Analysis of bending mechanism in multi-scanning laser bending process based on plastic strain development

By using multi-pass straight-line scan strategies,a larger bending angle can be achieved.There is,however,a limited understanding of the variation in bending angle per pass during multi-pass under various process parameters.In multi-pass laser scanning,the bending angle cannot always linearly increase with scanning passes and this phenomenon can be observed mostly in low heat input.Strain hardening is the common explanation for this phenomenon.However,it could not explain why this bending angle reduction phenomenon occurs at low heat input scanning rather than at high heat input scanning.In this study,this phenomenon is discussed based on strain development in experiments and numerical simulation.The different growing mechanism of plastic strain is analyzed to reveal the effects of laser power and scanning velocity.Furthermore,the opposite bending trend that occurred at larger laser power is discussed in comparison to the plastic strain development.The study shows that relatively larger heat input below 6.7 J/mm can help to avoid the bending angle reduction phenomenon and the opposite bending trend is highly dependent on the larger laser power.For achieving the expected cumulative bending angle in multi-pass laser bending,it is recommended to decrease the scanning velocity at a relatively low laser power level while increase the scanning velocity at a high level of laser power.

Determining Atmospheric Boundary Layer Height with the Numerical Differentiation Method Using Bending Angle Data from COSMIC

This paper presents a new method to estimate the height of the atmospheric boundary layer(ABL) by using COSMIC radio occultation bending angle(BA) data. Using the numerical differentiation method combined with the regularization technique, the first derivative of BA profiles is retrieved, and the height at which the first derivative of BA has the global minimum is defined to be the ABL height. To reflect the reliability of estimated ABL heights, the sharpness parameter is introduced, according to the relative minimum of the BA derivative. Then, it is applied to four months of COSMIC BA data(January, April, July, and October in 2008), and the ABL heights estimated are compared with two kinds of ABL heights from COSMIC products and with the heights determined by the finite difference method upon the refractivity data. For sharp ABL tops(large sharpness parameters), there is little difference between the ABL heights determined by different methods, i.e.,the uncertainties are small; whereas, for non-sharp ABL tops(small sharpness parameters), big differences exist in the ABL heights obtained by different methods, which means large uncertainties for different methods. In addition, the new method can detect thin ABLs and provide a reference ABL height in the cases eliminated by other methods. Thus, the application of the numerical differentiation method combined with the regularization technique to COSMIC BA data is an appropriate choice and has further application value.

The Variational Assimilation Experiment of GPS Bending Angle

More and more new types of observational data provide many new opportunities for improving numerical weather forecasts. Among these, the GPS (Global Positioning System) bending angle is undoubtedly very important. There are many advantages of the GPS bending angle, such as high resolution, availability in all weather conditions, and global data coverage. Thus it is very valuable to assimilate GPS bending angle data into numerical weather models. This paper introduces how to obtain and assimilate the GPS bending angle. There are two methods of assimilation: the indirect method and direct method, and they are both introduced in this paper. During the minimizing process of variational assimilation, calculation efficiency is very important and the optimal step size greatly influences the algorithm efficiency. Based on the characteristics of the minimizing algorithm, we obtain an adaptive method for calculating the optimizing step suitable for all kinds of minimization algorithms through mathematical deduction. Finally, a numerical variational assimilation experiment is performed using the GPS bending angle data of 11 October 1995. The numerical results indicate the validity of the variational assimilation method and the adaptive method introduced here.

Bending Properties of GCr15 Steel Guide Rail under the Multi-step Loading

To analyze the bending properties of GCr15 steel guide rail based on the elastic-plastic theory, the novel bending loading method consisting of multi-step loading and corresponding unloading was applied in three specimens with different cross section shape and different heat treatment condition. According to the experimental results, using numerical calculation software program and the numerical simulation with finite element analysis （FEA）, the relationships among the maximal load and displacement on cross section shape with each step bend loading, the loading stroke with the heat treatment condition, and the loading stroke with cross section shape were gained, and also those curves were discussed qualitatively. Finally, the contrast results between the numerical simulation and experiment were carried out to study the influence about the multi-step loading on specimen. It is put forward that enlightenment for the straightening stroke in the precision linear guide rail manufacture process.

Optimisation of Effective Design Parameters for an Automotive Transmission Gearbox to Reduce Tooth Bending Stress

Optimisation of effective design parameters to reduce tooth bending stress for an automotive transmission gearbox is presented. A systematic investigation of effective design parameters for optimum design of a five-speed gearbox is studied. For this aim contact ratio effect on tooth bending stress by the changing of contact ratio with respect to pressure angle is analysed. Additionally, profile modification effects on tooth bending stress are presented. During the optimisation, the tooth bending stress is considered as the objective function, and all the geometric design parameters such as module, teeth number etc. are optimised under two different constraints, including tooth contact stress and constant gear centre distance. It can be concluded that higher the contact ratio results in a reduced tooth bending stress, while higher the pressure angle caused an increase in tooth bending stress and contact stress, since decreases in the contact ratio. In addition, application of positive profile modification on tooth reduces tooth bending stress. All of the obtained optimum solutions satisfy all constraints.

Experimental and theoretical analyses of package-on-package structure under three-point bending loading

High density packaging is developing toward miniaturization and integration, which causes many difficulties in designing, manufacturing, and reliability testing. Package-on-Package （POP） is a promising three-dimensional high- density packaging method that integrates a chip scale package （CSP） in the top package and a fine-pitch ball grid array （FBGA） in the bottom package. In this paper, in-situ scanning electron microscopy （SEM） observation is carried out to detect the deformation and damage of the PoP structure under three-point bending loading. The results indicate that the cracks occur in the die of the top package, then cause the crack deflection and bridging in the die attaching layer. Furthermore, the mechanical principles are used to analyse the cracking process of the PoP structure based on the multi-layer laminating hypothesis and the theoretical analysis results are found to be in good agreement with the experimental results.

Improvement of springback prediction of wide sheet metal air bending process

Accurate springback prediction of wide sheet metal air bending process is important to improve product quality and ensure the precision in dimension. The definition of elastic limit bend angle was proposed. Based on cantilever beam elastic deforming theory, the geometrical parameters of forming tools, sheet thickness and the material yielding strain were derived and validated by the finite element method (FEM). Employing the degree of elastic limit bend angle, the equation for springback prediction was constructed, the results calculated fit well with experimental data. Especially for the small bend angle, the predicted results by equation were applied to conduct the springback prediction and compensation in industries and give closer correlation to the experimental data than those calculated by engineering theory of plastic bending.

Improved knowledge-based neural network(KBNN)model for predicting spring-back angles in metal sheet bending

We develop an efficiently improved knowledge-based neural network(KBNN)associated with optimization algorithms and finite element analysis(FEA)to accurately predict spring-back angles in metal sheet bending.The well-known V and U prevalent processes of bending are considered.The KBNN predictive results are based on the empirical model and artificial neural network(ANN)modeling.The empirical model is constructed from the FEA results using response surface method,while the multilayer perceptron is employed to create the ANN.The trained KBNN can accurately model the relation-ship between the spring-back angles and process parameters.The obtained results are validated against other existing methods showing a high accuracy.

Forming limits under multi-index constraints in NC bending of aluminum alloy thin-walled tubes with large diameters

With increasing diameters of aluminum alloy thin-walled tubes (AATTs), the tube forming limits, i.e. the minimum bending factors, and their predictions under multi-index constraints including wrinkling, thinning and flattening have been being a key problem to be urgently solved for improving tube forming potential in numerical control (NC) bending processes of AATTs with large diameters. Thus in this paper, a search algorithm of the forming limits is put forward based on a 3D elastic-plastic finite element (FE) model and a wrinkling energy prediction model for the bending processes under axial compression loading (ACL) or not. This algorithm enables to be considered the effects of process parameter combinations including die, friction parameters on the multi-indices. Based on this algorithm, the forming limits of the different size tubes are obtained, and the roles of the process parameter combinations in enabling the limit bending processes are also revealed. The followings are found: the first, within the appropriate ranges of friction and clearances between the different dies and the tubes enabling the bending processes with smaller bending factors, the ACL enables the tube limit bending processes after a decrease of the mandrel ball thickness and diameters; then, without considering the effects of the tube geometry sizes on the tube constitutive equations, the forming limits will be decided by the limit thinning values for the tubes with diameters smaller than 80 mm, while the wrinkling for the tubes with diameters no less than 80 mm. The forming limits obtained from this algorithm are smaller than the analytical results, and reduced by 57.39%; the last, the roles of the process parameter combinations in enabling the limit bending processes are verified by experimental results.

Determination of rice panicle numbers during heading by multi-angle imaging

Plant phenomics has the potential to accelerate progress in understanding gene functions and environmental responses. Progress has been made in automating high-throughput plant phenotyping. However, few studies have investigated automated rice panicle counting. This paper describes a novel method for automatically and nonintrusively determining rice panicle numbers during the full heading stage by analyzing color images of rice plants taken from multiple angles. Pot-grown rice plants were transferred via an industrial conveyer to an imaging chamber. Color images from different angles were automatically acquired as a turntable rotated the plant. The images were then analyzed and the panicle number of each plant was determined. The image analysis pipeline consisted of extracting the i2 plane from the original color image, segmenting the image, discriminating the panicles from the rest of the plant using an artificial neural network, and calculating the panicle number in the current image. The panicle number of the plant was taken as the maximum of the panicle numbers extracted from all 12 multi-angle images. A total of 105 rice plants during the full heading stage were examined to test the performance of the method. The mean absolute error of the manual and automatic count was 0.5, with 95.3% of the plants yielding absolute errors within ± 1. The method will be useful for evaluating rice panicles and will serve as an important supplementary method for high-throughput rice phenotyping.

Target detection for low angle radar based on multi-frequency order-statistics

For radar targets flying at low altitude, multiple pathways produce fade or enhancement relative to the level that would be expected in a free-space environment. In this paper, a new detec- tion method based on a wide-ranging multi-frequency radar for low angle targets is proposed. Sequential transmitting multiple pulses with different frequencies are first applied to decorrelate the cohe- rence of the direct and reflected echoes. After receiving all echoes, the multi-frequency samples are arranged in a sort descending ac- cording to the amplitude. Some high amplitude echoes in the same range cell are accumulated to improve the signal-to-noise ratio and the optimal number of high amplitude echoes is analyzed and given by experiments. Finally, simulation results are presented to verify the effectiveness of the method.

Damage Detection for Simply Supported Bridge with Bending Fuzzy Stiffness Consideration

The benchmark of a simply supported beam with damage and bending fuzzy stiffness consideration is established to be utilized for damage detection. The explicit expression describing the Rotational Angle Influence Lines(RAIL) of the arbitrary section in the benchmark is presented as the nonlinear relation between the moving load and the RAIL appeared, when the moving load is located on the damage area. The damage detection method is derived based on the Difference of the RAIL Curvature(DRAIL-C) prior to and following arbitrarily section damage in a simply supported beam with bending fuzzy stiffness consideration. The results demonstrate that the damage position can be located by the DRAIL-C graph and the damage extent can be calculated by the DRAIL-C curve peak. The simply supported box girder as a one-dimensional model and the simply supported truss bridge as a three-dimensional model with the bending fuzzy stiffness are simulated for the validity of the proposed method to be verified. The measuring point position and noise intensity effects are discussed in the simply supported box girder example. This paper provides a new consideration and technique for the damage detection of a simply supported bridge with bending fuzzy stiffness consideration.

Numerical simulation on the process of multi-point forming for tube

To apply the multi-point forming technology to the field of tube processing,the process of multi-point forming for tube is studied.Numerical simulation for the process of multi-point forming for tube is achieved by using elastic-plastic FEM in ABAQUS.During simulation,reasonable coefficient of mass scaling and friction model of penalty function are used.The influence of several major technological parameters on the process is analyzed.When the tube diameter is 60 mm and the forming curvature radius is 1000 mm,the distortion rate of cross-section and the absolute forming error gradually decrease with the increasing of tube wall thickness;However,when the tube wall thickness is constant,the smaller the curvature radius,the larger the distortion rate of cross-section,but as to forming part,its absolute forming error becomes smaller.

Helix Angle Effect on the Helical Gear Load Carrying Capacity

The aim of this study is to investigate the helix angle effect on the helical gear load carrying capacity, including the bending and contact load carrying capacity. During the simulation, the transverse contact ratio is calculated with respect to the constant pressure angle. By changing the helix angle, both the overlap contact ratio and total contact ratio are calculated and simulated. The bending stress and contact stress of a helical gear are calculated and simulated with respect to the helix angle. Solid (CAD) modelling of a pinion gear was obtained using SOLIDWORKS software. The analytically obtained results and finite elements method results are compared. It is observed that increasing the helix angle causes an increase of the contact ratio of the helical gear. Furthermore, increasing the contact ratio reduces the bending stress and contact stress of the helical gear. However, with a constant transverse contact ratio, it is possible to improve the total contact ratio depending on the helix angle. It is concluded that a higher helix angle increases the helical gear bending and contact load carrying capacity.

Articulated Lifting System Modeling Based on Dynamics of Flexible Multi-Body Systems

In lifting sub-system of deep-sea mining system, spherical joint is used to connect lifting pipes to replace fixed joint. Based on Dynamics of Flexible Multi-body systems, the mechanics model of articulated lifting system is established. Under the four-grade and six-grade oceanic condition, dynamic responses of lifting system are simulated and experiment verified. The simulation results are consistent with experimental ones. The maximum moment of flexion is 322 kN-m on the first pipe under six-grade sea condition. It is seen that the articulated connection can reduce the moment of flexion. The bending deformation of pipe center is researched, and the maximum is 0. 000479 m on the first pipe. Deformation has a little effect on the motion of system. It is feasible to analyze articulated lifting system by applying the theory of flexible multi-body dynamics. The articulated lifting system is obviously better than the fixed one.

Retrieval of Aerosol Optical Properties over a Vegetation Surface Using Multi-angular, Multi-spectral, and Polarized Data

An algorithm to retrieve aerosol optical properties using multi-angular,multi-spectral,and polarized data without a priori knowledge of the land surface was developed.In the algorithm,the surface polarized reflectance was estimated by eliminating the atmospheric scattering from measured polarized reflectance at 1640 nm.A lookup table （LUT） and an iterative method were adopted in the algorithm to retrieve the aerosol optical thickness （AOT,at 665 nm） and the （A）ngstr（o）m exponent （computed between the AOTs at 665 and 865 nm）.Experiments were performed in Tianjin to verify the algorithm.Data were provided by a newly developed airborne instrument,the Advanced Atmosphere Multi-angle Polarization Radiometer （AMPR）.The AMPR measurements over the target field agreed well with the nearby ground-based sun photometer.An algorithm based on Research Scanning Polarimeter （RSP） measurements was introduced to validate the observational measurements along a flight path over Tianjin.The retrievals were consistent between the two algorithms.The AMPR algorithm shows potential in retrieving aerosol optical properties over a vegetation surface.

A new scheme for retrieving ocean surface salinity from simulated multi-angular SMOS brightness temperature

The European Space Agency will launch the first salinity satellite for remotely sensing the global soil moisture and ocean salinity (SMOS) at a sun-synchronous orbit in 2009. One of the payloads on the satellite is a synthetic aperture microwave radiometer (MIRAS), which is an innovative instrument designed as a two-dimensional (2D) interferometer for acquiring brightness temperature (TB) at L-band (1.4 GHz). MIRAS allows measuring TB at a series of incidences for full polarizations. As the satellite travels, a given location within the 2D field of view is observed from different incidence angles. The authors develop a new scheme to retrieve the sea-surface salinity (SSS) from SMOS's TB at multi-incidence angles in a pixel, utilizing the properties of emissivity changing with incidence angles. All measurements of a given Stokes parameter in a pixel are first fitted to incidence angles in three order polynomial, and then the smoothed data are used for retrieving the SSS. The procedure will remove the random noise in TB greatly. Furthermore, the new method shows that the error in retrieved SSS is very sensitive to the system biases in the calibrated TB of the sensor, but the error in the retrieval is also a system bias, which can be corrected by post-launch validation. Therefore, this method may also serve as a means to evaluate the calibration precision in TB.

Nickel multilayers and their effects on bend fatigue strength of leads

Nickel is commonly coated on the outer leads for T8 metal package. The leadselectrodeposited by conventional dull or bright nickel over 5μm at direct current from Watt bathare hard to pass the bend fatigue test for three times. Nickel electrodeposited at multi waveformcurrent including direct current, single and double pulse from sulfamate bath can improve the bendfatigue strength of leads. Such nickel plating has a multilayer structure, its morphology ofsublayers can be clearly seen in its cross section with SEM. The electrochemical study shows thatthese sublayers have different corrosion potentials. The bend fatigue test of leads with suchplating for T8 metal package shows that the number of bend increases with the decrease of averagecurrent density of multi waveform, which can be attributed to the reduction of every sublayerthickness and the increase of layer numbers under the same condition of total thickness.

Concurrent multi-scale design optimization of composite frame structures using the Heaviside penalization of discrete material model

This paper deals with the concurrent multi-scale optimization design of frame structure composed of glass or carbon fiber reinforced polymer laminates. In the composite frame structure, the fiber winding angle at the micro-material scale and the geometrical parameter of components of the frame in the macro-structural scale are introduced as the independent variables on the two geometrical scales. Considering manufacturing requirements, discrete fiber winding angles are specified for the micro design variable. The improved Heaviside penalization discrete material optimization interpolation scheme has been applied to achieve the discrete optimization design of the fiber winding angle. An optimization model based on the minimum structural compliance and the specified fiber material volume constraint has been established. The sensitivity information about the two geometrical scales design variables are also deduced considering the characteristics of discrete fiber winding angles. The optimization results of the fiber winding angle or the macro structural topology on the two single geometrical scales, together with the concurrent two-scale optimization, is separately studied and compared in the paper. Numerical examples in the paper show that the concurrent multi-scale optimization can further explore the coupling effect between the macro-structure and micro-material of the composite to achieve an ultralight design of the composite frame structure. The novel two geometrical scales optimization model provides a new opportunity for the design of composite structure in aerospace and other industries.

SCATTERING OF CIRCULAR CAVITY IN RIGHT-ANGLE PLANAR SPACE TO STEADY SH-WAVE

Complex function method and multi-polar coordinate transformation technology are used here to study scattering of circular cavity in right-angle planar space to SH-wave with out-of-plane loading on the horizontal straight boundary. At first, Green function of right-angle planar space which has no circular cavity is constructed; then the scattering solution which satisfies the free stress conditions of the two right-angle boundaries with the circular cavity existing in the space is formulated. Therefore, the total displacement field can be constructed using overlapping principle. An infinite algebraic equations of unknown coefficients existing in the scattering solution field can be gained using multi-polar coordinate and the free stress condition at the boundary of the circular cavity. It can be solved by using limit items in the infinite series which can give a high computation precision. An example is given to illustrate the variations of the tangential stress at the boundary of the circular cavity due to different dimensionless wave numbers, the location of the circular cavity, the loading center and the distributing range of the out-of-plane loading. The results show the efficiency and effectiveness of the mothod introduced here.