Computer simulation of a 1.0 GPa piston–cylinder assembly using finite element analysis (FEA)

The paper reports a preliminary study of the behavior of a high performance controlled-clearance piston gauge (CCPG) in the pressure range up to 1 GPa through finite elemental analysis (FEA). The details of the experimental characterization of this CCPG has already been published (Yadav et al., 2007 [1]). We have already pointed out that the use of Heydemann–Welch (HW) model for the characterization of any CCPG, has some limitation due to the fact that the linear extrapolation of the cube root of the fall rate versus jacket pressure (v^1/3–p_j) curve is assumed to be independent of the rheological properties of the pressure transmitting fluids. The FEA technique addresses this problem through simulation and optimization with a standard ANSYS program where the material properties of the piston and cylinder, pressure dependent density and viscosity of the pressure transmitting fluid etc. are to be used as the input parameters. Thus it provides characterization of a pressure balance in terms of effective area and distortion coefficient of the piston and cylinder. The present paper describes the results obtained on systematic studies carried out on the effect of gap profile between piston and cylinder of this controlled-clearance piston gauge, under the influence of applied pressure (p) from 100 MPa to 1000 MPa, on the pressure distortion coefficient (λ) of the assembly. The gap profile is also studied at different applied jacket pressure (p_j) such that p_j/p varied from 0.3, 0.4 and 0.5.     

Use of a higher order Heydemann–Welch model to characterize a controlled clearance piston gauge

We present a new method for characterizing a controlled-clearance piston gauge as a primary pressure standard. This method requires operating the piston gauge to jacket pressures of over 80% of the system pressure. We present measurements on a hydraulic piston gauge with a 290 MPa maximum pressure and a nominal piston diameter of 3.27 mm. Measurements showed that the cylinder becomes stiffer as the jacket pressure increases, and that non-linear models of the Heydemann–Welch parameters improve the determination of the effective area. The relative standard uncertainty in the effective area of the piston gauge ranges from 16.0 × 10⁻⁶ to 17.6 × 10⁻⁶, and the agreement to the present NIST pressure scale is within the standard uncertainty.     

Measurement of the elastic constants of pressure balance materials using resonance ultrasound spectroscopy

To minimise the uncertainty in pressure measured with a pressure balance its pressure distortion coefficient should be determined with a sufficiently low uncertainty. The elastic constants of piston–cylinder assembly (PCA) materials are used in the calculation of the pressure distortion coefficient and thus are one of the uncertainty sources. In this work, the resonant ultrasound spectroscopy (RUS) is applied to determine the elastic constants of PCAs’ tungsten carbide (WC) materials. A validation of the RUS technique has been carried out by measurements on rectangular parallelepiped and cylindrical samples of fused quartz, steel D22S (30CrNiMo8) and a well-known WC material. The WC materials which are used in new 7 MPa absolute pressure balances aimed at a redetermination of the Boltzmann constant have been studied. The measurements demonstrate RUS to be suitable for determining the Young modulus (E) and the Poisson ratio (μ) with standard uncertainties as low as 0.03% and 0.05%, respectively. They show variations in E and μ of up to 4% and 2%, respectively, for different batches of nominally the same material. In a few cases, even for samples cut out of the same WC piece, material inhomogeneities have been observed in both RUS and the density measurements with variations in E and μ of up to 0.8% and 0.5%, respectively.     

FEA calculation of pressure distortion coefficients of gas-operated pressure balances – EURAMET project 1039

Finite element analysis methods were developed and applied to gas piston–cylinder units (PCUs) of piston- and cylinder-floating configuration (2, 5, 10 and 20) cm² nominal effective area, operated in gauge and absolute mode at pressures (0.06–7.5) MPa to determine their zero pressure and pressure-dependent effective areas, as well as pressure distortion coefficients (λ) with associated uncertainties. Real dimensional properties of the PCUs were used. λ were found to be independent of gas (ideal, N₂, He) within the viscous flow model, but strongly dependent on the gap shape, operation mode and elastic properties. Results demonstrate good agreement for λ, with its uncertainty for different PCUs varying between (0.03 and 0.21) × 10⁻⁶ MPa⁻¹ corresponding to maximum relative uncertainties in pressure of (0.07–0.34) × 10⁻⁶.     

Analysis of damping resistor’s effects on pulse response of self-integrating Rogowski coil with magnetic core

A self-integrating Rogowski coil with magnetic core is investigated for accurate measurement of high-impulse current in this paper. Usually, the distributed parameters of Rogowski coil generate deleterious high-frequency resonant signal parasitizing in the useful signal of the coil circuit. Damping resistors can be used to eliminate the parasitic resonant component of the signal. In this paper, damping effects of the damping resistors on the output signal of Rogowski coil are studied in detail. According to circuit theory, approximate circuit equations of Rogowski coil with lumped parameters in simplification are put forward. Response signal of coil is analyzed and a reasonable method for choosing damping resistance is also presented. When the 50 Ω damping resistance is used, the amplitude of parasitic resonant signal has been damped by 5.7 times in contrast to the situation without any damping resistance. Result of Pspice circuit simulation corresponds to the theoretical calculation result. A standard 10 ns square pulse has been used to calibrate the coil signal before and after the damping resistors soldering on the coil, respectively. Experimental results show that the response time of the coil with magnetic core is 1.1 ns and the parasitic resonance in the coil signal is almost eliminated. The coil can accurately detect high-pulse current at kA range.     

1–15,000 Pa Absolute mode comparisons between the NIST ultrasonic interferometer manometers and non-rotating force-balanced piston gauges

The National Institute of Standards and Technology (NIST) Low Pressure Manometry Project maintains and operates primary standard ultrasonic interferometer manometers (UIMs) over the pressure range of 1 mPa to 360 kPa. Over the past decade a new type of customer gauge, the non-rotating force-balanced piston gauge or FPG (model 8601, DH Instruments, a Fluke Company¹) has been introduced to the standards community that covers the range of ≈1–15,000 Pa and is capable of both absolute and differential measurement modes. Since 2002, NIST customers² have requested that four different FPG units be compared to the NIST primary pressure ultrasonic interferometer manometer standards (UIMs). The results of the comparisons were that all four FPG units were within manufacturers stated uncertainty (0.008 Pa + 30 × 10⁻⁶ × P for absolute mode) when compared against the NIST UIMs at pressures between 10 Pa and 15,000 Pa (absolute mode). At pressures between 5 Pa and 10 Pa, the results were generally within manufacturer’s specifications. Below 5 Pa some of the FPG units were outside of manufacturer’s uncertainty specifications. The use of an isolating capacitance diaphragm gauge (CDG) was necessary during the comparisons to prevent humidified gas from the FPG from entering the NIST 160 kPa mercury UIM primary pressure standard. The results of these four different comparison tests will be discussed in detail, along with test conditions, equipment set-up, and test uncertainty analysis.     

Development of high-precision micro-coordinate measuring machine: Multi-probe measurement system for measuring yaw and straightness motion error of XY linear stage

Today, with the development of microsystem technologies, demands for three-dimensional (3D) metrologies for microsystem components have increased. High-accuracy micro-coordinate measuring machines (micro-CMMs) have been developed to satisfy these demands. A high-precision micro-CMM (M-CMM) is currently under development at the National Metrology Institute of Japan in the National Institute of Advanced Industrial Science and Technology (AIST), in collaboration with the University of Tokyo. The moving volume of the M-CMM is 160 mm × 160 mm × 100 mm (XYZ), and our aim is to achieve 50-nm measurement uncertainty with a measuring volume of 30 mm × 30 mm × 10 mm (XYZ). The M-CMM configuration comprises three main parts: a cross XY-axis, a separate Z-axis, and a changeable probe unit. We have designed a multi-probe measurement system to evaluate the motion accuracy of each stage of the M-CMM. In the measurement system, one autocollimator measures the yaw error of the moving stage, while two laser interferometers simultaneously probe the surface of a reference bar mirror that is fixed on top of an XY linear stage. The straightness motion error and the reference bar mirror profile are reconstructed by the application of simultaneous linear equations and least-squares methods. In this paper, we have discussed the simulation results of the uncertainty value of the multi-probe measurement method using different intervals and standard deviations of the laser interferometers. We also conducted pre-experiments of the multi-probe measurement method for evaluating the motion errors of the XY linear stage based on a stepper motor system. The results from the pre-experiment verify that the multi-probe measurement method performs the yaw and straightness motion error measurement extremely well. Comparisons with the simulation results demonstrate that the multi-probe measurement method can also measure the reference bar mirror profile with a small standard deviation of 10 nm.     

A calibration system for PTU devices

Devices measuring pressure, temperature and humidity simultaneously are known as PTU devices. There are hardly any commercial calibration systems for the PTU devices available for low temperatures (<0 °C). To obtain more comprehensive data on the performance of PTU devices, a new calibration system is developed at MIKES. In this PTU Apparatus, pressure, temperature and humidity can be controlled simultaneously so that all combinations over the ranges are possible. The nominal ranges of the system are the following: absolute pressure 500–1100 hPa, temperature −52 °C to +80 °C and relative humidity 10–95%. The target uncertainties (k = 2) of the pressure, temperature and humidity are 10 Pa, 0,1–0,3 °C and 1–3% RH, respectively. The construction and operation as well as the results of operational tests of the PTU Apparatus are reported in this paper.     

重型多轴车辆互连油气悬架特性分析

以重型多轴车辆互连悬架系统为研究对象,建立了四轴互连油气悬架液压系统数学模型。模型中考虑了管路沿程压力损失、局部压力损失和油缸活塞杆运动摩擦力的影响,并进行仿真分析,通过台架试验验证了模型的正确性。基于互连油气悬架液压系统数学模型,对比分析了垂向和侧倾工况下互连悬架和独立悬架的刚度和阻尼特性,以及对互连悬架阻尼特性进行参数化分析。结果表明：在垂向工况下,互连悬架蓄能器内气体体积变化量相当于各活塞杆进出油缸的体积,与独立悬架蓄能器内气体体积变化量相等,因此互连悬架与独立悬架刚度特性相同,但其阻尼力大于独立悬架;侧倾工况下,互连悬架在增加侧倾刚度的同时也明显增大了阻尼力。两种工况下,独立悬架阻尼特性不变,互连悬架阻尼力随单向阀直径增大、阻尼阀直径增大、油管直径增大、油缸内径减小和活塞杆直径增大而减小。     

变排量非对称轴向柱塞泵控制性能分析

变排量非对称轴向柱塞泵直接控制非对称液压缸闭式系统具有能效高、结构紧凑等优势.针对变排量三配流窗口轴向柱塞泵存在变量阻力矩脉动大、斜盘倾角振荡频率高等问题,提出在变排量机构中增加阻尼孔以提高变排量控制性能的方案,推导了变排量控制系统的传递函数;通过AMESim仿真模型分别研究了有无阻尼孔情况下的斜盘倾角振荡、变量缸活塞...     

Dynamic Modeling of Floating Valve Plate Motion in an Axial Piston Pump

The objectives of this study were to analytically and experimentally investigate the motion of the floating valve plate in an axial piston pump under various operating conditions. To achieve the objectives of the analytical investigation, the equations of motion for the valve plate were coupled with a time-dependent lubrication model. The balance pistons that support the floating valve plate were represented by equivalent spring and dashpot systems. The system of equations was then solved using the Runge-Kutta and the control volume finite difference methods to determine the pressure, film thickness, and motion of the valve plate for various operating conditions. To achieve the experimental objectives, a previously developed axial piston pump test rig was instrumented with proximity probes to measure the motion of the valve plate. The stiffness and damping of the balance pistons supporting the floating valve plate were determined using the impact and frequency response methods. Using the experimentally determined stiffness and damping coefficients in the coupled dynamic lubrication model, the analytical and experimental results of the valve plate motions were compared. The model was then used to conduct a parametric study to determine the overall system stiffness and damping coefficients during pump operation. Using the stiffness and damping coefficients from the parametric study in the dynamic lubrication model, the pressure, film thickness, and motion of the valve plate were calculated for various operating conditions. The experimental and analytical displacements of the valve plate were then corroborated and found to be in good agreement.     

The behavior of an elastic-perfectly plastic sinusoidal surface under contact loading

The goal of this paper is to provide the foundation for an analysis of contact between elastic-plastic solids, whose surface roughness is idealized with a Weierstrass profile. To this end, we conduct a parametric study of the plastic deformation and residual stress developed by the two-dimensional contact between a flat, rigid platen and an elastic-perfectly plastic solid with a sinusoidal surface. Our analysis shows that the general characteristics of the deformation can be characterized approximately by two parameters: α = a/λ, where a is the half-width of the contact and λ is the period of the surface waviness; ψ = E^*g/σ_Yλ, where E^* and σ_Y are the effective modulus and yield stress of the substrate, respectively, and g is the amplitude of the surface roughness. Depending on the values of these parameters, we identify eight general types of behavior for the asperity contacts: (a) elastic, elastic-plastic or fully plastic isolated Hertz type contacts; (b) elastic, or elastic-plastic non-Hertzian isolated contacts; and (c) elastic, elastic-plastic or fully plastic, interacting contacts. Relationships between contact pressure, contact size, effective indentation depth and residual stress are explored in detail in each regime of behavior. Implications on rough surface contacts are discussed.     

Characterization of MEMS piezoresistive pressure sensors using AFM

Atomic force microscope (AFM) is adapted to characterize an ultrasensitive piezoresistive pressure sensor based on microelectromechanical system (MEMS) technology. AFM is utilized in contact mode to exert force on several different micromachined diaphragm structures using a modified silicon cantilever with a particle attached to its end. The applied force is adjusted by changing the trigger voltage during each engage step of the probe-tip on the diaphragm surface. The contact force is determined from the force plots obtained for each trigger voltage in advanced force mode. Low force values in the range of 0.3–5 μN have been obtained with this method. This force induces strain on the bridge-arm of the diaphragm where the polysilicon resistor is located. The resultant change in the resistance produced due to varying force/pressure is measured using a delta mode current–voltage (I–V) measurement set-up. The contact mode AFM in conjunction with a nanovoltmeter enables the calibration of very sensitive force sensors down to 0.3 μN.     

Measuring radial pressure distributions of piston rings based on partial-thin-walled cylinder

The measurement of radial pressure distribution of piston rings is very important for minimizing the wastages of lubricating oils and hence the lower gas emissions; for improving the friction status to reduce the gasoline consumption and for the reasonable heat transfer efficiency for the desired accuracy levels. For accurate and efficient measurement of radial pressure distribution of piston rings, a new PC based prototype instrument based on a partial-thin-walled cylinder sensor is designed and developed. The present paper describes the details of the measurement principle, hardware and software of this instrument. The measurement results thus obtained using the proposed instrument during experiments performed on a conical ring of diameter 110 mm and a drum ring of diameter 120 mm, are quite accurate, consistent and repeatable within the desired level of accuracy.     

Stick–slip motion in the atomic force microscope

Measurements of atomic friction in the atomic force microscope frequently show periodic variations at the lattice spacing of the surface being scanned, which have the saw‐tooth wave form characteristic of “stick–slip” motion. Simple models of this behaviour have been proposed, in which the “dynamic element” of the system is provided by the elastic stiffness and inertia of the cantilever which supports the tip of the microscope, in its lateral, i.e., torsional mode of vibration. These models have been successful in predicting the observed motion, but only by assuming that the cantilever is heavily damped. However, the source of this damping in a highly elastic cantilever is not explained. To resolve the paradox, it is shown in this note that it is necessary to introduce the elastic stiffness of the contact into the model. The relationship between the contact stiffness, the cantilever stiffness and the amplitude of the periodic friction force is derived in order for stick–slip motion at lattice spacing to be achieved. This revised version was published online in July 2006 with corrections to the Cover Date.     

The damping capacity of a flat surface to roller contact

The behaviour of the damping capacity of a flat surface to roller contact with various beam hardnesses and thicknesses was investigated. It was established that the hardness and thickness of the beam have a marked effect on the characteristics of its damped vibrations. The logarithmic damping decrement increases proportionately with the real area of contact A_r = Q/H_v until the preload reaches a value at which plastic deformation of the contact surfaces commences and the value of the logarithmic damping decrement is a maximum.     

Development of low-pressure calibration system using a pressure balance

A new calibration system for low-pressure is now under development at NMIJ/AIST. The new system is designed to calibrate pressure transducers in the pressure range of less than 10 kPa in absolute mode. The pressure generation technique needs only a single pressure balance and the pressure in the bell-jar is used as a calibration pressure instead of the system pressure. In this paper, the outline of the calibration system and the measurement results are described.     

Dynamic stability of ferromagnetic plate under transverse magnetic field and in-plane periodic compression

The dynamic stability of a soft ferromagnetic rectangular and simply supported plate immersed in an applied transverse magnetic field, as well as subjected to an in-plane periodic compression is presented in this paper. The fundamental equations involving magnetoelastic interaction and magnetic damping effect for the ferromagnetic plate are developed. In the theoretical model, the expression of induced magnetic force is based on a generalized magnetoelastic variational model, and the magnetic damping is due to the Lorentz body force arising from eddy current in the ferromagnetic material. By means of a linearized magnetoelastic theory and perturbation technique, the motion equation of the ferromagnetic plate is reduced to a damped Mathieu's equation and solved. The dynamic stability of the magnetoelastic system without in-plane compression is theoretically analyzed first, to show that there exist two stable states: magnetic damped stable oscillation, and over-damped asymptotically stable motion before static divergence instability of the ferromagnetic plate occurs. The dynamic instability and stability regions for the parametric excitation of the ferromagnetic plate due to the harmonically excited in-plane compression are obtained next. The effects of magnetic damping and excitation frequency of the in-plane periodic compression on the stability regions are discussed in detail.     

Nonlinear dynamic response of rotating circular cylindrical shells with precession of vibrating shape—Part I: Numerical solution

The nonlinear dynamic response of a cantilever rotating circular cylindrical shell subjected to a harmonic excitation about one of the lowest natural frequency, corresponding to mode (m=1, n=6),where m indicates the number of axial half-waves and n indicates the number of circumferential waves, is investigated by using numerical method in this paper. The factor of precession of vibrating shape ? is obtained, with damping accounted for. The equation of motion is derived by using the Donnell’s nonlinear shallow-shell theory, and is general in the sense that it includes damping, Coriolis force and large-amplitude shell motion effects. The problem is reduced to a system of ordinary differential equations by means of the Galerkin method. Three different mode expansions are studied for finding the proper one which is more contracted and accurate to investigate the principal mode (i.e., m=1, n=6) response. From the present investigation, it can be found that for principal mode resonant response, there are two traveling waves with different linear frequencies due to the effect of precession of vibrating shape of rotating circular cylindrical shells; the effects of additional modes n and k (multiples of frequency) on the principal mode resonant response are insignificant compared with an additional mode m, showing that it is better to adopt two neighboring axial modes to study the principal resonant response of the system.     

Analysis of composition dependence of some thermal transport properties in glassy Se80−xTe20Snx (0 ⩽ x ⩽ 10) alloys using transient plane source measurements

In the present work, we have studied simultaneous measurements of thermal transport properties (effective thermal conductivity, diffusivity, specific heat per unit volume, thermal inertia I_T) of glassy Se_80−xTe₂₀Sn_x (0 ? x ? 10) system using their twin pellets. The glassy system is prepared under a load of 5 tons and measurements have been made at room temperature using Transient Plane Source (TPS) technique. The composition dependence of the thermal transport properties of given glassy system is also discussed.