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DOI：10.1186/s10033-019-0409-8
Ultrasonic Welding of Magnesium–Titanium Dissimilar Metals: A Study on Thermo-mechanical Analyses of Welding Process by Experimentation and Finite Element Method
Dewang Zhao, Daxin Ren, Kunmin Zhao, Pan Sun, Xinglin Guo & Liming Liu
Abstract：Ultrasonic welding is an effective ways to achieve a non-reactive/immiscible heterogeneous metal connection, such as the connection of magnesium alloy and titanium alloy. But the thermal mechanism of magnesium alloy/titanium alloy ultrasonic welding has not been defined clearly. In this paper, the experimental and the finite element analysis were adopted to study the thermal mechanism during welding. Through the test, the temperature variation law during the welding process is obtained, and the accuracy of the finite element model is verified. The microscopic analysis indicates that at the welding time of 0.5 s, the magnesium alloy in the center of the solder joint is partially melted and generates the liquid phase. Through the finite element analysis, the friction coefficient of the magnesium–titanium ultrasonic welding interface can be considered as an average constant value of 0.28. The maximum temperature at the interface can exceed 600 °C to reach the melting point temperature of the magnesium alloy. The plastic deformation begins after 0.35 s and occurs at the magnesium side at the center of the interface.
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https://cjme.springeropen.com/articles/10.1186/s10033-019-0409-8
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Dewang Zhao, Daxin Ren, Kunmin Zhao, et al.Ultrasonic Welding of Magnesium–Titanium Dissimilar Metals: A Study on Thermo-mechanical Analyses of Welding Process by Experimentation and Finite Element Method. Chinese Journal of Mechanical Engineering, 2019, 32: 97.
DOI：10.1186/s10033-019-0418-7
Ultrasonic Scattered Field Distribution of One and Two Cylindrical Solids with Phased Array Technique
Xiaozhou Liu, Jian Ma, Haibin Wang, Sha Gao, Yifeng Li & Jiehui Liu
Abstract：The scattered fields of plane waves in a solid from a cylinder or sphere are critical in determining its acoustic characteristics as well as in engineering applications. This paper investigates the scattered field distributions of different incident waves created by elastic cylinders embedded in an elastic isotropic medium. Scattered waves, including longitudinal and transverse waves both inside and outside the cylinder, are described with specific modalities under an incident plane wave. A model with a scatterer embedded in a structural steel matrix and filled with aluminum is developed for comparison with the theoretical solution. The frequency of the plane wave ranged from 235 kHz to 2348 kHz, which corresponds to scaling factors from 0.5 to 5. Scattered field distributions in matrix materials blocked by an elastic cylindrical solid have been obtained by simulation or calculated using existing parameters. The simulation results are in good agreement with the theoretical solution, which supports the correctness of the simulation analysis. Furthermore, ultrasonic phased arrays are used to study scattered fields by changing the characteristics of the incident wave. On this foundation, a partial preliminary study of the scattered field distribution of double cylinders in a solid has been carried out, and the scattered field distribution at a given distance has been found to exhibit particular behaviors at different moments. Further studies on directivities and scattered fields are expected to improve the quantification of scattered images in isotropic solid materials by the phased array technique.
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https://cjme.springeropen.com/articles/10.1186/s10033-019-0418-7
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Xiaozhou Liu, Jian Ma, Haibin Wang, et al.Ultrasonic Scattered Field Distribution of One and Two Cylindrical Solids with Phased Array Technique. Chinese Journal of Mechanical Engineering, 2019, 32: 96.
DOI：10.1186/s10033-019-0417-8
New Leiderman–Khlystov Coefficients for Estimating Engine Full Load Characteristics and Performance
Dariusz Szpica
Abstract：The paper presents a method of calculating the full load engine characteristics based on the Leiderman–Khlystov relation. Because the values of the coefficients of the discussed function available in literature were determined for obsolete engine designs, an attempt was made to update them. To this end, a chassis dynamometer was used where a database of results had been built for a variety of vehicles. Following the data collection, the coefficients for variety of fueling system (six groups: fuel injected gasoline and turbocharged gasoline, spark ignition LPG I–II and IV generation, naturally aspirated diesel and turbocharged diesel) were determined. The identification of the coefficients was carried out in Matlab-Simulink indicating the applicability of the said function for most of the engines, yet the recent popularity of turbocharged gasoline engines requires an additional analysis of the possibility of use of a different functional description. The full load engine characteristics is a basis for the vehicle performance characteristics and, further, for modeling of traffic in a variety of aspects of the vehicle operation.
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https://cjme.springeropen.com/articles/10.1186/s10033-019-0417-8
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Dariusz Szpica. New Leiderman–Khlystov Coefficients for Estimating Engine Full Load Characteristics and Performance. Chinese Journal of Mechanical Engineering, 2019, 32: 95.
DOI：10.1186/s10033-019-0408-9
Optimization of Cutting Parameters for Trade-off Among Carbon Emissions, Surface Roughness, and Processing Time
Zhipeng Jiang, Dong Gao, Yong Lu & Xianli Liu
Abstract：As the manufacturing industry is facing increasingly serious environmental problems, because of which carbon tax policies are being implemented, choosing the optimum cutting parameters during the machining process is crucial for automobile panel dies in order to achieve synergistic minimization of the environment impact, product quality, and processing efficiency. This paper presents a processing task-based evaluation method to optimize the cutting parameters, considering the trade-off among carbon emissions, surface roughness, and processing time. Three objective models and their relationships with the cutting parameters were obtained through input–output, response surface, and theoretical analyses, respectively. Examples of cylindrical turning were applied to achieve a central composite design (CCD), and relative validation experiments were applied to evaluate the proposed method. The experiments were conducted on the CAK50135di lathe cutting of AISI 1045 steel, and NSGA-II was used to obtain the Pareto fronts of the three objectives. Based on the TOPSIS method, the Pareto solution set was ranked to find the optimal solution to evaluate and select the optimal cutting parameters. An S/N ratio analysis and contour plots were applied to analyze the influence of each decision variable on the optimization objective. Finally, the changing rules of a single factor for each objective were analyzed. The results demonstrate that the proposed method is effective in finding the trade-off among the three objectives and obtaining reasonable application ranges of the cutting parameters from Pareto fronts.
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https://cjme.springeropen.com/articles/10.1186/s10033-019-0408-9
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Zhipeng Jiang, Dong Gao, Yong Lu, et al. Optimization of Cutting Parameters for Trade-off Among Carbon Emissions, Surface Roughness, and Processing Time. Chinese Journal of Mechanical Engineering, 2019, 32: 94.
DOI：10.1186/s10033-019-0406-y
Present Status and Prospect of High-Frequency Electro-hydraulic Vibration Control Technology
Yi Liu, Tao Wang, Guofang Gong & Rujun Gao
Abstract：Electro-hydraulic vibration equipment (EHVE) is widely used in vibration environment simulation tests, such as vehicles, weapons, ships, aerospace, nuclear industries and seismic waves replication, etc., due to its large output power, displacement and thrust, as well as good workload adaptation and multi-controllable parameters. Based on the domestic and overseas development of high-frequency EHVE, dividing them into servo-valve controlled vibration equipment and rotary-valve controlled vibration equipment. The research status and progress of high-frequency electro-hydraulic vibration control technology (EHVCT) are discussed, from the perspective of vibration waveform control and vibration controller. The problems of current electro-hydraulic vibration system bandwidth and waveform distortion control, stability control, offset control and complex vibration waveform generation in high-frequency vibration conditions are pointed out. Combining the existing rotary-valve controlled high-frequency electro-hydraulic vibration method, a new twin-valve independently controlled high-frequency electro-hydraulic vibration method is proposed to break through the limitations of current electro-hydraulic vibration technology in terms of system frequency bandwidth and waveform distortion. The new method can realize independent adjustment and control of vibration waveform frequency, amplitude and offset under high-frequency vibration conditions, and provide a new idea for accurate simulation of high-frequency vibration waveform.
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https://cjme.springeropen.com/articles/10.1186/s10033-019-0406-y
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Yi Liu, Tao Wang, Guofang Gong, et al. Present Status and Prospect of High-Frequency Electro-hydraulic Vibration Control Technology. Chinese Journal of Mechanical Engineering, 2019, 32: 93.
DOI：10.1186/s10033-019-0405-z
Microstructure and Mechanical Properties of Wire + Arc Additively Manufactured 2050 Al–Li Alloy Wall Deposits
Hao Zhong, Bojin Qi, Baoqiang Cong, Zewu Qi & Hongye Sun
Abstract：Aluminum–Lithium (Al–Li) alloy is a topic of great interest owing to its high strength and light weight, but there are only a few applications of Al–Li alloy in wire + arc additive manufacturing (WAAM) process. To identify its feasibility in WAAM process, a special AA2050 Al–Li alloy wire was produced and employed in the production of straight-walled components, using a WAAM system based on variable polarity gas tungsten arc welding (VP-GTAW) process. The influence of post-deposited heat treatment on the microstructure and property of the deposit was investigated using optical micrographs (OM), scanning electron microscopy (SEM), X-ray diffraction (XRD), hardness and tensile properties tests. Results revealed that the microstructures of AA2050 aluminum deposits varied with their location layers. The upper layers consisted of fine equiaxed grains, while the bottom layer exhibited a coarse columnar structure. Mechanical properties witnessed a significant improvement after post-deposited heat treatment, with the average micro-hardness reaching 141HV and the ultimate tensile strength exceeding 400 MPa. Fracture morphology exhibited a typical ductile fracture.
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https://cjme.springeropen.com/articles/10.1186/s10033-019-0405-z
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Hao Zhong, Bojin Qi, Baoqiang Cong, et al. Microstructure and Mechanical Properties of Wire + Arc Additively Manufactured 2050 Al–Li Alloy Wall Deposits. Chinese Journal of Mechanical Engineering, 2019, 32: 92.
DOI：10.1186/s10033-019-0407-x
Surface Texture Analysis after Hydrostatic Burnishing on X38CrMoV5-1 Steel
Slawomir Swirad
Abstract：Ball burnishing is a plastic deformation process used as a surface smoothing and surface improvement finishing treatment after turning or milling processes. This process changes the surface stereometrics of the previously machining surface. Burnishing with hydrostatic tools can be easily and effectively used on both conventional and Computer Numeric Control (CNC) machines. The existing research of the burnishing process mainly focuses on the functional surface characterization, for example, surface roughness, wear resistance, surface layer hardness, etc. There is a lack of references reporting a detailed analysis of 3D parameters calculation with a mathematical model to evaluate the results of the ball burnishing. This paper presents the effect of ball burnishing process parameters with hydrostatic tools on the resulting surface structure geometry. The surface topography parameters were calculated using the TalyMap software. Studies were conducted based on Hartley’s static, determined plan. Such a plan can be built on a hypersphere or hypercube. In this work, a hypercube was used. In the case of Hartley’s plan makes it possible to define the regression equation in the form of a polynomial of the second degree. The input process parameters considered in this study include the burnishing rate, applied pressure, and line-to-line pitch. The significant influence of these parameters was confirmed and described as a mathematical power model. The results also showed a positive effect of hydrostatic burnishing on the roughness and geometric structure of the surface.
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https://cjme.springeropen.com/articles/10.1186/s10033-019-0407-x
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Slawomir Swirad. Surface Texture Analysis after Hydrostatic Burnishing on X38CrMoV5-1 Steel. Chinese Journal of Mechanical Engineering, 2019, 32: 91.
DOI：10.1186/s10033-019-0404-0
An Improved Measurement Uncertainty Calculation Method of Profile Error for Sculptured Surfaces
Chenhui Liu, Zhanjie Song, Yicun Sang & Gaiyun He
Abstract：The current researches mainly adopt “Guide to the expression of uncertainty in measurement (GUM)” to calculate the profile error. However, GUM can only be applied in the linear models. The standard GUM is not appropriate to calculate the uncertainty of profile error because the mathematical model of profile error is strongly non-linear. An improved second-order GUM method (GUMM) is proposed to calculate the uncertainty. At the same time, the uncertainties in different coordinate axes directions are calculated as the measuring points uncertainties. In addition, the correlations between variables could not be ignored while calculating the uncertainty. A k-factor conversion method is proposed to calculate the converge factor due to the unknown and asymmetrical distribution of the output quantity. Subsequently, the adaptive Monte Carlo method (AMCM) is used to evaluate whether the second-order GUMM is better. Two practical examples are listed and the conclusion is drawn by comparing and discussing the second-order GUMM and AMCM. The results show that the difference between the improved second-order GUM and the AMCM is smaller than the difference between the standard GUM and the AMCM. The improved second-order GUMM is more precise in consideration of the nonlinear mathematical model of profile error.
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https://cjme.springeropen.com/articles/10.1186/s10033-019-0404-0
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Chenhui Liu, Zhanjie Song, Yicun Sang, et al. An Improved Measurement Uncertainty Calculation Method of Profile Error for Sculptured Surfaces. Chinese Journal of Mechanical Engineering, 2019, 32: 90.
DOI：10.1186/s10033-019-0403-1
Type Synthesis of 1T2R Parallel Mechanisms Using Structure Coupling-Reducing Method
Haitao Liu, Ke Xu, Huiping Shen, Xianlei Shan & Tingli Yang
Abstract：Direct kinematics with analytic solutions is critical to the real-time control of parallel mechanisms. Therefore, the type synthesis of a mechanism having explicit form of forward kinematics has become a topic of interest. Based on this purpose, this paper deals with the type synthesis of 1T2R parallel mechanisms by investigating the topological structure coupling-reducing of the 3UPS&UP parallel mechanism. With the aid of the theory of mechanism topology, the analysis of the topological characteristics of the 3UPS&UP parallel mechanism is presented, which shows that there are highly coupled motions and constraints amongst the limbs of the mechanism. Three methods for structure coupling-reducing of the 3UPS&UP parallel mechanism are proposed, resulting in eight new types of 1T2R parallel mechanisms with one or zero coupling degree. One obtained parallel mechanism is taken as an example to demonstrate that a mechanism with zero coupling degree has an explicit form for forward kinematics. The process of type synthesis is in the order of permutation and combination; therefore, there are no omissions. This method is also applicable to other configurations, and novel topological structures having simple forward kinematics can be obtained from an original mechanism via this method.
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https://cjme.springeropen.com/articles/10.1186/s10033-019-0403-1
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Haitao Liu, Ke Xu, Huiping Shen, et al. Type Synthesis of 1T2R Parallel Mechanisms Using Structure Coupling-Reducing Method. Chinese Journal of Mechanical Engineering, 2019, 32: 89.
DOI：10.1186/s10033-019-0399-6
Train Vehicle Structure Design from the Perspective of Evacuation
Hanzhao Qiu & Weining Fang
Abstract：The safety of trains, a highly efficient mode of transportation, has attracted significant attention. In the vehicle structure design of a train, the evaluation of the passenger evacuation time is necessary. The establishment of a simulation model is the fastest, most convenient, and practical way to achieve this goal. However, few scholars have focused on the reliability of a passenger train evacuation simulation model. This paper proposes a new validation method based on dynamic time warping and multidimensional scaling. The proposed method validates the dynamic process of a simulation model, provides statistical results, and can be used for small-sample scenarios such as a train evacuation scenario. The results of a case study indicate that the proposed method is an effective and quantitative approach to the validation of simulation models in a dynamic process. Thus, this paper describes the influence of the train structure size on an evacuation based on the results of simulation experiments. The structural size factors include the door width, aisle width, and seat pitch. The experiment results indicate that a wide aisle and reasonable seat pitch can promote a proper evacuation. In addition, a normal train door width has no effect on an evacuation.
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https://cjme.springeropen.com/articles/10.1186/s10033-019-0399-6
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Hanzhao Qiu, Weining Fang. Train Vehicle Structure Design from the Perspective of Evacuation. Chinese Journal of Mechanical Engineering, 2019, 32: 88.
DOI：10.1186/s10033-019-0398-7
Corner Transition Toolpath Generation Based on Velocity-Blending Algorithm for Glass Edge Grinding
Kun Ren, Yujia Pan, Danyan Jiang, Jun Pan, Wenhua Chen & Xuxiao Hu
Abstract：Sharp corners usually are used on glass contours to meet the highly increasing demand for personalized products, but they result in a broken wheel center toolpath in edge grinding. To ensure that the whole wheel center toolpath is of G1 continuity and that the grinding depth is controllable at the corners, a transition toolpath generation method based on a velocity-blending algorithm is proposed. Taking the grinding depth into consideration, the sharp-corner grinding process is planned, and a velocity-blending algorithm is introduced. With the constraints, such as traverse displacement and grinding depth, the sharp-corner transition toolpath is generated with a three-phase motion arrangement and with confirmations of the acceleration/deceleration positions. A piece of glass with three sharp corners is ground on a three-axis numerical-control glass grinding equipment. The experimental results demonstrate that the proposed algorithm can protect the sharp corners from breakage efficiently and achieve satisfactory shape accuracy. This research proposed a toolpath generation method based on a velocity-blending algorithm for the manufacturing of personalized glass products, which generates the transition toolpath as needed around a sharp corner in real time.
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https://cjme.springeropen.com/articles/10.1186/s10033-019-0398-7
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Kun Ren, Yujia Pan, Danyan Jiang, et al. Corner Transition Toolpath Generation Based on Velocity-Blending Algorithm for Glass Edge Grinding. Chinese Journal of Mechanical Engineering, 2019, 32: 87.
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