Mar 2007, Volume 2 Issue 1
    

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  • Residual stresses in coating-based systems, part I: Mechanisms and analytical modeling
    ZHANG Xiancheng, WU Yixiong, XU Binshi, WANG Haidou
    2007, 2(1): 1-12. https://doi.org/10.1007/s11465-007-0001-2
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    Thin films and multi-layered coatings comprised of different classes of materials are often used for various functional devices. The thermo-mechanical integrity of these systems is becoming a major concern and is strongly related to the residual stresses because of the fabrication processes. In this paper, the sources of the residual stresses in the coating-based systems and the concept of misfit strain  were briefly reviewed. Analytical models were developed to predict the residual stresses in multi-layered film structures or coating-based systems using the force and moment balances. In addition, the residual stress distributions in the func tionally and compositionally graded coatings were also analyzed.
  • Theoretical analysis and experimental investigation of valveless piezoelectric pump with unsymmetrical ridges
    ZHANG Jianhui, LU Jizhuang, XIA Qixiao, LI Hong
    2007, 2(1): 13-19. https://doi.org/10.1007/s11465-007-0002-1
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    A novel valveless piezoelectric pump with unsymmetrical ridges is presented at first. It ingeniously utilizes the inner space of its chamber by developing its chamber bottom into unsymmetrical ridges along the direction of the inlet and outlet of the pump. Hence, a series of cuneiform channels are asymmetrically and alternately formed between the unsymmetrical ridges and the piezoelectric vibrator, which enables the pump to form a one-way flow instead of the function of the traditional diffuse or nozzle elements fitted outside the chamber. Then, by analyzing the vibration of the piezoelectric vibrator, the vibration deformation function and the equation of volume change are established. Meanwhile, the theoretical equation of the pump flow rate is established. Finally, a real valveless piezoelectric pump with unsymmetrical ridges is manufactured, and the flow rate of the pump is measured through experiments. It is proved that the theory is rational and correct by comparing the experimental flow rate and the theoretical flow rate. In addition, for calculating the theoretical flow rate, the positive and converse flow resistance coefficients of unsymmetrical ridges are measured through experiments, when one slope angle of the unsymmetrical ridges is 90º and another is changing from 20º to 60º, respectively.
  • Dilution rate and microstructure of TIG arc Ni-Al powder surfacing layer
    SHAN Jiguo, DONG Wei, TAN Wenda, ZHANG Di, REN Jialie
    2007, 2(1): 20-24. https://doi.org/10.1007/s11465-007-0003-0
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    Surfacing beads are prepared by a direct current tungsten inert gas arc nickel-aluminum (Ni-Al) powder surfacing process. With the aim of controlling the dilution rate and obtaining surfacing beads rich in intermetallic compounds, the effects of surfacing parameters on geometric parameters, dilution rate, composition, and microstructure of the bead are investigated. An assistant cooler, which can potentially reduce the temperature of the base metal, is used in the surfacing process and its effect on dilution rate and microstructure is studied. The result indicates that with the surfacing parameter combination of low current and speed, the width and penetration of the bead decrease, reinforcement increases, and dilution rate drops markedly. With the reduction of the parameter combination, the intergranular phase ?-(Fe, Ni) is formed in the grain boundaries of Ni-Al intermetallic matrix instead of the intergranular phase ?-Fe, and large amount of intermetallics are obtained. With the use of an assistant cooler on a selected operation condition during the surfacing process, the reinforcement of the bead increases, penetration decreases, and dilution rate declines. The use of an assistant cooler helps obtain a surfacing bead composed of only intermetallics.
  • Feature extraction from slice data for reverse engineering
    ZHANG Yingjie, LU Shangning
    2007, 2(1): 25-31. https://doi.org/10.1007/s11465-007-0004-z
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    A new approach to feature extraction for slice data points is presented. The reconstruction of objects is performed as follows. First, all contours in each slice are extracted by contour tracing algorithms. Then the data points on the contours are analyzed, and the curve segments of the contours are divided into three categories: straight lines, conic curves and B-spline curves. The curve fitting methods are applied for each curve segment to remove the unwanted points with pre-determined tolerance. Finally, the features, which consist of the object and connection relations among them, are founded by matching the corresponding contours in adjacent slices, and 3D models are reconstructed based on the features. The proposed approach has been implemented in OpenGL, and the feasibility of the proposed method has been verified by several cases.
  • Analysis of the dynamic hysteresis characteristic of finger seal
    LEI Yanni, CHEN Guoding
    2007, 2(1): 32-36. https://doi.org/10.1007/s11465-007-0005-y
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    The research about hysteresis characteristic of finger seal (FS), which was carried out based on the model with static loads, could not reflect the dynamics behavior of FS system when the rotor runs at high speed. To solve this problem, the relations between the dynamics parameters, structure parameters as well as working parameters in the system were given out through the analysis of finite element analysis result. A mass spring damper dynamics model of FS system was proposed and the hysteresis characteristic of the FS system was analyzed. This work shows that the dynamics characteristic analysis of the FS is necessary and the dynamics model proposed in this paper is valid. This dynamics model is the basis for the optimization design of FS system.
  • Analysis of stability and nonlinear response of rotor system with elliptical sliding bearing supports
    LU Yanjun, LIU Heng, YU Lie, LI Qi, JIANG Ming, ZHANG Zhiyu
    2007, 2(1): 37-45. https://doi.org/10.1007/s11465-007-0006-x
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    Based on the variational constraint approach, the variational form of Reynolds equation in hydrodynamic lubrication is revised continuously to satisfy certain constraints in the cavitation zone of oil film field. According to the physical characteristic of oil film, an eight-node isoparametric finite element method is used to convert the revised variational form of Reynolds equation to a discrete form of finite dimensional algebraic variational equation. By this approach, a perturbance equation can be obtained directly on the finite element equation. Consequently, nonlinear oil film forces and their Jacobian matrices are calculated simultaneously, and compatible accuracy is obtained without increasing the computational costs. A method, which is a combination of predictor corrector mechanism and Newton Raphson method, is presented to calculate equilibrium position and critical speed corresponding to Hopf bifurcation point of bearing-rotor system, as by-product dynamic coefficients of bearing are obtained. The timescale, i.e., the unknown whirling period of Hopf bifurcation solution of bearing-rotor system is drawn into the iterative process using Poincar?Newton Floquet method. The stability of the Hopf bifurcation solution can be detected when estimating Hopf bifurcation solution and its periods. The nonlinear unbalanced T periodic responses of the system are obtained by using PNF method and path-following technique. The local stability and bifurcation behaviors of T periodic motions are analyzed by Floquet theory. Chaotic motions are analyzed by Lyapunov exponents. The numerical results revealed the rich and complex nonlinear behavior of the system, such as periodic, quasiperiodic, jumped solution, chaos, and coexistence of multisolution, and so on.
  • Blind identification of threshold auto-regressive model for machine fault diagnosis
    LI Zhinong, HE Yongyong, CHU Fulei, WU Zhaotong
    2007, 2(1): 46-49. https://doi.org/10.1007/s11465-007-0007-9
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    A blind identification method was developed for the threshold auto-regressive (TAR) model. The method had good identification accuracy and rapid convergence, especially for higher order systems. The proposed method was then combined with the hidden Markov model (HMM) to determine the auto-regressive (AR) coefficients for each interval used for feature extraction, with the HMM as a classifier. The fault diagnoses during the speed-up and speed-down processes for rotating machinery have been successfully completed. The result of the experiment shows that the proposed method is practical and effective.
  • Test investigation on hydraulic losses in the discharge passage of an axial-flow pump
    QIU Baoyun, CAO Haihong, JIANG Wei, GAO Zhaohui, WANG Fei
    2007, 2(1): 50-56. https://doi.org/10.1007/s11465-007-0008-8
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    In a discharge passage with a guide blade discharge circulation and secondary flow because of bend pipe, the flow in a 1-channel discharge passage of an axial flow pump is a complicated spiral flow. For a 2-channel passage, the discharge in the left channel is bigger than that in the right, and the passage hydraulic losses are abnormal. In this study, the section current energy of the passage is accurately measured and determined with a 5-hole probe. The hydraulic loss characteristics are determined and analyzed. The methods deducing the hydraulic losses are investigated. The results indicate that the passage hydraulic losses are not proportional to the flow discharge. Compared with a circular pipe, the hydraulic losses of a divergent discharge passage are smaller and the pump assembly efficiency is 10% 30% higher. As for the 1-channel passage, the axial-flow pump outlet circulation is usually too big; the passage hydraulic losses are also big, but a small circulation can slightly reduce hydraulic losses. As for the 2-channel passage, discharges in the two channels are not equal and the hydraulic losses increase. The outlet guide blade with a small discharge circulation or without circulation could reduce discharge passage hydraulic losses and increase pump assembly efficiency by 6% 11%.
  • Thermally developing forced convection and the corresponding thermal stresses in a porous plate channel
    YANG Xiao, LIU Xuemei
    2007, 2(1): 57-61. https://doi.org/10.1007/s11465-007-0009-7
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    Based on the Darcy fluid model, by considering the effects of viscous dissipation due to the interaction between solid skeleton and pore fluid flow and thermal conduction in the direction of the fluid flow, the thermally developing forced convection of the local thermal equilibrium and the corresponding thermal stresses in a semi-infinite saturated porous plate channel are investigated in this paper. The expressions of temperature, local Nusselt number and corresponding thermal stresses are obtained by means of the Fourier series, and the distributions of the same are also shown. Furthermore, influences of the P晱let number (Pe) and Brinkman number (Br) on temperature, Nusselt number (Nu) and thermal stress are revealed numerically.
  • Research on acoustic-structure sensitivity using FEM and BEM
    ZHANG Jun, ZHAO Wenzhong, ZHANG Weiying
    2007, 2(1): 62-67. https://doi.org/10.1007/s11465-007-0010-1
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    Acoustic-structure sensitivity is used to predict the change of acoustic pressure when a structure design variable is changed. The sensitivity is significant for reducing noise of structure. Using FEM (finite element method) and BEM (boundary element method) acoustic-structure sensitivity was formulated and presented. The dynamic response and response velocity sensitivity with respect to structure design variable were carried out by using structural FEM, the acoustic response and acoustic pressure sensitivity with respect to structure velocity were carried out by using acoustic BEM. Then, acoustic-structure sensitivity was computed by linking velocity sensitivity in FEM and acoustic sensitivity in BEM. This method was applied to an empty box as an example. Acoustic pressure sensitivity with respect to structure thickness achieved in frequency ranges 1 100 Hz, and its change rule along with stimulating frequency and design variable were analyzed. Results show that acoustic-structure sensitivity method linked with FEM and BEM is effective and correct.
  • The prediction technology study of fatigue life for key parts of a tracked vehicle’s suspension system
    WANG Hongyan, RUI Qiang, HE Xiaojun
    2007, 2(1): 68-71. https://doi.org/10.1007/s11465-007-0011-0
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    In allusion to fatigue life of a tracked vehicle torsion bar, a virtual prototype model of the tracked vehicle suspension system including a flexible torsion bar was built based on dynamic simulation software ADAMS. Node force and stress results of the torsion bar from last step simulation were acquired; taking into account the material characteristics and influential factors, fatigue life of the flexible body of the torsion bar was predicted. Engineering results can be acquired through the contrast of the result of virtual test and statistical fatigue.
  • Closed surface modeling with helical line measurement data
    LI Ruqiong, LI Guangbu, WANG Yuhan
    2007, 2(1): 72-76. https://doi.org/10.1007/s11465-007-0012-z
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    Models for surface modeling of free-form surface and massive data points are becoming an important feature in commercial computer aided design/computer-aided manufacturing software. However, there are many problems to be solved in this area, especially for closed free-form surface modeling. This article presents an effective method for cloud data closed surface modeling from asynchronous profile modeling measurement. It includes three steps: first, the cloud data are preprocessed for smoothing; second, a helical line is segmented to form triangle meshes; and third, Bezier surface patches are created over a triangle mesh and trimmed to shape on an entire surface. In the end, an illustrative example of shoe last surface modeling is given to show the availability of this method.
  • Research on swimming by undulatory long dorsal fin propulsion
    WANG Guangming, SHEN Lincheng, WU Yonghui
    2007, 2(1): 77-81. https://doi.org/10.1007/s11465-007-0013-y
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    The kinematics of steady forward swimming of Gymnarchus niloticus is described. The geometric features of the body and locomotive characteristic and parameters of the flexible dorsal fin are discussed. On the basis of observation and experimental data, a simplified kinematic model on locomotion of the undulatory long dorsal fin propulsion is promoted. The hydromechanical performances of the undulatory long dorsal fin propeller of G. niloticus are estimated with the large-amplitude elongated-body theory. The hydromechanical efficiency of the undulatory long dorsal fin system ranged from 81.664% to 86.420% over a speed range of 0.728 0.985 length " s-1. It is suggested that the undulatory long dorsal fin propulsion is an adaptation to swimming with high hydromechanical efficiency.
  • Variable identification and automatic tuning of the main module of a servo system of parallel mechanism
    YANG Zhiyong, XU Meng, HUANG Tian, NI Yanbing
    2007, 2(1): 82-88. https://doi.org/10.1007/s11465-007-0014-x
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    The variables of the main module of a servo system for miniature reconfigurable parallel mechanism were identified and automatically tuned. With the reverse solution module of the translation, the module with the exerted translation joint was obtained, which included the location, velocity and acceleration of the parallelogram carriage-branch. The rigid dynamic reverse model was set as the virtual work principle. To identify the variables of the servo system, the triangle-shaped input signal with variable frequency was adopted to overcome the disadvantages of the pseudo-random number sequence, i.e., making the change of the vibration amplitude of the motor dramatically, easily impact the servo motor and make the velocity loop open and so on. Moreover, all the variables including the rotary inertia of the servo system were identified by the additive mass. The overshoot and rise time were the optimum goals, the limited changing load with the attitude was considered, and the range of the controller variables in the servo system was identified. The results of the experiments prove that the method is accurate.
  • Research on integrating customization design for mechanical product
    TAI Ligang, LI Dianqi, ZHONG Tingxiu, LI Zhi
    2007, 2(1): 89-93. https://doi.org/10.1007/s11465-007-0015-9
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    This paper proposes an integrating rapid customization design system which combines various technologies such as Web, knowledge based engineering (KBE), engineering database and Computer Aided Design (CAD) and has been used in elevator design. The whole system is set up on the base of engineering database technology, integrating Product Data Management (PDM), Enterprise Resource Planning (ERP) etc. It adopts Web technology to enable customers to individually customize products remo tely through the internet. The system also adopts KBE to manage and reuse product design knowledge, while combining the technology of product family modeling and technologies of feature modeling and parametric design, based on the assembly of the CAD system of Unigraphics Solutions Inc., to create a product family case library that achieves intelligent, rapid design customization.
  • Novel drive mechanism for in-tube micro robots
    CHEN Yangzhi, XING Guangquan, PENG Xuefei, LIU Wenguang, YAO Huaping
    2007, 2(1): 94-98. https://doi.org/10.1007/s11465-007-0016-8
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    The volume of an in-tube micro robot is small and its interior space is very limited. However, conventional transmission methods are unfit to drive in-tube micro robots. A novel micro drive mechanism called the micro-elastic-meshing-wheel is presented in this paper. It can be used for transmitting power and locomotion between two shafts, which are upright and cross in a micro space. The mechanical model of the novel drive mechanism is built, and the maximal transmission force is deduced. Then, sufficient experiments are carried out to test maximal transmission force produced by the novel drive mechanism. The calculation and experiment results show that the novel drive mechanism can transmit sufficient power to in-tube micro robots.
  • Acoustic analysis of lightweight auto-body based on finite element method and boundary element method
    LIANG Xinhua, ZHU Ping, LIN Zhongqin, ZHANG Yan
    2007, 2(1): 99-103. https://doi.org/10.1007/s11465-007-0017-7
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    A lightweight automotive prototype using alternative materials and gauge thickness is studied by a numerical method. The noise, vibration, and harshness (NVH) performance is the main target of this study. In the range of 1 150 Hz, the frequency response function (FRF) of the body structure is calculated by a finite element method (FEM) to get the dynamic behavior of the auto-body structure. The pressure response of the interior acoustic domain is solved by a boundary element method (BEM). To find the most contributing panel to the inner sound pressure, the panel acoustic contribution analysis (PACA) is performed. Finally, the most contributing panel is located and the resulting structural optimization is found to be more efficient.
  • Process Planning Support System for Green Manufacturing and its application
    HE Yan, LIU Fei, CAO Huajun, ZHANG Hua
    2007, 2(1): 104-109. https://doi.org/10.1007/s11465-007-0018-6
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    Owing to a lack of practical methods and software tools in the existing researches on green manufacturing (GM), process planning support system for green manufacturing (GMPPSS) was developed to deal with the problems in optimization of environment-benign process planning. The GMPPSS consisted mainly of three function modules and related model repositories including: selection of process elements, optimization of process courses, and evaluation of process projects for GM. The database of the GMPPSS was used to provide plentiful information on resources consumption and environmental impact in manufacturing processes, which consisted of process attribute database, inventory database, machine database, tool database, and the cutting fluid database. Raw materials, secondary material consumption, energy consumption, and environment impacts of process planning were optimized to improve the green attribute of process planning of parts with the supports of the databases and model repositories. The gear processing in the machining tool factory was presented to verify the system s applicability.
  • Output tracking control of mobile manipulators based on dynamical sliding-mode control
    WUYuxiang, FENG Ying, HU Yueming
    2007, 2(1): 110-115. https://doi.org/10.1007/s11465-007-0019-5
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    A dynamical sliding-mode controller is devised to track the output of mobile manipulators. During the investigation, firstly a reduced dynamic model considering the dynamics of the driving motor is developed for mobile manipulators. Then, the system is decomposed into four lower-dimensional subsystems by means of diffeomorphism and nonlinear input transformation. Moreover, a design method of the dynamical sliding-mode controller that is applied to the output tracking of mobile manipulators is proposed. The simulation results indicate that the dynamical sliding-mode controller can not only track the given trajectory correctly but also reduce the chattering of sliding-mode control system considerably.
  • Modular structure of a self-reconfigurable robot
    FEI Yanqiong, DONG Qinglei, ZHAO Xifang
    2007, 2(1): 116-119. https://doi.org/10.1007/s11465-007-0020-z
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    This paper proposes a novel, hermaphroditic, and lattice self-reconfigurable modular robot. Each module is composed of a center body a cubic part and six sides that can rotate independently. There are two holes and two extensible pegs on each side. The rotary motion of each side and the extensible motion of the pegs are generated by a motor connected to a reducer, using a cone-shaped gear, belt, clutch, etc. The structure of the module is compact, and has space to extend further.
  • Effect of extrusion temperature on the physical properties of high-silicon aluminum alloy
    YANG Fuliang, GAN Weiping, CHEN Zhaoke
    2007, 2(1): 120-124. https://doi.org/10.1007/s11465-007-0021-y
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    Light-weight high-silicon aluminum alloys are used for electronic packaging in the aviation and space-flight industry. Al-30Si and Al-40Si are fabricated with air-atomization and vacuum-canning hot-extrusion process. The density, thermal conductivity, hermeticity and thermal expansion coefficients of the material are measured, and the relationship between extrusion temperature and properties is obtained. Experimental results show that the density of high-silicon aluminum alloys prepared with this method is as high as 99.64% of the theory density, and increases with elevating extrusion temperature. At the same time, thermal conductivity varies between 104-140 W/(m " K); with the extrusion temperature, thermal expansion coefficient also increases but within 13?10-6 (at 100?C) and hermeticity of the material is high to 10-9 order of magnitude.