Anisotropic Force Ellipsoid Based Multi-axis Motion Optimization of Machine Tools

The existing research of the motion optimization of multi-axis machine tools is mainly based on geometric and kinematic constraints, which aim at obtaining minimum-time trajectories and finding obstacle-free paths. In motion optimization, the stiffness characteristics of the whole machining system, including machine tool and cutter, are not considered. The paper presents a new method to establish a general stiffness model of multi-axis machining system. An analytical stiffness model is established by Jacobi and point transformation matrix method. Based on the stiffness model, feed-direction stiffness index is calculated by the intersection of force ellipsoid and the cutting feed direction at the cutter tip. The stiffness index can help analyze the stiffness performance of the whole machining system in the available workspace. Based on the analysis of the stiffness performance, multi-axis motion optimization along tool paths is accomplished by mixed programming using Matlab and Visual C＋＋. The effectiveness of the motion optimization method is verified by the experimental research about the machining performance of a 7-axis 5-linkage machine tool. The proposed research showed that machining stability and production efficiency can be improved by multi-axis motion optimization based on the anisotropic force ellipsoid of the whole machining system.

The development of real time data driving multi-axis linkage and synergic movement control system of 3D variable cross-section roll forming machine

The three dimensional variable cross-section roll forming is a kind of new metal forming technol- ogy which combines large forming force, multi-axis linkage movement and space synergic movement, and the sequential synergic movement of the ganged roller group is used to complete the metal sheet forming according to the shape of the complicated and variable forming part data. The control system should meet the demands of quick response to the test requirements of the product part. A new kind of real time data driving multi-axis linkage and synergic movement control strategy of 3D roll forming is put forward in the paper. In the new control strategy, the forming data are automatically generated according to the shape of the parts, and the multi-axis linkage movement together with cooperative motion among the six stands of the 3D roll forming machine is driven by the real-time information, and the control nodes are also driven by the forming data. The new control strategy is applied to a 48 axis 3D roll forming machine developed by our research center, and the control servo period is less than 10ms. A forming experiment of variable cross section part is carried out, and the forming preci- sion is better than ＋ 0.5mm by the control strategy. The result of the experiment proves that the control strategy has significant potentiality for the development of 3D roll forming production line with large scale, multi-axis ganged and svner^ic movement

Mach数和壁面温度对HyTRV边界层转捩的影响

典型的高超声速飞行器流场存在着复杂的转捩现象,其对飞行器的性能有着显著的影响。针对HyTRV这款接近真实高超声速飞行器的升力体模型,采用数值模拟方法,研究Mach数和壁面温度对HyTRV转捩的影响规律。采用课题组自研软件开展数值计算,Mach数的范围为3~8,壁面温度的范围为150~900 K。首先对■转捩模型和SST湍流模型进行了高超声速修正:将压力梯度系数修正、高速横流修正引入到■转捩模型,并对SST湍流模型闭合系数β~*和β进行可压缩修正;然后开展了网格无关性验证,通过与实验结果对比,确认了修正后的数值方法和软件平台;最终开展Mach数和壁面温度对HyTRV边界层转捩规律的影响研究。计算结果表明,转捩区域主要集中在上表面两侧、下表面中心线两侧;增大来流Mach数,上下表面转捩起始位置均大幅后移,湍流区大幅缩小,但仍会存在,同时上表面层流区摩阻系数不断增大,下表面湍流区摩阻系数不断减小;升高壁面温度,上下表面转捩起始位置先前移,然后快速后移,最终湍流区先后几乎消失。

Effect of Sweptback Angle of a Delta Wing on Surface Pressure Distribution at Supersonic Mach Numbers

The purpose of this work is to shed light on the effect of the pivot position on the surface pressure distribution over a 3D wing in different flight conditions.The study is intended to support the design and development of aerospace vehicles where stability analysis,performance optimization,and aircraft design are of primary importance.The following parameters are considered:Mach numbers(M)of 1.3,1.8,2.3,2.8,3.3,and 3.8,angle of incidence(θ)in the range from 5°to 25°,pivot position from h=0.2 to 1.The results of the CFD numerical simulations match available analytical data,thereby providing evidence for the reliability of the used approach.The findings provide valuable insights into the relationship between the surface pressure distribution,the Mach number and the angle of incidence.

Base Pressure Control with Semi-Circular Ribs at Critical Mach Number

When better fuel-air mixing in the combustion chamber or a reduction in base drag are required in vehicles,rockets,and aeroplanes,the base pressure control is activated.Controlling the base pressure and drag is necessary in both scenarios.In this work,semi-circular ribs with varying diameters(2,4,and 6 mm)positioned at six distinct positions(0.5D,1D,1.5D,2D,3D,and 4D)inside a square duct with a side of 15 mm are proposed as an efficient way to apply the passive control technique.In-depth research is done on optimising rib size for various rib sites.According to this study,the base pressure rises as rib height increases.Furthermore,the optimal location for the semi-circular ribs with a diameter of 2 mm is at 0.5D.The 1D location appears to be optimal for the 4 mm size as well.For the 6 mm size,however,the 4D position fills this function.

圆柱及切割圆柱低Mach数绕流气动声辐射

以柱体绕流声辐射为研究对象,探讨低Mach数流动气动声定量预测方法。首先,理论分析Lighthill声类比理论与基于流体动力学压力对时间求导的扰动分离模型之间内在联系。其次,利用计算流体动力学对圆柱及其尾部切割后的亚临界流态绕流进行二维数值求解,分析两种湍流模型的流场计算效果。最后,分别使用声类比理论FW-H方程及扰动分离模型进行柱体绕流气动声辐射定量预测,分析声指向性及频谱特性。数值结果表明声类比理论与扰动分离模型预测的声辐射频谱相似,但前者的幅值略高;圆柱尾部切割使尾流脉动增强,导致声辐射变大。

基于Mach-Zehnder干涉装置的散射体偏振特性研究

根据偏振度测量原理推导了相干矩阵中各个参数的测量公式,主要是复参量的实部与虚部.基于Mach-Zehnder干涉装置搭建了散射体偏振度测试平台,并对同一粒径不同浓度散射体的偏振特性进行了测试.结果表明:浓度为0.00625%的聚苯乙烯(Polystyrene,PS)散射介质光散射较弱,偏振度值高达0.992,散射体具有良好的保偏特性;随着聚苯乙烯散射介质浓度增大到0.025%,光散射增强,偏振度值降至0.545,散射体的退偏效果显著.

Three-dimensional Tool Radius Compensation for Multi-axis Peripheral Milling

Few function about 3D tool radius compensation is applied to generating executable motion control commands in the existing computer numerical control (CNC) systems. Once the tool radius is changed, especially in the case of tool size changing with tool wear in machining, a new NC program has to be recreated. A generic 3D tool radius compensation method for multi-axis peripheral milling in CNC systems is presented. The offset path is calculated by offsetting the tool path along the direction of the offset vector with a given distance. The offset vector is perpendicular to both the tangent vector of the tool path and the orientation vector of the tool axis relative to the workpiece. The orientation vector equations of the tool axis relative to the workpiece are obtained through homogeneous coordinate transformation matrix and forward kinematics of generalized kinematics model of multi-axis machine tools. To avoid cutting into the corner formed by the two adjacent tool paths, the coordinates of offset path at the intersection point have been calculated according to the transition type that is determined by the angle between the two tool path tangent vectors at the corner. Through the verification by the solid cutting simulation software VERICUTwith different tool radiuses on a table-tilting type five-axis machine tool, and by the real machining experiment of machining a soup spoon on a five-axis machine tool with the developed CNC system, the effectiveness of the proposed 3D tool radius compensation method is confirmed. The proposed compensation method can be suitable for all kinds of threeto five-axis machine tools as a general form.

Design of a Multi-axis Motion Control Platform Based on LabVIEW’s Fuzzy Control Algorithm

This paper presents a fuzzy control algorithm applied to the position control of a multi-axis motion platform to achieve high precision motion control of the multi-axis motion platform.A LabVIEW-based multi-axis motion control system is designed.This system controls stepper motors using trapezoidal acceleration/deceleration pulse types and fuzzy control algorithms,which effectively avoids mechanical jitter and loss of step in the process of multi-angle motion of the stepper motor,and achieves accurate control of the stepper motor.The TCP/IP(transmission control protocol/internet protocol)communication protocol is used,so that data are output stably and not lost in the process of transmission and communication,achieving the purpose of interconnection of different systems and remote control of equipment.This control system has been tested to maintain a high level of stability and repeatability during actual operation.

Laser Interferometer Based Measurement for Positioning Error Compensation in Cartesian Multi-Axis Systems

Accuracy is one of the most important key indices to evaluate multi-axis systems’ (MAS’s) characteristics and performances. The accuracy of MAS’s such as machine tools, measuring machines and robots is adversely affected by various error sources, including geometric imperfections, thermal deformations, load effects, and dynamic disturbances. The increasing demand for higher dimensional accuracy in various industrial applications has created the need to develop cost-effective methods for enhancing the overall performance of these mechanisms. Improving the accuracy of a MAS by upgrading the physical structure would lead to an exponential increase in manufacturing costs without totally eliminating geometrical deviations and thermal deformations of MAS components. Hence, the idea of reducing MAS’s error by a software-based alternative approach to provide real-time prediction and correction of geometric and thermally induced errors is considered a strategic step toward achieving the full potential of the MAS. This paper presents a structured approach designed to improve the accuracy of Cartesian MAS’s through software error compensation. Four steps are required to develop and implement this approach: (i) measurement of error components using a multidimensional laser interferometer system, (ii) tridimensional volumetric error mapping using rigid body kinematics, (iii) volumetric error prediction via an artificial neural network model, and finally (iv) implementation of the on-line error compensation. An illustrative example using a bridge type coordinate measuring machine is presented.

Numerical Analysis of Cavity-Based Control of Base Pressure Variations at Supersonic Mach Numbers

In the present study,the base pressure variations induced by the presence of a cavity,known to have a strong influence of the behaviour of supersonic projectiles,are investigated through numerical solution of the balance equations for mass,momentum,and energy.An area ratio of four is considered and numerical simulations are carried out at Mach M=1.2,1.4,1.6,and 1.8 assuming no cavity or cavity locations 0.5D,1D,1.5D,and 2D.The inlet pressure of the nozzle is considered as a flow variable.The Taguchi method is also used,and the considered cases are then analyzed using a full factorial experimental design.The results show that the cavity is effective in increasing the base pressure for the conditions examined.For other nozzle pressure ratios,cavities do not lead to passive control due the change in the reattachment length.The distribution of wall pressure reveals that,in general,a cavity used to implement passive control of the base pressure does not adversely influence the flow pattern in the domain.

Modeling and Validation of Base Pressure for Aerodynamic Vehicles Based on Machine Learning Models

The application of abruptly enlarged flows to adjust the drag of aerodynamic vehicles using machine learning models has not been investigated previously.The process variables(Mach number(M),nozzle pressure ratio(η),area ratio(α),and length to diameter ratio(γ))were numerically explored to address several aspects of this process,namely base pressure(β)and base pressure with cavity(βcav).In this work,the optimal base pressure is determined using the PCA-BAS-ENN based algorithm to modify the base pressure presetting accuracy,thereby regulating the base drag required for smooth flow of aerodynamic vehicles.Based on the identical dataset,the GA-BP and PSO-BP algorithms are also compared to thePCA-BAS-ENNalgorithm.The data for training and testing the algorithmswas derived using the regression equation developed using the Box-Behnken Design(BBD).The results show that the PCA-BAS-ENN model delivered highly accurate predictions when compared to the other two models.As a result,the advantages of these results are two-fold,providing:(i)a detailed examination of the efficiency of different neural network algorithms in dealing with a genuine aerodynamic problem,and(ii)helpful insights for regulating process variables to improve technological,operational,and financial factors,simultaneously.

来流Mach数连续变化下的激波串运动特性

为了研究入射激波变化的隔离段内激波串的运动特性,设计并搭建了直连式变Mach数实验系统,捕捉了相同来流Mach数变化速率、不同背压变化速率下激波串的运动行为,揭示了入射激波与背压同时变化对激波串运动的影响机理。入射激波与背压同时变化时,共有3个方面的因素会影响激波串整体的上下游运动趋势,其一,Mach数变化,Mach数增大导致激波串向下游运动,该影响随Mach数增大逐渐减弱;其二,背景波系移动,背景激波反射点靠近激波串前缘时,可能引起激波串的突跳;其三,背压压比变化,背压压比增大时激波串向上游运动,该影响随背压压比增大逐渐增强。三方面因素共同作用下激波串表现出复杂的运动。

DEVELOPMENT OF NEW GENERATION THERMOMECHANICAL SIMULATOR-MULTI-AXIS RESTRAINT COMPRESSION(MARC-STRAIN^(TM))SYSTEM

Ultrafine grain size is often achieved by severe plastic deformation. A few techniques have been devel- oped to achieve severe plastic deformation,such as equal channel angular (ECA ) processing, torsion, and accumulative roll bonding (ARB) techmpues. This paper will introduce a moftiaxis deformation technique which can achieve essentially unlimited strain with constant deformation volume. The mul- tiaxis deformation can be fully restrained or unrestrained.The bulk volume of a multiaxis restraint compression specimen can be easily machined into mechanical testing specimens for mechanical property measurement and other studies.

Observation of tropospheric NO_2 by airborne multi-axis differential optical absorption spectroscopy in the Pearl River Delta region,south China

An airborne multi-axis differential optical absorption spectroscopic （AMAX-DOAS） instrument was developed and applied to measure tropospheric NO2 in the Pearl River Delta region in the south of China. By combining the measurements in nadir and zenith directions and analyzing the UV and visible spectral region using the DOAS method, information about tropospheric NO2 vertical columns was obtained. Strong tropospheric NO2 signals were detected when flying over heavilly polluted regions and point sources like plants. The AMAX-DOAS results were compared with ground-based MAX-DOAS observations in the southwest of Zhuhai city using the same parameters for radiative transport calculations. The difference in vertical column data between the two instruments is about 8%. Our data were also compared with those from OMI and fair agreement was obtained with a correlation coefficient R of 0.61. The difference between the two instruments can be attributed to the different spatial resolution and the temporal mismatch during the measurements.

基于Mach-Zehnder干涉仪的自相似激光器压缩系统设计

为了研究自相似脉冲在Mach-Zehnder干涉仪的压缩特性,采用非线性薛定谔方程对自相似脉冲的演化和压缩进行了模拟,分析了基于级联单模光纤的Mach-Zehnder干涉仪的光纤参数对脉冲压缩的影响。结果表明,在不考虑高阶色散的情况下,当上臂的两种单模光纤长度分别为8.16 m和2.16 m、下臂的单模光纤长度为8.16 m时,获得半峰全宽为27.85 fs、峰值功率为1860.59 W、基座能量比例为10.241%的最佳压缩脉冲;考虑高阶色散时,脉冲在单模光纤中传输呈现出峰值功率增大、基座增大的现象,且脉冲右移不利于输出基座较小的压缩脉冲;当3阶色散系数小于0.001 ps^(3)/km时,利用Mach-Zehnder干涉仪来压缩能获得质量较好的飞秒脉冲。该研究结果对于自相似脉冲的压缩研究具有一定的参考价值。

Research on Contour Error Based on CNC Multi-axis Motion Control System

The contour error was analyzed based on CNC multi-axis motion control, the contour error model was obtained focused on beeline and different radius of curvature and common contour of curve, for a CNC biaxial motion control system and the mechanism of producing contour error and the relationship between tracking error and contour error were presented. The theoretical and practical significance of modeling error and controlling error in motion control systems was carried out.

Computation of Stiffness and Damping Derivatives of an Ogive in a Limiting Case of Mach Number and Specific Heat Ratio

This work aims to compute stability derivatives in the Newtonian limit in pitch when the Mach number tends to infinity.In such conditions,these stability derivatives depend on the Ogive’s shape and not the Mach number.Generally,the Mach number independence principle becomes effective from M=10 and above.The Ogive nose is obtained through a circular arc on the cone surface.Accordingly,the following arc slopes are consideredλ=5,10,15,−5,−10,and−15.It is found that the stability derivatives decrease due to the growth inλfrom 5 to 15 and vice versa.Forλ=5 and 10,the damping derivative declines with an increase inλfrom 5 to 10.Yet,for the damping derivatives,the minimum location remains at a pivot position,h=0.75 for large values ofλ.Hence,whenλ=−15,the damping derivatives are independent of the cone angles for most pivot positions except in the early twenty percent of the leading edge.

THE LOW MACH NUMBER LIMIT FOR ISENTROPIC COMPRESSIBLE NAVIER-STOKES EQUATIONS WITH A REVISED MAXWELL'S LAW

We investigate the low Mach number limit for the isentropic compressible NavierStokes equations with a revised Maxwell's law(with Galilean invariance) in R^(3). By applying the uniform estimates of the error system, it is proven that the solutions of the isentropic Navier-Stokes equations with a revised Maxwell's law converge to that of the incompressible Navier-Stokes equations as the Mach number tends to zero. Moreover, the convergence rates are also obtained.

A Low Mach Number IMEX Flux Splitting for the Level Set Ghost Fluid Method

Considering droplet phenomena at low Mach numbers,large differences in the magnitude of the occurring characteristic waves are presented.As acoustic phenomena often play a minor role in such applications,classical explicit schemes which resolve these waves suffer from a very restrictive timestep restriction.In this work,a novel scheme based on a specific level set ghost fluid method and an implicit-explicit(IMEX)flux splitting is proposed to overcome this timestep restriction.A fully implicit narrow band around the sharp phase interface is combined with a splitting of the convective and acoustic phenomena away from the interface.In this part of the domain,the IMEX Runge-Kutta time discretization and the high order discontinuous Galerkin spectral element method are applied to achieve high accuracies in the bulk phases.It is shown that for low Mach numbers a significant gain in computational time can be achieved compared to a fully explicit method.Applica-tions to typical droplet dynamic phenomena validate the proposed method and illustrate its capabilities.