Plastic Deformation Mechanism in Double-Roller Clamping Spinning of Flanged Thin-Walled Cylinder

Double?roller clamping spinning(DRCS) is a new process for forming a thin?walled cylinder with a complex surface flange. The process requires a small spinning force,and can visibly improve forming quality and production e ciency. However,the deformation mechanism of the process has not been completely understood. Therefore,both a finite element numerical simulation and experimental research on the DRCS process are carried out. The results show that both radial force and axial force dominate the forming process of DRCS. The deformation area elongates along the radial direction and bends along the axial direction under the action of the two forces. Both the outer edge and round corner of the flange show the tangential tensile stress and radial compressive stress. The middle region shows tensile tangential stress and radial stress,while the inner edge shows compressive tangential stress and radial stress. Tan?gential tensile strain causes a wall thickness reduction in the outer edge and middle regions of the flange. The large compressive thickness strain causes material accumulation and thus,an increase in the wall thickness of the round corner. Because of bending deformation,the round corner shows a large radial tensile strain in addition. The inner edge of the flange shows small radial compressive strain and tensile strain in thickness. Thus,the wall thickness on the inner edge of the flange continues to increase,although the increment is small. Furthermore,microstructure analysis and tensile test results show that the flanged thin?walled cylinder formed by DRCS has good mechanical properties. The results provide instructions for the application of the DRCS process.

EFFECT OF TOOL-PATH ON MILLING ACCURACY UNDER CLAMPING

To resolve the deformation problem for thin-walled aero-parts in the actual production, this paper simulates the effect of the tool-path on the machining accuracy of the thin-walled frame. The frame is shaped in the part milling under a given clamping condition by using the three-dimensional finite element method （FEM）. Result shows that the sidewall deformation has a big difference if only the tool-path changes. When the tool-path from the outside to the inside is used, the machining deformation is smaller than another three kinds of toolpaths. Simulation results are compared with experimental data, and the correctness of the simulation is verified.Reasonable processing paths can be found by FEM.

Running Accuracy Analysis of a 3-RRR Parallel Kinematic Machine Considering the Deformations of the Links

Parallel kinematic machines have drawn considerable attention and have been widely used in some special fields.However,high precision is still one of the challenges when they are used for advanced machine tools.One of the main reasons is that the kinematic chains of parallel kinematic machines are composed of elongated links that can easily suffer deformations,especially at high speeds and under heavy loads.A 3-RRR parallel kinematic machine is taken as a study object for investigating its accuracy with the consideration of the deformations of its links during the motion process.Based on the dynamic model constructed by the Newton-Euler method,all the inertia loads and constraint forces of the links are computed and their deformations are derived.Then the kinematic errors of the machine are derived with the consideration of the deformations of the links.Through further derivation,the accuracy of the machine is given in a simple explicit expression,which will be helpful to increase the calculating speed.The accuracy of this machine when following a selected circle path is simulated.The influences of magnitude of the maximum acceleration and external loads on the running accuracy of the machine are investigated.The results show that the external loads will deteriorate the accuracy of the machine tremendously when their direction coincides with the direction of the worst stiffness of the machine.The proposed method provides a solution for predicting the running accuracy of the parallel kinematic machines and can also be used in their design optimization as well as selection of suitable running parameters.

Simulation and experiment analysis on thermal deformation of tool system in single-point diamond turning of aluminum alloy

The aim of this work is to simulate thermal deformation of tool system and investigate the influence of cutting parameters on it in single-point diamond turning(SPDT) of aluminum alloy. The experiments with various cutting parameters were conducted. Cutting temperature was measured by FLIR A315 infrared thermal imager. Tool wear was measured by scanning electron microscope(SEM). The numerical model of heat flux considering tool wear generated in cutting zone was established. Then two-step finite element method(FEM) simulations matching the experimental conditions were carried out to simulate the thermal deformation. In addition, the tests of deformation of tool system were performed to verify previous simulation results. And then the influence of cutting parameters on thermal deformation was investigated. The results show that the temperature and thermal deformation from simulations agree well with the results from experiments in the same conditions. The maximum thermal deformation of tool reaches to 7 μm. The average flank wear width and cutting speed are the dominant factors affecting thermal deformation, and the effective way to decrease the thermal deformation of tool is to control the tool wear and the cutting speed.

Iterative reverse deformation optimization design of castings based on numerical simulation of solidification thermal stress

In the casting process,in order to compensate for the solidification shrinkage to obtain higher dimensional accuracy of the casting,it is often necessary to modify the original design of castings,and a suitable compensation method has a decisive impact on the dimensional accuracy of the actual casting.In this study,based on solidification simulation,a design method of reverse deformation is proposed,and two compensation methods,empirical compensation and direct reverse deformation,are implemented.The simulation results show that the empirical compensation method has problems such as difficulty in determining the parameters and satisfaction of both the overall and local accuracy at the same time;while based on the simulation results for each node of the casting,the direct reverse deformation design achieves the design with shape.In addition,the casting model can be optimized through iterative revisions,so that higher dimensional accuracy can be continuously obtained in the subsequent design process.Therefore,the direct reverse deformation design is more accurate and reasonable compared to empirical compensation method.

Pre-deformation for Assembly Performance of Machine Centers

The current research of machine center accuracy in workspace mainly focuses on the poor geometric error subjected to thermal and gravity load while in operation, however, there are little researches focusing on the effect of machine center elastic deformations on workspace volume. Therefore, a method called pre-deformation for assembly performance is presented. This method is technically based on the characteristics of machine tool assembly and collaborative computer-aided engineering （CAE） analysis. The research goal is to enhance assembly performance, including straightness, positioning, and angular errors, to realize the precision of the machine tool design. A vertical machine center is taken as an example to illustrate the proposed method. The concept of travel error is defined to obtain the law of the guide surface. The machine center assembly performance is analyzed under cold condition and thermal balance condition to establish the function of pre-deformation. Then, the guide surface in normal direction is processed with the pre-deformation function, and the machine tool assembly performance is measured using a laser interferometer. The measuring results show that the straightness deviation of the Z component in the Y-direction is 158.9% of the allowable value primarily because of the gravity of the spindle head, and the straightness of the X and Y components is minimal. When the machine tool is processed in pre-deformation, the straightness of the Z axis moving component is reduced to 91.2%. This research proposes a pre-deformation machine center assembly method which has sufficient capacity to improving assembly accuracy of machine centers.

Gaussian Radial Basis Function interpolation in vertical deformation analysis

In many deformation analyses,the partial derivatives at the interpolated scattered data points are required.In this paper,the Gaussian Radial Basis Functions(GRBF)is proposed for the interpolation and differentiation of the scattered data in the vertical deformation analysis.For the optimal selection of the shape parameter,which is crucial in the GRBF interpolation,two methods are used:the Power Gaussian Radial Basis Functions(PGRBF)and Leave One Out Cross Validation(LOOCV)(LGRBF).We compared the PGRBF and LGRBF to the traditional interpolation methods such as the Finite Element Method(FEM),polynomials,Moving Least Squares(MLS),and the usual GRBF in both the simulated and actual Interferometric Synthetic Aperture Radar(InSAR)data.The estimated results showed that the surface interpolation accuracy was greatly improved by LGRBF and PGRBF methods in comparison withFEM,polynomial,and MLS methods.Finally,LGRBF and PGRBF interpolation methods are used to compute invariant vertical deformation parameters,i.e.,changes in Gaussian and mean Curvatures in the Groningen area in the North of Netherlands.

Constrained geometry analysis to resolve 3-D deformations from three ground-based radars

When multiple ground-based radars(GB-rads)are utilized together to resolve three-dimensional(3-D)deformations,the resolving accuracy is related with the measurement geometry constructed by these radars.This paper focuses on constrained geometry analysis to resolve 3-D deformations from three GB-rads.The geometric dilution of precision(GDOP)is utilized to evaluate 3-D deformation accuracy of a single target,and its theoretical equation is derived by building a simplified 3-D coordinate system.Then for a 3-D scene,its optimal accuracy problem is converted into determining the minimum value of an objective function with a boundary constraint.The genetic algorithm is utilized to solve this constrained optimization problem.Numerical simulations are made to validate the correctness of the theoretical analysis results.

Hyper accuracy three-dimensional virtual anatomical rainbow model facilitates surgical planning and safe selective clamping during robot-assisted partial nephrectomy

ObjectiveTo highlight the role of hyper accuracy three-dimensional(3D)reconstruction in facilitating surgical planning and guiding selective clamping during robot-assisted partial nephrectomy(RAPN).MethodsA transperitoneal RAPN was performed in a 62-year-old male patient presenting with a 4 cm right anterior interpolar renal mass(R.E.N.A.L nephrometry score 7A).An abnormal vasculature was observed,with a single renal vein and two right renal arteries originating superiorly to the vein and anterior,when dividing in their segmental branches.According to the hyper accuracy 3D(HA3D^(®))rainbow model(MEDICS Srl,Turin,Italy),one branch belonging to one of the segmental arteries was feeding the tumor.This allowed for an accurate prediction of the area vascularized by each arterial branch.The 3D model was included in the intraoperative console view during the whole procedure,using the TilePro feature.A step-by-step explanation of the procedure is provided in the video attached to the present article.ResultsThe operative time was 90 min with a warm ischemia time on selective clamping of 13 min.Estimated blood loss was 180 mL.No intraoperative complication was encountered and no drain was placed at the end of the procedure.The patient was discharged on postoperative Day 2,without any early postoperative complications.The final pathology report showed a pathological tumor stage 1 clear cell renal cell carcinoma with negative surgical margins.ConclusionThe present study and the attached video illustrate the value of 3D rainbow model during the planning and execution of a RAPN with selective clamping.It shows how the surgeon can rely on this model to be more efficient by avoiding unnecessary surgical steps,and to safely adopt a“selective”clamping strategy that can translate in minimal functional impact.

脊柱手术机器人治疗脊柱疾病的研究发展趋势及热点剖析

背景:近年来在脊柱外科领域,手术机器人的应用已成为研究热点,但目前中国尚缺乏脊柱手术机器人的的文献可视化分析相关研究。目的:对脊柱手术机器人治疗脊柱疾病的研究热点进行文献可视化分析,以期为中国脊柱手术机器人的研究和发展提供有益的参考。方法:在Web of Science核心集数据库中检索脊柱手术机器人治疗脊柱疾病的相关文献,最终纳入900篇文献。采用VOSviewer 1.6.19软件对纳入文献的发文量、期刊、机构、国家、关键词、共被引文献和高被引文献进行可视化分析。结果与结论:(1)脊柱手术机器人治疗脊柱疾病研究领域的文献呈逐年上升趋势,尤其在2023年达到了发文量的高峰。美国、中国和德国是该领域的研究热点国家。中国国家自然科学基金是该领域的主要资助基金。(2)中国北京积水潭医院和美国特殊外科医院在该领域的研究具有较高的发文量。(3)《World Neurosurgery》《Spine》和《Operative Neurosurgery》是该领域的主要发文期刊。(4)关键词分析显示,研究主要集中在机器人辅助脊柱手术的准确性、微创手术、机器人脊柱手术和导航技术等方面。(5)文献共被引分析结果显示了机器人辅助技术在脊柱手术中具有显著优势,与传统手术相比,脊柱手术机器人如ROSA?Spine,ExcelsiusGPS,Mazor X及TiRobot等,具有高精度导航、精确椎弓根螺钉置入及实时反馈等优点,它们通过减少手术中X射线辐射暴露,降低患者并发症风险,提高手术成功率,显示出其在脊柱外科领域的应用前景。(6)尽管如此,相关技术的应用和精确度仍需不断积累经验以提高;机器人手术技术在降低手术辐射暴露和提高手术精度方面显示出成本效益,但还需深入探讨其在椎弓根螺钉置入过程中的精确度、手术时间影响及经济效益。(7)2021-2024年的高被引文献分析结果进一步显示,目前该领域最新研究热点主要集中在虚拟现实和增强现实技术的应用、机器人辅助椎弓根螺钉置入的准确性提升以及导航机器人脊柱手术平台的应用等。例如,通过创新技术如有机电化学神经元为脑机接口、假肢和智能软机器人技术提供了新的集成方案。同时,虚拟现实和增强现实技术在脊柱畸形矫正等领域展示了广泛应用前景。

基于有限元分析多件装夹夹具体结构设计研究

为了研究某汽车制动泵缸体件多件装夹夹具体结构刚性,利用UG软件建立多件装夹夹具体模型,通过ANSYS有限元分析比较无拉杆和有拉杆两种夹具体结构变形情况。结果表明,设置拉杆的夹具体结构变形比无拉杆的夹具体结构变形小,可有效地控制装夹变形量。基于此,设计一种对称式多件装夹夹具体,装夹时无需考虑夹具体变形量,只需关注被装夹工件的变形,简化了夹具体整体结构。在多件装夹夹具中,优先采用对称式夹具体结构设计,其次是拉杆式夹具体结构设计。研究结果可为企业设计多件装夹夹具体结构提供参考。

基于新一代几何技术规范的装配误差建模

针对由于公差设计不合理而导致的服役于复杂工况的机械装备性能下降等问题,提出一种综合考虑制造与装配误差的机械产品装配精度分析方法。该方法首先利用有限元分析机械装备零部件装配误差导致的变形,并提取发生形变的关键特征面;然后基于新一代几何技术规范(GPS)将特征面的变形转化为尺寸与形位公差数据,并与设计公差进行叠加,实现变形—误差—公差的转换;随后基于雅可比旋量理论,构建综合考虑制造与装配误差的公差分析模型支撑机械装备的公差精量化设计;最后以某型机载作动筒为工程应用对象,对比分析了是否考虑受力变形条件下装配精度分析的结果差异,结果显示该方法相较于原有方法具有更高的计算准确性,能为精密机械产品精度设计提供更加准确的指导。

多路径误差对BDS-3变形监测精度的影响

为定量分析BDS-3观测值多路径误差对变形监测精度的影响,选取包含7个站点的某水利工程2022年共128 d的BDS-3监测数据,对监测站点周围树木裁剪树枝前后BDS-3观测值多路径误差、变形监测精度及二者的相关性进行研究。结果表明:1)多路径误差与BDS-3变形监测精度间存在强相关性,与其平面和高程精度的相关系数分别大于0.93和0.81;2)监测站点周围树枝裁剪后,使用B1I和B3I观测值的平均多路径误差从0.676 m、0.426 m降低至0.329 m、0.230 m,N、E、U方向的平均监测精度分别达0.9 mm、0.8 mm、1.7 mm和1.1 mm、1.0 mm、2.2 mm,较裁剪树枝前分别提高63%、69%、58%和52%、61%、48%;3)改变周围观测环境削弱多路径误差的影响后,使用B1I观测值的精度优于使用B3I观测值的精度,因此在BDS-3短基线变形监测的应用中推荐使用B1I观测值。

真空夹具在梁类零件数控加工中的应用

针对航空梁类零件传统加工定位方法中装夹效率低、质量不稳定等问题,基于真空吸附原理设计一种可以实现工件准确定位、快速夹紧的快速定位装夹工艺装备,从而有效抑制切削过程中因刚性不足引起的切削振颤,减小夹紧力不均对加工变形的影响,提高生产效率和加工精度。

EEMD-小波在高边坡变形信息提取中的应用研究

针对高边坡变形呈现非平稳性及数据“噪声”多源的问题,提出了一种定向滤波的变形信息提取方法。首先,利用集合经验模态分解方法分解变形时序数据,结合定量分析法判别模态分量信号频段;然后,对高频模态分量中的“噪声”利用小波函数进行“靶向”消噪处理,并对趋势项进行傅里叶级数拟合;最后,重构高边坡变形分析模型,实现真实变形量的提取。结果表明,对比分析各项检验指标,通过“靶向”消噪,各高频模态分量消噪效果明显,重构后的集合经验模态分解(Ensemble Empirical Mode Decomposition,EEMD)-小波高边坡变形分析模型较原始形变和其他模型在精度指标方面提升显著,该方法可用于高边坡的变形预测分析和真实变形量提取。

振动轮两侧加速度差异及连续压实指标优化研究

连续压实控制技术主要通过振动轮单侧振动响应描述土体压实状态,已在工程中得到广泛应用。然而,研究发现压实过程中存在振动轮两侧加速度响应不一致的现象,这可能导致现有测试方法在相同位置出现不同的刚度测试结果,因此研究振动轮两侧振动差异性对提高连续压实测试精度具有重要意义。结合现场试验,采集压路机振动轮两侧的加速度信号,重点分析了不同压实遍数、振动频率下两侧加速度峰值、倍频幅值的变化与分布规律;以双侧响应为基础提出平均指标,通过相关性分析对指标适用性进行验证。研究结果表明:随着压实遍数的增加,两侧加速度峰值差异逐渐减小,经4遍压实后差异由24.4%降至13.3%;振动轮结构偏心会造成振动轮两侧加速度频谱中基频幅值差异的产生,被压土体两侧刚度不均会造成2倍频、3倍频幅值差异的产生;双侧平均指标μAICV与动态变形模量的相关性为0.75,表明双侧平均指标μAICV可用于路基压实质量控制,相比单侧连续压实控制指标,可有效提高现场质量控制精度。

大型射电望远镜日照热误差及其补偿的仿真研究

射电望远镜广泛应用于射电天文、测控导航等领域,随着其工作频率的升高、口径的增大,日照引起的结构热变形对其性能的影响愈发严重;本文针对待建的新疆110 m口径射电望远镜,建立了其日照热力耦合模型,分析了天线在不同时刻、风速及姿态下的温度、变形情况,总结了结构日照温度场、变形场的时空分布特征,最后采用最佳吻合抛物面方法对反射面精度进行了评价,并通过副反射面位置补偿量的变化趋势揭示了天线热变形的共性规律及机理。结果表明:对于日照引起的天线热变形误差,风速越大,结构温度分布越均匀,其越接近等温膨胀变形,反射面形状精度越高;温差引起的结构不均匀变形是反射面精度下降的主要原因,温差越大结构的不均匀变形越大,反射面的形状精度越低;同一姿态不同风速下反射面热误差空间分布具有相似性,该分布与太阳直射点位置直接相关,且会跟随直射点位置发生变化,但由于日照强度、风速等因素的不同,其变形幅度不同。各种姿态下反射面精度变化规律相似,与风速的相关性均为反射面精度随风速上升而提高;采用副反射面位置补偿技术可明显缓解日照热误差影响。本文的分析方法与结论对大口径全可动射电望远镜的设计建造及其热误差控制具有一定参考价值。

薄壁圆环件装夹变形理论分析与仿真预测

薄壁圆环类零件广泛应用在离心压缩机设备中,在车削加工中由于装夹力的影响会发生弹性变形,从而影响工件加工精度,为探究零件装夹变形影响,保障离心压缩机运行效率,通过理论分析与有限元仿真模拟相结合的方法,分别建立了薄壁圆环零件在卧式车床四爪卡盘装夹下的理论变形模型和有限元仿真模型进行优化研究。通过两种模型对比可知:有限元仿真模型变形结果与理论模型变形结果较为一致,得出薄壁圆环件普通装夹径向变形较为敏感。据此,提出轴向装夹和均布式径向装夹两种优化装夹方案来减小薄壁圆环件在加工过程中的径向变形,通过计算可知,该两种装夹方式都可有效减小薄壁圆环类零件装夹变形,为提高薄壁圆环类零件加工精度提供理论基础。

基于分割法的抛物面固面天线热变形抑制

为满足未来高分辨率微波遥感航天器对于大口径高形面精度的空间可展开天线的需求,提出了一种能有效降低偏馈固面天线在轨因热变形造成形面误差的新方法,即分割法。采用5 m口径的偏馈固面抛物面天线,分析了天线热变形对其电性能尤其是主波束效率的影响。对连续固面天线六点支撑下不同支撑位置对其热变形的影响进行了研究。在温差为200℃的均匀温度场下,分析了不同形状单胞的形面误差,随后确认采用正六边形作为分割单胞并对其形面误差与尺寸的关系进行了研究。研究了分割单胞的尺寸及排布方式对天线的形面误差及电性能的影响,并验证了分割单胞之间的缝隙对天线电性能的影响,最终确定分割方案。结果显示,分割后天线形面误差从500μm降低至5μm,主波束效率下降值从6.72%下降至1.77%。

基于CNN-LSTM-AM的大坝变形预测

为提高大坝变形预测模型的预测精度,以长短期记忆(LSTM)作为基础模型预测大坝变形,在LSTM网络层前加入卷积神经网络(CNN)卷积层,以卷积层中卷积核刻画数据的局部模式实现数据特征的深度挖掘,提取大坝变形多因素序列时空特征;LSTM网络层后加入注意力机制层用于区分特征信息的重要程度并给予不同的关注度,进一步优化网络模型,构建了基于CNN-LSTM-AM的大坝预测模型。应用该大坝预测模型在工程实例中与LSTM、CNN-LSTM、LSTM-AM模型的预测结果和残差进行对比分析,CNN-LSTM-AM模型的预测结果和拟合度均更优;并以均方误差、均方根误差、平均绝对误差及决定系数R2作为精度评定指标对比各模型间预测性能,结果表明引入注意力机制能够提升模型预测性能,证实了基于CNN-LSTM-AM构建的大坝预测模型具有工程应用价值。