of a generating worm.  The generated double-crowned pinion was then introduced into the low-angle face gear drive. The TCA was implemented and the influences of misalignments on the contact were researched. Stress analysis was performed for the purpose of evaluating the performance of the proposed face gear drives. And the stresses of the low-angle face gear drive were compared with the conical involute gear and cylindrical involute gear pair. The results show that the application of double-crowned pinion avoids edge contact， providing lower contact and bending stresses compared with the face-gear drive with a longitudinal modification pinion. Under the same conditions， the contact and bending stresses of the tapered face gear are 27% decrease than that of the conical involute gears. 

Analysis and Comparison of Kinematic Characteristics for Two Typical 6-DOF Suspension Mechanisms at High Angles of Attack

CHEN Hengtong, WANG Xiaoguang, JIANG Hailong, LIN Qi

2023, 34(06):  641-649.  DOI: 10.3969/j.issn.1004-132X.2023.06.002

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 To meet the requirements of multi-DOF (degree of freedom) coupled motion for the aircraft model， it was urgent to develop new suspension technologies. The motion characteristics of two typical six-DOF rigid and flexible parallel suspension mechanisms at high angles of attack were investigated. Firstly， a transverse 6-PUS rigid parallel suspension mechanism was designed， and the aircraft models pose workspace was solved based on the geometric and kinematic restraints. The mechanism stiffness matrix was also derived. As to the wire-driven parallel suspension mechanism， a symmetrical configuration with 8 wires was proposed and the dynamic motion workspace was obtained. By analyzing and comparing the workspace and internal frequencies of the two mechanisms， it is known that both of the rigid and flexible suspension methods may achieve large scale 6-DOF motion， but wire-driven parallel suspension system (WDPSS) has a larger workspace in the transverse and pitch motions with high natural frequency. Finally， the feasibility and effectiveness of WDPSS is experimentally validated through an example of pitch motions at high angle of attack. 

Simulation and Experimental Study of Magnetic Field-assisted Shear Thickening Fluid Polishing for Cemented Carbide Blades

LI Hongyu, HUANG Xiangming, MING Yang, LI Xiyang, ZENG Qing, ZHOU Dongdong

2023, 34(06):  650-659.  DOI: 10.3969/j.issn.1004-132X.2023.06.003

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In order to improve the surface quality of ground cemented carbide blades， a new method for polishing cemented carbide blades， magnetic field-assisted shear thickening fluid polishing， was proposed. The basic principles of the polishing method were introduced， the polishing liquid was prepared， and the rheological properties were tested and analyzed. Based on the rheological test results， the optimal preparation scheme of the polishing liquid was obtained. The flow field state of the workpiece surface under different placement methods was obtained by the ANSYS FLUENT module， and the distribution of dynamic pressure and shear stress on the workpiece surfaces was analyzed under different polishing speeds and magnetic induction strengths， and the placement mode and processing parameters of the workpiece were determined. A polishing experimental platform was established， and the effects of polishing speed， magnetic induction intensity and other processing parameters on the surface roughness and material removal rate were explored. The experimental results show that the surface roughness Ra decreases with the increasing polishing speed， but it is not significantly affected by the magnetic induction intensity. And the product of the shear stress and velocity of the polishing liquid on the workpiece surfaces has a positive correlation with the material removal rate. By optimizing the polishing processing parameters（The workpiece is placed vertically， the polishing speed is as 100 r/min， and the magnetic induction intensity is as 30 mT）， the ultra-precision machined surfaces with surface roughness Ra=15 nm and the high material removal rate（11.1 μm/h） may be obtained. 

Applicability Analysis of Connected Transverse Damper in Metro Vehicles

ZHU Chen, CHI Maoru, ZHAO Minghua, DAI Liangcheng, CHEN Shiqi

2023, 34(06):  660-667，676.  DOI: 10.3969/j.issn.1004-132X.2023.06.004

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With the improvement of the running speed level of metro vehicles， due to the limitation of installation spaces and costs， the fast metro without yew dampers would have the problems of insufficient vehicle running stability. In view of this problem， a connected secondary transverse damper was proposed， which might provide the functions of transverse damper， and achieve the purpose of anti-hunting damping. Based on the working principles of the connected transverse damper， the mathematical model of the connected transverse damper and a more accurate AMESim simulation model were established， and the damping characteristics of the connected transverse damper under different vehicle motion states were analyzed. Finally， MATLAB/Simulink was used to co-simulate the connected transverse damper model and the subway vehicle dynamic model. The influences of the connected transverse dampers on the dynamics performance of the vehicle system were further studied. The simulation results show that the connected transverse damper may greatly improve the nonlinear critical speed of the vehicles and improve the operation stability of the subway vehicles under the conditions of ensuring the stability of the vehicle running in a straight line and the safety of passing through a curve.

Study on Modeling of Material Removal Depth for Blisk Polishing by ABFW Based on Hertz Contact Theory

ZHANG Junfeng, WU Xiaojun, SHI Yaoyao, LIN Xiaojun

2023, 34(06):  668-676.  DOI: 10.3969/j.issn.1004-132X.2023.06.005

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To investigate the material removal mechanism in complex curved surface polishing with ABFW， it was assumed that the distribution of abrasive grain protrusion heights was normal distribution. The distribution model of polishing pressure between ABFW and blade was obtained based on Hertz contact theory. The force analysis of a single abrasive grain was carried out based on the elastic-plastic contact theory， and then the cutting depth model of the abrasive grain was established combined the height distribution function. Thus， the material removal volume of single abrasive grain was determined by synthesizing the spindle speed， feed speed and the shape of abrasive grain cutting groove， and the material removal depth model was established by integrating along the polishing trajectory. The experimental results show that the maximum deviation and average deviation between the predicted values and the experimental ones of material removal depth are 4.85% and 2.95%， respectively， which verifies the correctness and effectiveness of the established model. 

Surface Morphology Characteristics and Effectiveness Analysis of Ultrasonic Longitudinal Torsion Assisted Milling of Titanium Alloys

LI Fengqin, ZHAO Bo, HAO Wangshen, WANG Xiaobo

2023, 34(06):  677-684，693.  DOI: 10.3969/j.issn.1004-132X.2023.06.006

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 In order to solve the problems that the surface quality of difficult-to-cut titanium alloy materials was difficult to be controlled in milling，  a combination of ultrasonic longitudinal-torsional vibration and milling was proposed， and the experimental platform of ultrasonic longitudinal-torsional milling system was built. A single factor test was carried out from four aspects of cutting speed， feed per tooth， cutting depth， and ultrasonic amplitude， and the surface textures and roughnesses of ultrasonic longitudinal-torsional milling and ordinary milling were compared and analyzed. It is found that the surface textures produced by ultrasonic longitudinal-torsional milling were uniform， while the common milling has obvious adhesion phenomena accompanied by scale-spikes. The surface roughness values of ultrasonic longitudinal-torsional milling are obviously lower than that of ordinary milling， and it is concluded that the higher the speed， the larger the amplitude and the smaller the surface roughness value during ultrasonic longitudinal-torsional milling. The simulation and experiments were contrasted and effectively analysed for the feed per tooth， which has a great influence on the surface topography. The results show that the trends of experiment and simulation are consistent and have a high degree of agreement with the theoretical analysis， and the relative errors of ultrasonic longitudinal-torsional milling are lower than that of ordinary milling， and the quality of ultrasonic surface milling is obviously higher than that of ordinary milling. 

Braking Torque Model in Liquid-cooled Permanent-magnet Retarders Accounting for Temperature Effects

GUO Wenguang, WANG Fei

2023, 34(06):  685-693.  DOI: 10.3969/j.issn.1004-132X.2023.06.007

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 A pre-transmission liquid-cooled permanent-magnet retarder（PMR） was proposed to solve the problems of braking torque heat-fade for conventional PMRs. The calculation models of static and transient air-gap magnetic field were established considering the influences of magnetic flux leakage in the retarders based on the magnetic equivalent circuit（MEC）and piecewise function method. The braking torque model of the PMR was obtained and verified by finite element analysis method based on the transient air-gap magnetic field model. An iterative model of braking torque considering the influences of temperature was established based on the established braking torque model and the electro-thermal coupling theory. The bench test results show that the calculated values of the braking torque model are in good agreement with the braking torque-speed characteristic test. The torque values calculated by the iterative model of braking torque considering the temperature effects are in good agreement with the continuous braking test results， and the errors are less than 7%. 

Fault Diagnosis Method of Rolling Bearings Based on Simulation Data Drive and Domain Adaptation

DONG Shaojiang, ZHU Peng, ZHU Sunke, LIU Lanhui, XING Bin, HU Xiaolin

2023, 34(06):  694-702.  DOI: 10.3969/j.issn.1004-132X.2023.06.008

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To solve the problem that it was difficult to obtain a large number of high-quality rolling bearing fault data in the actual industrial environment， and the generalization performance of the intelligent diagnosis model was poor， a fault diagnosis method was proposed based on simulation data driven and domain adaptation. Firstly， a physical model was established to obtain rich simulation data， which simulated different failure forms of bearings according to bearing parameters and corresponding operating conditions. Secondly， the transfer learning method was used to solve the problem of inconsistent data feature distributions between simulation and actual fault data. The residual channel attention mechanism network was used to extract the transfer fault features of different domains， and the adaptive operation of different domains in the network training processes was carried out through the condition maximum mean discrepancy metric criterion， which taken into account the conditional distribution discrepancies between different domains. Finally， different transfer model tests were carried out on the bearing data sets damaged by man-made damage and accelerated life test. The results show that the method proposed may obtain better recognition accuracy when the target domain contains a small number of labels. 

Clustering of Component Assembly Units with Hierarchical Branching for Trunks of Tree Structures

CHENG Bin, ZHANG Songsong, WANG Xiaoming

2023, 34(06):  703-711.  DOI: 10.3969/j.issn.1004-132X.2023.06.009

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A method of clustering component assembly units with hierarchical branching for the trunks of tree structure was proposed aiming at the problems of low parallelism of assembly work and difficult analysis of feature deviation in the component assembly processes. Firstly， the component tree structure was constructed according to the assembly association among the parts， and the assembly feature association index among the branches was analyzed. The index system and the application rules were established to express the closeness between the branches， and the closeness matrix was constructed to complete the representation of the trunks of the component tree. Secondly， with the closeness between branches as the initial input， an improved Dijkstra path planning algorithm was introduced， and the optimal solution of the local shortest path between the trunk and multiple branches was obtained by using the advantages of the algorithm itself. The stem-branch hierarchy matrix was constructed to realize the stem-branch hierarchy of the component tree structure， and then the assembly unit clustering was completed by merging the branches. Finally， virtual assembly was carried out with the results of unit partition， and interference was analyzed in the physical workshops to optimize the final partition result. The feasibility and effectiveness of the proposed method were verified by an example of assembly unit clustering of a vehicle differential assembly. 

Control Strategies for Industrial Robot Motion along Slot Based on Force and Position Hybrid Guidances

ZHANG Junxin, CHEN Wei, HUANG Sikai, WU Haibin

2023, 34(06):  712-719，726.  DOI: 10.3969/j.issn.1004-132X.2023.06.010

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 Aiming at the problems of the robot motion  along slot  was constrained by the combination of multi-directional positions and forces， a force and position hybrid guidance strategy was proposed， and an ADRC was designed based on the impedance model to optimize the force control loop of the strategy. Then， the ADRC was improved based on the double fuzzy structure， and a switching variable universe fuzzy ADRC was obtained， so as to enhance the adaptability of the industrial robots to the unknown environment in the hybrid control of force and position. Finally， the performance of the proposed algorithm was simulated， and the experiments were carried out by taking the parallel slot assembly of mobile phone RF(radio frequency) line as an example. Simulation and experimental results show that compared with the general control method， the proposed control strategy has better force and position hybrid control performance， and may be better applied to the along slot motion of industrial robots.

Performance Improvement of Flexible Pressure Sensors by Dual-level Microstructure

ZHOU Danyan, HUANG Hanxiong, LUO Duyu

2023, 34(06):  720-726.  DOI: 10.3969/j.issn.1004-132X.2023.06.011

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The flexible thermoplastic polyurethane sheets with the single- and dual-level microcolumn arrays were rapidly prepared by using injection-compression molding with two different template design schemes. The microstructured flexible sensing substrates were obtained after cutting the sheets and spraying gold layer on them. The flexible pressure sensors were prepared by assembling the sensing substrates with the single-/dual-level microcolumns and the flat sensing substrate face-to-face， which were denoted as sensor 1 and sensor 2， respectively. The simulated results show that higher contact stress appeares around the edges on the top surfaces of the microcolumns under pressure. The longitudinal sections of the single- and dual-level microcolumns under pressure exhibit  “bowl” and “bud” geometries， respectively. The dual-level microcolumn can be deformed under lower pressure， and the contact deformation and contact area with the flat sensing substrate under pressure are larger. Therefore， compared to sensor 1， sensor 2 exhibits a higher sensitivity（0.53 kPa-1,0~1 kPa）， shorter response time/relaxation time（100 ms/80 ms）， lower detection limit（about 58 Pa）. Sensor 2 has a wide detection range（0.058～600 kPa）and maintaines a relatively stable piezoresistive response in 4000 cycles of compression/release tests（under a peak pressure of about 500 kPa）， which is ascribed to higher pressure resistance of the microcolumn. Sensor 2 may accurately detect human pulse, vocalisation and movement, demonstrating its potential for smart wearable applications. 

Progressive Failure Mechanism of Scarf Repaired in Honeycomb Sandwich Structures with Plain Weave Panels under Edgewise Compression

WANG Xuan, MA Ruiyun, ZHOU Chunping

2023, 34(06):  727-738.  DOI: 10.3969/j.issn.1004-132X.2023.06.012

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 For three scarf repair methods of the unilateral panel repair， the unilateral panel and core repair， the bilateral panel and core repair， the one-dimensional stepped-scarf model was used instead of the three-dimensional model to study the progressive failure mechanism of scarf repaired in honeycomb sandwich structures with plain weave panels under edgewise compressive loads. A finite element model that might simulate the damage evolution of honeycomb wall was established. And the cohesive model was used to simulate the damages of the adhesive layers. The results show that the failure modes of pristine and repaired sandwich structures are the concave buckling deformations to the non-repaired panels. The recovery rate of edgewise compression strength of repaired sandwich structures is above 75%， and the data are ranked from largest to smallest as follows：the unilateral panel repair， the bilateral panel and core repair， the unilateral panel and core repair. No damages may be seen on the panels of pristine and repaired specimens. The transverse and shear damages occur on the honeycomb wall， and the former appears first. Stress concentration occurs at the adhesive layer connected to the honeycomb core with large deformation. The longitudinal damages of the honeycomb wall only appear on the unilateral panel repair specimens， and the damages of adhesive layer appear on the bilateral panel and core repair specimens. The damages of honeycomb wall occur on the parent core materials close to the replacement core. 

Design of Deep-sea Non-contact Magnetic Drive Sediment Penetration Measurement Devices Based on Jiaolong Manned Submersible

REN Yugang, LIU Yanjun, DING Zhongjun

2023, 34(06):  739-745.  DOI: 10.3969/j.issn.1004-132X.2023.06.013

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 Sediment penetration test was an important in-situ testing technique for deep-sea sediment strength. In view of the extreme environmental characteristics of the 7000 meter deep sea and the scientific demands for fine in-situ measurement， a deep-sea non-contact strong magnetic sediment penetration strength in-situ measurement device was developed based on the Jiaolong manned submersible， which broke through the problem that the original penetration measurement techniques in the 7000 meter deep sea structure was complex and could not achieve in-situ and fine measurement， A new method of solving deep-sea pressure resistance and strain gauge deformation conduction was proposed based on the non-contact principle of permanent magnetic force balance conduction of manned submersible. The prototype development and deep-sea sea tests were completed， and good test results were obtained. The whole system adopted self-contained working mode to collect and store data， and might be connected with the computer to realize in-situ data reading. The operating water depth is as 7000 m， the maximum penetration depth is as 250 mm， the measuring range is as 0～100 kPa， and the accuracy may reach 5%~10% FS(full scale). In March 2021， the Jiaolong manned submersible completed 5200 m and 6650 m sea trials in 181 and 185 dives in the Parihivila basin， and successfully obtained geotechnical data. 

Energy Regeneration Assistance of Soft Braking and Corresponding Thermal Dissipation Management System

ZHOU Xin, LEI Xianqing, LI Geqiang

2023, 34(06):  746-755.  DOI: 10.3969/j.issn.1004-132X.2023.06.014

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In order to improve the power performance and the management level of hydraulic system temperature, the hydraulic system design was optimized for mine wide-body truck. This improved hydraulic system was installed in one mine wide-body truck which was used to do a full load transfer comparison test with a mine wide-body truck that was of the same model but enhanced with the engine capacity. At the same time, a physical model was established with AMESim and AVL Cruise to simulate dynamic properties of each module and power performance of the whole mine wide-body truck of the hydraulic system under normal working circumstances. The simulation and testing results show that the system may achieve soft braking during heavy load downhill transportation. The energy regeneration module may improve the power performance index as same as the mine wide-body truck which utilized larger displacement engine, and reduce the combined fuel consumption by about 17%. The energy regeneration module may effectively absorb wheel edge impacts and instantaneous pressure impacts caused by hydraulic system module switching. The thermal management module of the hydraulic system may make the mine wide-body truck working under ambient temperatures ranging from -5 ℃ to 45 ℃, and keep the thermal equilibrium temperature of the system at 70±5 ℃. Meanwhile, carriage auxiliary heating employed in extreme cold weather may improve the lighter efficiency as well as the energy utilization of the hydraulic system by 19%.