Grain mapping to freeform surface for machining using parameter-based incremental tracking method

This paper presents a novel method for mapping a texture for machining onto a freeform surface. When a grain texture designed on a 2D plane is projected onto a freeform surface simply, the texture is distorted along the curvature of the surface in the projection direction. Therefore, a method is required to suppress this distortion. The algorithm proposed in this paper rapidly generates a point cloud that represents a texture with less distortion on a simply connected parametric surface. Specifically, four equations that express local geometry constraints instead of conventional parameterization methods are presented to reduce the distortion between adjacent points on the point cloud. Solving these equations can generate grain textures on freeform surfaces. This paper examines two grain images mapped to two freeform surfaces that were prepared as case studies to demonstrate the effectiveness of the proposed method.     

Technical and economic analysis of solvent-based lithium-ion electrode drying with water and NMP

Processing lithium-ion battery (LIB) electrode dispersions with water as the solvent during primary drying offers many advantages over N-methylpyrrolidone (NMP). An in-depth analysis of the comparative drying costs of LIB electrodes is discussed for both NMP- and water-based dispersion processing in terms of battery pack $/kWh. Electrode coating manufacturing and capital equipment cost savings are compared for water vs. conventional NMP organic solvent processing. A major finding of this work is that the total electrode manufacturing costs, whether water- or NMP-based, contribute about 8–9% of the total pack cost. However, it was found that up to a 2?×?reduction in electrode processing (drying and solvent recovery) cost can be expected along with a $3–6?M savings in associated plant capital equipment (for a plant producing 100,000 10-kWh Plug-in Hybrid Electric Vehicle (PHEV) batteries) using water as the electrode solvent. This paper shows a different perspective in that the most important benefits of aqueous electrode processing actually revolve around capital equipment savings and environmental stewardship and not processing cost savings.     

CFD Modeling of Active Volume Creation in a Non‐Newtonian Fluid Agitated by Submerged Recirculating Jets

Computational fluid dynamics (CFD) models were employed to investigate flow conditions inside a model reactor in which yield stress non‐Newtonian liquid is mobilized using submerged recirculating jets. The simulation results agree well with the experimental results of active volume in the reactor obtained using flow visualization by the authors in a previous study. The models developed are capable of predicting a critical jet velocity (v_c) that determines the extent of active volume obtained due to jet mixing. The v_c values are influenced both by the rheological properties of the liquid and the nozzle orientation. The liquid with higher effective viscosity leads to higher v_c for a downward facing injection nozzle. However, an upward facing injection nozzle along with a downward facing suction nozzle generates enhanced complementary flow fields which overcome the rheological constraints of the liquid and lead to lower v_c.     

Thermal Bending Analysis of Doubly Curved Composite Laminated Shell Panels with General Boundary Conditions and Laminations

Thermal bending analysis of doubly curved laminated shell panels with general boundary conditions and laminations is presented. The equations of equilibrium are derived in the form of two coupled sets of ordinary differential equations based on a general shell theory and solved through the state-space approach in a repeated manner. It is depicted that the results of the present method are in great agreement with analytical solutions. Cylindrical shell panels with general boundary conditions and laminations, where no analytical solution is available, are solved. It is found that the present method exhibits a high convergence rate as well as presenting accurate results in all cases.     

Bearing Failure Optimization of Composite Double-Lap Bolted Joints Based on a Three-Step Strategy Marked By Feasible Region Reduction and Model Decoupling

To minimize the mass and increase the bearing failure load of composite doublelap bolted joints, a three-step optimization strategy including feasible region reduction, optimization model decoupling and optimization was presented. In feasible region reduction, the dimensions of the feasible design region were reduced by selecting dominant design variables from numerous multilevel parameters by sensitivity analyses, and the feasible regions of variables were reduced by influence mechanism analyses. In model decoupling, the optimization model with a large number of variables was divided into various sub-models with fewer variables by variance analysis. In the third step, the optimization sub-models were solved one by one using a genetic algorithm, and the modified characteristic curve method was adopted as the failure prediction method. Based on the proposed optimization method, optimization of a double-lap single-bolt joint was performed using the ANSYS^® code. The results show that the bearing failure load increased by 13.5% and that the mass decreased by 8.7% compared with those of the initial design of the joint, which validated the effectiveness of the three-step optimization strategy.     

基于射流冲击作用的舰机适配性数值分析与优化

准确分析和控制射流冲击对航母甲板环境的影响是新型喷气偏流板设计和布局的关键所在。为了确定射流冲击影响最小的偏流板布局，运用有限体积法，采用分区混合网格方案，结合雷诺时均纳维斯托克斯（RANS）方程和SST k-ω湍流模型对喷气偏流板在不同布局下的射流冲击效应进行三维数值模拟。选取舰载机双发动机全加力状态时喷气偏流板与发动机距离不同、喷气偏流板倾角不同共12种布局组合进行射流冲击效应的对比计算,计算结果显示了喷气偏流板各布局下的流场参数、传热特性、尾喷口温升、冲击力和力矩等分布规律。定性和定量分析了燃气射流冲击下温度场和速度场的危险区域，结果表明，偏流板与发动机距离5 m、偏流板倾角45°时的布局更有利于将燃气射流向上引导。在此基础上，基于倾角最小化原则及二次导流原理优化设计了一种导流隔热性能好、工作稳定性高的被动隔热式喷气偏流板装置。     

多元合金化大断面球墨铸铁组织和性能的分析

为了提升大断面球墨铸铁综合力学性能，通过复合添加微量合金元素铜、锑、锡、钼对大断面球墨铸铁进行微合金化处理，借助金相显微镜(OM)、扫描电子显微镜(SEM)及力学性能测试等手段，研究了Cu Sb Sn Mo复合微合金化大断面球墨铸铁微观组织和力学性能。结果表明，试验球墨铸铁具有良好的综合力学性能。大断面球墨铸铁中添加铜、锑、锡、钼后优化了材料的组织结构，基体组织为珠光体＋少量牛眼状铁素体；试样石墨组织细小、圆整，分布均匀。同时，合金元素的复合加入使得其抗拉强度达到800 MPa以上，硬度约为280HB，伸长率达到5%以上。拉伸断口分析表明，微合金化大断面球墨铸铁断裂模式以解理断裂为主，伴有少量的塑性变形。     

埋地管道泄漏内封堵装置设计与研究

针对流体输送埋地管道泄漏问题,设计了一种利用管道机器人携带封堵气囊进行快速应急封堵修复的埋地管道泄漏内封堵装置。采用矩阵变换方法建立了牵引系统驱动轮过弯方程,利用MATLAB软件对过弯方程进行了验证,同时利用ADAMS软件仿真分析过弯路径与驱动轮转角对牵引系统行走速度的影响。研究结果表明:由两个串联封堵器组成的应急封堵系统可满足复杂工况下的管道泄漏封堵要求;牵引系统驱动轮在弯管内部行走时,单轮速度呈周期性变化,但三个驱动轮整体周期运动特性一致;驱动轮转角在25°~40°时,牵引系统行走速度与驱动轮转角成正比,且转角为30°时驱动效果最好。该内封堵装置的结构设计可为管道泄漏应急封堵领域装备的研发提供重要参考。     

运输机皮带撕裂原因分析及特征实验研究

带式运输机是重要的连续性运输设备，皮带撕裂是造成带式运输机运输失效的重要因素。详细分析了引起皮带撕裂的常见原因，并给出了合理的预防措施。针对皮带撕裂现象构建皮带撕裂实验平台，并通过皮带受力应变实验分析掌握了皮带撕裂的特征，为预防皮带撕裂的发生提供了一定的理论依据。