Optimization of Fixture Number in Large Thin-Walled Parts Assembly Based on IPSO

There are lots of researches on fixture layout optimization for large thin-walled parts.Current researches focus on the positioning problem,i.e.,optimizing the positions of a constant number of fixtures.However,how to determine the number of fixtures is ignored.In most cases,the number of fixtures located on large thin-walled parts is determined based on engineering experience,which leads to huge fixture number and extra waste.Therefore,this paper constructs an optimization model to minimize the number of fixtures.The constraints are set in the optimization model to ensure that the part deformation is within the surface profile tolerance.In addition,the assembly gap between two parts is also controlled.To conduct the optimization,this paper develops an improved particle swarm optimization(IPSO)algorithm by integrating the shrinkage factor and adaptive inertia weight.In the algorithm,particles are encoded according to the fixture position.Each dimension of the particle is assigned to a sub-region by constraining the optional position range of each fixture to improve the optimization efficiency.Finally,a case study on ship curved panel assembly is provided to prove that our method can optimize the number of fixtures while meeting the assembly quality requirements.This research proposes a method to optimize the number of fixtures,which can reduce the number of fixtures and achieve deformation control at the same time.

Warm bending mechanism of extrados and intrados of large diameter thin-walled CP-Ti tubes

In order to develop the warming bending technology of the large diameter thin-walled（LDTW） commercial pure titanium alloy CP-Ti tubes, the warm bending mechanism of the extrados and intrados of LDTW CP-Ti tubes was researched. By EBSD analysis and Vickers hardness test, the changes of microstructure and strength of the tubes at different bending temperatures of 293, 423 and 573 K, were analyzed. The results show： 1） The extrados of the bent tube deforms mainly by slip, along with few twinning, and the preferred orientation is similar to that of the initial tube; the intrados of the bent tube experiences compression deformation mainly by {1 012} tensile twinning, and the twinning makes the preferred orientation of wall materials change sharply. 2） The Vickers hardness values of both the extrados and intrados of the samples after bending increase greatly; the Vickers hardness values of the intrados are much higher than those of the extrados, and Vickers hardness values of the RD-TD planes are always higher than those of the RD-LD planes, which are related to the different deformation mechanisms.

Eliminating shrinkage defects and improving mechanical performance of large thin-walled ZL205A alloy castings by coupling travelling magnetic fields with sequential solidification

ZL205 A alloys with large thin-walled shape were continuously processed by coupling travelling magnetic fields(TMF)with sequential solidification,to eliminate the shrinkage defects and optimize the mechanical performance.Through experiments and simulations,the parameter optimization of TMF and the influence on feeding behavior,microstructure and properties were systematically studied.The results indicate that the magnetic force maximizes at the excitation current of 20 A and frequency of 200 Hz under the experimental conditions of this study,and increases from center to side-walls,which is more convenient to process thin-walled castings.TMF can break secondary dendritic arm and dendrites overlaps,widen feeding channels,prolong the feeding time,optimize the feeding paths,eliminate shrinkage defects and improve properties.Specifically,for as-cast state,TMF with excitation current of 20 A increases ultimate tensile strength,elongation and micro-hardness from 186 MPa,7.3%and 82.1 kg/mm^(2) to 221 MPa,11.7%and 100.5 kg/mm^(2),decreases porosity from 1.71%to 0.22%,and alters brittle fracture to ductile fracture.

STRESS CONCENTRATIONS IN CYLINDRICAL SHELLS WITH LARGE OPENINGS

Based on Donnell's shallow shell equation, a new method is given in this paper to analyze theoretical solutions of stress concentrations about cylindrical shells with large openings. With the method of complex variable function, a series' of conformal mapping functions are obtained from different cutouts' boundary curves in the developed plane of a cylindrical shell to the unit circle. And, the general expressions for the equations of a cylindrical shell, including the solutions of stress concentrations meeting the boundary conditions of the large openings' edges, are given in the mapping plane. Furthermore, by applying the orthogonal function expansion technique, the problem can be summarized into the solution of infinite algebraic equation series. Finally, numerical results are obtained for stress concentration factors at the cutout's edge with various opening's ratios and different loading conditions. This new method, at the same time, gives a possibility to the research of cylindrical shells with large non-circular openings or with nozzles.

Strip Layer Method for Analysis of the Three-Dimensional Stresses and Spread of Large Cylindrical Shell Rolling

As the traditional forging process has many problems such as low efficiency, high consumption of material and energy, large cylindrical shell rolling is introduced. Large cylindrical shell rolling is a typical rotary forming technology, and the upper and lower rolls have different radii and speeds. To quickly predict the three-dimensional stresses and eliminate fishtail defect, an improved strip layer method is developed, in which the asymmetry of the upper and lower rolls, non-uniform deformation and stress, as well as the asymmetrical spread on the end surface are considered. The deformation zone is divided into a certain number of layers and strips along the thickness and width, respectively. The transverse displacement model is constructed by polynomial function, in order to increase the computation speed greatly. From the metal plastic mechanics principle, the three-dimensional stress models are established. The genetic algorithm is used for optimization calculation in an industrial experiment example. The results show that the rolling pressure, the normal stresses, the upper and lower friction stress distributions are not similar with those of a general plate rolling. There are two relative maximum values in rolling pressure distribution. The upper and lower longitudinal friction stresses change direction nearby the upper and lower neutral points, respectively. The fishtail profile of spread on the end surface is predicted satisfactorily. The reduction could be helpful to eliminate fishtail defect. The large cylindrical shell rolling example illustrates the calculation results acquired rapidly are good agreements with the finite element simulation and experimental values of previous study. A highly effective and reliable three-dimensional simulation method is proposed for large cylindrical shell rolling and other asymmetrical rolling.

A MODIFIED HELLINGER-REISSNER VARIATIONAL FUNCTIONAL INCLUDING ONLY TWO INDEPENDENT VARIABLES FOR LARGE DISPLACEMENT OF THIN SHALLOW SHELL

The variational functional of the Hellinger-Reissner variational principle for the large displacement problem of a thin shallow shell with an arbitrary shape is first established. Then the functional of the modified principle suitable for the finite element method is derived. In the functional only two independent variables, the deflection w and the stress function F are included. The displacement expressions in the middle surface on the boundary of the shell is also derived by means of the previous two variables.

ITERATIVE METHOD FOR LARGE DEFLECTION NONLINEAR PROBLEM OF LAMINATED COMPOSITE SHALLOW SHELLS AND PLATES

Based on the results by Wang,in this paper, the iterative method is presented for the study of large deflection nonlinear problem of laminated composite shallow shells and plates. The rectangular laminated composite shallow shells have been analyzed. The results have been compared with the small deflection linear analytical solution and finite element nonlinear solution. The results proved that the solution coincide with small deflection linear analytical solution in the condition of the low loads and finite element nonlinear solution in the condition of the high loads.

AN ANALYTICAL SOLUTION TO LARGE DEFLECTION EQUATIONS OF SIMPLY－SUPPORTED RECTANGULAR HYPERBOLOIDAL SHALLOW SHELLS OF ORTHOTROPIC COMPOSITES

Based on the product rule of the Fourier series and some relevant results inreferences[1, 2]. a method on solving the large deflection equations of plates and shells by means of the Fourier series is proposed in the present paper,Applying this method .we derive a type solution to the Navier’s solution of the nonlinear differential equations of the rectangular hyperboloidal shallow shells of the orthotropic compositessimply supported .This solution is suitable for plates and shells with large deflection orsmall deflection whether it is isotropic or orthotropic.Their data processing results are correlative with those found in the classical examples and from the experiments.

Design Scheme of New Type Shell Raising and Feeding System of Medium-large Caliber Naval Gun

The medium -large caliber naval gun is still playing an important role in modern war. The development of highly automatic Shell Raising and Feeding System (SRFS) in the world has been briefly outlined. Several typical SRFS of medium-large caliber naval guns have been analyzed. A re-design of the system is introduced, in which systematic design method has been used to demonstrate its feasibility. The design goal of the system is to realize rapid shell feeding, with application to many types of shells, quick change of shell types , accurate and reliable feeding operation, simple mechanical structure and easy realization of shell withdrawing.

NON-SYMMETRICAL LARGE DEFORMATION OFA SHALLOW THIN CONICAL SHELL

In this paper, non-symmetrical large deformation problem of a shallow conical shell is studied by two-parameter perturbation method. The third-order approximate analytical solution of the deformation of a shallow conical shell subjected to linear loads is obtained and the characteristic curves of load-deflection on a perturbing point are portrayed. The similar questions of other kind of shell and plate can be discussed by using this paper's method. As the examples, the large deflection of plate and shallow conical shells with different initial deflections is discussed.

Analysis of Dynamic Failure of Plastic Spherical Shells Under Local Impact

Aim To study the dynamic failure of the plastic spherical shell impacted by a missile. Methods The deformation mode of spherical shells was given by introducing isometric transformation. The governing equation of motion of the rigid plastic spherical shell was given by energy balance. This equation was solved by using Runge Kutta method. Results The relationships between the impact force, dimple radius, central point deflection and time were obtained. The response time initial velocity, the maximal impact force permanent initial velocity, the central point deflection initial velocity and the dimple radius initial velocity characteristics were respectively plotted. Conclusion A comparison made between the theoretical results and the experimental ones indicates that the two groups of results are in conformity with each other.

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.

Shell粉煤气化炉大渣块形成机理探讨

为了弄清实际生产过程中Shell粉煤气化炉大块渣的形成机理,文章运用XRD、SEM-EDX技术,对比分析气化炉稳定运行期间排出的灰渣和堵渣停车期间采集的大块渣的矿物组成、表观形貌及微区化学组成。结果表明:在Shell气化炉内大块渣形成期间,煤中含铁和含钙矿物存在明显的富集和析晶现象,在高温还原气氛下含钙矿物与石英形成大量低温共熔物—钙长石,钙长石在熔融状态下易吸附小块渣样,从而使渣块增长变大;含铁矿物质在气化炉里逐渐演变成(Fe-S-O)共熔体,这种物质具有很强的吸附粘结性,从而使渣块迅速增长变大。

NONLINEAR DEFORMATION THEORY OF THIN SHELL

The exact relation between strain and displacement is given for nonlinear deformation of thin shell. The! fundamental formula of large deformation when the deflection is on the same class with the thickness of the shell is derived after simplified rationally. The fundamental formula of large deformation when the deflection is art the same class with the length of the shell is derived exactly for cylinder shell deformed cylindrical shaped.

A 3-Node Co-Rotational Triangular Finite Element for Non-Smooth,Folded and Multi-Shell Laminated Composite Structures

Based on the first-order shear deformation theory,a 3-node co-rotational triangular finite element formulation is developed for large deformation modeling of non-smooth,folded and multi-shell laminated composite structures.The two smaller components of the mid-surface normal vector of shell at a node are defined as nodal rotational variables in the co-rotational local coordinate system.In the global coordinate system,two smaller components of one vector,together with the smallest or second smallest component of another vector,of an orthogonal triad at a node on a non-smooth intersection of plates and/or shells are defined as rotational variables,whereas the two smaller components of the mid-surface normal vector at a node on the smooth part of the plate or shell(away from non-smooth intersections)are defined as rotational variables.All these vectorial rotational variables can be updated in an additive manner during an incremental solution procedure,and thus improve the computational efficiency in the nonlinear solution of these composite shell structures.Due to the commutativity of all nodal variables in calculating of the second derivatives of the local nodal variables with respect to global nodal variables,and the second derivatives of the strain energy functional with respect to local nodal variables,symmetric tangent stiffness matrices in local and global coordinate systems are obtained.To overcome shear locking,the assumed transverse shear strains obtained from the line-integration approach are employed.The reliability and computational accuracy of the present 3-node triangular shell finite element are verified through modeling two patch tests,several smooth and non-smooth laminated composite shells undergoing large displacements and large rotations.

AN APPLICATION OF THEORETICAL SOLUTIONS ABOUT CYLINDRICAL SHELLS WITH SMALL OPENINGS

Stress concentrations about thin cylindrical shells with small openings are reconsidered front a nerv angle. There is a sort of special internal relation between theoretical solutions about cylindrical shells,vith large openings and one,with small openings. Using this relation, the extent of applying the theory about small openings to engineering practice is estimated again, thus an idea of how to use this theory and a nerv appraisal of the application of theoretical solutions about cylindrical shells with small openings to engineering practice are given.

Mechanics analysis of thin-walled box continuous girder with variable cross-sections in considering effect of large deflection and shear lag

In order to study the mechanics behavior of a thin-walled box continuous girder with variable crosssections,using potential variation theories,considering the effect of shear lag of flange’s stress and the nonlinear geometry of vertical displacement,and evolving five generalized displacements with the spline function,the large deflection problem of the thin-walled box continuous girder with variable cross-section was transformed to a nonlinear algebraic equation,which was solved using the Newton-Raphon iterative method.The results of the calculation show that different shear lag warp functions to the cantilever,top and bottom plate should be taken to analyze the mechanics behavior of the thin-walled box continuous girder reliably.The thin-walled box continuous girder with variable cross-sections has more reasonable stress state and is more adaptable for the longitudinal change of internal forces than that with equal crosssections.The effect of large deflection on the stress and displacement of the thin-walled box continuous girder with variable cross-sections depends on the values of the load.

A variational differential quadrature solution to finite deformation problems of hyperelastic shell-type structures:a two-point formulation in Cartesian coordinates

A new numerical approach is presented to compute the large deformations of shell-type structures made of the Saint Venant-Kirchhoff and Neo-Hookean materials based on the seven-parameter shell theory.A work conjugate pair of the first Piola Kirchhoff stress tensor and deformation gradient tensor is considered for the stress and strain measures in the paper.Through introducing the displacement vector,the deformation gradient,and the stress tensor in the Cartesian coordinate system and by means of the chain rule for taking derivative of tensors,the difficulties in using the curvilinear coordinate system are bypassed.The variational differential quadrature(VDQ)method as a pointwise numerical method is also used to discretize the weak form of the governing equations.Being locking-free,the simple implementation,computational efficiency,and fast convergence rate are the main features of the proposed numerical approach.Some well-known benchmark problems are solved to assess the approach.The results indicate that it is capable of addressing the large deformation problems of elastic and hyperelastic shell-type structures efficiently.

用纯H_2进行变换催化剂升温硫化在Shell煤气化配套甲醇装置的应用

河南龙宇煤化工有限公司在国内大型甲醇装置中首次采用纯H2进行变换催化剂的升温硫化。阐述了采用纯H2进行升温硫化的前提条件和必要性;介绍了升温硫化的准备工作以及升温、硫化等有关情况。结果表明,采用纯H2进行变换催化剂的升温硫化,操作稳定,硫化效果好,CS2的消耗量仅为煤气硫化的1/2。由于采用纯H2,可提前安排变换催化剂的升温硫化,为甲醇装置试车并打通全流程节省了7天时间,节约试车费用1400万元。

Shallow Axi-symmetric Bimetallic Shell as a Switching Element in a Non-Homogenous Temperature Field

In this contribution we discuss the stability of thin, axi-symmetric, shallow bimetallic shells in a non-homo- geneous temperature field. The presented model with a mathematical description of the geometry of the system, displacements, stresses and thermoelastic deformations on the shell, is based on the theory of the third order, which takes into account not only the equilibrium of forces on a deformed body but also the non-linear terms of the strain tensor. The equations are based on the large displacements theory. As an example, we pre- sent the results for a bimetallic shell of parabolic shape, which has a temperature point load at the apex. We translated the boundary-value problem with the shooting method into saving the initial-value problem. We calculate the snap-through of the system numerically by the Runge-Kutta fourth order method.