Prediction of Wing Aerodynamic Performance in Rain Using Neural Net

A new method for prediction of wing aerodynamic performance in rain condition was presented.Three-and four-layer artificial neural networks based on improved algorithm for error Back Propagation(BP)network were respectively built.Detailed approaches to determine the optical parameters for network model were introduced and the specific steps for applying BP network model to predict wing aerodynamic performance in rain were given.On this basis,the established optimal three-and four-layer BP network model was used for this prediction.Results indicate that both of the network models are appropriate for predicting wing aerodynamic performance in rain.The sum of square error level produced by two models is less than 0.2%,and the prediction accuracy by four-layer network model is higher than that of three-layer network.     

Prediction of dynamic cutting force and regenerative chatter stability in inserted cutters milling

Currently, the modeling of cutting process mainly focuses on two aspects: one is the setup of the universal cutting force model that can be adapted to a broader cutting condition; the other is the setup of the exact cutting force model that can accurately reflect a true cutting process. However, there is little research on the prediction of chatter stablity in milling. Based on the generalized mathematical model of inserted cutters introduced by ENGIN, an improved geometrical, mechanical and dynamic model for the vast variety of inserted cutters widely used in engineering applications is presented, in which the average directional cutting force coefficients are obtained by means of a numerical approach, thus leading to an analytical determination of stability lobes diagram (SLD) on the axial depth of cut. A new kind of SLD on the radial depth of cut is also created to satisfy the special requirement of inserted cutter milling. The corresponding algorithms used for predicting cutting forces, vibrations, dimensional surface finish and stability lobes in inserted cutter milling under different cutting conditions are put forward. Thereafter, a dynamic simulation module of inserted cutter milling is implemented by using hybrid program of Matlab with Visual Basic. Verification tests are conducted on a vertical machine center for Aluminum alloy LC4 by using two different types of inserted cutters, and the effectiveness of the model and the algorithm is verified by the good agreement of simulation result with that of cutting tests under different cutting conditions. The proposed model can predict the cutting process accurately under a variety of cutting conditions, and a high efficient and chatter-free milling operation can be achieved by a cutting condition optimization in industry applications.     

Effect of RANS Turbulence Model on Aerodynamic Behavior of Trains in Crosswind

The numerical simulation based on Reynolds time-averaged equation is one of the approved methods to evaluate the aerodynamic performance of trains in crosswind.However,there are several turbulence models,trains may present different aerodynamic performances in crosswind using different turbulence models.In order to select the most suitable turbulence model,the inter-city express 2(ICE2) model is chosen as a research object,6 different turbulence models are used to simulate the flow characteristics,surface pressure and aerodynamic forces of the train in crosswind,respectively.6 turbulence models are the standard k-ε,Renormalization Group(RNG) k-ε,Realizable k-ε,Shear Stress Transport(SST) k-ω,standard k-ω and Spalart-Allmaras(SPA),respectively.The numerical results and the wind tunnel experimental data are compared.The results show that the most accurate model for predicting the surface pressure of the train is SST k-ω,followed by Realizable k-ε.Compared with the experimental result,the error of the side force coefficient obtained by SST k-ω and Realizable k-ε turbulence model is less than 1 %.The most accurate prediction for the lift force coefficient is achieved by SST k-ω,followed by RNG k-ε.By comparing 6 different turbulence models,the SST k-ω model is most suitable for the numerical simulation of the aerodynamic behavior of trains in crosswind.     

Effect of working position on vertical motion straightness of open hydrostatic guideways in grinding machine

Hydrostatic guideways have various applications in precision machine tools due to their high motion accuracy. The analysis of motion straightness in hydrostatic guideways is generally ignoring the external load on the slider. A variation force also exists, caused by the different working positions, together with the dead load of the slider and that of other auxiliary devices. The effect of working position on vertical motion straightness is investigated based on the equivalent static model, considering the error averaging effort of pressured oil film in open hydrostatic guideways. Open hydrostatic guideways in LGF1000 are analyzed with this approach. The theoretical results show that the slider has maximum vertical motion straightness when the working position is closer the guiderail of Y axis. The vertical motion straightness reaches a minimum value as the working position is located at the center of the two guiderails on the Y axis. The difference between the maximum and minimum vertical motion straightness is 34.7%. The smaller vertical motion straightness is attributed to the smaller spacing of the two pads centers, along the Y direction. The experimental results show that the vertical motion straightness is 4.15 μm/1200 mm, when the working position is located in the middle of the X beam, and 5.08 μm/1200 mm, when the working position is approaching the Y guiderails, denoting an increase of 18.3%. The changing trends of the measured results validate the correctness of the theoretical model. The research work can be used to reveal the variation law of accuracy of the open hydrostatic guideways, under different working positions, to predict the machining precision, and provides the basis for an error compensation strategy for gantry type grinding machines.     

Investigation of CFD calculation method of a centrifugal pump with unshrouded impeller

Currently, relatively large errors are found in numerical results in some low-specific-speed centrifugal pumps with unshrouded impeller because the effect of clearances and holes are not accurately modeled. Establishing an accurate analytical model to improve performance prediction accuracy is therefore necessary. In this paper, a three-dimensional numerical simulation is conducted to predict the performance of a low-specific-speed centrifugal pump, and the modeling, numerical scheme, and turbulent selection methods are discussed. The pump performance is tested in a model pump test bench, and flow rate, head, power and efficiency of the pump are obtained. The effect of taking into consideration the back-out vane passage, clearance, and balance holes is analyzed by comparing it with experimental results, and the performance prediction methods are validated by experiments. The analysis results show that the pump performance can be accurately predicted by the improved method. Ignoring the back-out vane passage in the calculation model of unshrouded impeller is found to generate better numerical results. Further, the calculation model with the clearances and balance holes can obviously enhance the numerical accuracy. The application of disconnect interface can reduce meshing difficulty but increase the calculation error at the off-design operating point at the same time. Compared with the standard k-ε, renormalization group k-ε, and Spalart-Allmars models, the Realizable k-ε model demonstrates the fastest convergent speed and the highest precision for the unshrouded impeller flow simulation. The proposed modeling and numerical simulation methods can improve the performance prediction accuracy of the low-specific-speed centrifugal pumps, and the modeling method is especially suitable for the centrifugal pump with unshrouded impeller.     

ANALYTICAL CHIP FORMATION MODEL OF MICRO-END-MILLING

A new analytical chip formation model is proposed for micro-end-milling operations. The model calculates an instantaneous uncut chip thickness by considering the combination of exact trochoidal trajectory of the tool tip and tool run-out, while the simplified circular trajectory and the neglected run-out create negligible change in conventional-scale chip formation models. Newton-Raphson iterative method is employed during the calculation to obtain quadratic convergence. The proposed approach allows the calculation of instantaneous uncut chip thickness to be done accurately and rapidly, and the prediction accuracy of this model is also verified by comparing the simulation results to experimental cutting forces.     

ANALYSIS OF METHOD FOR DETERMINING AZIMUTH OF PRINCIPAL AXIS OF INERTIA BASED ON DYNAMIC BALANCE MEASUREMENT

The dynamic balance quality of a rotating object is an important factor to maintain the stability and accuracy for motion. The azimuth of the principal axis of inertia is a major sign of dynamic balance. A usual method is measuring moment of inertia matrix relative to some base coordinates on a rotary inertia machine so as to calculate the azimuth of principal axis of inertia. By using the measured unbalance results on the two trimmed planes on a vertical hard bearing double-plane dynamic balancing machine, the dimension and direction of couple unbalance can be found. An azimuth angle formula for the principal axis of inertia is derived and is solved by using unbalance quantities. The experiments indicate that method based on dynamic balancing measurement is proved rational and effective and has a fine precision.     

Wear Analysis of Disc Cutters of Full Face Rock Tunnel Boring Machine

Wear is a major factor of disc cutters’ failure. No current theory offers a standard for the prediction of disc cutter wear yet. In the field the wear prediction method commonly used is based on the excavation length of tunnel boring machine（TBM） to predict the disc cutter wear and its wear law, considering the location number of each disc cutter on the cutterhead（radius for installation）; in theory, there is a prediction method of using arc wear coefficient. However, the preceding two methods have their own errors, with their accuracy being 40% or so and largely relying on the technicians’ experience. Therefore, radial wear coefficient, axial wear coefficient and trajectory wear coefficient are defined on the basis of the operating characteristics of TBM. With reference to the installation and characteristics of disc cutters, those coefficients are modified according to penetration, which gives rise to the presentation of comprehensive axial wear coefficient, comprehensive radial wear coefficient and comprehensive trajectory wear coefficient. Calculation and determination of wear coefficients are made with consideration of data from a segment of TBM project（excavation length 173 m）. The resulting wear coefficient values, after modification, are adopted to predict the disc cutter wear in the follow-up segment of the TBM project（excavation length of 5621 m）. The prediction results show that the disc cutter wear predicted with comprehensive radial wear coefficient and comprehensive trajectory wear coefficient are not only accurate（accuracy 16.12%） but also highly congruous, whereas there is a larger deviation in the prediction with comprehensive axial wear coefficient（accuracy 41%, which is in agreement with the prediction of disc cutters’ life in the field）. This paper puts forth a new method concerning prediction of life span and wear of TBM disc cutters as well as timing for replacing disc cutters.     

Error Compensation of Thin Plate-shape Part with Prebending Method in Face Milling

Low weight and good toughness thin plate parts are widely used in modern industry, but its flexibility seriously impacts the machinability. Plenty of studies focus on the influence of machine tool and cutting tool on the machining errors. However, few researches focus on compensating machining errors through the fixture. In order to improve the machining accuracy of thin plate-shape part in face milling, this paper presents a novel method for compensating the surface errors by prebending the workpiece during the milling process. First, a machining error prediction model using finite element method is formulated, which simplifies the contacts between the workpiece and fixture with spring constraints. Milling forces calculated by the micro-unit cutting force model are loaded on the error prediction model to predict the machining error. The error prediction results are substituted into the given formulas to obtain the prebending clamping forces and clamping positions. Consequently, the workpiece is prebent in terms of the calculated clamping forces and positions during the face milling operation to reduce the machining error. Finally, simulation and experimental tests are carried out to validate the correctness and efficiency of the proposed error compensation method. The experimental measured flatness results show that the flatness improves by approximately 30 percent through this error compensation method. The proposed method not only predicts the machining errors in face milling thin plate-shape parts but also reduces the machining errors by taking full advantage of the workpiece prebending caused by fixture, meanwhile, it provides a novel idea and theoretical basis for reducing milling errors and improving the milling accuracy.     

NONLINEAR DYNAMIC BEHAVIOR OF VISCOELATIC TPANSMISSION BELT

The nonlinear dynamic responses of viscoelastic axially transmssion belts are investigatedand the Kelvin viscoelastic differential constitutive model is employed to characterize the materialproperty of belts. The generalized equation of motion is obtained for a viscoelatic axially transmissionbelts with geometric nonlinearity first, and then is reduced to be a set of second-order nonlinear ordi-nary differential equations by applying Galerkin's method. Finally the effects of viscosity parameterand elastic parameter and the moving velocity of the belts on the transient responses are investigatedby the research of digital simulation.     

Physics-based Modeling and Simulation for Motional Cable Harness Design

The design work of motional cable in products is vital due to the difficulty in estimating the potential issues in current researches.In this paper,a physics-based modeling and simulation method for the motional cable harness design is presented.The model,based on continuum mechanics,is established by analyzing the force of microelement in equilibrium.During the analysis procedure,three coordinate systems：inertial,Frenet and main-axis coordinate systems are used.By variable substitution and dimensionless processing,the equation set is discretized by differential quadrature method and subsequently becomes an overdetermined nonlinear equation set with boundary conditions solved by Levenberg-Marquardt method.With the profile of motional cable harness obtained from the integral of arithmetic solution,a motion simulation system based on＂path＂and＂profile＂as well as the experimental equipments is built.Using the same parameters as input for the simulation and the real cable harness correspondingly,the issue in designing,such as collision,can be easily found by the simulation system.This research obtains a better result which has no potential collisions by redesign,and the proposed method can be used as an accurate and efficient way in motional cable harness design work.     

Simulations and experimental investigation on motion stability of a flexible rotor-bearing system with a transverse crack

In the classical process for stability studies on the rotor-bearing system with crack faults, the simple discrete model is adopted for research on such problems, which neglect some needful dynamical influence factor, such as the material damping, shearing effect and gyroscopic effects, etc. Therefore, it is necessary to find a precise calculation model for simulation of the rotor-bearing system with cracks faults. In this paper, instead of the traditional simple discrete model, finite element （FE） model is adopted to investigate the motion stability of a nonlinear rotor system with crack fault. According to finite element theory, the FE model of the cracked rotor system is established firstly. It should be pointed out that the element where the crack occurs is modeled by a particular crack element and the supports at both ends are simulated by two nonlinear loads. Then, based on dimensionless and dimensionality reduction, the Newmark-[3 method and the shooting method are employed to study the effect of eccentricity and the depth of crack on instability speed and bifurcation feature. Furthermore, the simulation results are verified by some corresponding experiments. The simulation and experimental results show that instability speed does not change monotonically, but decreases firstly and then increases when the amount of eccentricity increases. Moreover, as the type of instability changes, the instability speed jumps concomitantly. Additionally, the presence of crack fault can disturb the oil whirl, as a result, instability speed tends to increase slightly, but it does not affect the type of instability and jumping phenomenon. This research presents an effective and convenient method which uses the finite element method （FEM） to research the motion stability of the nonlinear rotor-bearing system with cracked faults and other nonlinear force, and the proposed method can provide a theoretical reference for stability analysis and vibration control in more complex relevant rotor-bearing system.     

Simulation on a car interior aerodynamic noise control based on statistical energy analysis

How to simulate interior aerodynamic noise accurately is an important question of a car interior noise reduction. The unsteady aerodynamic pressure on body surfaces is proved to be the key effect factor of car interior aerodynamic noise control in high frequency on high speed. In this paper, a detail statistical energy analysis (SEA) model is built. And the vibra-acoustic power inputs are loaded on the model for the valid result of car interior noise analysis. The model is the solid foundation for further optimization on car interior noise control. After the most sensitive subsystems for the power contribution to car interior noise are pointed by SEA comprehensive analysis, the sound pressure level of car interior aerodynamic noise can be reduced by improving their sound and damping characteristics. The further vehicle testing results show that it is available to improve the interior acoustic performance by using detailed SEA model, which comprised by more than 80 subsystems, with the unsteady aerodynamic pressure calculation on body surfaces and the materials improvement of sound/damping properties. It is able to acquire more than 2 dB reduction on the central frequency in the spectrum over 800 Hz. The proposed optimization method can be looked as a reference of car interior aerodynamic noise control by the detail SEA model integrated unsteady computational fluid dynamics (CFD) and sensitivity analysis of acoustic contribution.     

Numerical robust stability estimation in milling process

The conventional prediction of milling stability has been extensively studied based on the assumptions that the milling process dynamics is time invariant. However, nominal cutting parameters cannot guarantee the stability of milling process at the shop floor level since there exists many uncertain factors in a practical manufacturing environment. This paper proposes a novel numerical method to estimate the upper and lower bounds of Lobe diagram, which is used to predict the milling stability in a robust way by taking into account the uncertain parameters of milling system. Time finite element method, a milling stability theory is adopted as the conventional deterministic model. The uncertain dynamics parameters are dealt with by the non-probabilistic model in which the parameters with uncertainties are assumed to be bounded and there is no need for probabilistic distribution densities functions. By doing so, interval instead of deterministic stability Lobe is obtained, which guarantees the stability of milling process in an uncertain milling environment. In the simulations, the upper and lower bounds of Lobe diagram obtained by the changes of modal parameters of spindle-tool system and cutting coefficients are given, respectively. The simulation results show that the proposed method is effective and can obtain satisfying bounds of Lobe diagrams. The proposed method is helpful for researchers at shop floor to making decision on machining parameters selection.     

Experimental model and analytic solution for real-time observation of vehicle’s additional steer angle

The current research of real-time observation for vehicle roll steer angle and compliance steer angle（both of them comprehensively referred as the additional steer angle in this paper） mainly employs the linear vehicle dynamic model, in which only the lateral acceleration of vehicle body is considered. The observation accuracy resorting to this method cannot meet the requirements of vehicle real-time stability control, especially under extreme driving conditions. The paper explores the solution resorting to experimental method. Firstly, a multi-body dynamic model of a passenger car is built based on the ADAMS/Car software, whose dynamic accuracy is verified by the same vehicle＇s roadway test data of steady static circular test. Based on this simulation platform, several influencing factors of additional steer angle under different driving conditions are quantitatively analyzed. Then ε-SVR algorithm is employed to build the additional steer angle prediction model, whose input vectors mainly include the sensor information of standard electronic stability control system（ESC）. The method of typical slalom tests and FMVSS 126 tests are adopted to make simulation, train model and test model＇s generalization performance. The test result shows that the influence of lateral acceleration on additional steer angle is maximal （the magnitude up to 1°）, followed by the longitudinal acceleration-deceleration and the road wave amplitude （the magnitude up to 0.3°）. Moreover, both the prediction accuracy and the calculation real-time of the model can meet the control requirements of ESC This research expands the accurate observation methods of the additional steer angle under extreme driving conditions.     

KINEMATICS FEATURE ANALYSIS OF A 3-DOF COMPLIANT MECHANISM FOR MICRO MANIPULATION

Kinematics and its related issues of a 3-DOF in-parallel compliant mechanism are focused on. The micro manipulation application that requires high accuracy is developed. Design of the developed micromanipulator is based on the modified Delta mechanism. The main advantages of this manipulator are the use of only revolute flexure hinges and the capability to produce pure translation theoretically. The aim is to develop an efficient kinematic model used for positioning control. For this purpose, the Jacobian matrix relating the end effector position with the actuator displacements is obtained by both theoretical derivation and experiment. Aiming at the abnormality in the motion capabilities of the micromanipulator found in calibration experiment, the mobility of the compliant mechanism on a theoretical level is analyzed by using the matrix method and screw theory. Both the experimental and theoretical results have verified that the compliant mechanism does have rotational motion.     

Modeling method for assembly variation propagation taking account of form error

The propagation of variations, such as fixture errors and datum errors resulting from assembly and machining processes, has been extensively studied. However, only a few studies that focus on form error propagation in assembly systems have been implemented. Machining errors, especially form errors, have great impact on assembly accuracy and accuracy stability of precision mechanical systems. With form errors being the research object, a method for calculating mating variation and specifying mating coordinate is proposed to improve the accuracy of the variation propagation model. Taking into account the form error of mating surfaces, the assembly variation propagation of a precision mechanical system is analyzed, and the brief derivation procedure of the variation propagation model is introduced afterwards. The variation propagation model involves a new concept of mating variation specified by the two mating surfaces. An innovative method, the difference surface search based method, is proposed to calculate the mating variation amongst the mating surfaces. The obtained mating variation is then utilized to specify the mating coordinate in the variation propagation model. Moreover, FEM is employed to simulate the contact state of the two mating surfaces to demonstrate effectiveness of the proposed method. Meanwhile, the mating variation and mating coordinate obtained are incorporated into the assembly variation propagation model, which is then verified by a following case study through a comparison between the calculated results and the experimental results. The comparing results indicate that the established model improves the prediction of assembly accuracy. The developed model enables the investigation of various fundamental issues in variation reduction, including variation analysis, process monitoring, accuracy prediction, and accuracy control.     

Numerical Research on Performance Prediction for Centrifugal Pumps

Performance prediction for centrifugal pumps is now mainly based on numerical calculation and most of the studies merely focus on one model. Therefore, the research results are not representative. To make an improvement of numerical calculation method and performance prediction for centrifugal pumps, performance of six centrifugal pump models at design flow rate and off design flow rates, whose specific speed are different, were simulated by using commercial code FLUENT. The standard k-ε turbulence model and SIMPLEC algorithm were chosen in FLUENT. The simulation was steady and moving reference frame was used to consider the impeller-volute interaction. Also, how to dispose the gap between impeller and volute was presented and the effect of grid number was considered. The characteristic prediction model for centrifugal pumps is established according to the simulation results. The head and efficiency of the six models at different flow rates are predicted and the prediction results are compared with the experiment results in detail. The comparison indicates that the precision of head and efficiency prediction are all less than 5%. The flow analysis indicates that flow change has an important effect on the location and area of low pressure region behind the blade inlet and the direction of velocity at impeller inlet. The study shows that using FLUENT simulation results to predict performance of centrifugal pumps is feasible and accurate. The method can be applied in engineering practice.     

Thermal influence of the Couette flow in a hydrostatic spindle on the machining precision

Hydrostatic spindles are increasingly used in precision machine tools. Thermal error is the key factor affecting the machining accuracy of the spindle, and research has focused on spindle thermal errors through examination of the influence of the temperature distribution, thermal deformation and spindle mode. However, seldom has any research investigated the thermal effects of the associated Couette flow. To study the heat transfer mechanism in spindle systems, the criterion of the heat transfer direction according to the temperature distribution of the Couette flow at different temperatures is deduced. The method is able to deal accurately with the significant phenomena occurring at every place where thermal energy flowed in such a spindle system. The variation of the motion error induced by thermal effects on a machine work-table during machining is predicated by establishing the thermo-mechanical error model of the hydrostatic spindle for a high precision machine tool. The flow state and thermal behavior of a hydrostatic spindle is analyzed with the evaluated heat power and the coefficients of the convective heat transfer over outer surface of the spindle are calculated, and the thermal influence on the oil film stiffness is evaluated. Thermal drift of the spindle nose is measured with an inductance micrometer, the thermal deformation data 1.35 μm after running for 4 h is consistent with the value predicted by the finite element analysis's simulated result 1.28 μm, and this demonstrates that the simulation method is feasible. The thermal effects on the processing accuracy from the flow characteristics of the fluid inside the spindle are analyzed for the first time.