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.

Development of Fixture Layout Optimization for Thin-Walled Parts:A Review

An increasing number of researchers have researched fixture layout optimization for thin-walled part assembly during the past decades.However,few papers systematically review these researches.By analyzing existing literature,this paper summarizes the process of fixture layout optimization and the methods applied.The process of optimization is made up of optimization objective setting,assembly variation/deformation modeling,and fixture layout optimization.This paper makes a review of the fixture layout for thin-walled parts according to these three steps.First,two different kinds of optimization objectives are introduced.Researchers usually consider in-plane variations or out-of-plane deformations when designing objectives.Then,modeling methods for assembly variation and deformation are divided into two categories:Mechanism-based and data-based methods.Several common methods are discussed respectively.After that,optimization algorithms are reviewed systematically.There are two kinds of optimization algorithms:Traditional nonlinear programming and heuristic algorithms.Finally,discussions on the current situation are provided.The research direction of fixture layout optimization in the future is discussed from three aspects:Objective setting,improving modeling accuracy and optimization algorithms.Also,a new research point for fixture layout optimization is discussed.This paper systematically reviews the research on fixture layout optimization for thin-walled parts,and provides a reference for future research in this field.

Meter-Scale Thin-Walled Structure with Lattice Infill for Fuel Tank Supporting Component of Satellite:Multiscale Design and Experimental Verification

Lightweight thin-walled structures with lattice infill are widely desired in satellite for their high stiffness-to-weight ratio and superior buckling strength resulting fromthe sandwich effect.Such structures can be fabricated bymetallic additive manufacturing technique,such as selective laser melting(SLM).However,the maximum dimensions of actual structures are usually in a sub-meter scale,which results in restrictions on their appliance in aerospace and other fields.In this work,a meter-scale thin-walled structure with lattice infill is designed for the fuel tank supporting component of the satellite by integrating a self-supporting lattice into the thickness optimization of the thin-wall.The designed structure is fabricated by SLM of AlSi10Mg and cold metal transfer welding technique.Quasi-static mechanical tests and vibration tests are both conducted to verify the mechanical strength of the designed large-scale lattice thin-walled structure.The experimental results indicate that themeter-scale thin-walled structure with lattice infill could meet the dimension and lightweight requirements of most spacecrafts.

An electromagnetic semi-active dynamic vibration absorber for thin-walled workpiece vibration suppression in mirror milling

As critical components of aircraft skins and rocket fuel storage tank shells,large thin-walled workpieces are susceptible to vibration and deformation during machining due to their weak local stiffness.To address these challenges,we propose a novel tunable electromagnetic semi-active dynamic vibration absorber(ESADVA),which integrates with a magnetic suction follower to form a followed ESADVA(follow-ESADVA)for mirror milling.This system combines a tunable magnet oscillator with a follower,enabling real-time vibration absorption and condition feedback throughout the milling process.Additionally,the device supports self-sensing and frequency adjustment by providing feedback to a linear actuator,which alters the distance between magnets.This resolves the traditional issue of being unable to directly monitor vibration at the machining point due to space constraints and tool interference.The frequency shift characteristics and vibration absorption performance are comprehensively investigated.Theoretical and experimental results demonstrate that the prototyped follow-ESADVA achieves frequency synchronization with the milling tool,resulting in a vibration suppression rate of approximately 47.57%.Moreover,the roughness of the machined surface decreases by18.95%,significantly enhancing the surface quality.The results of this work pave the way for higher-quality machined surfaces and a more stable mirror milling process.

Numerical Analysis of Cold-Formed Thin-Walled Steel Short Columns with Pitting Corrosion during Bridge Construction

Pitting corrosion is harmful during bridge construction,which will lead to uneven roughness of steel surfaces and reduce the thickness of steel.Hence,the effect of pitting corrosion on the mechanical properties of cold-formed thin-walled steel stub columns is studied,and the empirical formulas are established through regression fitting to predict the ultimate load of web and flange under pitting corrosion.In detail,the failure modes and load-displacement curves of specimens with different locations,area ratios,and depths are obtained through a large number of non-linear finite element analysis.As for the specimens with pitting corrosion on the web,all the specimens are subject to local buckling failure,and the failure mode will not change with pitting corrosion,but the failure location will change with pitting corrosion location;the size,location,and area ratio of pitting corrosion have little influence on the ultimate load of cold-formed thin-walled steel short columns,but the loss rate of pitting corrosion section area has a greater impact on the ultimate bearing capacity.As for the specimen with flange pitting corrosion,the location and area ratio of pitting corrosion have less influence on the ultimate load of cold-formed thin-walled steel short columns,and the section area loss rate has greater influence on the ultimate bearing capacity;the impact of web pitting corrosion on the ultimate load is greater than that of flange pitting corrosion under the same condition of pitting corrosion section area.The prediction formulas of limit load which are suitable for pitting corrosion of web and flange are established,which can provide a reference for performance evaluation of corroded cold-formed thin-walled steel.

Boundary Element Analysis forModeⅢCrack Problems of Thin-Walled Structures from Micro-to Nano-Scales

This paper develops a new numerical framework for modeⅢcrack problems of thin-walled structures by integrating multiple advanced techniques in the boundary element literature.The details of special crack-tip elements for displacement and stress are derived.An exponential transformation technique is introduced to accurately calculate the nearly singular integral,which is the key task of the boundary element simulation of thin-walled structures.Three numerical experiments with different types of cracks are provided to verify the performance of the present numerical framework.Numerical results demonstrate that the present scheme is valid for modeⅢcrack problems of thin-walled structures with the thickness-to-length ratio in the microscale,even nanoscale,regime.

Geometric Accuracy and Energy Absorption Characteristics of 3D Printed Continuous Ramie Fiber Reinforced Thin-Walled Composite Structures

The application of continuous natural fibers as reinforcement in composite thin-walled structures offers a feasible approach to achieve light weight and high strength while remaining environmentally friendly.In addition,additive manufacturing technology provides a favorable process foundation for its realization.In this study,the printability and energy absorption properties of 3D printed continuous fiber reinforced thin-walled structures with different configurations were investigated.The results suggested that a low printing speed and a proper layer thickness would mitigate the printing defects within the structures.The printing geometry accuracy of the structures could be further improved by rounding the sharp corners with appropriate radii.This study successfully fabricated structures with vari-ous configurations characterized by high geometric accuracy through printing parameters optimization and path smoothing.Moreover,the compressive property and energy absorption characteristics of the structures under quasi-static axial compression were evaluated and compared.It was found that all studied thin-walled structures exhibited progressive folding deformation patterns during compression.In particular,energy absorption process was achieved through the combined damage modes of plastic deformation,fiber pullout and delamination.Furthermore,the com-parison results showed that the hexagonal structure exhibited the best energy absorption performance.The study revealed the structure-mechanical property relationship of 3D printed continuous fiber reinforced composite thin-walled structures through the analysis of multiscale failure characteristics and load response,which is valuable for broadening their applications.

Experimental and numerical study of effecting core configurations on the static and dynamic behavior of honeycomb plate with aluminum material

The sandwich panel incorporated a honeycomb core,a widely utilized composite structure recognized as a fundamental classification of composite materials.Comprised a core resembling a honeycomb,possessing thickness and softness,and is flank by rigid face sheets that sandwich various shapes and materials.This paper presents an examination of the static and dynamic analysis of lightweight plates made of aluminum honeycomb sandwich composites.Honeycomb sandwich plate samples are 300 mm long,and 300 mm wide,the heights of the core have been varied at four values ranging from 10 to 25 mm.The honeycomb core is manufactured from Aluminum material by using a novel technique namely resistance spot welding(RSW)instead of using adhesive material,which is often used when an industrial flaw is detected.Numerical optimization based on response surface methodology(RSM)and design of experiment software(DOE)was used to verify the current work.A theoretical examination of the crashworthiness behavior(maximum bending load,maximum deflection)and vibration attributes(natural frequency,damping ratio,transient temporal response)of honeycomb sandwich panels with different design parameters was also carried out.In addition,the finite element method-based ANSYS software was used to confirm the theoretical conclusions.The findings of the present work showed that the relationship between the natural frequency,core height,and cell size is direct.In contrast,the relationship between the natural frequency and the thickness of the cell wall is inverse.Conversely,the damping ratio is inversely proportional to the core height and cell size but directly proportional to the thickness of the cell wall.The study indicates that altering the core height within 10-25 mm leads to a significant increase of 82%in the natural frequency and a notable decrease of 49%in the damping ratio.These findings are based on a specific cell size value of 0.01 m and a cell wall thickness of 0.001 m.Also,the results indicate that for a given set of cell wall thickness and size values,an increase in core height from(0.01-0.025)m,leads to a reduction of the percentage of maximum response approX imately 76%.Conversely,the increasing thickness of the wall of cell wall,ranging 0.3-0.7 mm with a constant core height equal to 0.015 m,resulted in a de crease of maximum transient response by 7.8%.

Dynamic response of honeycomb-FGS shells subjected to the dynamic loading using non-polynomial higher-order IGA

The main goal of this study is to use higher-order isogeometric analysis(IGA)to study the dynamic response of sandwich shells with an auxetic honeycomb core and two different functionally graded materials(FGM)skin layers(namely honeycomb-FGS shells)subjected to dynamic loading.Touratier's non-polynomial higher-order shear deformation theory(HSDT)is used due to its simplicity and performance.The governing equation is derived from Hamilton's principle.After verifying the present approach,the effect of input parameters on the dynamic response of honeycomb-FGS shells is carried out in detail.

Control and vibration analyses of a sandwich doubly curved micro-composite shell with honeycomb,truss,and corrugated cores based on the fourth-order shear deformation theory

Curved shells are increasingly utilized in applied engineering due to their shared characteristics with other sandwich structures,flexibility,and attractive appearance.However,the inability of controlling and regulating vibrations and destroying them afterward is a challenge to scientists.In this paper,the curve shell equations and a linear quadratic regulator are adopted for the state feedback design to manage the structure vibrations in state space forms.A five-layer sandwich doubly curved micro-composite shell,comprising two piezoelectric layers for the sensor and actuator,is modeled by the fourth-order shear deformation theory.The core(honeycomb,truss,and corrugated)is analyzed for the bearing of transverse shear forces.The results show that the honeycomb core has a greater effect on the vibrations.When the parameters related to the core and the weight percentage of graphene increase,the frequency increases.The uniform distribution of graphene platelets results in the lowest natural frequency while the natural frequency increases.Furthermore,without taking into account the piezoelectric layers,the third-order shear deformation theory(TSDT)and fourth-order shear deformation theory(FOSDT)align closely.However,when the piezoelectric layers are incorporated,these two theories diverge significantly,with the frequencies in the FOSDT being lower than those in the TSDT.

Dynamics of a rotating ring-stiffened sandwich conical shell with an auxetic honeycomb core

The free vibration analysis of a rotating sandwich conical shell with a reentrant auxetic honeycomb core and homogenous isotropic face layers reinforced with a ring support is studied.The shell is modeled utilizing the first-order shear deformation theory(FSDT)incorporating the relative,centripetal,and Coriolis accelerations alongside the initial hoop tension created by the rotation.The governing equations,compatibility conditions,and boundary conditions are attained using Hamilton’s principle.Utilizing trigonometric functions,an analytical solution is derived in the circumferential direction,and a numerical one is presented in the meridional direction via the differential quadrature method(DQM).The effects of various factors on the critical rotational speeds and forward and backward frequencies of the shell are studied.The present work is the first theoretical work regarding the dynamic analysis of a rotating sandwich conical shell with an auxetic honeycomb core strengthened with a ring support.

Experimental Study on Entropy Features in Machining Vibrations of A Thin-Walled Tubular Workpiece

In machining processes,chatter vibrations are always regarded as one of the major limitations for production quality and efficiency.Accurate and timely monitoring of chatter is helpful to maintain stable machining operations.At present,most chatter monitoring methods are based on the energy level at specified chatter frequencies or frequency bands.However,the spectral features of chatter could change during machining operations due to complexity and time-varying dynamics of the physical machining process.The purpose of this paper is to investigate the time-varying chatter features in turning of thin-walled tubular workpieces from the perspective of entropy.The airborne acoustics was selected as the source of information for machining condition monitoring.First,corresponding to the distinguishing surface topographies relevant to machining conditions,the features of the sound signal emitted during turning of the thin-walled cylindrical workpieces were extracted using the spectral analysis and wavelet packet transform,respectively.It was shown that the dominant vibration frequency as well as the energy distribution could shift with the transition of the machining status.After that,two relative entropy indicators based on the spectrum and the wavelet packet energy were constructed to identify chattering events in turning of the thin-walled tubes.The experimental results demonstrate that the proposed indicators could accurately reflect the transition of machining conditions with high sensitivity and robustness in comparison with the traditional FFT-based methods.The achievement of this study lays the foundations of the online chatter monitoring and control technique for turning of the thin-walled tubular workpieces.

Impact Performance Research of Re-Entrant Octagonal Negative Poisson’s Ratio Honeycomb with Gradient Design

Based on the traditional re-entrant honeycomb,a novel re-entrant octagon honeycomb(ROH)is proposed.The deformation mode of the honeycomb under quasi-static compression is analyzed by numerical simulation,and the results are in good agreement with the experimental ones.The deformation modes,mechanical properties,and energy absorption characteristics of ROH along the impact and perpendicular directions gradient design are investigated under different velocities.The results indicated that the deformation mode of ROH is affected by gradient design along the direction of impact and impact speed.In addition,gradient design along the direction of impact can increase the initial peak stress of ROH and accelerate its densification phase.Gradient design perpendicular to the impact direction can enhance the energy absorption performance of ROH,especially for ROH,with wall thickness increasing from the inside outwards.Compared to ROH with uniform wall thickness at the same relative density,ROH with a gradient design can increase the plateau stress by over half.With the elevation of impact velocity,the plateau stress and specific energy absorption exhibit an upward trend,aligning with the dynamic performance pattern observed in conventional honeycombs.The results can be used as a reference for the design and application of honeycomb and provide a new idea for developing more efficient and reliable energy-absorbing materials.

Experimental crushing behavior and energy absorption of angular gradient honeycomb structures under quasi-static and dynamic compression

The high variability of shock in terrorist attacks poses a threat to people's lives and properties,necessitating the development of more effective protective structures.This study focuses on the angle gradient and proposes four different configurations of concave hexagonal honeycomb structures.The structures'macroscopic deformation behavior,stress-strain relationship,and energy dissipation characteristics are evaluated through quasi-static compression and Hopkinson pressure bar impact experiments.The study reveals that,under varying strain rates,the structures deform starting from the weak layer and exhibit significant interlayer separation.Additionally,interlayer shear slip becomes more pronounced with increasing strain rate.In terms of quasi-static compression,symmetric gradient structures demonstrate superior energy absorption,particularly the symmetric negative gradient structure(SNG-SMS)with a specific energy absorption of 13.77 J/cm~3.For dynamic impact,unidirectional gradient structures exhibit exceptional energy absorption,particularly the unidirectional positive gradient honeycomb structure(UPG-SML)with outstanding mechanical properties.The angle gradient design plays a crucial role in determining the structure's stability and deformation mode during impact.Fewer interlayer separations result in a more pronounced negative Poisson's ratio effect and enhance the structure's energy absorption capacity.These findings provide a foundation for the rational design and selection of seismic protection structures in different strain rate impact environments.

Restrained Bending of Thin-Walled Box Beam with Honeycomb Core

Restrained bending of thin-walled box beam with honeycomb core is analyzed on the basis of rigid profile assumption. The method of variable separation is applied and two ordinary differential governing equations are established and solved. The boundary conditions are satisfied rigorously and the solutions are expressed by means of eigen function expansions. The diagram of shearing force is formulated by trigonometric series and used to determine the coefficients in above expansions. The computational resuits give the chord and span wise distributions of nomal and shear stress in the cover plate and the honeycomb core. At the same time, the attenuation of additional stress from fixed end to free end along the length of beam is shown clearly.

Restrained Torsion of Thin-walled Box Beam with Honeycomb Core

Restrained torsion of thin-walled box beam with honeycomb core is analyzed on the basis of rigid profile assumption. The method of variable separation is applied and two ordinary differential governing equations are established and solved. The boundary conditions are satisfied rigorously and the solutions are expressed by means of eigen function expansions. The diagram of torque is formulated by trigonometric series and used to determine the coefficients in above expansions. The results of computation provide the chord-wise and span-wise distributions of normal and shear stress in the face plate along with shear stress in the honeycomb core.

Microstructures and Properties of Honeycomb Sulfur/carbon Black/MoS_(2) Composites

Microstructure and property of sulfur/carbon black composites prepared by ball milling were studied.Sulfur/carbon black composites were obtained by melting the mixture of sulfur and carbon black in 155℃and dispersing evenly in carbon black after hydrothermal reaction.Thus,its conductive properties were improved.Moreover,microstructure and property of honeycomb sulfur/carbon black/MoS_(2) prepared by hydrothermal method as a cathode material for lithium-sulfur batteries were studied.The initial discharge specific capacity of the material at 0.2 A/g current density is 838.495 mA·h/g,and the 55.14%after 100 weeks of cycling.It is indicated that MoS_(2) can not only combine with polysulfides through electrostatic action or the action of chemical bonds,but also honeycomb porous structure.MoS_(2) can fix polysulfides groups and prevent their shuttle.Therefore,the cycling performance of the battery is effectively improved.

Transient responses of double-curved sandwich two-layer shells resting on Kerr's foundations with laminated three-phase polymer/GNP/fiber surface and auxetic honeycomb core subjected to the blast load

This work uses refined first-order shear theory to analyze the free vibration and transient responses of double-curved sandwich two-layer shells made of auxetic honeycomb core and laminated three-phase polymer/GNP/fiber surface subjected to the blast load.Each of the two layers that make up the double-curved shell structure is made up of an auxetic honeycomb core and two laminated sheets of three-phase polymer/GNP/fiber.The exterior is supported by a Kerr elastic foundation with three characteristics.The key innovation of the proposed theory is that the transverse shear stresses are zero at two free surfaces of each layer.In contrast to previous first-order shear deformation theories,no shear correction factor is required.Navier's exact solution was used to treat the double-curved shell problem with a single title boundary,while the finite element technique and an eight-node quadrilateral were used to address the other boundary requirements.To ensure the accuracy of these results,a thorough comparison technique is employed in conjunction with credible statements.The problem model's edge cases allow for this kind of analysis.The study's findings may be used in the post-construction evaluation of military and civil works structures for their ability to sustain explosive loads.In addition,this is also an important basis for the calculation and design of shell structures made of smart materials when subjected to shock waves or explosive loads.

Acoustical properties of a 3D printed honeycomb structure filled with nanofillers:Experimental analysis and optimization for emerging applications

The novelty of this research lies in the successful fabrication of a 3D-printed honeycomb structure filled with nanofillers for acoustic properties,utilizing an impedance tube setup in accordance with ASTM standard E 1050-12.The Creality Ender-3,a 3D printer,was used for printing the honeycomb structures,and polylactic acid(PLA)material was employed for their construction.The organic,inorganic,and polymeric compounds within the composites were identified using fourier transformation infrared(FTIR)spectroscopy.The structure and homogeneity of the samples were examined using a field emission scanning electron microscope(FESEM).To determine the sound absorption coefficient of the 3D printed honeycomb structure,numerous samples were systematically developed using central composite design(CCD)and analysed using response surface methodology(RSM).The RSM mathematical model was established to predict the optimum values of each factor and noise reduction coefficient(NRC).The optimum values for an NRC of 0.377 were found to be 1.116 wt% carbon black,1.025 wt% aluminium powder,and 3.151 mm distance between parallel edges.Overall,the results demonstrate that a 3Dprinted honeycomb structure filled with nanofillers is an excellent material that can be utilized in various fields,including defence and aviation,where lightweight and acoustic properties are of great importance.

A Modified Principal Component Analysis Method for Honeycomb Sandwich Panel Debonding Recognition Based on Distributed Optical Fiber Sensing Signals

The safety and integrity requirements of aerospace composite structures necessitate real-time health monitoring throughout their service life.To this end,distributed optical fiber sensors utilizing back Rayleigh scattering have been extensively deployed in structural health monitoring due to their advantages,such as lightweight and ease of embedding.However,identifying the precise location of damage from the optical fiber signals remains a critical challenge.In this paper,a novel approach which namely Modified Sliding Window Principal Component Analysis(MSWPCA)was proposed to facilitate automatic damage identification and localization via distributed optical fiber sensors.The proposed method is able to extract signal characteristics interfered by measurement noise to improve the accuracy of damage detection.Specifically,we applied the MSWPCA method to monitor and analyze the debonding propagation process in honeycomb sandwich panel structures.Our findings demonstrate that the training model exhibits high precision in detecting the location and size of honeycomb debonding,thereby facilitating reliable and efficient online assessment of the structural health state.