转子—密封系统非线性动力学特性分析

在超临界汽轮机和超超临界汽轮机中,气流激振力对系统影响显著。因此,本文研究了气流激振力对转子－密封系统动力学特性的影响,采用Muszynska密封模型建立转子－密封系统非线性动力学方程,利用Floquet理论研究系统周期解稳定性,根据系统的周期响应、频谱图、Poincaré映射图、分岔图,分析了系统在特定转速及特定转子系统参数下的非线性动力学特性。     

数控机床切削稳定性分析及实验研究

针对因机床结构的复杂性及零件加工轨迹不确定性,刀尖频响函数切削中难以保持恒定易造成稳定域图变化,导致机床切削参数选择不确定性问题,结合模态实验分别研究数控机床沿不同进给方向及机床主轴处于不同位置的颤振稳定域图预测;对同型号两台数控机床的切削稳定性进行对比分析。由实验采集切削中声音信号验证机床沿不同进给方向的切削稳定性存在差别。研究结果对实际加工中避免切削颤振及工艺参数选择具有指导意义。     

Dependence of lead time on batch size studied by a system dynamics model

Most planning models treat lead time as a constant independent of workload, but the resulting order rate implies capacity utilisation that, in turn, affects the lead time. An important factor that determines production order rate is the batch size, and one therefore expects a relationship between batch size and lead time. This dependency is examined for different operational conditions using system dynamics simulation of a manufacturing model comprising a quality control unit that is also the bottleneck of the system. It is shown that there is an optimal batch size that results in a minimum lead time and that inventory level at optimum matches the desired inventory. Below optimal batch size, lead time increases sharply due to congestion at the bottleneck. The results have implications for production planning and implementation of process improvement.     

磁控挤压油膜阻尼器转子系统动力特性试验研究

为了改善传统挤压油膜阻尼器动力特性不可控的不足，提出了一种通过电磁效应来控制挤压油膜阻尼器动力特性的新结构，在一个双盘柔性转子系统上测量了不同磁场强度条件下磁控挤压油膜阻尼器转子系统在非旋转状态下的传递函数、在恒定转速下的运动轨道以及在慢加速运行过程中的不平衡响应曲线。结果表明了这种新型磁控挤压油膜阻尼器不仅具有良好的特性可控性，而且在设计合理的条件下还能够显著地减小转子系统的振动，是一种被动和主动兼备、具有良好发展和应用前景的转子系统阻尼结构。     

Simulation of random tool lives in metal cutting on a flexible machine

Much research into multi-level lot-sizing problems has concentrated on fixed horizon problems ignoring more realistic conditions such as appending new demand(s) in the planning periods. The aim of this paper is to illustrate that a heuristic, which was developed earlier by the authors, is applicable to the multilevel lot-sizing problem with a bottleneck under a rolling schedule environment. The results illustrate that the Silver-Meal (SM) approach performed better than the Economic Order Quantity (EOQ) approach in terms of cost measures, when incorporated within the heuristic procedure. The results also show that, although the total cost of the problem is increased in a rolling schedule environment, the heuristic continues to perform favourably in producing low cost solutions.     

An experimental investigation of the physical effects in a dynamic magnetic system

It is demonstrated that a magnetic system based on rare-earth magnets is capable of converting various forms of the energy, provided that certain critical operating regime is set. As the critical regime is attained, the experimental setup becomes energetically fully autonomous. This is accompanied by local variations in the total structure weight, a decrease in the surrounding air temperature, and the formation of concentric “magnetic walls” at a distance of up to 15 m from the experimental setup.     

Comparative study of the effect of surface texturing on cutting tool in dry cutting

Recent researches in the field of dry machining have indicated that surface texture has the potential to influence tribological conditions. Researchers have studied the application of controlled surface microtextures on cutting tool surfaces to improve machining performance by changing the tribological conditions at the interfaces of tool–chip and tool–work piece. An experiment to study the performance of the microtextured high-speed steel cutting implement within the machining of steel and aluminum samples was performed. Surface textures were introduced using Rockwell hardness tester, Vickers hardness tester, and by scratching with diamond dresser on the face of single point cutting tool. Machining in dry conditions was applied on mild steel (EN3B) and aluminum (AA 6351) samples using lathe machine with microtextured and traditional cutting tool for the constant range of feed, depth of cut, and for varying range of cutting speeds. Measurement of cutting force, cutting temperature, and surface roughness of the work surfaces after machining were made. The results showed reduction in cutting forces and cutting temperature with textured tools in comparison with those of the untextured tool. Chips collected from different samples were studied under a microscope and the results showed that textures created on the tool surface by various methods exhibited variations in chip formation. Cutting tools without texture and with texture were comparatively studied and the outcomes of the experimental study are presented in this paper.     

Fracture analysis of a cutting tool used in a straightening and twin bended system for coiled re-bars machine

A company produces prefabricated stirrup cages for the reinforcement of concrete. The process consists of straightening, cutting and twin bending of coiled steel re-bars, in a custom produced machine. The punch of the cutting system failed repeatedly. Its cutting edges lose their functionality much earlier than expected. Two representative pieces were analyzed. The study included visual inspection, chemical analysis, hardness and micro-hardness measurements. Optical metallographic examination on representative samples was carried out. The fracture areas were analyzed using a scanning electron microscope (SEM) and the crack initiation and propagation were discussed. The punches failed by chipping wear mechanism due to low-cycle fatigue. Their repeating failures provoked by faulty machine design. Problem solving suggestions are proposed. In addition, alternatives related to material selection are provided in order to reduce crack susceptibility, in an economical way. Moreover, conclusions and recommendations can be useful, resulting in higher productivity of prefabricated stirrup cages.     

Propagation dynamics of a liquid injected into an aquifer

With the aid of the Phoenics program package the filtration processes in the underground permeable collector upon injection of a liquid into it have been considered. The time dependences of the injected liquid velocity for a real gas-saturated aquifer have been obtained. The indices of using a geothermal cogenerating plant operating on gas-saturated thermal water have been estimated.     

Multi-pulse chaotic dynamics of non-autonomous nonlinear system for a honeycomb sandwich plate

The global bifurcations and multi-pulse chaotic dynamics of a simply supported honeycomb sandwich rectangular plate under combined parametric and transverse excitations are investigated in this paper for the first time. The extended Melnikov method is generalized to investigate the multi-pulse chaotic dynamics of the non-autonomous nonlinear dynamical system. The main theoretical results and the formulas are obtained for the extended Melnikov method of the non-autonomous nonlinear dynamical system. The nonlinear governing equation of the honeycomb sandwich rectangular plate is derived by using the Hamilton’s principle and the Galerkin’s approach. A two-degree-of-freedom non-autonomous nonlinear equation of motion is obtained. It is known that the less simplification processes on the system will result in a better understanding of the behaviors of the multi-pulse chaotic dynamics for high-dimensional nonlinear systems. Therefore, the extended Melnikov method of the non-autonomous nonlinear dynamical system is directly utilized to analyze the global bifurcations and multi-pulse chaotic dynamics of the two-degree-of-freedom non-autonomous nonlinear system for the honeycomb sandwich rectangular plate. The theoretical results obtained here indicate that multi-pulse chaotic motions can occur in the honeycomb sandwich rectangular plate. Numerical simulation is also employed to find the multi-pulse chaotic motions of the honeycomb sandwich rectangular plate. It also demonstrates the validation of the theoretical prediction.     

Experimental investigation of cutting parameters influence on surface roughness and cutting forces in hard turning of X38CrMoV5-1 with CBN tool

This experimental investigation was conducted to determine the effects of cutting conditions on surface roughness and cutting forces in hard turning of X38CrMoV5-1. This steel was hardened at 50 HRC and machined with CBN tool. This is employed for the manufacture of helicopter rotor blades and forging dies. Combined effects of three cutting parameters, namely cutting speed, feed rate and depth of cut, on the six performance outputs-surface roughness parameters and cutting force components, are explored by analysis of variance (ANOVA). Optimal cutting conditions for each performance level are established. The relationship between the variables and the technological parameters is determined through the response surface methodology (RSM), using a quadratic regression model. Results show how much surface roughness is mainly influenced by feed rate and cutting speed. The depth of cut exhibits maximum influence on cutting force components as compared to the feed rate and cutting speed.     

An experimental investigation into the formation of an equiaxed zone in ingot casting: Pb-Sb alloy system

An experimental investigation was undertaken to obtain a better understanding of the phenomenon of equiaxed zone formation in ingot castings with particular attention to the thermal conditions during dendritic growth and the mechanism of columnar-to-equiaxed transition. Thermal conditions during dendritic growth were measured in the laboratory-scale Pb-Sb castings. Solidification was also directly observed in castings of the cyclohexanol-phenol red system. A close correlation was noted between the general behaviour of the thermal history curves, especially when taken on the centreline of the ingots, and the resulting macrostructure. The dendritic solidification front was found to grow with considerable solute undercooling and also with a slight, but positive, temperature gradient ahead of the front in the bulk liquid. Moreover, the dendritic front temperature was also noted to increase with distance from the mould wall surface, the nominal rate of advance of the front being sensitive to the solute content and the cooling rate. Heterogeneous nucleation ahead of the columnar front was believed to have played a major role in equiaxed zone formation. However, columnar-to-equiaxed transition was observed not to take place immediately when the equiaxed crystals formed, but some time later, equiaxed dendrites growing at a somewhat higher temperature than the columnar dendritic front. Finally, combining the information gained from thermal analysis data with the observations made upon non-metallic castings, a novel picture of how columnar-to-equiaxed transition takes place has been proposed.Associate Professor of Physical Metallurgy.     

Metallurgical investigation into the failure of a chopper blade used for cutting of hot-rolled steel coils

In the present work, failure investigation of a chopper blade received from an integrated steel plant has been presented. Chopper blades are used in chopping machines for cutting trimmed edges of hot-rolled coils into pieces to convert them into scrap. These blades are manufactured from hot forged or rolled billets or flats of high carbon high chromium cold work tool steel. The investigation consists of visual examination, chemical analysis, microstructural analysis through optical and scanning electron microscopy (SEM), energy dispersive spectroscopy (EDS) and hardness measurement. The chemical analysis confirmed the steel as equivalent to D2 grade in AISI notation. Carbide volume fraction of the broken blade was in the normal range of 10–15% as commonly observed in D2 tool steel. Microstructural examination under light and scanning electron microscopy showed non-uniform distribution of large eutectic primary carbides of irregular morphology forming strings or bands in tempered martensite matrix preferentially aligned in a specific direction. The uneven carbide arrangement in the matrix made the structure highly anisotropic and susceptible to localized stress concentration. The carbides were identified mainly as M₂₃C₆ type. Cracks were observed to initiate at the edges of the blade and propagate to the interior through clustered zones of carbides. SEM study suggests that the crack initiation was associated with decohesion of carbide particles in the cluster which culminated into final fracture by the mechanism of void coalescence and subsequent crack growth.     

Experimental investigation of transient nonlinear phenomena in an annular thermoacoustic prime-mover: observation of a double-threshold effect

Thermoacoustic engines have been subjected to numerous studies for the past 10 years. Our current research is focused on the transient regime in an annular thermoacoustic prime-mover. It appears that several nonlinear phenomena can play a role in the amplification and saturation regimes. Indeed, acoustically induced conductivity, forced convection due to acoustic streaming, minor loss phenomenon, and saturation due to harmonic generation can be quoted among the others. The experiments presented here show for the first time a double-threshold phenomenon during the amplification regime. The first threshold, which corresponds to the setting of the thermoacoustic instability, is followed by a saturation regime. Then after a time delay, without any changes in the control parameters, a second threshold corresponding to an additional amplification has been observed.     

非线性连续转子轴承系统碰摩故障动力学行为研究

采用有限元法建立碰摩故障转子系统的连续模型,考虑了转子的回转效应、剪切效应、惯量分布效应、横向扭转以及系统结构的几何参数等重要影响因素,使模型更为具体化,避免系统参数选取的随意性.采用Newmark-β法对文中连续模型的碰摩故障问题进行动力学求解,发现由于不同参数变化的影响,系统的碰摩故障响应特征呈现非常丰富的非线性现象.本模型考虑了更多影响因素,使计算结果更趋于问题实际情况,也使计算结果的特征更为丰富,其结果可以为复杂转子系统的非线性动态设计、故障诊断以及设备的安全运行提供更为准确合理的理论参考.     

动力设备荷载模拟及设备－桩基体系非线性动力分析

采用人工模拟设备动力荷载对桩基和上部设备协同工作体系进行了非线性振动时程分析。在分析过程中,针对设备振动荷载不易确定的特点,根据实测的荷载时程曲线,以及设备的极限荷载,按平稳高斯过程三角级数模型构造人工荷载时程曲线,将其作为设备的外部施加动荷载。在设备－桩基体系协同工作有限元模型中,采用粘滞边界模拟承台周边的地基土,地基弹簧弹性系数采用粘-弹性半空间法计算,使得整个体系的计算规模得到简化。利用模态叠加法对该体系进行动力时程分析。将上述方法应用到常州盘固水泥厂水泥立磨设备基础分析,并与实测结果进行对比,验证了该方法的计算精度。     

A nonlinear dynamic S/H-ADC device model based on a modified Volterra series: identification procedure and commercial CAD tool implementation

A nonlinear, dynamic empirical model, based on a Volterra-like approach, was previously proposed by the authors for the time-oriented characterization of sample/hold (S/H) and analog-to-digital conversion (ADC) devices. In this paper, the experimental procedure for model parameter measurement is presented, as well as techniques devoted to the implementation of the model in the framework of the main commercial CAD tools for circuit analysis and design. Examples of simulations, performed both in the time and frequency domain on the model obtained for a commercial device, are proposed, which show the model's capability of pointing out the dynamic nonlinear effects in the S/H-ADC response.     

Design and construction of a dynamometer to evaluate the influence of cutting tool rake angle on cutting forces

In this study, the influence of cutting tool rake angle on the cutting forces developed during turning operation was evaluated. For this purpose, a dynamometer was designed and constructed to measure cutting forces. In this dynamometer design, measurement of the cutting tool deflection under the cutting forces was aimed using two beam type load cells located suitably according to the cutting tool. In order to examine the influence of rake angle, turning tests were carried out on AISI 1040 steel workpiece using eight different rake angles. The turning tests at each rake angle were conducted at five different cutting speeds while depth of cut and feed rate were kept constant. The results showed that cutting forces decreased with increasing the rake angle.     

磁流变流体挤压油膜阻尼器柔性转子系统动力特性的试验研究

通过测量不同激励条件下磁流变流体挤压油膜阻尼器(magnetorheological fluid squeeze filmdamper,简写为MRFSFD)转子系统的运动轨迹和不平衡响应,研究了MRFSFD转子系统的动力特性以及MRFSFD对转子系统动力特性的可控性和对转子系统的振动进行控制的有效性.结果表明MRFSFD的动力特性是可控的,在合理选择激励磁场的条件下MRFSFD能够有效地抑制转子系统的振动.MRFSFD转子系统对激励的响应时间较长,这种阻尼器更适合对转子系统的振动进行半主动控制.利用MRFSFD对转子的振动进行分段控制可以使转子系统平稳地通过多阶临界转速.