大型直线振动筛疲劳寿命的分析与研究

文中利用有限元分析软件ANSYS对大型直线型振动筛工作状态下的应力进行分析,得出振动筛的最大应力集中位于筛箱箱体侧板和筛箱支撑横梁连接处,筛箱箱体后挡板横梁处。根据迈纳尔损伤积累理论对振动筛最大应力处的节点进行疲劳寿命分析,分别得出振动筛最大应力节点的疲劳寿命,为大型振动筛的疲劳寿命设计奠定了基础。     

航空发动机传动轴承多支承台架试验失效机理分析

作为航空发动机的关键部件之一,传动系统的工作性能直接决定整机的运行状态与可靠性。传动系统的支承轴承因工作环境恶劣,在其工作过程中极易出现早期失效故障。针对某航空发动机传动系统支承球轴承台架试验中出现早期失效的问题,采用有限元方法,建立了多点支撑柔性传动系统动力学模型,分析了转速和轴承游隙对系统各支承轴承的动态载荷与弹性变形的影响规律,确定了支承轴承发生失效的位置及其原因;采用Lundberg和Palmgre的疲劳寿命计算方法,基于多点支撑柔性传动系统动力学模型获得的轴承内部动态载荷,计算了台架系统中出现早期失效的支承球轴承的疲劳寿命。结果表明,支承轴承的游隙匹配会导致各轴承内部载荷存在较大差异,该差异是导致其疲劳失效的主要原因,该仿真结果与实际情况基本一致。论文的研究可为该型航空发动机传动系统支承轴承的优化设计提供新的思路和理论支撑。     

某轻卡制动阀支架失效分析及其优化设计

针对某轻卡制动阀支架失效问题,首先采集车架横梁两端的搓板路激励载荷对该制动阀支架进行模态频响计算,分析结果表明该制动阀支架的最大应力大于材料许用值,其最大应力位置与失效位置一致;然后基于功率谱载荷对其进行随机振动疲劳分析,分析结果表明该制动阀支架的疲劳寿命不满足疲劳性能要求,其与振动强度分析薄弱位置和失效位置相吻合;再通过集成优化平台对制动阀支架进行结构优化,优化之后制动阀支架的最大应力值和疲劳寿命值均符合性能要求值,其疲劳、强度性能显著提升,支架总重量也降低了,达到了轻量化的要求;最后对制动阀支架的优化方案进行道路可靠性验证,试验结果表明该制动阀支架的振动加速度明显减小,并且没有发生失效,科学地解决了该制动阀支架的失效问题。     

某ABS阀支架振动疲劳分析及其优化设计

为了解决某ABS阀支架断裂失效问题,首先基于有限元方法对其进行模态分析,分析结果表明其前两阶固有模态频率与发动机的激励频率相一致,将产生共振,不满足模态性能要求。然后采集横梁左、右端的载荷谱,将其转换为功率谱密度载荷,并通过单位激励的频率响应分析,建立单位激励与应力之间的传递函数,以此对其进行振动疲劳分析,分析结果表明该支架的疲劳循环次数低于目标值,不满足疲劳性能要求,并且其危险点与断裂位置相同。再采用霍克-吉维斯直接搜索算法对该支架进行参数优化,并新增一条加强筋,得到最终对优化方案。优化之后该支架的第一阶频率能够避开发动机激励频率,其疲劳循环次数高于目标值,其重量也降低了16%,能够同时满足模态性能、疲劳性能和轻量化的要求。最后对优化方案进行道路验证和测试,测试结果表明该支架的振动激励降低了39.3%,优化效果比较明显,并且没有出现开裂现象。     

发动机ECU支架振动疲劳分析及其优化设计

为了解决某发动机ECU支架开裂失效问题,首先采集ECU与车架端的实车加速度,并且将其时域信号转换为频域信号。然后基于有限元方法建立ECU支架分析模型,对其进行频率响应分析,分析结果表明其最大应力值超过其材料屈服强度。再基于Miner线性累积损伤理论和功率谱密度函数对其进行振动疲劳分析,分析结果表明其最小寿命为低于设计要求值,与实际失效位置相吻合。最后基于Isight集成优化平台并且采用多岛遗传算法对ECU支架进行优化设计,得到了其最佳的设计参数,优化之后其最大应力值和疲劳寿命均能够满足设计要求,并且其优化方案通过了路试验证,成功解决了该故障问题。     

3000型压裂车高压管汇疲劳强度仿真研究

高压管汇是油田酸化压裂作业中必不可少的设备,随着压裂作业深度的不断增大,管汇承受越来越高的压裂压力,其强度直接影响着压裂作业中安全问题。为了验证弯头冲蚀疲劳破坏是3000型压裂车作业用高压管汇失效的主要原因,以真实参数在三维建模软件Pro/E中创建管汇分析模型,通过计算流体动力学软件CFD对压裂作业过程高压管汇中弯头处的流场进行了仿真分析,利用流固耦合完成了管结构的疲劳强度计算,并提出了预防冲蚀疲劳破坏的措施和建议,仿真计算结果与实际失效案例进行了对比,结果表明,管弯头是高压管汇最易发生冲蚀和疲劳破坏的地方,且弯头外侧内壁面处为最大危险区。     

某新型转膛自动机换向器的疲劳寿命分析

转膛驱动机构是转膛自动机关键部件之一,其寿命直接影响转膛炮的性能和寿命.为研究某新型转膛自动机换向器在正常工作循环下的使用及疲劳失效情况,使用虚拟样机仿真软件对换向器正常工作下的载荷进行分析,通过有限元软件模拟得到换向器的应力和应变等情况,并对其失效及疲劳寿命曲线进行分析,最终得出转膛换向器主要损坏位置为与滚轮接触处,其理论疲劳寿命为击发316次,与试验结果较为符合,该结论可为换向器后续的优化设计提供参考.     

某新型转膛自动机换向器的疲劳寿命分析

转膛驱动机构是转膛自动机关键部件之一,其寿命直接影响转膛炮的性能和寿命.为研究某新型转膛自动机换向器在正常工作循环下的使用及疲劳失效情况,使用虚拟样机仿真软件对换向器正常工作下的载荷进行分析,通过有限元软件模拟得到换向器的应力和应变等情况,并对其失效及疲劳寿命曲线进行分析,最终得出转膛换向器主要损坏位置为与滚轮接触处,其理论疲劳寿命为击发316次,与试验结果较为符合,该结论可为换向器后续的优化设计提供参考.     

某新型转膛自动机换向器的疲劳寿命分析

转膛驱动机构是转膛自动机关键部件之一,其寿命直接影响转膛炮的性能和寿命.为研究某新型转膛自动机换向器在正常工作循环下的使用及疲劳失效情况,使用虚拟样机仿真软件对换向器正常工作下的载荷进行分析,通过有限元软件模拟得到换向器的应力和应变等情况,并对其失效及疲劳寿命曲线进行分析,最终得出转膛换向器主要损坏位置为与滚轮接触处,其理论疲劳寿命为击发316次,与试验结果较为符合,该结论可为换向器后续的优化设计提供参考.     

煤层气用抽油机横梁的仿真研究

针对在煤层气特殊工况下运转的游梁式抽油机,对其基础结构的部件横梁,进行了深入的仿真研究。首先,通过横梁的力学研究,得出了受力模型;而后利用ANSYS-workbench模块对其设计强度进行了计算,其中引入了惯性释放的分析方法,同时与理论计算结果对比,得出了相应结论;最后以应力循环次数为目标,对横梁的疲劳寿命进行预测,此方法对抽油机相关部件的疲劳寿命分析,具有重要的参考价值。     

A Further Discussion on Trends in the Development of Advanced Manufacturing Technology

This paper is a supplement to “Trends in the Development of Advanced Manufacturing Technology” (Yang and Wu in Chin. J. Mech. Eng., 39: 73, 2003) but delves deeper into it. It first points out the strategic status of manufacturing industry in state development. Then, a detailed analysis is given on the features and trends in the development of advanced manufacturing technology in a total of 12 points from three aspects: “precision,” “extreme,” and “culture” from the aspect of the product itself; “green,” “rapidness,” “saving,” and “efficiency” during the manufacturing process; and “digit,” “auto,” “integration,” “networking,” and “intelligence” in view of the manufacturing method. In addition, it emphasizes that all the above aspects should be based on two base points: “manufacture” and “machinery.” Finally, it puts forth the guiding ideologies for the development of advanced manufacturing technology and the aspects China should give priority to in development, while stressing on the principles of independence, innovation and “human orientation.”     

A dual-purpose positioner-fixture for precision six-axis positioning and precision fixturing: Part II. Characterization and calibration

The kinematics, stiffness, and repeatability of a moving groove, dual-purpose positioner-fixture were determined experimentally. A dual-purpose positioner-fixture is an alignment device that may be operated in a fixture mode or a six-axis nanopositioning mode. When operated in fixture mode, experiments show standard deviation in repeatability of 11, 11, and 38 nm in x, y, and z; and 0.7, 0.3, and 0.3 μrad in θ_x, θ_y, and θ_z. The stiffness characteristics were shown to match predictions within 5%. When operated in nanopositioner mode, the device demonstrated 4 nm resolution and a range, of 40 μm × 40 μm × 80 μm in translation and 800 μrad × 800 μrad × 400 μrad in rotation. The fixture possesses a load capacity of 450 N and a natural frequency of 200 Hz when the fixture is preloaded to 225 N.     

Loading strategies for a class of just-in-time manufacturing system

In this paper, based on the group technology and the just-in-time manufacturing concepts, two loading models for optimal utilisation of the processing capabilities of an integrated manufacturing system consisting of a set of heterogeneous workstations are developed. These loading models are developed to integrate and utilise the available information from both the bill of materials and the process plans. The objective functions for these models are: the maximum tardiness and the makespan. In these models, the production quantity of each customer order for any part or product always equals its corresponding demand quantity; each part requires a finite number of aggregated stages of operation; job splitting is allowed; and the processing priorities of all the jobs during the planning time horizon are specified based on a desirable dispatching rule. The proposed mathematical programming models are fixed charge problems which are solved by compatible mixed integer programming algorithms. Finally, to provide additional decision-making capabilities, based on these models and their corresponding solution algorithms, a compatible decision support system is suggested.Notation l(1 toL) the product index - t(1 toN) the component (e.g., job type) index - i(1 toN) the job type priority index - j(1 toM) the workstation index - r(1 toR) the processing stage priority index - k(1 toK) the due date priority index - J _i,j,r,k the job with the job type priority indexi of the customer with the processing stage priority indexr and the due date priority indexk which has to be processed at the workstationj - L _i,r,k the number of units of the job with the job type priority indexi of the customer with processing stage priority indexr and the due date priority indexk (e.g. demand quantities) - t _i,j,r the required time to perform the processing stage priority indexr of each unit of the job with the job type priority indexi at the workstationj - D _i,r,k the due date of the job with the job type priority indexi of the customer with the processing stage priority indexr and the due date priority indexk - s _i,j,r the required time for setting up the workstationj for processing the job with the processing stage priority indexr, and the job type priority indexi - X _i,j,r,k the number of units of the job with job type priority indexi of the customer with the processing stage priority indexr, and the due date priority indexk to be produced at the workstationj - l _i,j,r,k the idle time at the workstationj prior to processing the job with the job type priority indexi and the processing stage priority indexr with the due date priority indexk - V the maximum tardiness - W the makespan of the operation - Y _i,j,r,k=1 ifX _i,j,r,k>0 - Y _i,j,r,k=0 ifX _i,j,r,k=0 - _i,j,r,k a sufficiently large constant (e.g. _i,j,r,kL _i,r,k)     

Preparation of ultrafine α -Al2O3 using precipitation-azeotropic distillation method

Ammonium aluminum carbonate hydroxide (AACH) was prepared by a precipitation-azeotropic distillation method, which uses aluminum sulfate as the Al source and ammonium carbonate as the precipitant. Then, AACH was calcined into ultrafine α-Al₂O₃ powder. The factors that influence the dispersion property of ultrafine α-Al₂O₃ powder are discussed in this paper, such as the methods of adding materials, surfactant, and drying methods. The changes of the structure and property of ultrafine alumina in the thermal treatment process are also studied. The morphological structure and properties of AACH are characterized by DTA/TGA, SEM, XRD, and ICP measurements. The results show that ultrafine α-Al₂O₃ powder with a uniform particle size and well-distributed property can be synthesized only after aluminum sulfate atomizes into ammonium carbonate, proper amount of PEG1000 is added as the dispersant, and the product is treated by azeotropic distillation. The phase transformation of alumina during the calcination process can be described as amorphous Al₂O₃→γ-Al₂O₃→ϑ-Al₂O₃→α-Al₂O₃. The crystal grain size and density of ultrafine alumina powder increase with the increase of the calcination temperature. After AACH has been calcined at 1200°C for 2 h, the ultrafine α-Al₂O₃ with uniform particle size, spherical shape, and more than 99.97% purity is obtained and its powder is well dispersed. __________ Translated from Journal of Hunan University of Science & Technology (Natural Science Edition), 2007, 22(2): 35–39 [译自: 湖南科技大学学报(自然科学版)]     

Design of a six-axis micro-scale nanopositioner—μHexFlex

This paper presents the design of a small-scale nanopositioner, the μHexFlex, which is comprised of a six-axis compliant mechanism and three pairs of two-axis thermo-mechanical micro-actuators. In this paper, we cover the modeling, design and fabrication of the μHexFlex. Specific attention is given to: (1) the use of constraint-based design in generating the compliant mechanism design, (2) the modeling of the actuators, and (3) the system model which links the actuator input and mechanism response. The measured, quasi-static performance of a 3 mm diameter prototype shows a maximum range of 8.4 μm × 12.8 μm × 8.8 μm and 19.2 mrad × 17.5 mrad × 33.2 mrad (1.1° × 1.0° × 1.9°). Experimental results indicate that a constant mechanical/electrical material property system model may be used to predict the position and orientation over a range of 3.0 μm × 4.4 μm × 3.0 μm and 6.3 mrad × 6.3 mrad × 8.7 mrad (0.36° × 0.36° × 0.5°). The dynamic characteristics of the device were investigated experimentally. Experimental results show a lowest natural frequency of 4 kHz. The resolution characteristics of the device have been measured at 1 Å/mV. The device was created using deep reactive ion etching (DRIE). Bulk fabrication costs are estimated at less than $ 2 per device.     

Influence of nozzle exit tip thickness on the performance and flow field of jet pump

The influence of exit tip thickness of nozzle δ _e on the flow field and performance of a jet pump was studied numerically in this paper. It is found that δ _e has influence on the distribution of turbulence kinetic energy k. If δ _e is ignored, k takes the highest value but dissipates rapidly than that of nozzle with a certain tip thickness. δ _e also affect apparently the development of tip vortex, which will occur near the exit tip of nozzle. The bigger the δ _e is, the larger the vortex is. The tip vortex develops with the increase of flow rate ratio q. When q=1 and δ _e =0.6∼0.8mm, a small vortex will be found downstream the tip vortex. And a concomitant vortex happens down the tip vortex in the case of q=1 and δ _e =0.8mm. As q increases to 2, the downstream small vortex disappears and the concomitant vortex becomes bigger. It is also found that the tip vortex might interact with the possible backflow that formed in the throat tube and parts of suction chamber. The center of backflow was affect evidently by δ _e . With the increase of δ _e , the center of backflow under the same q will go downstream. When δ _e =0.4mm, the center of backflow goes farthest. Then, as the further increase of δ _e , the center of backflow will go back some distance. Although, δ _e has relatively great influence on the flow field within the jet pump, it exerts only a little impact on the performance of jet pump. When δ _e =0.2∼0.6mm, the jet pump possess better performance. In most case, it is reasonable to ignore the nozzle exit tip thickness in performance prediction for the purpose of simplicity. This paper was presented at the 9^th Asian International Conference on Fluid Machinery (AICFM9), Jeju, Korea, October 16–19, 2007.     

Affine integral geometry and convex bodies

Given a convex body Q in Euclidean n-dimensional space, the affine invariant measure of the set of pairs of parallel hyperplanes containing Q is an affine invariant J(Q) of Q, which, for ellipsoids, parallelepipeds and possibly for simplices of any dimensions, is proportional to V^?1, where V represents the volume of Q. Consequently, for the kind of bodies mentioned, it is possible to estimate V^?1 from its breadth measured in uniform random directions. If the boundary of Q is of class C², we obtain a set of affine invariants J_h(Q) (h = any integer) which is easily calculable for ellipsoids. In particular, J_-n(Q) coincides with J(Q) and J_-(n+1)(Q) is the affine invariant measure of all pairs of parallel hyperplanes that ‘support’ Q as described by Firey(1972, 1985), Schneider (1978, 1979) and Weil (1979, 1981). For a general convex body Q the values of J_h(Q) cannot be expressed in terms of simple metric invariants (such as volume, surface area, breadth, width) and this justifies the study in the last section of certain inequalities between them.     

Tribological Properties of Twin Electron-Beam Evaporated Cr–N and Al–Cr–N Coatings Under Laboratory Sliding and Drill Experiments

The tribological behavior of substoichiometric Cr–N and Al–Cr–N coatings prepared by twin electron-beam evaporation at 450 °C was studied. Al–Cr–N coatings with Al to Cr ratios in the range of 1–8 (and nitrogen concentrations of ~45 at.%) were synthesized and compared to Cr–N reference samples. The focus of this work is on Al–Cr–N (Al ≥ 30 at.%) coatings with the aim of (a) replacing Cr with Al due to environmental concerns and (b) achieving improved mechanical properties, and tribological performance. The composition, structure, mechanical and tribological properties of the coatings were determined using X-ray photoelectron spectroscopy, X-ray diffraction, and scanning electron microscopy in combination with nanoindentation measurements, laboratory controlled ball-on-disk sliding experiments, and wet and dry drilling experiments. It was found that all Al–Cr–N coatings exhibit higher hardness values compared to Cr–N coatings. Al–Cr–N coatings with Al contents and Al/Cr ratios of ≤38 at.% and ≤1.7, respectively, showed better performance than the rest of the coatings during both drilling and laboratory tribological experiments.     

液体润滑剂的黏度对边界滑移影响的实验研究

为了了解微纳米间隙中流体的流动特性,采用原子力显微镜对微纳米间隙中的固体和液体边界滑移进行了实验研究,主要研究了液体润滑剂的黏度对边界滑移的影响。实验中采用的固体样品为SiO2,液体样品为两种不同黏度的季戊四醇油酸酯,分子式为C77H140O8,黏度分别为32mm2/s和150mm2/s。采用相对速度法对实验数据进行了处理,结果表明,不同黏度的季戊四醇油酸酯和SiO2表面作用时都会发生边界滑移,黏度大,产生的滑移大。其原因是,随着黏度升高,邻近固体表面的液体分子与和固体表面相接触的液体分子之间的剪切力增大,可更加容易地克服固液界面间的作用力,更加容易产生边界滑移。     

A Study of the Influence of Superimposed Low-Frequency Modulation on the Drilling Process

A preliminary investigation of the effects of low-frequency modulation of the force in drilling has been completed. Important changes occur in the drilling of aluminum with the imposition of modulation at frequencies below 200 Hz. The effects depend on the amplitude of the modulation and the relationship of the frequency of modulation f_p to the frequency of rotation of the drill f_d. When f_p/f_d is an even integer, the modulation introduces no significant effects in the force, torque, or chip morphology. When f_p/f_d is an odd integer, the average drilling force decreases, and a large dynamic component of force and torque is seen with a frequency dependence f_p. For peak-to-peak amplitudes of vibration that are greater than one-half of the drill feed/rev, the chips are broken. A simple explanation of these effects is provided.