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Surface accuracy optimization of mechanical parts with multiple circular holes for additive manufacturing

Jinghua XU, Hongsheng SHENG, Shuyou ZHANG, Jianrong TAN, Jinlian DENG

《机械工程前沿（英文）》 2021年 第16卷 第1期   页码 133-150 doi: 10.1007/s11465-020-0610-6

摘要： Surface accuracy directly affects the surface quality and performance of mechanical parts. Circular hole, especially spatial non-planar hole set is the typical feature and working surface of mechanical parts. Compared with traditional machining methods, additive manufacturing (AM) technology can decrease the surface accuracy errors of circular holes during fabrication. However, an accuracy error may still exist on the surface of circular holes fabricated by AM due to the influence of staircase effect. This study proposes a surface accuracy optimization approach for mechanical parts with multiple circular holes for AM based on triangular fuzzy number (TFN). First, the feature lines on the manifold mesh are extracted using the dihedral angle method and normal tensor voting to detect the circular holes. Second, the optimal AM part build orientation is determined using the genetic algorithm to optimize the surface accuracy of the circular holes by minimizing the weighted volumetric error of the part. Third, the corresponding weights of the circular holes are calculated with the TFN analytic hierarchy process in accordance with the surface accuracy requirements. Lastly, an improved adaptive slicing algorithm is utilized to reduce the entire build time while maintaining the forming surface accuracy of the circular holes using digital twins via virtual printing. The effectiveness of the proposed approach is experimentally validated using two mechanical models.

关键词： surface accuracy optimization     multiple circular holes     additive manufacturing (AM)     part build orientation     triangular fuzzy number (TFN)     digital twins    

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Impact of crude distillation unit model accuracy on refinery production planning

Gang FU, Pedro A. Castillo CASTILLO, Vladimir MAHALEC

《工程管理前沿（英文）》 2018年 第5卷 第2期   页码 195-201 doi: 10.15302/J-FEM-2017052

摘要： In this work, we examine the impact of crude distillation unit (CDU) model errors on the results of refinery-wide optimization for production planning or feedstock selection. We compare the swing cut+ bias CDU model with a recently developed hybrid CDU model (Fu et al., 2016). The hybrid CDU model computes material and energy balances, as well as product true boiling point (TBP) curves and bulk properties (e.g., sulfur % and cetane index, and other properties). Product TBP curves are predicted with an average error of 0.5% against rigorous simulation curves. Case studies of optimal operation computed using a planning model that is based on the swing cut+ bias CDU model and using a planning model that incorporates the hybrid CDU model are presented. Our results show that significant economic benefits can be obtained using accurate CDU models in refinery production planning.

关键词： impact of model accuracy on production planning     swing cut+ bias CDU model     hybrid CDU model     refinery feedstock selection optimization     optimization of refinery operation    

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Multi-objective optimization of surface texture for the slipperswash plate interface in EHA pumps

《机械工程前沿（英文）》 2022年 第17卷 第4期 doi: 10.1007/s11465-022-0704-4

摘要： Well-designed surface textures can improve the tribological properties and the efficiency of the electro-hydrostatic actuator (EHA) pump under high-speed and high-pressure conditions. This study proposes a multi-objective optimization model to obtain the arbitrarily surface textures design of the slipper/swash plate interface for improving the mechanical and volumetric efficiency of the EHA pump. The model is composed of the lubrication film model, the component dynamic model considering the spinning motion, and the multi-objective optimization model. In this way, the arbitrary-shaped surface texture with the best comprehensive effect in the EHA pump is achieved and its positive effects in the EHA pump prototype are verified. Experimental results show a reduction in wear and an improvement in mechanical and volumetric efficiency by 1.4% and 0.8%, respectively, with the textured swash plate compared with the untextured one.

关键词： electro-hydrostatic actuator     axial piston pump     slipper/swash plate interface     multi-objective optimization     surface texture    

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Coal-based activated carbon prepared by HO activation process for supercapacitors using response surfaceoptimization method

《化学科学与工程前沿（英文）》 2024年 第18卷 第6期 doi: 10.1007/s11705-024-2422-4

摘要： The scalable production of high grade activated carbon from abundant coal for supercapacitors application is an efficient way to achieve high value-added utilization of coal sources. However, this technology is challenging due to lack of comprehensive understanding on the mechanism of activation process and effect of external factors. In this paper, the effect of activating temperature and time on the specific capacitance of coal-based activated carbon prepared by H2O steam activation was studied using the response surface method. Under optimal conditions, coal-based activated carbon exhibits the largest specific capacitance of 194.35 F·g–1, thanks to the appropriate pore/surface structure and defect degree. Density functional theory calculations explain in detail the mechanism of contraction of aromatic rings and overflow of H2 and CO during the activation. Meanwhile, oxygen-containing functional groups are introduced, contributing to the pseudocapacitance property of coal-based activated carbon. This mechanism of reactions between aromatic carbon and H2O vapor provides understanding on the role of water during coal processing at the molecular level, offering great potential to regulate product distribution and predict rate of pore generation. This insight would contribute to the advancement of other coal processing technology such as gasification.

关键词： response surface optimization     coal-based activated carbon     supercapacitor     activating mechanism    

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XFEM schemes for level set based structural optimization

Li LI, Michael Yu WANG, Peng WEI

《机械工程前沿（英文）》 2012年 第7卷 第4期   页码 335-356 doi: 10.1007/s11465-012-0351-2

摘要：

In this paper, some elegant extended finite element method (XFEM) schemes for level set method structural optimization are proposed. Firstly, two- dimension (2D) and three-dimension (3D) XFEM schemes with partition integral method are developed and numerical examples are employed to evaluate their accuracy, which indicate that an accurate analysis result can be obtained on the structural boundary. Furthermore, the methods for improving the computational accuracy and efficiency of XFEM are studied, which include the XFEM integral scheme without quadrature sub-cells and higher order element XFEM scheme. Numerical examples show that the XFEM scheme without quadrature sub-cells can yield similar accuracy of structural analysis while prominently reducing the time cost and that higher order XFEM elements can improve the computational accuracy of structural analysis in the boundary elements, but the time cost is increasing. Therefore, the balance of time cost between FE system scale and the order of element needs to be discussed. Finally, the reliability and advantages of the proposed XFEM schemes are illustrated with several 2D and 3D mean compliance minimization examples that are widely used in the recent literature of structural topology optimization. All numerical results demonstrate that the proposed XFEM is a promising structural analysis approach for structural optimization with the level set method.

关键词： structural optimization     level set method     extended finite element method (XFEM)     computational accuracy and efficiency    

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Development of a combined approach for improvement and optimization of karanja biodiesel using responsesurface methodology and genetic algorithm

Sunil DHINGRA, Gian BHUSHAN, Kashyap Kumar DUBEY

《能源前沿（英文）》 2013年 第7卷 第4期   页码 495-505 doi: 10.1007/s11708-013-0267-5

摘要： This paper described the production of karanja biodiesel using response surface methodology (RSM) and genetic algorithm (GA). The optimum combination of reaction variables were analyzed for maximizing the biodiesel yield. The yield obtained by the RSM was 65% whereas the predicted value was 70%. The mathematical regression model proposed from the RSM was coupled with the GA. By using this technique, 90% of the yield was obtained at a molar ratio of 38, a reaction time of 8 hours, a reaction temperature of 40 oC, a catalyst concentration of 2% oil, and a mixing speed of 707 r/min. The yield produced was closer to the predicted value of 94.2093%. Hence, 25% of the improvement in the biodiesel yield was reported. Moreover the different properties of karanja biodiesel were found closer to the American Society for Testing & Materials (ASTM) standard of biodiesel.

关键词： optimization of karanja biodiesel     genetic algorithm (GA)     response surface methodology (RSM)     percentage improvement in the biodiesel yield     properties of biodiesel    

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Reliability analysis of kinematic accuracy for the elastic slider-crank mechanism

TUO Yaofei, CHEN Jianjun, ZHANG Chijiang, CHEN Yongqin

《机械工程前沿（英文）》 2007年 第2卷 第2期   页码 214-217 doi: 10.1007/s11465-007-0037-3

摘要： This paper deals with the static and dynamic output kinematic accuracy of a group of elastic slider-crank mechanisms with the same design parameters by taking the bar length, the joint-gaps, the mass density, and the sectional and the physical parameters as random variables. According to the principle of linear pile-up of small displacement, the static and dynamic output kinematic errors are synthesized, and the reliability model of the kinematic accuracy of the mechanism is built. Through an example, a study of the influencing factors on the reliability of the output kinematic accuracy of the mechanism is made. The results obtained reveal the following facts: with the increase of the crank s rotating speed, the dynamic elastic deformation of the mechanism becomes the principal factor that greatly affects the reliability of the output kinematic accuracy of the mechanism.

关键词： output kinematic     group     slider-crank     kinematic accuracy     displacement    

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Utilization threshold of surface water and groundwater based on the system optimization of crop planting

Qiang FU,Jiahong LI,Tianxiao LI,Dong LIU,Song CUI

《农业科学与工程前沿（英文）》 2016年 第3卷 第3期   页码 231-240 doi: 10.15302/J-FASE-2016101

摘要： Based on the diversity of the agricultural system, this research calculates the planting structures of rice, maize and soybean considering the optimal economic-social-ecological aspects. Then, based on the uncertainty and randomness of the water resources system, the interval two-stage stochastic programming method, which introduces the uncertainty of the interval number, is used to calculate the groundwater exploitation and the use efficiency of surface water. The method considers the minimum cost of water as the objective of the uncertainty model for surface water and groundwater joint scheduling optimization for different planting structures. Finally, by calculating harmonious entropy, the optimal exploitation utilization interval of surface water and groundwater is determined for optimal cultivation in the Sanjiang Plain. The optimal matching of the planting structure under the economic system is suitable when the mining ratio of the surface is in 44.13%–45.45% and the exploitation utilization of groundwater is in 54.82%–66.86%, the optimal planting structure under the social system is suitable when surface water mining ratio is in 47.84%–48.04% and the groundwater exploitation threshold is in 67.07%–72.00%. This article optimizes the economic-social-ecological-water system, which is important for the development of a water- and food-conserving society and providing a more accurate management environment.

关键词： economic-social-ecological     uncertainty     harmonious entropy     surface water and groundwater     utilization threshold    

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New response surface model and its applications in aerodynamic optimization of axial compressor blade

LIU Xiaojia, NING Fangfei

《能源前沿（英文）》 2008年 第2卷 第4期   页码 541-549 doi: 10.1007/s11708-008-0077-3

摘要： A parametric method for the axial compressor 2D blade profiles is proposed in which the blade geometries are defined with the parameters commonly used for blade definition, which ensures that the geometric significance is clear and an unreasonable blade profile is not generated. Several illustrations are presented to show the fitting precision of the method. A novel response surface model is proposed which regards the objective distribution function in the vicinity of a sample as normal school, and then generates the response surface function in the whole design space by a linear combination of distribution functions of all the samples. Based on this model, a numerical aerodynamic optimization platform for the axial compressor 2D blade profiles is developed, by which aerodynamic optimization of two compressor blade profiles are presented.

关键词： definition     objective distribution     fitting precision     combination     numerical aerodynamic    

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Robust optimization of the billet for isothermal local loading transitional region of a Ti-alloy rib-webcomponent based on dual-response surface method

Ke WEI, Xiaoguang FAN, Mei ZHAN, Miao MENG

《机械工程前沿（英文）》 2018年 第13卷 第3期   页码 376-384 doi: 10.1007/s11465-018-0500-3

摘要：

Billet optimization can greatly improve the forming quality of the transitional region in the isothermal local loading forming (ILLF) of large-scale Ti-alloy rib-web components. However, the final quality of the transitional region may be deteriorated by uncontrollable factors, such as the manufacturing tolerance of the preforming billet, fluctuation of the stroke length, and friction factor. Thus, a dual-response surface method (RSM)-based robust optimization of the billet was proposed to address the uncontrollable factors in transitional region of the ILLF. Given that the die underfilling and folding defect are two key factors that influence the forming quality of the transitional region, minimizing the mean and standard deviation of the die underfilling rate and avoiding folding defect were defined as the objective function and constraint condition in robust optimization. Then, the cross array design was constructed, a dual-RSM model was established for the mean and standard deviation of the die underfilling rate by considering the size parameters of the billet and uncontrollable factors. Subsequently, an optimum solution was derived to achieve the robust optimization of the billet. A case study on robust optimization was conducted. Good results were attained for improving the die filling and avoiding folding defect, suggesting that the robust optimization of the billet in the transitional region of the ILLF was efficient and reliable.

关键词： isothermal local loading forming     rib-web component     transitional region     robust optimization     dual response surface method    

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Aerodynamic design by jointly applying S2 flow surface calculation and modern optimization methods on

ZHAO Honglei, WANG Songtao, HAN Wanjin, FENG Guotai

《能源前沿（英文）》 2008年 第2卷 第1期   页码 93-98 doi: 10.1007/s11708-008-0007-4

摘要： A three-stage axial turbine was redesigned by jointly applying S2 flow surface direct problem calculation methods and multistage local optimization methods. A genetic algorithm and artificial neural network were jointly adopted during optimization. A three-dimensional viscosity Navier–Stokes equation solver was applied for flow computation. H-O-H-topology grid was adopted as computation grid, that is, an H-topology grid was adopted for inlet and outlet segment, whereas an O-topology grid was adopted for stator zone and rotor zone. Through the optimization design, the total efficiency increases 1.1%, thus indicating that the total performance is improved and the design objective is achieved.
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emission characteristics of a diesel engine operating on different water in diesel emulsion fuels: optimizationusing response surface methodology (RSM)

Seyed Saeed HOSEINI, Mohammad Amin SOBATI

《能源前沿（英文）》 2019年 第13卷 第4期   页码 636-657 doi: 10.1007/s11708-019-0646-7

摘要： The nitrogen oxide (NO ) release of diesel engines can be reduced using water in diesel emulsion fuel without any engine modification. In the present paper, different formulations of water in diesel emulsion fuels were prepared by ultrasonic irradiation. The water droplet size in the emulsion, polydisperisty index, and the stability of prepared fuel was examined, experimentally. Afterwards, the performance characteristics and exhaust emission of a single cylinder air-cooled diesel engine were investigated using different water in diesel emulsion fuels. The effect of water content (in the range of 5%–10% by volume), surfactant content (in the range of 0.5%–2% by volume), and hydrophilic-lipophilic balance (HLB) (in the range of 5–8) was examined using Box-Behnken design (BBD) as a subset of response surface methodology (RSM). Considering multi-objective optimization, the best formulation for the emulsion fuel was found to be 5% water, 2% surfactant, and HLB of 6.8. A comparison was made between the best emulsion fuel and the neat diesel fuel for engine performance and emission characteristics. A considerable decrease in the nitrogen oxide emission (–18.24%) was observed for the best emulsion fuel compared to neat diesel fuel.

关键词： water in diesel emulsion fuel     hydrophilic-lipophilic balance (HLB)     response surface methodology (RSM)     emulsion stability     engine performance     exhaust emission    

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Adsorption property of direct fast black onto acid-thermal modified sepiolite and optimization of adsorptionconditions using Box-Behnken response surface methodology

Chengyuan SU, Weiguang LI, Yong WANG

《环境科学与工程前沿（英文）》 2013年 第7卷 第4期   页码 503-511 doi: 10.1007/s11783-012-0477-9

摘要： The adsorption of direct fast black onto acid-thermal modified sepiolite was investigated. Batch adsorption experiments were performed to evaluate the influences of experimental parameters such as initial dye concentration, initial solution pH and adsorbent dosage on the adsorption process. The three-factor and three-level Box-Behnken response surface methodology (RSM) was utilized for modeling and optimization of the adsorption conditions for direct fast black onto the acid-thermal modified sepiolite. The raw sepiolite was converted to acid-thermal modified sepiolite, and changes in the fourier transform infrared spectrum (FTIR) adsorption bands of the sample were noted at 3435 cm and 1427 cm . The zeolitic water disappeared and the purity of sepiolite was improved by acid-thermal modification. The decolorization rate of direct fast black adsorbed increased from 68.2% to 98.9% on acid-thermal modified sepiolite as the initial solution pH decreased from 10 to 2. When the adsorbent dosage reached to 2.5 g·L , 2.0 g·L , 1.5 g·L and 1.0 g·L , the decolorization rate was 90.3%, 86.7%, 61.0% and 29.8%, respectively. When initial dye concentration increased from 25 to 200 mg·L , the decolorization rate decreased from 91.9% to 60.0%. The RSM results showed that the interaction between adsorbent dosage and pH to be a significant factor. The optimum conditions were as follows: the adsorbent dosage 1.99 g·L , pH 4.22, and reaction time 5.2 h. Under these conditions, the decolorization rate was 95.1%. The three dimensional fluorescence spectra of direct fast black before and after treatment showed that the direct fast black was almost all adsorbed by the acid-thermal modified sepiolite.

关键词： direct fast black     acid-thermal modified sepiolite     adsorption     response surface methodology    

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Wastewater-nitrogen removal using polylactic acid/starch as carbon source: Optimization of operatingparameters using response surface methodology

Yan GUO, Chuanfu WU, Qunhui WANG, Min YANG, Qiqi HUANG, Markus MAGEP, Tianlong ZHENG

《环境科学与工程前沿（英文）》 2016年 第10卷 第4期 doi: 10.1007/s11783-016-0845-y

摘要： The use of PLA/starch blends for nitrogen removal was achieved. The influence of different operating parameters on responses was verified using RSM. The conditions for desired responses were successfully optimized simultaneously. Blends material may have a promising application prospect in the future. Nitrogen removal from ammonium-containing wastewater was conducted using polylactic acid (PLA)/starch blends as carbon source and carrier for functional bacteria. The exclusive and interactive influences of operating parameters (i.e., temperature, pH, stirring rate, and PLA-to-starch ratio (PLA proportion)) on nitrification ( ), denitrification ( ), and COD release rates ( ) were investigated through response surface methodology. Experimental results indicated that nitrogen removal could be successfully achieved in the PLA/starch blends through simultaneous nitrification and denitrification. The carbon release rate of the blends was controllable. The sensitivity of , , and to different operating parameters also differed. The sequence for each response was as follows: for , pH>stirring rate>PLA proportion>temperature; for , pH>PLA proportion>temperature>stirring rate; and for , stirring rate>pH>PLA proportion>temperature. In this study, the following optimum conditions were observed: temperature, 32.0°C; pH 7.7; stirring rate, 200.0 r·min ; and PLA proportion, 0.4. Under these conditions, , , and were 134.0 μg-N·g-blend ·h , 160.9 μg-N·g-blend ·h , and 7.6 × 10 μg-O·g-blend ·h , respectively. These results suggested that the PLA/starch blends may be an ideal packing material for nitrogen removal.

关键词： Nitrogen removal     Polylactic acid     Starch     Carbon source     Response surface methodology    

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Fluoride removal from secondary effluent of the graphite industry using electrodialysis: Optimizationwith response surface methodology

Xiaomeng Wang, Ning Li, Jianye Li, Junjun Feng, Zhun Ma, Yuting Xu, Yongchao Sun, Dongmei Xu, Jian Wang, Xueli Gao, Jun Gao

《环境科学与工程前沿（英文）》 2019年 第13卷 第4期 doi: 10.1007/s11783-019-1132-5

摘要：

RSM was utilized to optimize and model influential parameters on fluoride removal.

Regression models involving independent variables and main response were developed.

Interactive effects and optimum of process factors were illuminated and determined.

Fluoride removal efficiency of 99.69% was observed in optimal process conditions.

关键词： Response surface methodology     Fluoride removal     Electrodialysis     Box-Behnken design    

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标题 作者 时间 类型 操作

Surface accuracy optimization of mechanical parts with multiple circular holes for additive manufacturing

Jinghua XU, Hongsheng SHENG, Shuyou ZHANG, Jianrong TAN, Jinlian DENG

期刊论文

Impact of crude distillation unit model accuracy on refinery production planning

Gang FU, Pedro A. Castillo CASTILLO, Vladimir MAHALEC

期刊论文

Multi-objective optimization of surface texture for the slipperswash plate interface in EHA pumps

期刊论文

Coal-based activated carbon prepared by HO activation process for supercapacitors using response surfaceoptimization method

期刊论文

XFEM schemes for level set based structural optimization

Li LI, Michael Yu WANG, Peng WEI

期刊论文

Development of a combined approach for improvement and optimization of karanja biodiesel using responsesurface methodology and genetic algorithm

Sunil DHINGRA, Gian BHUSHAN, Kashyap Kumar DUBEY

期刊论文

Reliability analysis of kinematic accuracy for the elastic slider-crank mechanism

TUO Yaofei, CHEN Jianjun, ZHANG Chijiang, CHEN Yongqin

期刊论文

Utilization threshold of surface water and groundwater based on the system optimization of crop planting

Qiang FU,Jiahong LI,Tianxiao LI,Dong LIU,Song CUI

期刊论文

New response surface model and its applications in aerodynamic optimization of axial compressor blade

LIU Xiaojia, NING Fangfei

期刊论文

Robust optimization of the billet for isothermal local loading transitional region of a Ti-alloy rib-webcomponent based on dual-response surface method

Ke WEI, Xiaoguang FAN, Mei ZHAN, Miao MENG

期刊论文

Aerodynamic design by jointly applying S2 flow surface calculation and modern optimization methods on

ZHAO Honglei, WANG Songtao, HAN Wanjin, FENG Guotai

期刊论文

emission characteristics of a diesel engine operating on different water in diesel emulsion fuels: optimizationusing response surface methodology (RSM)

Seyed Saeed HOSEINI, Mohammad Amin SOBATI

期刊论文

Adsorption property of direct fast black onto acid-thermal modified sepiolite and optimization of adsorptionconditions using Box-Behnken response surface methodology

Chengyuan SU, Weiguang LI, Yong WANG

期刊论文

Wastewater-nitrogen removal using polylactic acid/starch as carbon source: Optimization of operatingparameters using response surface methodology

Yan GUO, Chuanfu WU, Qunhui WANG, Min YANG, Qiqi HUANG, Markus MAGEP, Tianlong ZHENG

期刊论文

Fluoride removal from secondary effluent of the graphite industry using electrodialysis: Optimizationwith response surface methodology

Xiaomeng Wang, Ning Li, Jianye Li, Junjun Feng, Zhun Ma, Yuting Xu, Yongchao Sun, Dongmei Xu, Jian Wang, Xueli Gao, Jun Gao

期刊论文