Optimal design of butterfly-shaped linear ultrasonic motor using finite element method and response surface methodology

A new method for optimizing a butterfly-shaped linear ultrasonic motor was proposed to maximize its mechanical output. The finite element analysis technology and response surface methodology were combined together to realize the optimal design of the butterfly-shaped linear ultrasonic motor. First, the operation principle of the motor was introduced. Second, the finite element parameterized model of the stator of the motor was built using ANSYS parametric design language and some structure parameters of the stator were selected as design variables. Third, the sample points were selected in design variable space using latin hypercube Design. Through modal analysis and harmonic response analysis of the stator based on these sample points, the target responses were obtained. These sample points and response values were combined together to build a response surface model. Finally, the simplex method was used to find the optimal solution. The experimental results showed that many aspects of the design requirements of the butterfly-shaped linear ultrasonic motor have been fulfilled. The prototype motor fabricated based on the optimal design result exhibited considerably high dynamic performance, such as no-load speed of 873 ram/s, maximal thrust of 27.5 N, maximal efficiency of 43%, and thrust-weight ratio of 45.8.

Effects of surface finish and treatment on the fatigue behaviour of vibrating cylinder block using frequency response approach

This paper presents the effects of surface finish and treatment on the high cycle fatigue behaviour of vibrating cylinder block of a new two-stroke free piston engine at complex variable amplitude loading conditions using frequency response approach. Finite element modelling and frequency response analysis was conducted using finite element analysis software Package MSC.PATRAN/MSC.NASTRAN and fatigue life prediction was carded out using MSC.FATIGUE software. Based on the finite element results, different frequency response approach was applied to predict the cylinder block fatigue life. Results for different load histories and material combinations are also discussed. Results indicated great effects for all surface finish and treatment. It is concluded that polished and cast surface finish conditions give the highest and lowest cylinder block lives, respectively; and that Nitrided treatment leads to longest cylinder block life. The results were used to draw contour plots of fatigue life and damage in the worst or most damaging case.

Nonlinear finite-element-based structural system failure probability analysis methodology for gravity dams considering correlated failure modes

The structural system failure probability(SFP) is a valuable tool for evaluating the global safety level of concrete gravity dams.Traditional methods for estimating the failure probabilities are based on defined mathematical descriptions,namely,limit state functions of failure modes.Several problems are to be solved in the use of traditional methods for gravity dams.One is how to define the limit state function really reflecting the mechanical mechanism of the failure mode;another is how to understand the relationship among failure modes and enable the probability of the whole structure to be determined.Performing SFP analysis for a gravity dam system is a challenging task.This work proposes a novel nonlinear finite-element-based SFP analysis method for gravity dams.Firstly,reasonable nonlinear constitutive modes for dam concrete,concrete/rock interface and rock foundation are respectively introduced according to corresponding mechanical mechanisms.Meanwhile the response surface(RS) method is used to model limit state functions of main failure modes through the Monte Carlo(MC) simulation results of the dam-interface-foundation interaction finite element(FE) analysis.Secondly,a numerical SFP method is studied to compute the probabilities of several failure modes efficiently by simple matrix integration operations.Then,the nonlinear FE-based SFP analysis methodology for gravity dams considering correlated failure modes with the additional sensitivity analysis is proposed.Finally,a comprehensive computational platform for interfacing the proposed method with the open source FE code Code Aster is developed via a freely available MATLAB software tool(FERUM).This methodology is demonstrated by a case study of an existing gravity dam analysis,in which the dominant failure modes are identified,and the corresponding performance functions are established.Then,the dam failure probability of the structural system is obtained by the proposed method considering the correlation relationship of main failure modes on the basis of the mechanical mechanism analysis with the MC-FE simulations.

Finite element model updating of a rod-type ultrasonicmotor based on response surface method

The conventional finite element model （FEM） of a rod-type ultrasonic motor is usually simplified by means of continuous composite structure. Because the actual contact characteristics between the parts of the ultrasonic motor is ignored, there is bigger error between the calculated values and experimental results. Aiming at solving problem, a new modeling method of a rod-type ultrasonic motor is presented to obtain a high-accuracy FEM. The bolt pretension and the normal contact stiffness and friction coefficient of the contact surface of ultrasonic motor are all considered in this method, and the significant parameters of working mode of the motor are selected by the response surface method, and the goal of calculating the structural response rapidly is realized by building the response surface model to replace the FEM. The result of finite element model updating shows that the average error of modal frequencies of updated model drops to 0.21% from 1.20%. The accuracy of FEM is obviously improved, which indicates that the FEM updating based on response surface method is of great application value on the design for a rod-type ultrasonic motor.

油罐车自主加注臂密封圈响应面优化及分析

为了提高油罐车自主加注臂前端快接装置的密封性能,设计了一种内胀式橡胶密封圈,并结合响应面法和有限元法对密封圈进行了优化和分析。首先,基于有限元软件ANSYS Workbench对密封圈进行建模和仿真,研究了密封圈的倒圆半径、厚度和压缩量对密封圈性能的影响;然后,将密封圈与管壁的接触面积、接触压力和所受等效应力作为优化目标,利用Design⁃Expert软件建立了密封结构的优化模型,并通过多目标优化获得最优设计方案;最后,进行了密封圈优化前后的性能对比和分析。数值测试表明,在最大3 MPa介质压力下,优化后密封圈的接触压力提升了1.3 MPa,有效接触面积更大,且接触带更加集中,有利于实现快接装置和油罐车加注口的有效密封,同时等效应力降低了4.3%,有助于延长密封圈的使用寿命。

介质粗糙面与组合目标宽带电磁散射特性研究

文中对介质粗糙面和组合目标的宽带复合电磁散射特性进行研究,通过数值计算得到了复合散射系数频率响应曲线。分析结果显示,后向复合散射系数在宽频带范围内随着频率的变化而产生振荡,粗糙面的高度均方根、介电常数、组合目标尺度、目标介电常数等因素对复合散射系数有显著的影响,且影响规律较为复杂。相比之下,粗糙面的相关长度对复合散射系数的影响较为微弱。当目标是理想导体时,频率响应曲线近似呈现出准周期性的振荡形态。

Controlling Flow Instability in Straight Spur Gear Forging Using Numerical Simulation and Response Surface Method

Workability domain without the onset of flow instability was developed by numerical simulation and response surface method （RSM） for complex-shaped straight spur gear forging. The processing map of AZ31B alloys was calculated from flow stress curves and then integrated with the finite element model to simulate the distribution of flow instability in the straight spur gear undergoing isothermal forging process. Occurrence of flow instability depends on forging temperature, punch velocity and billet reduction. Taking forging temperature and punch velocity as design variables, while billet reduction as response variable, RSM of workability domain was established. Analysis of variance indicates that forging temperature is the most significant factor determining the appearance of flow instability in the forged gear. Flow instability is easier to take place at lower temperatures of 250 and 300 ℃ in the early stage of forging but at higher temperatures of 350 and 400 ℃ in the later stage of forging, which is attributed to different deformation mechanisms and dynamic recrystallization behaviors at different temperatures or deformation levels. Meanwhile, increasing punch velocity further reduces the workability of the forged gear. Four different processing paths were chosen to carry out the gear forging trials. Visual observations and metallographic examinations demonstrate that the developed workability domain contributes to optimization of forging parameters.

基于响应面法与MOGA算法的竹集成材榫接合椅子节点力学分析及优化

竹集成材是符合“双碳”目标的可持续发展绿色材料,具有“以竹代木”的巨大潜力。本研究借助竹集成材优良材料性能,基于榫卯结构特性,以竹集成材榫接合椅子为例,运用有限元法(FEM)进行椅子静载荷及耐久性分析,探究竹集成材榫接合椅子及榫接合节点力学特性,搭建响应面模型求解竹集成材T型椭圆榫接合节点榫卯尺寸与其最大等效应力、总形变和最小安全系数的关系,并运用MOGA多目标遗传算法以形变最小化、安全系数最大化为优化目标,进行榫卯尺寸优化。结果表明:竹集成材榫接合椅子静载荷分析所得椅子最大等效应力为6.818 MPa,位于座面大边与椅后腿榫接合节点;最大等效应变值为4.245×10^(-3),位于椅子扶手与椅后腿榫接合节点;椅子发生的最大形变为4.433 mm,分布在椅子靠背位置。椅子耐久性分析所得最大等效应力及最大等效应变均位于椅子扶手与椅后腿榫接合节点,分别为4.999 MPa和3.113×10^(-3);椅子整体发生的最大形变为3.251 mm,位于椅子靠背上端。由竹集成材T型榫接合节点响应面分析可知,椭圆榫接合节点的最大等效应力及最大形变随着榫头厚度a及榫头长度l的增大而减小,安全系数随之增大,榫卯尺寸对T型榫接合节点力学强度的影响以榫头厚度a和榫头长度l为主,榫头宽度b影响不显著。运用MOGA算法优化竹集成材椭圆榫尺寸,优化结果与实际试验结果的相对误差为3.93%,相对误差较小,证明优化方法及结果有效。本研究为竹集成材椭圆榫的加工生产提供参考,并为竹集成材榫接合椅子的榫卯尺寸设计提供科学优化方法。

基于沥青混合料动态模量主曲线参数的沥青路面结构分析

为研究沥青混合料动态模量主曲线参数变化以及交互作用对沥青路面结构响应的影响,采用有限元方法建立沥青路面结构三维模型,并开展半刚性基层和柔性基层沥青路面结构计算;以动态模量主曲线参数δ、α、β、γ为影响因素,以沥青层底最大拉应变、路基顶面竖向压应变为响应目标,采用响应面法(RSM)建立动态模量主曲线参数与沥青路面关键结构响应的响应面模型,分析主曲线参数及其交互作用对沥青路面结构关键响应的影响。结果表明:动态模量主曲线参数对结构关键响应的影响受响应类型和路面结构类型的共同影响,其中参数δ的影响最大,α次之,β、γ的影响相对较小。半刚性基层路面结构的沥青面层层底拉应变和路基竖向压应变不受参数间的交互作用影响,参数α和β的交互作用对柔性基层路面结构的路基竖向压应变影响显著。

不同结构参数对高速开关阀液压力的影响研究

因其具有价格低廉、抗污染性强等优点,高速开关阀已被广泛运用到各种车辆的制动系统中,其动态性能直接影响到车辆的制动效果,而阀芯所受的液压力是决定高速开关阀动态特性优劣的关键参数。针对不同参数对高速开关阀液压力的影响,以及实际工程中阀芯液压力难以测量的问题,采用计算流体动力学(CFD)对高速开关阀进行了数值模拟。首先,基于有限体积法(FVM),建立了不同开度、压差、温度、以及结构参数(阀座节流孔直径和锥角)的三维仿真模型;然后,对比不同网格数量的仿真结果,排除了网格数量对于仿真结果的影响,并详细分析了各参数对液压力的影响,得出了高速开关阀液压力与各参数之间的变化规律;最后,采用响应面分析结合遗传算法对开关阀的结构参数进行了优化。研究结果表明:随着阀芯开度的增加,节流区域发生了转变;较大的压差会导致液压力产生较大幅度的变化;相较于高温,低温对液压力有着更加显著的影响;对结构参数进行优化后,最小开度的液压力提高了49.2%,提高了阀控制稳定性,为高速开关阀线性控制设计提供了理论基础。

基于田口法和响应面法的柔索冲击除锈机工艺参数优化研究

柔索冲击接触除锈是一种很好的钢板表面除锈及强化工艺方法,合理的工艺及结构参数组合对除锈质量有较大的影响,找到较优的参数组合对提高除锈质量有重要的意义。以项目组前期研发的柔索冲击接触钢板表面除锈机为研究对象,提出一种针对直接影响装置除锈质量的相关工艺参数的优化方法。建立除锈机的接触力学模型,根据力学模型影响因素,确定柔索直径、滚筒高度、滚筒转速为待优化参数;采用田口法及响应面优化方法,计算参数组合信噪比值评价方案稳定性,构建面向冲击接触应力的预测优化模型,进一步全局预测优化,获取稳定性最佳、接触应力最佳参数组合,实现除锈效果提升的同时,提高钢板表面机械性能。最后以最佳参数组合调整柔索冲击除锈机进行除锈测试,验证了所提出优化方法实现了柔索冲击除锈机的除锈性能提升的目标。

一种艾灸装置的结构设计及支撑座的优化设计

为了提高艾灸的质量和效率,设计了一种艾灸装置,整个艾灸装置既能实现自动清灰,且艾灸温度能精准控制。为了艾灸装置的使用方便和成本低减,对艾灸装置的关键部件艾灸支撑座进行了优化设计,以艾灸支撑座的三个结构尺寸为设计变量,利用OSF方法选取了设计变量的试验点,建立了径向基神经网络代理模型,并检验了该模型的精度。以艾灸支撑座的质量和最大变形量为多目标优化函数,以最大变形量和最大应力为约束条件,利用多岛遗传算法得到Pareto最优解集。在保证艾灸支撑座力学性能不降低的前提下,质量减轻了15.01%。结果表明,该方法具有较高的精度和较强的工程实用性。

PDC混合布齿钻头破碎非均质花岗岩数值模拟

非常规油气资源所处地层复杂,开采难度大,钻井过程中钻遇地层密实度高,对钻头性能提出了更高要求。普通PDC钻头主要依靠切削齿剪切破碎岩石,攻击性弱,不仅导致钻头寿命和破岩效率严重下降,而且增加了钻井成本。为探究混合布齿PDC钻头的破岩机理和效果,提升PDC钻头破岩效率和寿命,建立了非均质花岗岩模型,使用有限元方法对比了斧形、三棱形和圆形PDC齿混合布齿的破岩效果,优选了最佳布齿方案,并使用响应面法优化了齿间距,对前后排齿不同高度差情况下的钻头破岩效果及规律进行了分析,最后结合钻头的现场应用对比分析了混合布齿、斧形齿和三棱形齿PDC钻头的破岩过程。研究结果表明:①斧形齿攻击性强,有利于吃入岩石,适用于刀翼前排,而三棱形齿更稳定,适用于刀翼后排;②混合布齿最佳方案为前排斧形齿,后排三棱形齿与斧形齿交替布置,后排齿距离前排齿的最佳横向距离为10.0 mm、10.1 mm,最佳纵向距离均为7.0 mm;③前排齿破岩后能释放岩石内应力,便于后排齿的破岩,但产生的应力区域有限,建议前后排齿高度差不超过1 mm;④围压条件下按照最佳方案布齿的PDC钻头相较于单斧形齿和三棱形齿的PDC钻头,钻井进尺分别提升了21.4%和44.1%。结论认为,混合布齿钻头兼具高破岩效率和稳定性,在深部和难钻地层具有较好的钻进效果,具有良好的现场推广应用价值。

基于响应面法和ARO算法的桥梁有限元模型修正

针对桥梁结构模型修正过程中计算量大、全局寻优难等问题,提出一种基于响应面法和人工兔优化算法(artificial rabbits optimization, ARO)的桥梁有限元模型修正方法。该方法通过F检验法明确对结构响应影响显著的参数并建立响应面模型作为桥梁有限元模型的代理模型进行迭代计算,然后通过静动力联合修正法基于特征响应的响应面模型计算值和试验值构建目标函数,并通过人工兔优化算法对目标函数进行迭代计算进而获得精确的有限元模型参数。采用该方法对变截面连续刚构黄河特大桥有限元模型进行修正,结果显示:基于显著性分析结果建立的桥梁响应面模型相关系数大于0.98,且平均绝对误差低于0.05;模型修正后主梁关键截面竖向位移最大相对误差由32.97%降至5.72%,平均相对误差由20.67%降至3.61%,桥梁前3阶竖向自振频率平均相对误差仅为0.18%。可见,采用所提方法修正的模型能用于评价桥梁结构实际受力性能。

基于响应面法与遗传算法的梁式桥有限元模型更新

为了使自主开发的智能健康监测平台产生的海量监测数据利益最大化,在平台中添加结构分析模块,扩大平台的应用范围。针对有限元模型分析的准确性与可靠性,提出一种将响应面法和遗传算法相结合的有限元模型更新方法。首先,根据设计资料建立结构理论有限元模型并确定结构更新参数;其次,采用中心复合试验设计方法获取样本点并计算结构响应;接着,基于逐步回归分析进行显著性检验并利用最小二乘法拟合得到更新参数与特征响应之间的响应面函数关系;最后,联合结构静动力响应构造目标函数,利用遗传算法对其进行迭代优化求解,并将最优解代入理论有限元模型中,从而实现结构有限元模型更新。以简支梁为例,选择以弹性模量和截面惯性矩为更新参数,以频率和位移为结构响应,结合动静载试验结果,对其进行有限元模型更新,验证所提方法的有效性。结果表明:模型更新后的有限元模型计算分析结果与实测值的相对误差大幅度降低,且计算值更加接近于实测值。基于响应面法与遗传算法的有限元模型更新方法可以为智能健康监测平台提供更加准确的有限元模型,对损伤识别和预警评估等模块提供了便利。

基于响应曲面中心组合设计的介质阻挡负载特征参数分析与优化

为了充分发挥介质阻挡放电(DBD)负载的性能,以高频脉冲激励作为介质阻挡负载的激励波形,以第一次放电时的负载电流幅值作为优化目标。基于响应曲面法中心组合设计建立数学模型,分析介质阻挡层厚度、脉冲电压幅值、脉冲升降沿时间和相对介电常数4个因素对高频脉冲激励下DBD负载第一次放电时负载电流幅值的影响,优化介质阻挡负载特征参数。结果表明,对DBD负载电流的影响强度从大到小依次为介质阻挡层厚度、脉冲电压幅值、脉冲升降沿时间、相对介电常数。在本文设定条件下,负载电流幅值的最大值8.692A在脉冲升降沿时间为200ns、脉冲电压幅值为4kV、介质阻挡层厚度为1mm、相对介电常数为8时获得。

基于响应面法的纯钛小弯曲半径弯头液压成形优化设计

针对小弯曲半径弯头在成形时极易产生起皱、过度减薄等缺陷,本文中采用液压成形来成形规格为Φ69.2 mm×1 mm、弯曲半径为60 mm的TA2纯钛弯头。为了得到小弯曲半径弯头管材在充液压弯成形过程中的最佳工艺参数,通过有限元模拟方法,对小弯曲半径弯头进行了有限元模拟分析。首先研究了在充液压弯成形过程中,成形前内压力和单边补料量对小弯曲半径弯头管材成形效果的影响,然后结合响应面法,采用Central Composite Design(CCD)方式进行方案设计,建立有效的响应面模型,研究在成形过程中,以成形前内压力、单边补料量和摩擦系数为设计变量,以小弯曲半径弯头成形后的减薄量和增厚量为响应量。结果表明,在一定的范围内,采用较高的内压力和较高的单边补料量能够有效的提高小弯曲半径弯头的成形性。响应面优化结果表明,在内压力为12.164 MPa、单边补料量为7 mm以及摩擦系数小于0.2,能够使零件的减薄量控制在15.7%,增厚量控制在5.792%。实验验证得到的最大减薄率为15%,最大增厚率为5.7%,实验结果与数值模拟对比良好,未出现明显缺陷,验证了响应面模型的准确性,并得到最佳的充液压弯成形工艺路径。

基于响应面法的涂布机烘箱风嘴结构优化研究

为提升涂布机烘箱的干燥特性,本研究针对风嘴结构及其附近区域展开研究,分析风嘴多结构参数对内部流场特性的交互影响。借助有限元分析和响应面法,建立烘箱风嘴多结构参数交互影响下的流场特性数学回归模型,基于此进行风嘴结构的优化设计,并将优化结果与仿真值进行误差比较,验证所构建回归模型的准确性。结果表明,构建的含有多结构参数的风嘴流场特性回归模型拟合度较好,基材温度、基材表面风速、基材压力3组响应值的预测值和仿真实验值误差均小于3%,能够较好描述风嘴局部流场特性变化规律。

抓取机械臂的强度分析和优化设计

以DOBOT Magician机器人机械臂为研究对象,为降低其质量,减少材料消耗,采用尺寸优化和拓扑优化相结合的方法对其结构的优化设计进行了研究。首先使用建模软件建立三组机器人小臂的参数化模型,将其导入Workbench中进行应力分析和弯曲刚度分析,对三组结果进行对比分析确定危险工况。然后以质量、变形和应力为目标参数对危险工况下小臂的参数进行灵敏度分析,得到对目标参数影响最大的参数,并以这些参数为设计变量,采用响应面优化方法和拓扑优化方法对小臂代理模型进行尺寸和结构优化。优化结果表明:在保障精度和强度的前提下,通过对小臂的轻量化设计,使其质量降低了32.8%,最大应力值降低了21.1%,最大变形减小了24.3%,弯曲刚度增加31.8%,成功实现了小臂的轻量化。同时,该研究也为类似的优化设计提供了一种可行的实施方案流程。

刀具槽型参数对切屑流向的影响及响应面分析

为更好地控制切屑,通过ABAQUS建立了梯形断屑槽的切削有限元仿真模型,研究了梯形断屑槽参数中刀尖处最小槽间距、反屑面角、断屑槽斜角对切屑流向的影响,并通过响应面法分析并拟合出切屑流向与这三个影响因子的二次多项式响应模型。结果表明:断屑槽槽间距越小,反屑面角、断屑槽斜角对切屑流向的影响越大,且断屑槽斜角对切屑流向的影响最大,反屑面角次之。通过响应面法建立的二次多项式数学模型能够描述刀尖处的最小槽间距、反屑面角、断屑槽斜角对切屑流向的影响规律,并且可以在一定范围内进行预测。