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Determination of the feasible setup parameters of a workpiece to maximize the utilization of a five-axis

Aqeel AHMED, Muhammad WASIF, Anis FATIMA, Liming WANG, Syed Amir IQBAL

《机械工程前沿（英文）》 2021年 第16卷 第2期   页码 298-314 doi: 10.1007/s11465-020-0621-3

摘要： The machining industry must maximize the machine tool utilization for its efficient and effective usage. Determining a feasible workpiece location is one of the significant tasks performed in an iterative way via machining simulations. The maximum utilization of five-axis machine tools depends upon the cutting system’s geometry, the configuration of the machine tool, and the workpiece’s location. In this research, a mathematical model has been developed to determine the workpiece’s feasible location in the five-axis machine tool for avoiding the number of iterations, which are usually performed to eliminate the global collision and axis limit errors. In this research, a generic arrangement of the five-axis machine tool has been selected. The mathematical model of post-processor has been developed by using kinematic modeling methods. The machine tool envelopes have been determined using the post-processor and axial limit. The tooltip reachable workspace is determined by incorporating the post-processor, optimal cutting system length, and machining envelope, thereby further developing an algorithm to determine the feasible workpiece setup parameters accurately. The algorithm’s application has been demonstrated using an example. Finally, the algorithm is validated for feasible workpiece setup parameters in a virtual environment. This research is highly applicable in the industry to eliminate the number of iterations performed for the suitable workpiece setup parameters.

关键词： workpiece setup parameter     five-axis     space utilization     setup parameters     machine tool    

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of dispatching rules in a stochastic dynamic job shop manufacturing system with sequence-dependent setup

Pankaj SHARMA,Ajai JAIN

《机械工程前沿（英文）》 2014年 第9卷 第4期   页码 380-389 doi: 10.1007/s11465-014-0315-9

摘要：

Stochastic dynamic job shop scheduling problem with consideration of sequence-dependent setup times are among the most difficult classes of scheduling problems. This paper assesses the performance of nine dispatching rules in such shop from makespan, mean flow time, maximum flow time, mean tardiness, maximum tardiness, number of tardy jobs, total setups and mean setup time performance measures viewpoint. A discrete event simulation model of a stochastic dynamic job shop manufacturing system is developed for investigation purpose. Nine dispatching rules identified from literature are incorporated in the simulation model. The simulation experiments are conducted under due date tightness factor of 3, shop utilization percentage of 90 % and setup times less than processing times. Results indicate that shortest setup time (SIMSET) rule provides the best performance for mean flow time and number of tardy jobs measures. The job with similar setup and modified earliest due date (JMEDD) rule provides the best performance for makespan, maximum flow time, mean tardiness, maximum tardiness, total setups and mean setup time measures.

关键词： scheduling     stochastic dynamic job shop     sequence-dependent setup times     dispatching rule     simulation    

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Finite element model updating of a large structure using multi-setup stochastic subspace identification

Reza KHADEMI-ZAHEDI, Pouyan ALIMOURI

《结构与土木工程前沿（英文）》 2019年 第13卷 第4期   页码 965-980 doi: 10.1007/s11709-019-0530-x

摘要： In the present contribution, operational modal analysis in conjunction with bees optimization algorithm are utilized to update the finite element model of a solar power plant structure. The physical parameters which required to be updated are uncertain parameters including geometry, material properties and boundary conditions of the aforementioned structure. To determine these uncertain parameters, local and global sensitivity analyses are performed to increase the solution accuracy. An objective function is determined using the sum of the squared errors between the natural frequencies calculated by finite element method and operational modal analysis, which is optimized using bees optimization algorithm. The natural frequencies of the solar power plant structure are estimated by multi-setup stochastic subspace identification method which is considered as a strong and efficient method in operational modal analysis. The proposed algorithm is efficiently implemented on the solar power plant structure located in Shahid Chamran university of Ahvaz, Iran, to update parameters of its finite element model. Moreover, computed natural frequencies by numerical method are compared with those of the operational modal analysis. The results indicate that, bees optimization algorithm leads accurate results with fast convergence.

关键词： operational modal analysis     solar power plant structure     multi-setup stochastic subspace     bees optimization algorithm     sensitivity analysis    

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Relative vibration identification of cutter and workpiece based on improved bidimensional empirical mode

Jiasheng LI, Xingzhan LI, Wei WEI, Pinkuan LIU

《机械工程前沿（英文）》 2020年 第15卷 第2期   页码 227-239 doi: 10.1007/s11465-020-0587-1

摘要： In the process of cutting, the relative vibration between the cutter and the workpiece has an important effect on the surface topography. In this study, the bidimensional empirical mode decomposition (BEMD) method is used to identify such effect. According to Riesz transform theory, a type of isotropic monogenic signal is proposed. The boundary data is extended on the basis of a similarity principle that deals with serious boundary effect problem. The decomposition examples show that the improved BEMD can effectively solve the problem of boundary effect and decompose the original machined surface topography at multiple scales. The characteristic surface topography representing the relative vibration between the cutter and the workpiece through feature identification is selected. In addition, the spatial spectrum analysis of the extracted profile is carried out. The decimal part of the frequency ratio that has an important effect on the shape of the contour can be accurately identified through contour extraction and spatial spectrum analysis. The decomposition results of simulation and experimental surface morphology demonstrate the validity of the improved BEMD algorithm in realizing the relative vibration identification between the cutter and the workpiece.

关键词： bidimensional empirical mode decomposition     spatial spectrum analysis     boundary effect     vibration identification     surface topography    

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surface roughness prediction method considering compensated acceleration in milling of thin-walled workpiece

《机械工程前沿（英文）》 2021年 第16卷 第4期   页码 855-867 doi: 10.1007/s11465-021-0649-z

摘要： Machined surface roughness will affect parts’ service performance. Thus, predicting it in the machining is important to avoid rejects. Surface roughness will be affected by system position dependent vibration even under constant parameter with certain toolpath processing in the finishing. Aiming at surface roughness prediction in the machining process, this paper proposes a position-varying surface roughness prediction method based on compensated acceleration by using regression analysis. To reduce the stochastic error of measuring the machined surface profile height, the surface area is repeatedly measured three times, and Pauta criterion is adopted to eliminate abnormal points. The actual vibration state at any processing position is obtained through the single-point monitoring acceleration compensation model. Seven acceleration features are extracted, and valley, which has the highest R-square proving the effectiveness of the filtering features, is selected as the input of the prediction model by mutual information coefficients. Finally, by comparing the measured and predicted surface roughness curves, they have the same trends, with the average error of 16.28% and the minimum error of 0.16%. Moreover, the prediction curve matches and agrees well with the actual surface state, which verifies the accuracy and reliability of the model.

关键词： surface roughness prediction     compensated acceleration     milling     thin-walled workpiece    

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Ultrasonic assisted EDM: Effect of the workpiece vibration in the machining characteristics of FW4 Welded

Mohammadreza SHABGARD, Hamed KAKOLVAND, Mirsadegh SEYEDZAVVAR, Ramin Mohammadpour SHOTORBANI

《机械工程前沿（英文）》 2011年 第6卷 第4期   页码 419-428 doi: 10.1007/s11465-011-0246-7

摘要：

This paper presents the results of experimental studies carried out to conduct a comprehensive investigation on the influence of ultrasonic vibration of workpiece on the characteristics of Electrical Discharge Machining (EDM) process of FW4 Welding Metal in comparison with the conventional EDM process. The studied process characteristics included the material removal rate (MRR), tool wear ratio (TWR), and surface roughness (Ra and Rmax) of the workpiece after the EDM and ultrasonic assisted EDM (US-EDM) processes. The experiments performed under the designed full factorial procedure and the considered EDM input parameters included pulse on-time and pulse current. The experimental results show that in short pulse on-times, material removal rate in the US-EDM process is approximately quadruple than that of the EDM process. On the contrary, in the long pulse on-times, ultrasonic vibration of work??piece leads to the reduction in the MRR. On the other hand, in short pulse on-times, the TWR in the US-EDM process is lower than that of in the EDM process, and this condition reverses with increase in the pulse on-time. Furthermore, the surface roughness of the workpiece machined by EDM process is slightly lower than that of applied to the US-EDM process.

关键词： electrical discharge machining (EDM)     material removal rate (MRR)     tool wear ratio (TWR)     surface roughness    

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Processing parameter optimization of fiber laser beam welding using an ensemble of metamodels and MOABC

《机械工程前沿（英文）》 2022年 第17卷 第4期 doi: 10.1007/s11465-022-0703-5

摘要： In fiber laser beam welding (LBW), the selection of optimal processing parameters is challenging and plays a key role in improving the bead geometry and welding quality. This study proposes a multi-objective optimization framework by combining an ensemble of metamodels (EMs) with the multi-objective artificial bee colony algorithm (MOABC) to identify the optimal welding parameters. An inverse proportional weighting method that considers the leave-one-out prediction error is presented to construct EM, which incorporates the competitive strengths of three metamodels. EM constructs the correlation between processing parameters (laser power, welding speed, and distance defocus) and bead geometries (bead width, depth of penetration, neck width, and neck depth) with average errors of 10.95%, 7.04%, 7.63%, and 8.62%, respectively. On the basis of EM, MOABC is employed to approximate the Pareto front, and verification experiments show that the relative errors are less than 14.67%. Furthermore, the main effect and the interaction effect of processing parameters on bead geometries are studied. Results demonstrate that the proposed EM-MOABC is effective in guiding actual fiber LBW applications.

关键词： laser beam welding     parameter optimization     metamodel     multi-objective    

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Determination of effective stress parameter of unsaturated soils: A Gaussian process regression approach

Pijush Samui, Jagan J

《结构与土木工程前沿（英文）》 2013年 第7卷 第2期   页码 133-136 doi: 10.1007/s11709-013-0202-1

摘要： This article examines the capability of Gaussian process regression (GPR) for prediction of effective stress parameter ( ) of unsaturated soil. GPR method proceeds by parameterising a covariance function, and then infers the parameters given the data set. Input variables of GPR are net confining pressure ( ), saturated volumetric water content ( ), residual water content ( ), bubbling pressure ( ), suction ( ) and fitting parameter ( ). A comparative study has been carried out between the developed GPR and Artificial Neural Network (ANN) models. A sensitivity analysis has been done to determine the effect of each input parameter on . The developed GPR gives the variance of predicted . The results show that the developed GPR is reliable model for prediction of of unsaturated soil.

关键词： unsaturated soil     effective stress parameter     Gaussian process regression (GPR)     artificial neural network (ANN)     variance    

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1000 MW ultra-supercritical turbine steam parameter optimization

FENG Weizhong

《能源前沿（英文）》 2008年 第2卷 第2期   页码 187-193 doi: 10.1007/s11708-008-0030-5

摘要： The 2 × 1000 MW ultra-supercritical steam turbine of Shanghai Waigaoqiao Phase III project, which uses grid frequency regulation and overload control through an overload valve, is manufactured by Shanghai Turbine Company using Siemens technology. Through optimization, the steam pressure is regarded as the criterion between constant pressure and sliding pressure operation. At high circulating water temperature, the turbine overload valve is kept closed when the unit load is lower than 1000 MW while at other circulating water temperatures the turbine can run in sliding pressure operation when the unit load is higher than 1000 MW and the pressure is lower than 27 MPa This increases the unit operation efficiency. The 3D bending technology in the critical piping helps to reduce the project investment and minimize the reheat system pressure drop which improves the unit operation efficiency and safety. By choosing lower circulating water design temperature and by setting the individual Boiler Feedwater Turbine condenser to reduce the exhaust steam flow and the heat load to the main condenser, the unit average back pressure and the terminal temperature difference are minimized. Therefore, the unit heat efficiency is increased.
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Structural parameter design method for a fast-steering mirror based on a closed-loop bandwidth

Guozhen CHEN, Pinkuan LIU, Han DING

《机械工程前沿（英文）》 2020年 第15卷 第1期   页码 55-65 doi: 10.1007/s11465-019-0545-y

摘要： When a fast-steering mirror (FSM) system is designed, satisfying the performance requirements before fabrication and assembly is vital. This study proposes a structural parameter design approach for an FSM system based on the quantitative analysis of the required closed-loop bandwidth. First, the open-loop transfer function of the FSM system is derived. In accordance with the transfer function, the notch filter and proportional-integral (PI) feedback controller are designed as a closed-loop controller. The gains of the PI controller are determined by maximizing the closed-loop bandwidth while ensuring the robustness of the system. Then, the two unknown variables of rotational radius and stiffness in the open-loop transfer function are optimized, considering the bandwidth as a constraint condition. Finally, the structural parameters of the stage are determined on the basis of the optimized results of rotational radius and stiffness. Simulations are conducted to verify the theoretical analysis. A prototype of the FSM system is fabricated, and corresponding experimental tests are conducted. Experimental results indicate that the bandwidth of the proposed FSM system is 117.6 Hz, which satisfies the minimum bandwidth requirement of 100 Hz.

关键词： fast-steering mirror     structural parameter     PI controller     bandwidth     notch filter    

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Energy efficient cutting parameter optimization

Xingzheng CHEN, Congbo LI, Ying TANG, Li LI, Hongcheng LI

《机械工程前沿（英文）》 2021年 第16卷 第2期   页码 221-248 doi: 10.1007/s11465-020-0627-x

摘要： Mechanical manufacturing industry consumes substantial energy with low energy efficiency. Increasing pressures from energy price and environmental directive force mechanical manufacturing industries to implement energy efficient technologies for reducing energy consumption and improving energy efficiency of their machining processes. In a practical machining process, cutting parameters are vital variables set by manufacturers in accordance with machining requirements of workpiece and machining condition. Proper selection of cutting parameters with energy consideration can effectively reduce energy consumption and improve energy efficiency of the machining process. Over the past 10 years, many researchers have been engaged in energy efficient cutting parameter optimization, and a large amount of literature have been published. This paper conducts a comprehensive literature review of current studies on energy efficient cutting parameter optimization to fully understand the recent advances in this research area. The energy consumption characteristics of machining process are analyzed by decomposing total energy consumption into electrical energy consumption of machine tool and embodied energy of cutting tool and cutting fluid. Current studies on energy efficient cutting parameter optimization by using experimental design method and energy models are reviewed in a comprehensive manner. Combined with the current status, future research directions of energy efficient cutting parameter optimization are presented.

关键词： energy efficiency     cutting parameter     optimization     machining process    

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Hierarchical parameter estimation of DFIG and drive train system in a wind turbine generator

Xueping PAN, Ping JU, Feng WU, Yuqing JIN

《机械工程前沿（英文）》 2017年 第12卷 第3期   页码 367-376 doi: 10.1007/s11465-017-0429-y

摘要：

A new hierarchical parameter estimation method for doubly fed induction generator (DFIG) and drive train system in a wind turbine generator (WTG) is proposed in this paper. Firstly, the parameters of the DFIG and the drive train are estimated locally under different types of disturbances. Secondly, a coordination estimation method is further applied to identify the parameters of the DFIG and the drive train simultaneously with the purpose of attaining the global optimal estimation results. The main benefit of the proposed scheme is the improved estimation accuracy. Estimation results confirm the applicability of the proposed estimation technique.

关键词： wind turbine generator     DFIG     drive train system     hierarchical parameter estimation method     trajectory sensitivity technique    

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Variational mode decomposition based modal parameter identification in civil engineering

Mingjie ZHANG, Fuyou XU

《结构与土木工程前沿（英文）》 2019年 第13卷 第5期   页码 1082-1094 doi: 10.1007/s11709-019-0537-3

摘要： An out-put only modal parameter identification method based on variational mode decomposition (VMD) is developed for civil structure identifications. The recently developed VMD technique is utilized to decompose the free decay response (FDR) of a structure into to modal responses. A novel procedure is developed to calculate the instantaneous modal frequencies and instantaneous modal damping ratios. The proposed identification method can straightforwardly extract the mode shape vectors using the modal responses extracted from the FDRs at all available sensors on the structure. A series of numerical and experimental case studies are conducted to demonstrate the efficiency and highlight the superiority of the proposed method in modal parameter identification using both free vibration and ambient vibration data. The results of the present method are compared with those of the empirical mode decomposition-based method, and the superiorities of the present method are verified. The proposed method is proved to be efficient and accurate in modal parameter identification for both linear and nonlinear civil structures, including structures with closely spaced modes, sudden modal parameter variation, and amplitude-dependent modal parameters, etc.

关键词： modal parameter identification     variational mode decomposition     civil structure     nonlinear system     closely spaced modes    

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Shallow foundation response variability due to soil and model parameter uncertainty

Prishati RAYCHOWDHURY,Sumit JINDAL

《结构与土木工程前沿（英文）》 2014年 第8卷 第3期   页码 237-251 doi: 10.1007/s11709-014-0242-1

摘要： Geotechnical uncertainties may play crucial role in response prediction of a structure with substantial soil-foundation-structure-interaction (SFSI) effects. Since the behavior of a soil-foundation system may significantly alter the response of the structure supported by it, and consequently several design decisions, it is extremely important to identify and characterize the relevant parameters. Moreover, the modeling approach and the parameters required for the modeling are also critically important for the response prediction. The present work intends to investigate the effect of soil and model parameter uncertainty on the response of shallow foundation-structure systems resting on dry dense sand. The SFSI is modeled using a beam-on-nonlinear-winkler-foundation (BNWF) concept, where soil beneath the foundation is assumed to be an assembly of discrete, nonlinear elements composed of springs, dashpots and gap elements. The sensitivity of both soil and model input parameters on shallow foundation responses are investigated using first-order second-moment (FOSM) analysis and Monte Carlo simulation through Latin hypercube sampling technique. It has been observed that the degree of accuracy in predicting the responses of the shallow foundation is highly sensitive soil parameters, such as friction angle, Poisson’s ratio and shear modulus, rather than model parameters, such as stiffness intensity ratio and spring spacing; indicating the importance of proper characterization of soil parameters for reliable soil-foundation response analysis.

关键词： shallow foun dation     sensitivity analysis     centrifuge data     first-order-second-moment (FOSM) method     parameter uncertainty    

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Parameter studies on impact in a lap joint

Amir M. RAHMANI,Elizabeth K. ERVIN

《机械工程前沿（英文）》 2015年 第10卷 第1期   页码 64-77 doi: 10.1007/s11465-014-0322-x

摘要：

To represent a loose lap joint, a beam impacting four springs with gaps is modeled. Modal analysis with base excitation is solved, and time histories of contact points are closely monitored. Using the impulse during steady state response, six influential parameters are studied: damping ratio, contact stiffness, intermediate contact position, gap, excitation amplitude and beam height. For all parameters, the system response is highly controlled by modes with two contacting springs. Each parameter’s effect on system response is presented including unstable regions, unique trend behaviours result. Recommendations for structural designers are also noted.

关键词： impact mechanics     contact     joint behaviour     modal analysis     parameter study    

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标题 作者 时间 类型 操作

Determination of the feasible setup parameters of a workpiece to maximize the utilization of a five-axis

Aqeel AHMED, Muhammad WASIF, Anis FATIMA, Liming WANG, Syed Amir IQBAL

期刊论文

of dispatching rules in a stochastic dynamic job shop manufacturing system with sequence-dependent setup

Pankaj SHARMA,Ajai JAIN

期刊论文

Finite element model updating of a large structure using multi-setup stochastic subspace identification

Reza KHADEMI-ZAHEDI, Pouyan ALIMOURI

期刊论文

Relative vibration identification of cutter and workpiece based on improved bidimensional empirical mode

Jiasheng LI, Xingzhan LI, Wei WEI, Pinkuan LIU

期刊论文

surface roughness prediction method considering compensated acceleration in milling of thin-walled workpiece

期刊论文

Ultrasonic assisted EDM: Effect of the workpiece vibration in the machining characteristics of FW4 Welded

Mohammadreza SHABGARD, Hamed KAKOLVAND, Mirsadegh SEYEDZAVVAR, Ramin Mohammadpour SHOTORBANI

期刊论文

Processing parameter optimization of fiber laser beam welding using an ensemble of metamodels and MOABC

期刊论文

Determination of effective stress parameter of unsaturated soils: A Gaussian process regression approach

Pijush Samui, Jagan J

期刊论文

1000 MW ultra-supercritical turbine steam parameter optimization

FENG Weizhong

期刊论文

Structural parameter design method for a fast-steering mirror based on a closed-loop bandwidth

Guozhen CHEN, Pinkuan LIU, Han DING

期刊论文

Energy efficient cutting parameter optimization

Xingzheng CHEN, Congbo LI, Ying TANG, Li LI, Hongcheng LI

期刊论文

Hierarchical parameter estimation of DFIG and drive train system in a wind turbine generator

Xueping PAN, Ping JU, Feng WU, Yuqing JIN

期刊论文

Variational mode decomposition based modal parameter identification in civil engineering

Mingjie ZHANG, Fuyou XU

期刊论文

Shallow foundation response variability due to soil and model parameter uncertainty

Prishati RAYCHOWDHURY,Sumit JINDAL

期刊论文

Parameter studies on impact in a lap joint

Amir M. RAHMANI,Elizabeth K. ERVIN

期刊论文