Sep 2007, Volume 2 Issue 3
    

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  • Discussion on advanced manufacturing
    WANG Xiankui
    2007, 2(3): 251-262. https://doi.org/10.1007/s11465-007-0044-4
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    Advanced manufacturing consists of continuity of manufacturing, its broad sense, and the core of the manufacturing process. The technology of continuous manufacturing is discussed according to both historical and modern perspectives. The relationship between human development and manufacturing technology is also discussed. Manufacturing is a continuously evolving topic. It is not only the foundation and means of imagination, conception, the science, and the technology of material change, but also the expression of national economy, national defense, and the support industries. The broad sense of manufacturing theory, which extends the concept of manufacturing, is an important development in the 20th century. The sense is analyzed in connection with design, material forming theory, synthesis of manufacturing technology, manufacturing modes, life cycle of product, hardware and software, and support environment, etc. At the same time, the core action and the development of the theory and technology of process is also discussed. At the end of this paper, the development directions of mechanical manufacturing science and technology are mentioned.
  • Determination of the scheme of precision grinding compensation on the radome
    GUO Dongming, LIU Minjing, ZHANG Chunbo, SHENG Xianjun, SUN Yuwen
    2007, 2(3): 263-266. https://doi.org/10.1007/s11465-007-0045-3
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    The radome, which is often used to house airborne scanning radar antennas, causes a large boresight error and boresight error slope of the radar antenna. One way to decrease the boresight error induced by the radome is to modify its geometric thickness. Determining the grinding scheme from the boresight error performance is the most important problem to be solved. A typical inverse problem about electromagnetic fields is solving the precise grinding compensation area and allowance according to the antenna aperture distribution and the radome s boresight error performance, which could hardly be solved by a purely mathematical method. An effective approach combining theoretical analysis and mathematical calculations with experimental measurement is presented in this paper to determine the grinding area and allowance for compensating the boresight error performance of the radome. By comparing the calculated and measured data of the boresight error and the boresight error slope before and after grinding, it is shown that this method is simple and practical and can be used for many kinds of radomes.
  • Analysis of frequency characteristics of compliant mechanisms
    WANG Wenjing, YU Yueqing
    2007, 2(3): 267-271. https://doi.org/10.1007/s11465-007-0046-2
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    Much work is needed for a further study on the dynamic analysis of compliant mechanisms to improve their performance and operational accuracy. This paper uses the finite element method to develop a dynamic equation of the compliant mechanism. Natural frequencies and modes are derived. Using the differentials of a stiffness matrix to design parameters, a method for calculating the sensitivity of natural frequency is presented. The numerical simulation results indicate that the design parameters have an impact on the frequency characteristics of the compliant mechanisms and the proposed method is more accurate and convenient for analyzing frequency characteristics.
  • Cutting Force Model for a Small-diameter Helical Milling Cutter
    LI Xiwen, YANG Shuzi, YANG Mingjin, XIE Shouyong
    2007, 2(3): 272-277. https://doi.org/10.1007/s11465-007-0047-1
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    In the milling process, the major flank wear land area (two-dimensional measurement for the wear) of a small-diameter milling cutter, as wear standard, can reflect actual changes of the wear land of the cutter. By analyzing the wearing characteristics of the cutter, a cutting force model based on the major flank wear land area is established. Characteristic parameters such as pressure parameter and friction parameter are calculated by substituting tested data into their corresponding equations. The cutting force model for the helical milling cutter is validated by experiments. The computational and experimental results show that the cutting force model is almost consistent with the actual cutting conditions. Thus, the cutting force model established in the research can provide a theoretical foundation for monitoring the condition of a milling process that uses a small-diameter helical milling cutter.
  • Evaluation method of multiaxial low cycle fatigue life for cubic single crystal material
    CHEN Jiping, DING Zhiping
    2007, 2(3): 278-282. https://doi.org/10.1007/s11465-007-0048-0
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    The coupling effect of normal stress and shear stress on orthotropic materials happens when applied loading deflects from the directions of the principal axes of the material coordinate system. By taking account of the coupling effects, formulas of equivalent stress and strain for cubic single crystal materials are cited. Using the equivalent strain and equivalent stress for such material and a variable k, which is introduced to express the effect of asymmetrical cyclic loading on fatigue life, a low cycle fatigue (LCF) life prediction model for such material in multiaxial stress starts is proposed. On the basis of the yield criterion and constitutive model of cubic single crystal materials, a subroutine to calculate the thermo elastic-plastic stress-strain of the material on an ANSYS platform was developed. The cyclic stress-strain of DD3 notched specimens under asymmetrical loading at 680vH was analyzed. Low cycle fatigue test data of the single crystal nickel-based superalloy are used to fit the different parameters of the power law with multiple linear regression analysis. The equivalent stress and strain for a cubic single crystal material as failure parameters have the largest correlation coefficient. A power law exists between k and the failure cycle. The model was validated with LCF test data of CMSX-2 and DD3 single crystal nickel-based superalloys. All the test data fall into the factor of 2.5 for CMSX-2 hollow cylinder specimens and 2.0 scatter band for DD3 notched specimens, respectively.
  • Interfacial heat transfer coefficient between metal and die during high pressure die casting process of aluminum alloy
    GUO Zhipeng, XIONG Shoumei, CHO SangHyun, CHOI JeongKil
    2007, 2(3): 283-287. https://doi.org/10.1007/s11465-007-0049-z
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    The present work focused on the determination of the interfacial heat transfer coefficient (IHTC) between metal and die during the high pressure die casting (HPDC) process. Experiments were carried out on an aluminum alloy, ADC12Z, using step shape  casting so-called because of its shape. The IHTC was successfully determined by solving one of the inverse heat problems using the nonlinear estimation method first used by Beck. The calculation results indicated that the IHTC immediately increased after liquid metal was brought into the cavity by the plunger and decreased as the solidification process of the liquid metal proceeded. The liquid metal eventually solidified completely, a condition when the IHTC tended to be stable. Casting thickness played an important role in affecting the IHTC between the metal and die not only in terms of its value but also in terms of its change tendency. Also, under the test conditions, different change tendencies of the metal solid fraction were found between castings with different thicknesses and the die.
  • Correlation analysis of couple optical paths for micro stereovision with stereo light microscope
    WANG Yuezong, LI Desheng, YU Yaping
    2007, 2(3): 288-292. https://doi.org/10.1007/s11465-007-0050-6
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    A micro stereovision system with a stereo light microscope (SLM) has been applied in micromanipulation systems. There is a coupling connection between two optical paths of a stereo light microscope. The coupling intension corresponds with two factors: the structure of an SLM and the position of an object point in the view of an SLM. In this paper, a correlation function is proposed to describe the coupling intension between the couple optical paths of an SLM. The quantified results are applied to the error analysis of the imaging model. Experiments show that the correlation of the optical paths of a common main objective of stereo light microscope (CMO-SLM) is little more than that of a G-SLM, and the error must be considered when a pinhole imaging model is used to analyze its correlation.
  • High frequency group pulse electrochemical machining
    WU Gaoyang, ZHANG Zhijing, ZHANG Weimin, TANG Xinglun
    2007, 2(3): 293-296. https://doi.org/10.1007/s11465-007-0051-5
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    In the process of machining ultrathin metal structure parts, the signal composition of high frequency group pulse, the influence of frequency to reverse current, and the design of the cathode in high frequency group pulse electrochemical machining (HGPECM) are discussed. The experiments on process were carried out. Results indicate that HGPECM can greatly improve the characteristics of the inter-electrode gap flow field, reduce electrode passivation, and obtain high machining quality. The machining quality is obviously improved by increasing the main pulse frequency. The dimensional accuracy reaches 30 40 ?m and the roughness attained is at 0.30 0.35 ?m. High frequency group pulse electrochemical machining can be successfully used in machining micro-parts.
  • Elongation distribution between tension leveler and temper mill for pickling line 2030 in Baosteel
    LIU Xiancui, SU Lanhai, LI Zhongfu, ZHANG Qingdong, FU Zhilin, HE Chun
    2007, 2(3): 297-300. https://doi.org/10.1007/s11465-007-0052-4
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    Research into plate elongation distribution between the tension leveler and temper mill for pickling line 2030 at Baosteel is conducted. The study, which involved performance testing of mechanics, is designed at different elongation distributions and analyzed from many aspects. Finally, the optimal elongation of the tension leveler and temper mill is given.
  • New method for computer numerical control machine tool calibration: Relay method
    LIU Huanlao, SHI Hanming, LI Bin, ZHOU Huichen
    2007, 2(3): 301-304. https://doi.org/10.1007/s11465-007-0053-3
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    Relay measurement method, which uses the kilogram-meter (KGM) measurement system to identify volumetric errors on the planes of computer numerical control (CNC) machine tools, is verified through experimental tests. During the process, all position errors on the entire plane table are measured by the equipment, which is limited to a small field. All errors are obtained first by measuring the error of the basic position near the original point. On the basis of that positional error, the positional errors far away from the original point are measured. Using this analogy, the error information on the positional points on the entire plane can be obtained. The process outlined above is called the relay method. Test results indicate that the accuracy and repeatability are high, and the method can be used to calibrate geometric errors on the plane of CNC machine tools after backlash errors have been well compensated.
  • Research on physical shape preserving curve reconstruction
    TANG Kelun, ZHANG Xiangwei, CHENG Siyuan, XIONG Hanwei, ZHANG Hong
    2007, 2(3): 305-309. https://doi.org/10.1007/s11465-007-0054-2
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    Fusion of various data is an effective way to improve the precision and efficiency of acquiring information in reverse engineering. A method of physical shape preserving curve reconstruction is proposed to better realize the data fusion of coordinate measuring machine (CMM) and visual information. From the principle of materials mechanics, the strain energy of the curve corresponding to the distortion is advanced as the internal energy, and the elastic potential energy of the curve is established, using a few precise measured data points as the equilibrium position, to be the external energy. On the basis of the principle of variation calculus, the basic spline finite element method (B-spline FEM) is used to determine the equilibrium position of curve deformation. Numerical simulation indicates that there is an extremely good agreement between the new fitted curve and the actual curve.
  • Experimental research on cyclone performance at high temperature
    LI Wenqi, CHEN Jianyi
    2007, 2(3): 310-317. https://doi.org/10.1007/s11465-007-0055-1
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    To predict the influence of operating temperatures on cyclone performance, an experimental investigation was conducted on particle separation in a reverse flow, tangential volute-inlet cyclone separator with a diameter of 300 mm and with air heated up to 973 K. The test powder silica has a mass median diameter of 10 um, while inlet velocity range was 12-36 m/s. Both the separation efficiency and pressure drop of the cyclone were measured as a function of the inlet velocity and operating temperature. At the same inlet velocity, both the separation efficiency and pressure drop decrease with increasing temperature. In addition, optimum inlet velocity, at which the cyclone has its highest separation efficiency, tends to increase with a rise in temperature. An analysis on our own data and published results has shown that the fractional efficiency of a cyclone is a definite function of dimensionless numbers such as the Stokes number, the Reynolds number, the Froude number, dimensionless cyclone inlet area, and dimensionless outlet diameter. A nondimensional experimental correlation of the cyclone performance, including the influence of temperature, was obtained on the basis of our own previous work. The prediction of the influence of temperature on separation efficiencies and pressure drops is in fairly good agreement with experimental results.
  • Design method and magnetic field analysis of axial-magnetized permanent magnet micromotor
    YANG Jiewei, WU Yihui, JIA Hongguang, ZHANG Ping, WANG Shurong
    2007, 2(3): 318-322. https://doi.org/10.1007/s11465-007-0056-0
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    To investigate the impact of size on its performance in designing an axial-magnetized permanent magnet micro motor, the finite element method is adopted to simulate the magnetic field of the dual rotor motor, and the flux density wave form distributed in the airgap is obtained. The influence of the external dimensions, pole numbers and magnet thicknesses of the rotor, and the airgap distances on the flux density, are analyzed and analytical results are given. With the increase of the airgap distance, the flux density under more poles reduces more quickly than under fewer poles. With the increase of the magnet thickness, the flux density is a rising curve, and after the magnet thickness attains a certain point, the flux density is almost a constant. While reducing the diameter of the rotor, the decrease of the flux density slows down as magnet thickness is reduced. To avoid having a seriously distorted waveform, the distance between inner and outer radii of the rotor must be larger than 1.5 millimeter. Results of the magnetic field analysis can guide a microminiaturization of the motor. Moreover, the results are analyzed theoretically and the simulated values are almost consistent with the experimental values.
  • Error analysis of the parameters for non-coaxial grazing X-ray microscope
    ZHAO Lingling, HU Jiasheng, LI Xiang
    2007, 2(3): 323-329. https://doi.org/10.1007/s11465-007-0057-z
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    A non-coaxial grazing X-ray microscope, consisting of four spherical mirrors, is designed for diagnosis of inertial confinement fusion (ICF). The aberrations and imaging quality of the microscope are analyzed. To acquire excellent imaging quality, suitable tolerances for manufacturing and assembling the microscope are necessary. This paper researches the changes of Gauss parameters and aberrations due to component and subsystem parameters (such as the radius of the mirror, angle between mirrors, grazing angle, object distance, etc.). Here, spot diagrams and modulation transfer function (MTF) are first adopted to quantitatively evaluate the imaging quality of the microscope. Suitable manufacturing tolerances of components and assembly tolerances of the system are established on the basis of the discussion and analysis. A set of non-coaxial grazing X-ray microscopes is manufactured based on the tolerances. In site tests of ICF, the images with high resolution are obtained by the microscope.
  • Quality monitoring of resistance spot welding based on electrode displacement characteristics analysis
    ZHANG Pengxian, ZHANG Hongjie, CHEN Jianhong, MA Yuezhou
    2007, 2(3): 330-335. https://doi.org/10.1007/s11465-007-0058-y
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    A new method is developed to monitor joint quality based on the information collection and process in spot welding. First, twelve parameters related to weld quality are mined from electrode displacement signal on the basis of different phases of nugget formation marked by simultaneous dynamic resistance signal. Second, through correlation analysis of the parameters and taking tensile-shear strength of the spot-welded joint as evaluation target, different characteristic parameters are reasonably selected. At the same time, linear regression, nonlinear regression and radial basis function (RBF) neural network models are set up to evaluate weld quality between the selected parameters and tensile-shear strength. Finally, the validity of the proposed models is certified. Results show that all of the models can be used to monitor joint quality. For the RBF neural network model, which is more effective for monitoring weld quality than the others, the average error validated is 2.88% and the maximal error validated is under 10%.
  • Functional tolerance theory in incremental growth design
    YANG Bo, ZE Xiangbo, YANG Tao
    2007, 2(3): 336-343. https://doi.org/10.1007/s11465-007-0059-x
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    The evolutionary tolerance design strategy and its characteristics are studied on the basis of automation technology in the product structure design. To guarantee a successful transformation from the functional requirement to geometry constraints between parts, and finally to dimension constraints, a functional tolerance design theory in the process of product growth design is put forward. A mathematical model with a correlated sensitivity function between cost and the tolerance is created, in which the design cost, the manufacturing cost, the usage cost, and the depreciation cost of the product are regarded as control constraints of the tolerance allocation. Considering these costs, a multifactor-cost function to express quality loss of the product is applied into the model. In the mathematical model, the minimum cost is used as the objective function; a reasonable process capability index, the assembly function, and assembly quality are taken as the constraints; and depreciation cost in the objective function is expressed as the discount rate terminology in economics. Thus, allocation of the dimension tolerance as the function and cost over the whole lifetime of the product is realized. Finally, a design example is used to demonstrate the successful application of the proposed functional tolerance theory in the incremental growth design of the product.
  • Basic model study on efficiency evaluation in collaborative design work process
    XIE Qiu, YANG Yu, LI Xiaoli, ZHAO Ningyu
    2007, 2(3): 344-349. https://doi.org/10.1007/s11465-007-0060-4
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    During the efficiency evaluation process of collaborative design work, because of the lack of efficiency evaluation models, a basic analytical model for collaborative design work efficiency evaluation is proposed in this paper. First, the characteristics of the networked collaborative design system work process were studied; then, in accordance with those characteristics, a basic analytical model is created. This model, which is built for centralized collaborative design work, includes an analytical frame, a process view model, a function view model and an information view model. Finally, the application process and steps of this basic analytical model are elaborated when used for efficiency evaluation through an experiment.
  • Ultra-precision ductile grinding of BK7 using super abrasive diamond wheel
    ZHAO Qingliang, Brinksmeier Ekkard, Riemer Oltmann, Rickens Kai
    2007, 2(3): 350-355. https://doi.org/10.1007/s11465-007-0061-3
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    In this paper, a novel conditioning technique using copper bonded diamond grinding wheels of 91 yD grain size and electrolytic in-process dressing (ELID) is first developed to precisely and effectively condition a nickel-electroplated monolayer coarse-grained diamond grinding wheel of 151 μm grain size. Under optimised conditioning parameters, the super abrasive diamond wheel was well conditioned in terms of a minimized run-out error and flattened diamond grain surfaces of constant peripheral envelope. The conditioning force was monitored by a force transducer, while the modified wheel surface status was in-situ monitored by a coaxial optical distance measurement system. Finally, the grinding experiment on BK7 was conducted using the well-conditioned wheel with the corresponding surface morphology and subsurface damage measured by atomic force microscope (AFM) and scanning electric microscope (SEM), respectively. The experimental result shows that the newly developed conditioning technique is applicable and feasible to ductile grinding optical glass featuring nano scale surface roughness, indicating the potential of super abrasive diamond wheels in ductile machining brittle materials.
  • Novel precision piezoelectric step rotary actuator
    LIU Jianfang, YANG Zhigang, ZHAO Hongwei, CHENG Guangming
    2007, 2(3): 356-360. https://doi.org/10.1007/s11465-007-0062-2
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    A novel piezoelectric (PZT) precision step rotary actuator was developed on the basis of PZT technology. It adopts the principle of bionics and works with an inside anchoring/loosening of the stator and a distortion structure of the uniformly distributed thin flexible hinge to solve problems such as ineffective anchoring/loosening, low step rotary frequency, small travel, poor resolution, low speed and unsteady output. The developed actuator is characterized by high frequency (30 Hz), high speed (380 μrad/s), large travel (>270º), high resolution (1 μrad/step), and work stability. It greatly improves the ability to drive the existing PZT step rotary actuator. The new actuator can be applied in the field of micromanipulation and precision engineering, including precision driving and positioning and optics engineering.
  • Analysis of inventory level under procurement constraints in supply chain
    CHANG Guangshu
    2007, 2(3): 361-363. https://doi.org/10.1007/s11465-007-0063-1
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    Because the inventory is one of the major factors that affect the performance of the supply chain system, efficient reduction of an inventory can effectively reduce the cost level of the total supply chain. Therefore, inventory management is an important means to optimize the operation of a supply chain and enhance the competitive advantage. Considering the (s, S) policy in an inventory management, this paper establishes a model of the inventory level. Then, the change of the inventory level with and without the procurement constraints is analyzed, and their expectation and variance calculated. Consequently, the order point can be determined accurately to reduce the inventory level and the operation risk.
  • Regenerative braking control strategy in mild hybrid electric vehicles equipped with automatic manual transmission
    QIN Datong, YE Ming, LIU Zhenjun
    2007, 2(3): 364-369. https://doi.org/10.1007/s11465-007-0064-0
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    The actual regenerative braking force of an integrated starter/generator (ISG), which is varied with desired braking deceleration and vehicle speed, is calculated based on an analysis of the required deceleration, maximum braking force of ISG, engine braking force and state of charge (SOC) of battery. Braking force distribution strategies are presented according to the actual regenerative braking force of ISG. To recover the vehicle s kinetic energy maximally, braking shift rules for a mild hybrid electric vehicle (HEV) equipped with automatic manual transmission (AMT) are brought forward and effects of transmission ratios are considered. A test-bed is built up and regenerative braking tests are carried out. The results show that power recovered by the braking shift rules is more than that recovered by the normal braking control rules.
  • Design of a piezoelectric transducer cylindrical phase modulator for simulating acoustic emission signals
    HE Cunfu, HANG Lijun, WU Bin
    2007, 2(3): 370-373. https://doi.org/10.1007/s11465-007-0065-z
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    To conveniently carry out the pipeline leak experiment in a laboratory, leak acoustic signals are simulated by using the converse piezoelectric effect of a piezoelectric transducer (PZT) cylindrical phase modulator. On the basis of the piezoelectric equations and electromechanical equivalence principle, the transfer function of a PZT cylindrical phase modulator is delivered. A PZT cylindrical phase modulator is designed, and the numerical simulation is conducted. Results prove that the PZT cylindrical phase modulator can effectively simulate leak acoustic emission signals when the frequency is lower than 25 KHz.