Explosion-proof Tire with Multigrids

This new application of vehicle tire is particularly related to apply to a majority of vehicle tools which have explosion-proof tire with a multi-grids and the tire has a number of inflatable cavities which are independent of each other. Rubber tire body are set up with surface layer, the middle layer and the inner layer, the surface layer and the middle layer are provided several pieces of isolating layers, the space middle layer and surface layer are divided into several mutually independent cavities by isolating layer.     

Fabrication of nanoscale step height structure using atomic layer deposition combined with wet etching

The current techniques used for the fabrication of nanosteps are normally done by layer growth and then ion beam thinning. There are also extra films grown on the step surfaces in order to reduce the roughness. So the whole process is time consuming. In this paper, a nanoscale step height structure is fabricated by atomic layer deposition(ALD) and wet etching techniques. According to the traceable of the step height value, the fabrication process is controllable. Because ALD technology can grow a variety of materials, aluminum oxide(Al_2O_3) is used to fabricate the nanostep. There are three steps of Al_2O_3 in this structure including 8 nm, 18 nm and 44 nm. The thickness of Al_2O_3 film and the height of the step are measured by anellipsometer. The experimental results show that the thickness of Al_2O_3 film is consistent with the height of the step. The height of the step is measured by AFM. The measurement results show that the height is related to the number of cycles of ALD and the wet etching time. The bottom and the sidewall surface roughness are related to the wet etching time. The step height is calibrated by Physikalisch-Technische Bundesanstalt(PTB) and the results were 7.5±1.5 nm, 15.5±2.0 nm and 41.8±2.1 nm, respectively. This research provides a method for the fabrication of step height at nanoscale and the nanostep fabricated is potential used for standard references.     

One step positive approach for sheet metal forming simulation based on quasi-conjugate-gradient method

In one step inverse finite element approach, an initial blank shape is normally predicted from the final deformed shape. The final deformed shape needs to be trimmed into a final part after stamping, the trimmed area, therefore, needs to be compensated manually before using one step inverse approach, which causes low efficiency and in consistency with the real situation. To solve this problem, one step positive approach is proposed to simulate the sheet metal stamping process. Firstly the spatial initial solution of one step positive method is preliminarily obtained by using the mapping relationship and area coordinates, then based on the deformation theory the iterative solving is carried out in three-dimensional coordinate system by using quasi-conjugate-gradient method. During iterative process the contact judgment method is introduced to ensure that the nodes on the spatial initial solution are not separated from die surface. The predicted results of sheet metal forming process that include the shape and thickness of the stamped part can be obtained after the iterative solving process. The validity of the proposed approach is verified by comparing the predicted results obtained through the proposed approach with those obtained through the module of one step inverse approach in Autoform and the real stamped part. In one step positive method, the stamped shape of regular sheet can be calculated fast and effectively. During the iterative solution, the quasi-conjugate-gradient method is proposed to take the place of solving system of equations, and it can improve the stability and precision of the algorithm.     

Failure mechanisms and structural optimization of shredder hammer for metal scraps

Recycling retired cars can relieve the environmental pollution and resource waste efficiently. However, a few publications can be found on the failure mechanisms and optimization method of recycling equipment, shredders. Thus, the failure mechanisms and structural optimization of shredder hammers for retired cars are studied aiming improving shredding efficiency and reducing cost. Failure types of shredder hammer are studied theoretically, and it is found that wear failure and fatigue failure are the two main failure types of shredder hammer. The shredding process of metal scraps is analyzed by finite element method, and it can be divided into four stages based on the stress states: initial stage, collision stage, grinding stage and separation stage. It is proved that the shredding efficiency can be improved by increasing cutouts on the hammer head. Finally, it is determined that the hammer with two cutouts is the optimal structure for metal scraps, which can improve the shredding efficiency by 20% and lengthen the hammer life by 15%. This study provides scientific basis for the industry application and theoretical foundation for further research.     

PART BUILDING ORIENTATION OPTIMIZATION METHOD IN STEREOLITHOGRAPHY

Aiming at the part quality and building time problems in stereolithography (SL) caused by unreasonable building orientation, a part building orientation decision method in SL rapid prototyping (RP) is carried out. Bringing into fall consideration of the deformation, stair-stepping effect, overcure effect and building time related to the part fabrication orientation, and using evaluation function method, a multi-objective optimization model for the building orientation is defined. According to the difference in the angles between normal vectors of triangular facets in standard triangulation language (STL) model and z axis, the expressions of deformation area, stair-stepping area, overcure area are established. According to the characteristics in SL process, part building time is divided into four sections, that is, hatching scanning time, outline scanning time, support building time and layer waiting time. Expressions of each building time section are given. Considering the features of this optimization model, genetic algorithm (GA) is used to derive the optimization objective, related software is developed and optimization results are tested through experiments. Application shows that this method can effectively solve the quality and efficiency troubles caused by unreasonable part building orientation, an automatic orientation-determining program is developed and verified through test.     

Three-steps-meshing based multiple crack identification for structures and its experimental studies

Multiple crack identification plays an important role in vibration-based crack identification of structures. Traditional crack detection method of single crack is difficult to be used in multiple crack diagnosis. A three-step-meshing method for the multiple cracks identification in structures is presented. Firstly, the changes in natural frequency of a structure with various crack locations and depth are accurately obtained by means of wavelet finite element method, and then the damage coefficient method is used to determine the number and the region of cracks. Secondly, different regions in the cracked structure are divided into meshes with different scales, and then the small unit containing cracks in the damaged area is gradually located by iterative computation. Lastly, by finding the points of intersection of three frequency contour lines in the small unit, the crack location and depth are identified. In order to verify the effectiveness of the presented method, a multiple cracks identification experiment is carried out. The diagnostic tests on a cantilever beam under two working conditions show the accuracy of the proposed method: with a maximum error of crack location identification 2.7% and of depth identification 5.2%. The method is able to detect multiple crack of beam with less subdivision and higher precision, and can be developed as a multiple crack detection approach for complicated structures.     

NUMERICAL SOLUTION OF FLUID-STRUCTURE INTERACTION IN LIQUID-FILLED PIPES BY METHOD OF CHARACTERISTICS

Fluid-structure interaction (FSI) is essentially a dynamic phenomenon and always exists in fluid-filled pipe system. The four-equation model, which has been proved to be effective to describe and predict the phenomenon of FSI due to friction coupling and Poisson coupling being taken into account, is utilized to describe the FSI of fluid-filled pipe system. Terse compatibility equations are educed by the method of characteristics (MOC) to describe the fluid-filled pipe system. To shorten computing time needed to get the solutions under the condition of keeping accuracy requirement, two steps are adopted, firstly the time step Δt and divided number of the straight pipe are optimized, sec-ondly the mesh spacing Δz close to boundary is subdivided in several submeshes automatically ac-cording to the speed gradient of fluid. The mathematical model and arithmetic are validated by com-parisons between simulation solutions of two straight pipe systems and experiment known from lit-erature.     

Hardening Effect on Machined Surface for Precise Hard Cutting Process with Consideration of Tool Wear

During hard cutting process there is severe thermodynamic coupling effect between cutting tool and workpiece, which causes quenching effect on finished surfaces under certain conditions. However, material phase transformation mechanism of heat treatment in cutting process is different from the one in traditional process, which leads to changes of the formation mechanism of damaged layer on machined workpiece surface. This paper researches on the generation mechanism of damaged layer on machined surface in the process of PCBN tool hard cutting hardened steel Cr12MoV. Rules of temperature change on machined surface and subsurface are got by means of finite element simulation. In phase transformation temperature experiments rapid transformation instrument is employed, and the effect of quenching under cutting conditions on generation of damaged layer is revealed. Based on that, the phase transformation points of temperature under cutting conditions are determined. By experiment, the effects of cutting speed and tool wear on white layer thickness in damaged layer are revealed. The temperature distribution law of third deformation zone is got by establishing the numerical prediction model, and thickness of white layer in damaged layer is predicted, taking the tool wear effect into consideration. The experimental results show that the model prediction is accurate, and the establishment of prediction model provides a reference for wise selection of parameters in precise hard cutting process. For the machining process with high demanding on surface integrity, the generation of damaged layer on machined surface can be controlled precisely by using the prediction model.     

Formability of Materials with Small Tools in Incremental Forming

Single point incremental forming (SPIF) is an innovative sheet forming process with a high economic pay-o.The formability in this process can be maximized by executing forming with a tool of specific small radius,regarded as threshold critical radius.Its value has been reported as 2.2 mm for 1 mm thick sheet materials.However,with a change in the forming conditions specifically in the sheet thickness and step size,the critical radius is likely to alter due to a change in the bending condition.The main aim of the present study is to undertake this point into account and develop a relatively generic condition.The study is composed of experimental and numerical investigations.The maximum wall angle (θ_(max)) without sheet fracturing is regarded as sheet formability.A number of sheet materials are formed to fracture and the trends correlating formability with normalized radius (i.e.,R/T_o where R is the tool-radius and T_o is the sheet thickness) are drawn.These trends confirm that there is a critical tool-radius (R_c) that maximizes the formability in SPIF.Furthermore,it is found that the critical radius is not fixed rather it shows dependence on the sheet thickness such that R_c=βT_o,whereβvaries from 2.2 to 3.3 as the thickness increases from 1 mm to 3 mm.The critical radius,however,remains insensitive to variation in step size ranging from 0.3 mm to 0.7 mm.This is also observedthat the selection of tool with RR_c narrows down the formability window not only on the higher side but also on the lower side.The higher limit,as revealed by the experimental and FEA results,diminishes due to excessive shearing because of in-plane biaxial compression,and the lower limit reduces due to pillowing in the bottom of part.The new tool-radius condition proposed herein study would be helpful in maximizing the formability of materials in SPIF without performing experimental trials.     

The New Rigid Element for Laminated Cylindrical Shell

Thermal effects are incorporated into developed discrete layer mechanics for two-dimensional cylindrical shells structures. Finite element equations are developed according to layerwise theory of laminated structure. Following the layerwise theory, a variable kinematic model that incorporates mechanics and thermal conditions is also presented. The new element has a field of displacement compatible with the cylindrical shell element or plate and it can be used as a rigid element for this structural element.ln the laminate model construction, adjacent layers are arranged as bonded layers. The layer has a unique constant thickness that can be different to each layer. The fiber reinforced is used and the fibers in a laminate may be oriented arbitrarily. The shear stress is adopted equal to zero because the thin thickness, on the other hand, the normal stress is maintained in order to ensure the compatibility of stress in material. The previously authors of this methods neglect the implications of thermal effects on cylindrical shells structures. Thermal effects become important when the structure has to operate in either extremely hot or cold temperature environments. These extreme conditions may severely affect the response of structure in two distinct ways： （1） induction of thermal stresses due to differences in the coefficients of thermal expansion between the various composite plies and layers and （2） temperature dependence of the elastic properties. Only a limited amount of work has been reported concerning this topic. All in all, the main contribution of this work is the consideration of this kinematic for cylindrical shells that incorporate mechanics and thermal conditions. In addition, numerical results are presented to demonstrate the capability of the current formulation to represent the behavior of cylindrical shells with these characteristics.     

Adaptive direct slicing of a commercial CAD model for use in rapid prototyping

Slicing a 3D graphic model into layers of 2D contour plots is an essential step for all rapid prototyping (RP) machines. Various methods are available, such as stereo lithography (STL) file slicing, direct slicing and adaptive direct slicing. Amongst these, adaptive direct slicing is the most advanced for its capability of adapting the slicing thickness according to the curvature of any contour. In this study, an adaptive direct slicing method complete with the algorithm for calculating the thickness of each layer is proposed. As an illustration of the method, the algorithm was programmed within the commercial CAD software package, PowerSHAPE. The method was shown to be fast and accurate in comparison with STL file slicing and direct slicing, which both used a constant layer thickness. An erratum to this article can be found at     

快速成型技术中分层算法的研究综述

作为快速成型技术中必不可少的环节,根据对零件制造精度和装配要求及效率的侧重不同,多年来多种分层算法已被国内外学者开发出来。在同等加工条件下,根据加工精度要求和层厚变化的不同,将分层算法大致分为等层厚分层算法和适应性分层算法两类。从常用的立体光刻(STL)模型、原始计算机辅助设计(CAD)模型和点云数据3种数据模型入手,简述了两类分层算法的研究和发展;介绍了采用斜边的分层算法、基于区域划分的混合算法、曲面分层算法等先进分层算法;讨论了分层算法中待解决的问题:直接分层算法的文件格式标准和轮廓的精确拟合等问题。最后,总结得出了分层算法未来的研究方向和趋势。     

一种快速成形自适应分层层厚新算法

将现有的两种自适应层厚算法加以结合,阐述一种基于STL文件的快速成形自适应分层层厚的新算法。该算法弥补了上述两种算法原理上各自的不足,通过对该新算法的测试得到比较满意的结果。     

基于DLP的珠宝树脂3D打印工艺研究

DLP(数字光处理技术)是一种以面曝光的方式逐层成型的3D打印技术.在DLP的3D打印工艺过程中,当分层厚度确定时,零件的打印精度主要取决于曝光时间和成型方向.设计一个测试试样,研究了采用DLP工艺打印珠宝树脂材料过程中的单层曝光时间和零件成型方向对不同特征打印精度的影响规律.研究结果表明:对于所采用的珠宝铸造树脂曝光...     

A New Slicing Procedure for Rapid Prototyping Systems

The current slicing rule of most rapid prototyping (RP) systems cannot ensure unilateral tolerances on the whole prototype and often results in problems of overcut and undercut on the same part. This drawback leads to unsatisfactory precision of the part in post processing. In order to reduce the above problems, a new slicing method is proposed in this paper. Based on the geometry information in a stereolithography (STL) file, an algorithm is developed. The appropriate slicing rule is selected according to the inner product of the normal vector and working direction of the part, together with the function of the part to be manufactured. The STL file is cut into 2D sections and an accurate contour is calculated. After the slicing computation, an appropriate working path is produced. The rules proposed in this paper have been verified. This work contributes to the improvement of slicing rules in existing RP systems, especially in systems using uniform thickness slicing. It also improves manufacturing efficiency and working tolerances.     

基于自由曲面点云的RPM自适应分层研究

针对由激光三维扫描设备获取的点云数据及其后续RPM操作,提出基于栅带的自由曲面点云自适应分层方法.以栅带为基元,将点云投影栅带化,从中获取特征点集,结合相邻栅带距离最小值点找寻构建层间轮廓.定义投影点云栅带面积比为表面误差,建立其与堆层厚度的关系,通过表面误差逼近定值最终确定堆层厚度.经实例验证,此方法得到的分层模型充分满足RPM的要求.     

Direct slicing and G-code contour for rapid prototyping machine of UV resin spray using PowerSOLUTION macro commands

Rapid prototyping processes produce parts layer by layer directly from 3D CAD models. An important technique is required to slice the geometric model of a part into layers and to generate a motion code of the cross-sectional contour. Several slicing methods are available, such as slicing from sterolithgraphy (STL) files, tolerate-error slicing, adaptive slicing, direct slicing, and, adaptive and direct slicing. This paper proposes direct slicing from 3D CAD models and generating a G-code contour of each layer using PowerSOLUTION software (Delcam International, Birmingham, UK). PowerSOLUTION includes two main modules: PowerSHAPE is used to build 3D CAD models and PowerMILL is used to produce G-Code tool paths. It provides macro language, picture files and cutting paths for secondary development work.The authors used macro commands to write an interface generating direct slicing from 3D CAD models and G-code contours for all layers. Most well-known controllers in the market accept the G-Code. Therefore, it is easier to apply this scheme in a CNC-machining center to produce rapid prototyping such as laminated object manufacturing (LOM) for complex geometries. The interface was successfully applied the interface to the UV resin spray rapid prototyping (UVRS-RP) machine that was developed to produce RP.     

轴承滚子凸度轮廓的最小二乘拟合与误差评定

为了实现对轴承滚子凸度轮廓误差的精确评定,依据圆弧修正型轴承滚子凸度素线轮廓的几何特征和形状误差的定义,基于最小二乘原理,研究了轴承凸度轮廓(两段圆弧和一段直线)的最小二乘拟合和误差评定方法。首先利用各测量点的曲率差值确定了圆弧段与直线段的相切参考点;其次分别选取两个参考点临近的测量点作为辅助相切参考点,并与对应的圆弧段测量点一起拟合出一系列的最小二乘圆弧并计算拟合误差;然后基于直线与两段圆弧相切的原则确定出一系列的直线方程并计算对应的直线度误差;通过比较判断最终确定出圆弧修正型轴承滚子凸度轮廓的最小二乘拟合及误差评定。实例结果表明:圆弧修正型凸度轮廓曲线的总误差0.020 9mm与文中设定标准凸度轮廓曲线引入的法向误差0.02mm相差4.5%。本方法可以有效的实现轴承凸度轮廓的拟合与误差评定,为平面多段曲线的最小二乘拟合提供了一种新的思路。     

数控车床自动编程系统中的刀具干涉处理方法

分析数控车床自动编程系统中直线和圆弧刀具轨迹出现刀具干涉的条件,提出了解决刀具干涉的处理方法,给出了刀具路径验证的总体算法,实现了生成无干涉的刀具路径的功能。     

基于STL模型支撑生成算法的研究

针对快速成型制造中须对零件加支撑的需求,提出一种新的支撑生成方法。它首先提取零件待支撑区域的关键特征(如悬吊点、下棱线、待支撑下表面的轮廓线等),同时指出各种支撑的基本构件实质就是单边对应的多边形支撑面,并采用了局部斜板支撑的方案实现其生成算法,在此基础上生成零件的特征支撑;然后采用对生成的特征支撑STL模型分层后分区扫描填充加强支撑线来实现对待支撑下表面内部区域的有效支撑。应用表明：该方法实现了对成型零件关键特征的准确支撑和对待支撑面域的有效支撑,生成支撑效果良好。