Multi-mode data augmentation and fault diagnosis of rotating machinery using modified ACGAN designed with new framework

As one of the representative unsupervised data augmentation methods, generative adversarial networks (GANs) have the potential to solve the problem of insufficient samples in fault diagnosis of rotating machinery. However, the existing unsupervised GANs are usually incapable of simultaneously generating multi-mode fault samples and have some shortcomings such as mode collapse and gradient vanishing. To overcome these deficiencies, a supervised model called modified auxiliary classifier GAN (MACGAN) designed with new framework is proposed in this paper. Firstly, a new ACGAN framework is developed by adding an independent classifier to improve the compatibility between the classification and discrimination. Secondly, the Wasserstein distance is introduced in the new loss functions to overcome mode collapse and gradient vanishing. Finally, to achieve stable training, a spectral normalization is used to replace the weight clipping to constrain the weight parameters of discriminator. The proposed method is applied to fault diagnosis of bearing and gear. Compared with the existing GANs, the proposed method can more efficiently generate multi-mode fault samples with higher qualities, which can be used to assist the training of deep learning-based fault diagnosis models with high accuracy and good stability.     

Precision machining of micro tool electrodes in micro EDM for drilling array micro holes

Micro electro discharge machining (micro EDM) is suitable for machining micro holes on metal alloy materials, and the micro holes can be machined even to several microns by use of wire electro discharge grinding (WEDG) of micro electrodes. However, considering practicability of micro holes <Φ100 μm in batch processing, the controllable accuracy of holes’ diameter, the consistency accuracy of repeated machining and the processing efficiency are required to be systematically improved. On the basis of conventional WEDG method, a tangential feed WEDG (TF-WEDG) method combined with on-line measurement using a charge coupled device (CCD) was proposed for improving on-line machining accuracy of micro electrodes. In TF-WEDG, removal resolution of micro-electrode diameter (the minimum thickness to be removed from micro electrode) is greatly improved by feeding the electrode along the tangential direction of wire-guide arc, and the resolution is further improved by employing negative polarity machining. Taking advantage of the high removal resolution, the precise diameter of micro-electrode can be achieved by the tangential feed of electrode to a certain position after diameter feedback of on-line measurement. Furthermore, a hybrid process was presented by combining the TF-WEDG method and a self-drilled holes method to improve the machining efficiency of micro electrodes. A cyclic alternating process of micro-electrode repeated machining and micro holes’ drilling was implemented for array micro holes with high consistency accuracy. Micro-EDM experiments were carried out for verifying the proposed methods and processes, and the experimental results show that the repeated machining accuracy of micro electrodes was less than 2 μm and the consistency accuracy of array micro holes was ±1.1 μm.     

Comparison of spherical and truncated cone geometries for single abrasive-grain cutting

The purpose of the present work was to compare the cutting action of two different abrasive-grain geometries using experimental observations and a validated finite element model. A spherical tool was used to approximate a dull abrasive grain while a truncated cone tool was used to approximate an abrasive grain with a well defined cutting edge. The selected geometries were chosen to represent extreme cases in order to bracket the cutting action of a range of cutting geometries. The results showed that both tools produced similar normal and tangential forces per unit width up to a depth of cut of approximately 3 μm. The improved cutting geometry of the truncated cone tool caused the normal force per unit width to decrease and the tangential force per unit width to increase in relation to the spherical tool. The truncated cone tool was shown to experimentally and numerically be more efficient based on the reduced pile-up heights and improved stress distributions. It was also shown that both geometries converged towards the same specific energy to displace material at suitably large depths of cut, which suggests that there is a minimum specific energy obtainable for a given workpiece material that is independent of the grain geometry. However, specific energies to remove material were higher for the spherical tool as compared to the truncated cone tool. Analysis of the energy components of the finite element model showed that frictional energy contributions were high with the spherical tool and low with the truncated cone tool. Finally, it was found that both tools required approximately the same energy to shear a chip from a workpiece when friction was subtracted from the specific energy for material removal.     

激光熔覆制备高熵合金涂层研究进展

激光熔覆具有加热和冷却速度快、稀释度低(<5％)、热影响区小以及可以对表面性质进行精准调整等优点,是当今工业应用较为广泛的表面改性技术之一.利用激光熔覆技术制备高熵合金涂层,既能保证涂层具有简单的相结构和优异的性能,又可使涂层与基体之间获得良好的冶金结合.主要对激光熔覆制备高熵合金涂层的设计准则、性能及提高机理、凝固行为以及数值模拟的研究进行阐述.首先从设计理论方面对高熵合金进行概念阐述,由熵和吉布斯自由能可知,通过增加主元(至少5个)和位形熵来设计元素组成,通过吉布斯自由能控制相的稳定性.其次,对涂层的性能提高机理分类总结,其中高熵合金的四大效应与激光熔覆快冷快热的特点相结合是涂层性能提高的主要原因.此外,还阐述了激光熔覆过程中熔池的凝固行为,包括凝固过程中的晶粒生长方式和液相分离现象,以及其他因素引起的凝固行为变化.之后,对粉末流动特性、熔池温度场和熔覆层性能的数值模拟以及这些模型的缺陷进行综述与分析.最后,总结与展望激光熔覆制备高熵合金涂层研究的发展前景与应用方向.     

基于响应面法的激光熔覆3540Fe涂层形貌及质量预测研究

目的 实现激光熔覆3540Fe合金涂层几何形貌的精确控制。方法 基于响应面法设计了在不同的激光工艺参数下42CrMo钢表面激光熔覆3540Fe合金的试验,以激光功率、光斑直径、扫描速度为影响因素,熔覆层宽度、高度、熔池深度、熔覆层宽高比、显微硬度以及稀释率为响应目标,建立了熔覆层形貌的预测模型,以熔覆层显微硬度、宽高比作为优化条件对预测模型进行了实验验证。结果 激光功率与熔池深度和熔覆层稀释率成正比,熔覆层宽度、高度、宽高比随激光功率的增大表现为先升高后降低,熔覆层显微硬度与激光功率的关系呈负相关。扫描速度与熔覆层宽度、高度呈负相关性,与熔覆层宽高比、显微硬度成正比,对熔池深度和熔覆层稀释率的影响并不显著。光斑直径与熔池深度和稀释率呈负相关性,熔覆层高度随光斑直径的增大表现为先增大后减小,而宽高比表现为先减小后增大的趋势,光斑直径对熔覆层显微硬度的影响并不显著。通过对预测模型进行实验验证发现,宽高比、稀释率、显微硬度的误差分别为7.14%、5.70%、2.74%。结论 利用响应面法建立的3540Fe合金熔覆层形貌预测模型精确程度较高,能够实现对3540Fe合金熔覆层几何形貌的准确预测,为熔覆层形貌的精确控制提供了理论依据。     

The influence of grain geometry and wear conditions on the material removal mechanism in silicon carbide grinding with single grain

High efficiency and precision grinding of brittle materials is challenging due to material physical and chemical properties. To understand the effect of grain geometry and wear conditions on the material removal mechanism in brittle material precision grinding, a single diamond grain grinding experiment was conducted on Silicon Carbide (SiC). The cutting edge radius and deflection angle were measured by confocal scanning. Under six different cutting edge radius and three maximum undeformed chip thickness, grinding force and ground surface were measured. Diamond grain wear was investigated by observing the grain morphology, wear rate, grinding force, and ground surface change over accumulative material removal volume. The result showed the existence of a critical cutting edge radius for improving SiC ground surface quality.. Normal grinding force increased with the cutting edge radius increase. Tangential grinding force increased with the cutting edge radius increase and reached the peak value at the critical cutting edge radius. Flank wear was the major wear mode in precision SiC grinding. The grain wear was associated with the grinding force and ground surface.     

共固化阻尼复合材料研究进展

文中综述了共固化阻尼复合材料结构近年来的研究成果,包括共固化阻尼复合材料结构的共固化工艺类型、黏弹性阻尼材料的选择范围,并对阻尼薄膜的制作工艺、阻尼薄膜的结构以及处理方式行了概括。此外,对环氧树脂基与双马树脂基共固化阻尼复合材料的实验方法、数值模拟及理论分析做了总结,最后对共固化阻尼复合材料结构存在的不足及未来的发展趋势进行了展望。提出未来应用中需要继续研究解决的问题,以上工作对于深入探索大阻尼高刚度复合材料构件具有一定的参考意义。     

基于中型水果的自动分级包装一体机设备的设计

目的 为解决现有分级包装设备存在劳动强度大、效率低、易损伤果皮等问题,设计一种基于自动化水果筛选分级包装一体机。方法 将水果通过上料装置输送到果杯中,通过齿轮齿条的配合实现水果的360°旋转,筛选后通过特制的冲模分流装置进行一次分流,进入包装机后利用45DF型凸轮分割器搭配电机带动棘轮实现水果的二次单个分流,利用发泡型塑料网的物理特性,通过凸轮的急回特性来实现单个水果包装自动化。结果 基于机械原理和机械设计,对关键部件进行计算设计和仿真设计,得到传送盘与地面的安装角度为3°,传送盘工作时最大变形量为0.503 69 mm,棘轮工作时最大变形为5.763 9×10⁻⁵ mm,最大应变为4.799×10⁻⁷,最大应力为9.56×10⁻⁴ N,满足使用要求。结论 通过实现分级包装一体机的自动化,减少了劳动力,降低了人工成本,提高了经济效益。     

Predictive model for minimum chip thickness and size effect in single diamond grain grinding of zirconia ceramics under different lubricating conditions

To address the current bottleneck of debris formation mechanism in plastic removal for hard-brittle materials, a minimum chip thickness (h_min) model that considers lubrication conditions (represented by frictional angle β) is developed according to strain gradient, as well as geometry and kinematics analyses. Model results show that h_min decreases with increasing β. Furthermore, grinding experiments using single diamond grain under different lubricating conditions are carried out to verify the model. With increasing β, h_min values are 71.6, 57.8, 52.0, 50.7, 45.6, 39.7, and 32.4 nm, thereby verifying the trend of h_min decreasing with increasing β. Furthermore, the location of size effect occurs is determined according to the variation trend of single abrasive particle specific energy and unit grinding force curves. The size effect occurs in the border area of ploughing, the cutting region, and mainly, in the ploughing region. Theoretical analysis results are consistent with experimental results with a model error of 6.06%, thereby confirming the validity of the theoretical model.     

大斜度井段低沉没度工况排采泵阀动力学特性

目前对于煤系地层天然气井所配套有杆泵泵阀动力特性的研究,主要是移植和借鉴常规油气井抽油泵泵阀的分析方法,多针对油气井开采较高的沉没度,并没有考虑低沉没度和大斜度工况下的泵阀动力学和水力摩阻等参数的影响,也没有揭示水平井泵阀顺利开启所需要的具体条件。为此,综合考虑低沉没度和大斜度等因素耦合的影响,推导造斜段泵阀随井液运动微分方程组,建立有杆泵井液流经泵阀阀隙水力摩阻数学模型,基于数值模拟的方法研究了水平井泵阀动力学、水力摩阻与临界沉没度。研究结果表明:①低沉没度和大斜度耦合作用下,增大冲程和冲次会提高造斜段泵阀阀球的升程、速度和加速度,缩短加速度趋向平缓所用的时间,并且水平井泵阀开启瞬间阀球会出现短暂的周期性波动;②受弹簧力与阀球重力的双重作用,水平井有杆泵的临界沉没度明显低于直井工况且固定阀球伴随弹簧快速复位,这有利于顺利开启水平井的游动阀球和固定阀球并提高泵效;③增大冲程、冲次和泵径会使水平井有杆泵井液流经泵阀水力摩阻及其临界沉没度变大,并且增大冲程更有利于提高低流速井液入泵流速,但同时也会显著地提高临界沉没度。结论认为,该研究成果对于保障煤系地层天然气井连续稳定排采和提高有杆泵的可靠性都具有重要的参考意义。