Dec 2008, Volume 3 Issue 4
    

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  • Flux-free brazing of Mg-containing aluminium alloys by means of cold spraying
    BOBZIN Kirsten, ZHAO Lidong, ERNST Felix, RICHARDT Katharina
    2008, 3(4): 355-359. https://doi.org/10.1007/s11465-008-0055-9
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    In the present study, AlSi12 and AlSi10Cu4 were deposited onto Mg-containing aluminium alloys 6063 and 5754 by cold spraying. The influences of the two brazing alloys and spray parameters on coating formation were investigated. The microstructure of the coatings was characterized. Some coated samples were heat-treated at 590°C and 560°C in air to investigate the effect of the rupture of oxide scales on the diffusion of elements during heat-treatment. Some coated samples were brazed under argon atmosphere without any fluxes. The results show that AlSi12 had much better deposition behaviour than AlSi10Cu4. Due to the rupture of oxide scales, Cu and Si diffused into the substrate and a metallurgical bond formed between the brazing alloys and the substrates during heat-treatment. The coated samples could be brazed without any fluxes. Because the oxide scales prevented the formation of a metallurgical bond locally, the brazed samples had relatively low shear strengths of up to 43 MPa.
  • Fundamental frequency and testing mode of complicated elastic clamped-plate vibration
    QI Hongyuan, GUAN Yiduo
    2008, 3(4): 360-364. https://doi.org/10.1007/s11465-008-0084-4
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    Aimed at the modal analysis of complicated elastic clamped-plates, a trigonometric interpolation method of conformal mapping is applied to set up the mapping function between a complicated region and a unit dish region, and the fundamental frequency of the complicated vibrating region is analyzed with the help of the Galerkin method. Taking an elastic rectangle-plate with arc radius as an example, the testing mode frequency band of plates is determined by analyzing the fundamental frequency; meanwhile, according to hamming testing method of multi-point excitation to the single-point response, and by signal processing technology and its software programming, modal parameter recognition of the elastic clamped-plate is completed. Comparing the first order modal frequency with the theoretical fundament frequency, the validity of the testing mode method and theoretical analysis are verified.
  • Experiment and surge analysis of centrifugal two-stage turbocharging system
    HE Yituan, MA Chaochen
    2008, 3(4): 365-368. https://doi.org/10.1007/s11465-008-0073-7
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    To study a centrifugal two-stage turbocharging system’s surge and influencing factors, a special test bench was set up and the system surge test was performed. The test results indicate that the measured parameters such as air mass flow and rotation speed of a high pressure (HP) stage compressor can be converted into corrected parameters under a standard condition according to the Mach number similarity criterion, because the air flow in a HP stage compressor has entered the Reynolds number (Re) auto-modeling range. Accordingly, the reasons leading to a two-stage turbocharging system’s surge can be analyzed according to the corrected mass flow characteristic maps and actual operating conditions of HP and low pressure (LP) stage compressors.
  • Reliability-based design for automobiles in China
    ZHANG Yimin
    2008, 3(4): 369-374. https://doi.org/10.1007/s11465-008-0064-8
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    The level of automobile design and manufacturing is an important sign of leadership in science and technology and economic power. The achievements of theories and methods for reliability-based design of automobiles in China are reviewed. For reliability-based design, the theories and practices, optimization, sensitivity, and robustness are estimated. The techniques of reliability-based design for automobiles are developed. The techniques service to the “hollow” phenomena of kernel technology, product innovative power, and independent development power can be solved.
  • Noise control technology for generator sets in enclosures
    ZHANG Nailong, YANG Wentong, FEI Renyuan
    2008, 3(4): 377-384. https://doi.org/10.1007/s11465-008-0051-0
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    Currently, noise pollution is an environmental problem all over the world. The health and life of human beings are affected by loud noise from high power generator sets. To reduce such noise, a sound-attenuated enclosure is widely used for its high performance and convenient usage. By installing equipment in an enclosure, noise is controlled and prevented from radiating. In this paper, noise control techniques for enclosures are presented. Enclosure development trends are predicted.
  • Dynamic characteristics of NC table with SVD
    WANG Linhong, WU Bo, DU Runsheng, YANG Shuzi
    2008, 3(4): 385-391. https://doi.org/10.1007/s11465-008-0052-z
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    This paper employs the SVD (singular value decomposition) method to study dynamic characteristics of a numerical control (NC) table. Acceleration signals of the NC table at three directions are tested; the singular spectrum of the signals is acquired with SVD; principal components of the signals are found out; dynamic characteristics of the signals and their contributing factors are studied by extracting dynamic characteristics of principal components; and signals and principal components are quantitatively analyzed by calculating signal energy. Results indicate that signal characteristics of the previous two principal components are apparent, based on which dynamic characteristics of chaotic signal can be extracted. Signal at the perpendicular direction of the table is significantly correlated with that at the horizontal motion direction, which indicates that they are excited from the same vibration source. However, signals perpendicular to each other in terms of the motion direction at the horizontal level are rarely correlated; the total signal energy is maximum at the motion direction, minimum at the horizontal non-motion direction, and medium at the perpendicular non-motion direction. Bending vibration of the lead screw at the perpendicular direction is far more violent than that at the horizontal direction.
  • Task-space position/attitude tracking control of FAST fine tuning system
    QI Lin, ZHANG Hui, DUAN Guanghong
    2008, 3(4): 392-399. https://doi.org/10.1007/s11465-008-0056-8
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    This paper addresses the task-space position/attitude tracking control of a suspended parallel robot, which is being developed in the framework of a five-hundred meter aperture spherical radio telescope (FAST) project. Based on the quaternion algebra, a novel model-independent task-space PD controller that ensures end-effector position and attitude tracking is presented. The simulation and experimental results show that the new controller has better control effects than the traditional joint-space controller.
  • Air-bearing position optimization based on dynamic characteristics of ultra-precision linear stages
    CHEN Xuedong, LI Zhixin
    2008, 3(4): 400-407. https://doi.org/10.1007/s11465-008-0060-z
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    Air-bearings are installed between the stator and the mover of ultra-precision linear stages to suppress vibration and mechanical contact. Spring-damping elements are used to emulate the complex interaction of the finite element model (FEM) developed in this paper and the system dynamic behaviors are analyzed. Through the experimental modal test, the validity and reliability of the model are proven. However, the dynamic characteristics including mode frequency, mode shape, and response amplitude are obviously changed with the position of air-bearings. The combined optimization method is used to optimize the air-bearings position. The best and worst positions are obtained using the dynamic characteristic analysis. The method can be generalized to the connection position of different components in manufacture elements and to implement the system dynamic characteristics optimization when the connection position can be changed.
  • Theory analysis and system identification methods on thermal dynamics characteristics of ballscrews
    XIA Junyong, HU Youmin, WU Bo, SHI Tielin
    2008, 3(4): 408-415. https://doi.org/10.1007/s11465-008-0061-y
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    Empirical model of machine tools on thermal error has been widely researched, which can compensate for thermal error to some extent but not suitable for thermal dynamic errors produced by dynamic heat sources. The thermoelastic phenomenon of unidimensional heat transfer of ballscrews influenced by changeable heat sources is analyzed based on the theory of heat transfer. Two methods for system identification (the least square system identification and BP artificial neural network (ANN) system identification) are put forward to establish a dynamic characteristic model of thermal deformation of ballscrews. The model of thermal error of the X axis in a feed system of DM4600 vertical miller is established with a fine identification effect. Comparing the results of the two identification methods, the BP ANN system identification is more precise than the least square system identification.
  • Inner strain determination of three-dimensional braided preforms with co-braided optical fiber sensors
    LI Xianghua, LIU Xiaohui, YUAN Shenfang
    2008, 3(4): 416-420. https://doi.org/10.1007/s11465-008-0062-x
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    The experimental characterization of three-dimensional (3-D) braided composites is extremely important for their design and analysis. Because of their desirable attributes and outstanding performance, optical fiber sensors (OFSs) can be embedded to monitor mechanical properties of textile composites. This paper discusses two techniques to incorporate different OFSs into 3-D braided composite preforms. The operating principle of various sensor systems is first conducted. Experiments using Michelson interferometers, FBG sensors, and micro-bend sensors are performed to verify the concept of the proposed method. Strain curves of various OFSs tests are finally compared, and they all exhibit good linearity.
  • Precision control system of two-DOF stage with linear ultrasonic motor
    ZHANG Hanlei, SHI Yunlai, ZHAO Chunsheng
    2008, 3(4): 421-425. https://doi.org/10.1007/s11465-008-0063-9
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    Using an appropriate control method, linear ultrasonic motors can be used in applications requiring high position accuracy. In this paper, a closed loop PI control system is designed to achieve high position accuracy during the control of a two-DOF stage driven by linear ultrasonic motors. Two ultrasonic motors are mounted on the stage to generate motion in two orthogonal directions. The PI control algorithm is used to increase the stability and accuracy of position control. The x-axis mover covers 30 mm forward and backward in less than 0.3 s settling time and the y-axis mover in less than 0.4 s. Experimental results denote that the control strategy proposed in this paper appears to have high efficiency, quick response, and high accuracy.
  • Optimal localization of complex surfaces in CAD-based inspection
    XU Jinting, LIU Weijun, SUN Yuwen
    2008, 3(4): 426-433. https://doi.org/10.1007/s11465-008-0068-4
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    Complex surface inspection requires the optimal localization of the measured surface related to the design surface so that the two surfaces can be compared in a common coordinate frame. This paper presents a new technique for solving the localization problem. The basic approach consists of two steps: 1) rough localization of the measured points to the design surface based on curvature features, which can produce a good initial estimate for the optimal localization; 2) fine localization based on the least-square principle so that the deviation between the measured surface and the design surface is minimized. To efficiently compute the closest points on the design surface of the measured points, a novel method is proposed. Since this approach does not involve an iterative process of solving non-linear equations for the closest points, it is more convenient and robust. The typical complex surface is used to test the developed algorithm. Analysis and comparison of experimental results demonstrate the validity and applicability of the algorithm.
  • Power performance of circular piezoelectric diaphragm generators
    TANG Kehong, KAN Junwu, YANG Zhigang, CHENG Guangming, PENG Taijiang
    2008, 3(4): 434-440. https://doi.org/10.1007/s11465-008-0069-3
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    Energy generation performance of a piezoelectric generator depends mainly on several elements such as the structural style, boundary conditions, geometry parameters, materials, vibration-source frequency, and external load. To obtain the optimal energy-harvesting device, the Raleigh method is used to establish the analysis model of circular piezoelectric composite diaphragms. Simply supported and clamped boundary conditions were considered. The relationships between the output power and the structural parameters of piezoelectric composite diaphragms, and the external load resistance and frequency were shown. Given the correlative material parameters and boundary conditions, the output power, using structural parameters, external load, or vibrating frequency as variables, can be calculated. Simulation results show that there are optimal structural parameters and load for a composite diaphragm to achieve the maximum output power. A piezoelectric diaphragm generator with given dimensions tends to achieve higher output power under clamped boundary conditions than that under simply supported boundary conditions.
  • Numerical analysis of hydrodynamic process of circular-translational-moving polishing (CTMP)
    ZHAI Wenjie, LIU Changxiong, LIANG Yingchun
    2008, 3(4): 441-448. https://doi.org/10.1007/s11465-008-0074-6
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    By keeping a pad moving relative to a wafer along a circular path without rotation, we developed a polishing technique called circular-translational-moving polishing (CTMP), which permits multidirectional polishing of the work piece and thus bears the advantage of isotropic polishing and a potential increase of material removal rate (MRR) on the wafer. To illuminate the mechanisms of CTMP and determine the optimum process variables in a CTMP process, a three-dimensional hydrodynamic lubrication model for CTMP with a smooth and rigid pad under a quasi-stable state is established in a polar coordinate system. The model equations are further calculated numerically by the finite difference method. The instantaneous distribution of fluid pressure is obtained, which shows that a negative pressure exists. The reason for negative pressure in CTMP and its effect on polishing is discussed. Moreover, the nominal clearance of the fluid film, roll, and pitch angles under different working conditions are obtained in terms of the applied load, moments, and polishing velocity. The obtained numerical analysis can be used as guidance for choosing operation parameters in a practical CTMP application.
  • Piezoelectric diffuser/nozzle micropump with double pump chambers
    WANG Wei, ZHANG Ying, TIAN Li, CHEN Xiaojie, LIU Xiaowei
    2008, 3(4): 449-453. https://doi.org/10.1007/s11465-008-0076-4
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    To eliminate check valve fatigue and valve clogging, diffuser/nozzle elements are used for flow rectification in a valveless diffuser/nozzle micropump instead of valves. However, the application of this type of micropump is restricted because of its pulsating or periodic flow and low pump flux. In this paper, a diffuser/nozzle Si/Glass micropump with two pump chambers by IC and MEMS technology is designed. The fabrication process requires only one mask and one etch step, so that the fabrication has the advantages of low cost, short processing period, and facilitation of miniaturization. The pump is equipped with a glass cover board so as to conveniently observe the flow status. Pump-chambers and diffuser elements are fabricated by the anisotropic KOH-etch technique on the silicone substrate, and the convex corner is designed to compensate for an anisotropic etch. The driving force of the micropump is produced by the PZT piezoelectric actuator. The pump performance with both actuators actuated in anti- or same-phase mode is also researched. The result indicates that the micropump achieves great performance with the actuators working at anti-phase. This may be because the liquid flows steadily, pulse phenomenon is very weak, and the optimal working frequency, pump back pressure, and flow rate are both double that of the pump driven in same-phase.
  • Operation and control of flow manufacturing based on constraints management for high-mix/low-volume production
    GUAN Zailin, PENG Yunfang, MA Li, ZHANG Chaoyong, LI Peigen
    2008, 3(4): 454-461. https://doi.org/10.1007/s11465-008-0083-5
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    The existing technology of flow manufacturing, which is mainly appropriate for high volume and repetitive production, is proven difficult to be applied in high-mix/low-volume environments. To adapt lean production into the latter, a new type of flow manufacturing is proposed based on flow path management technology. This paper first describes the general operation framework of the proposed new mode. The main idea is the dynamic formation of adaptable virtual production lines (called flow paths) corresponding to different product families. The application of different theories of constraints/drum-buffer-rope (TOC/DBR) control policies depends on the differences in scope of variety and scale of demand for these product families. The overall architecture of the proposed mechanism of constraint management-based operation and control is introduced. For the implementation, a mathematical programming method is suggested for the dynamic planning of flow paths, and a TOC/DBR ‘path-specific’ mechanism with group scheduling is used for the control over each flow path. We also study other critical issues including the identification and management of resource bottlenecks, and the setting of the buffer size in the deployment of the TOC/DBR mechanism.
  • Equivalent thermal conductivity of heat pipes
    LU Zesheng, MA Binghui
    2008, 3(4): 462-466. https://doi.org/10.1007/s11465-008-0087-1
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    In precision machining, the machining error from thermal distortion carries a high proportion of the total errors. If a precision machining tool can transfer heat fast, the thermal distortion will be reduced and the machining precision will be improved. A heat pipe working based on phase transitions of the inner working liquid transfers heat with high efficiency and is widely applied in spaceflight and chemical industries. In mechanics, applications of heat pipes are correspondingly less. When a heat pipe is applied to a hydrostatic motorized spindle, the thermal distortion cannot be solved during the heat transfer process because thermal conductivity or equivalent thermal conductivity should be provided first for special application in mechanics. An equivalent thermal conductivity model based on equivalent thermal resistances is established. Performance tests for a screen wick pipe, gravity pipe, and rotation heat pipe are done to validate the efficiency of the equivalent thermal conductivity model. The proposed model provides a calculation method for the thermal distortion analysis of heat pipes applied in the motorized spindle.