An approach to optimize correlated multiple responses using principal component analysis and desirability function

While researchers have developed several approaches to attain design variable settings that simultaneously optimize multiple-quality characteristics, the multi-response optimization has become a common practice in complicated manufacturing processes. Most of these research works assume independency of responses where their variances are constant over the experimental space. However, there are many manufacturing processes in practice where the quality characteristics under consideration are correlated. In this study, an efficient approach based on principal component analysis and a conventional desirability function is proposed to optimize correlated multiple responses. This approach not only obtains optimal operating conditions, but also considers different variance and correlation levels of responses and enforces all objectives to satisfy constraints. Experimental results obtained using a standard example show the effectiveness of the proposed method.     

Application of principal component analysis in dynamic thermal testing data processing

The principles and features of the application of statistical principal component analysis (PCA) in active thermal testing are considered. A comparison between PCA and Fourier analysis in finding defects in composite materials, detecting corrosion in aluminum, and determining moisture content in construction materials is performed. It is concluded that, generally, images of principal components increase the signal-to-noise ratio and are close in performance to phase diagrams; nevertheless, the results of this method are poorly predictable and require further analysis.     

Development of a flow analysis code using an unstructured grid with the cell-centered method

A conservative finite-volume numerical method for unstructured grids with the cell-centered method has been developed for computing flow and heat transfer by combining the attractive features of the existing pressure-based procedures with the advances made in unstructured grid techniques. This method uses an integral form of governing equations for arbitrary convex polyhedra. Care is taken in the discretization and solution procedure to avoid formulations that are cell-shape-specific. A collocated variable arrangement formulation is developed, i.e. all dependent variables such as pressure and velocity are stored at cell centers. For both convective and diffusive fluxes the forms superior to both accuracy and stability are particularly adopted and formulated through a systematic study on the existing approximation ones. Gradients required for the evaluation of diffusion fluxes and for second-order-accurate convective operators are computed by using a linear reconstruction based on the divergence theorem. Momentum interpolation is used to prevent the pressure checkerboarding and a segregated solution strategy is adopted to minimize the storage requirements with the pressure-velocity coupling by the SIMPLE algorithm. An algebraic solver using iterative preconditioned conjugate gradient method is used for the solution of linearized equations. The flow analysis code (PowerCFD) developed by the present method is evaluated for its application to several 2-D structured-mesh benchmark problems using a variety of unstructured quadrilateral and triangular meshes. The present flow analysis code by using unstructured grids with the cell-centered method clearly demonstrate the same accuracy and robustness as that for a typical structured mesh.     

Experimental analysis of the thermal properties of fused quartz-reinforced Al-6061alloy matrix composites using RSM approach

Journal of Mechanical Science and Technology - This study investigates the thermal property of fused quartz-reinforced aluminum 6061 alloy metal matrix composites for three different chill material...     

Contact and thermal analysis of transfer film covered real composite-steel surfaces in sliding contact

For composite-steel surfaces in sliding contact an anisotropic numerical contact algorithm has been developed to study the ‘layer type’ problems. An FE contact analysis was applied to evaluate the contact parameters (real contact area, contact pressure distribution and normal approach). The contact temperature rise was determined by using both a numerical thermal algorithm for stationary and a FE transient thermal technique for ‘fast sliding’ problems.The effect of a continuous transfer film layer (TFL), that had built up during wear of the PEEK matrix material on the steel counterpart, was considered. Its thickness was assumed to be t=1 μm, and its material properties were that of PEEK at room temperature or, in the case of frictional heating, at a temperature of 150°C (i.e. above the glass transition temperature of the polymer matrix).Results are presented for a spherical steel asperity, with/without TFL, sliding over composite surfaces of different fibre orientation, and in addition, for real composite-steel surfaces (based on measured surface roughness data) in sliding contact. The TFL has an effect on the contact parameters especially at higher operating temperatures (i.e. 150°C); it results in the production of a larger contact area and a lower contact pressure distribution. The contact temperature rise is clearly higher if a TFL is present. Due to the low thermal conductivity of PEEK, the TFL is close to the melting state or it even gets molten within a small vicinity of the contact area.     

光栅尺光刻过程中的热辐射模拟分析

国产光栅尺的动态性能和精度均达不到数控机床的要求,而影响光栅尺精度的关键步骤是光刻,光刻过程中的影响因素包括机床安装的垂直度和抗干扰度,机床轨道的表面精度和水平度以及环境温度等等,其中对环境温度影响却少有研究。为了能更好的提高光栅尺的精度,本文基于Matlab对光刻过程中的曝光灯热辐射做了数据模拟分析,发现曝光灯的热辐射对光刻时的子光栅刻度等距性有很大影响,而控制这个热辐射数值目前在国内可行性更高,因为无论对于这个控制系统的复杂程度还是所需成本,相比于高精度的温度梯度微环境控制,都有一定的优越性。     

重载点接触热弹流润滑中油膜速度分析

对HKD-1型航空润滑油进行了重载点接触热弹流计算和不同滑滚比下油膜速度分析,并进行了试验验证.结果表明:油膜速度随滑滚比的增加而增大,油膜速度沿滚动方向和厚度方向越来越大,不同模型下得到的油膜速度分布形状不同.Evans-Johnson模型预测的速度分布较准确,牛顿模型预测误差较大.重载下,该润滑油表现为非牛顿特性.     

A computational study of annular cascade flows using aq-ω turbulence model with a wall function

A computational code has been developed for steady viscous flows in three dimensional annular cascades. This code solves a special form of the thin-layer Navier-Stokes equations with a two-equationq-ω turbulence model in curvilinear coordinates using a time asymptotic method for steady state solutions. It employs a scalar implicit approximate factorization in time and a finite volume formulation with second-order upwind-differencing in space. A wall function treatment is implemented at solid boundaries for turbulence equations instead of integration to the wall to relieve gridding requirements. In order to validate the effectiveness of this code, computational studies have been made to access modeling capability for complex turbulent flow fields in three dimensional annular cascade geometries which typically include laminar-turbulent boundary layer transition. The results have been compared with both the computational studies with integration to the wall and the experimental studies. The wall function treatment was found to be reliable by predicting secondary flows and loss contours reasonably well.     

钢包包壁内衬膨胀缝对钢包应力的影响仿真研究

膨胀缝对钢包复合结构体的热膨胀应力具有重要影响,热膨胀应力是其损坏的重要原因之一,热膨胀应力计算具有很大的实用价值。内衬之间的膨胀缝问题可以归结为一类接触问题,并建立其物理模型。利用有限元法建立钢包内衬膨胀缝的有限元模型,探讨膨胀缝对钢包热膨胀应力的影响,研究采用不同膨胀缝和不同温度下钢包热膨胀应力变化,找出膨胀缝对热膨胀应力的影响规律,并得到较佳的膨胀缝值[4]。研究结果表明,设置2mm膨胀缝可降低热膨胀应力,其应力之差占内衬耐压强度的1/6~1/5。     

Improved 3-omega measurement of thermal conductivity in liquid, gases, and powders using a metal-coated optical fiber

A novel 3ω thermal conductivity measurement technique called metal-coated 3ω is introduced for use with liquids, gases, powders, and aerogels. This technique employs a micron-scale metal-coated glass fiber as a heater/thermometer that is suspended within the sample. Metal-coated 3ω exceeds alternate 3ω based fluid sensing techniques in a number of key metrics enabling rapid measurements of small samples of materials with very low thermal effusivity (gases), using smaller temperature oscillations with lower parasitic conduction losses. Its advantages relative to existing fluid measurement techniques, including transient hot-wire, steady-state methods, and solid-wire 3ω are discussed. A generalized n-layer concentric cylindrical periodic heating solution that accounts for thermal boundary resistance is presented. Improved sensitivity to boundary conductance is recognized through this model. Metal-coated 3ω was successfully validated through a benchmark study of gases and liquids spanning two-orders of magnitude in thermal conductivity.     

基于oldroyd-B本构模型的磨料流加工壁面滑移仿真分析

基于oldroyd-B粘弹性本构模型,应用POLYFLOW软件对流体磨料在圆管中的壁面滑移状态进行了模拟仿真。将得到的圆管中流体磨料的压力值与磨料流加工机床上测试点的压力值进行比较,得到二者的相对误差不超过5%,验证了模拟仿真的可行性。通过仿真可知,流体磨料在工件壁面上的滑移存在速度临界点。通过比较不同管道入口流量、流体磨料黏度和壁面滑移系数对壁面滑移速度的影响可知,当管道入口流量越大、流体磨料的黏度越高,以及壁面滑移系数越小时,加工过程中的壁面滑移速度越大。     

Robustness analysis by a probabilistic approach for propagation of uncertainties in a component mode synthesis context

Modelling uncertainties in an industrial application require a thorough knowledge of their sources and types. Uncertainties can be split into aleatory and epistemic types. Using parametric and non-parametric methods successively can be an adapted approach to model these uncertainties types on a given finite elements model (FEM). However, we propose in this paper to proceed more appropriately by introducing a hybrid approach combining the parametric and non-parametric methods. This approach consists of applying, on a given FEM, parametric and non-parametric methods simultaneously with respect to uncertainties types of each model region. Complexity and size of industrial FEMs often impose model reductions. This introduces necessarily the problem of reduction basis robustness. We are interested in the effectiveness of two methods for model reduction in the case of a hybrid model of uncertainties. We consider the case of component mode synthesis (CMS) based on normal modes of clamped interfaces components. Therefore, we analyze robustness of two methods based on improved Craig-Bampton's basis: the first one is enriched by static residual vectors (ESRV), the second one is a variant of the combined approximations method (VCA) adapted to CMS. Finally, a dynamic application on a railway electric motor stator, allows comparing methods' performances in terms of robustness and gain in computing time. Conclusion highlights relevance of the combined approximations method when using a hybrid approach for modelling uncertainties.     

A numerical analysis of the interaction between the piston oil film and the component deformation in a reciprocating compressor

The piston secondary motion significantly influences the major characteristics of lubrication in a reciprocating compressor, such as the oil leakage, the piston slap phenomenon and the frictional power loss. Therefore, the design parameters governing piston dynamics should be carefully determined based upon a reliable dynamic characteristic investigation. As a preliminary research step, this paper is concerned with the finite element analysis for the piston dynamic response. By coupling FDM for the lubricating pressure field with FEM for the piston dynamic motion, we numerically approximate the lubricant–structure interaction in a reciprocating compressor. Numerical results illustrating the theoretical work are presented.     

Detection and analysis of micro cracks in low modulus materials with thermal loading using laser speckle interferometry

Micro-defect detection is an essential field of failure analysis for the assessment and reliability of engineering materials under various loading conditions. This paper illustrates the effect of thermal loading on micro crack formation in certain low modulus materials used for aerospace applications and further analysis. The demands of increased performance of polymeric materials have created a need for new experimental techniques for accurate measurements of their structural defects through non-destructive ways. The present work employs one such optical non-destructive technique such as Laser Speckle Interferometry (LSI) to study the micro crack formation in the low modulus material used as an insulator in solid rocket motors. The low modulus material used is a nitrile based rubber compound which, when thermally loaded to a differential temperature in the range of 20°C to 28°C generates an optimum fringe pattern for the analysis of defects. Extremely small defects in the micrometer scale can be detected by analyzing the anomalies in the generated fringe pattern.     

非参数似然率独立分量分析算法的OFDM系统载波频偏盲估计

研究提出了一种利用非参数似然比(NLR)新算法获得OFDM系统频偏估计的新方法,给出基于NLR的ICA算法的OFDM系统数学模型,利用NLR算法分离各个子载波,然后利用本地载波与子载波的频差估计出OFDM的频偏(CFO),该算法获得的CFO可以包括信道的传输特性对CFO的影响.经典的ICA算法(如FAST-ICA)对源信号的统计特性具有依赖性,源信号统计特性的变化可能使算法的性能降低甚至无法得到希望的分离信号,非参数似然算法(NLR)的独立分量分析(ICA),不依赖于源信号的统计特性,而且能够对混合信号实行连续分离,因此是一个全盲的算法.仿真结果表明,将跟踪到的频偏在接收端进行补偿后,减小了子载波的串扰,降低系统解调后的误码率,提高了OFDM系统性能.     

Localization and quantification of damage in beam-like structures using sensitivities of principal component analysis results

Principal component analysis (PCA) is known as an efficient method for dynamic system identification and diagnosis. This paper addresses a damage diagnosis method based on sensitivities of PCA in the frequency domain for linear-form structures. The aim is not only to detect the presence of damage, but also to localize and to evaluate it. The Frequency response functions measured at different locations on the beam are considered as data for the PCA process. Sensitivities of principal components obtained from PCA to beam parameters are computed and inspected according to the location of sensors; their variation from the healthy state to the damaged state indicates damage locations. The damage can be evaluated next providing that a structural model is available; this evaluation is based on a model updating procedure. It is worth noting that the diagnosis process does not require a modal identification achievement. Both numerical and experimental examples are used for better illustration.     

Detection of signal transients using independent component analysis and its application in gearbox condition monitoring

This paper addresses feature extraction of the higher-order statistics, which can effectively characterize the transients, using independent component analysis (ICA) for the one-dimensional measured vibration signal, and then proposes a novel automatic technique for detecting the transients in vibration signals with the low signal-to-noise ratio by ICA feature extraction. The basic principle of the ICA-based transient detection method is that the independent components (ICs) coefficients of the transients and the noise can be effectively distinguished by their different sparseness properties. Specifically, the proposed method mainly includes three steps: training the ICA basis features from the signal segments, denoising the sparse ICs coefficients using the shrinkage function deduced by the maximum a posteriori (MAP) estimation, and reconstructing the transient segments by the shrunken coefficients through the ICA basis functions. Experimental results through the simulated signal analysis and the vibration signal analysis show that the ICA-based method is very effective for transient detection outperforming the traditional methods and is valuable for gearbox condition monitoring and fault diagnosis.     

A quick deviation zone fitting in coordinate metrology of NURBS surfaces using principle component analysis

Evaluation of the tolerance zone using discrete measured points plays a critical role in today’s manufacturing, metrology, and many industrial applications. The deviation zone is typically evaluated using a fitting method that locates an ideal desired geometry corresponding to a set of measured points while a function of the Euclidean distances of the measured points to the ideal surface becomes minimum. This paper presents a quick and reliable algorithm called Dynamic Principle Component Alignment (DPCA) for fitting complex surfaces to the coordinate metrology measured points using the information that is dynamically generated by Principal Component Analysis (PCA) of the measurement data and the corresponding fitted geometry. The developed algorithm efficiently eliminates the necessity for applying commonly used optimization methods for the fitting (localization) process, which decreases the computational cost and uncertainty of the evaluation process. Moreover, DPCA is very reliable and practical in coordinate metrology with large data sets in processes such as laser scanning and other optical methods. The results show that the proposed methodology more accurately finds fitting parameters in comparison with the other commonly used methods while the computational cost is considerably reduced.     

Multicriterion analysis of the loading problem in flexible manufacturing systems using Min-Max approach

The loading problem in flexible manufacturing systems warrants the consideration of multiple objectives for effective use of its capabilities. The problem is formulated as a multicriterion programming model. The min-max approach is used to find the solution. The results of a particular example are presented to illustrate the application of the model.     

Thermophoretic transport and deposition of particles in vertical tube flow with variable wall temperature and thermal radiation

A particulate two phase flow with variable wall temperature has been studied for examining the deposition of particles in the thermal radiation and mixed convection flow associated with the manufacture of optical fiber preforms. The two-dimensional governing equations of continuity, momentum and energy have been solved numerically including the effects of thermal radiation and buoyancy (upward or downward flow) in the vertical tube flow. A particle trajectory model has been adopted to predict the particle transport, and P-1 approximation has been used to evaluate the radiation heat transfer. In the upward flow case, a high deposition efficiency is obtained and the deposition zone of the downward flow is broader than that of the upward flow. Thermal radiation makes the deposition zone broader and the deposition efficiency smaller.