Product Design and Manufacture

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Authors: Hong Qiang Zhao, Peng Liu, Min Fei Shu, Guo Chen Wen
Abstract: Based on assumed condition, this paper sets up the digital simulation model and basic movement equations of a new hydraulic impactor’s dynamic mathematics numerical model. Upon analysis, the result of the simulation and optimization is close to that of the test, which indicates that the simulation and optimization dynamic mathematics numerical model is correct. This model facilitates accurate analysis of parameters affecting the property of impactor, thus providing a better design method for the optimization design of hydraulic impactor.
Authors: Surasak Suranuntchai, Prarop Kritboonyarit
Abstract: The purpose of the present research is to investigate and improve the quality of car brake booster deformed under drawing processes by using Finite Element (FE) program known as AutoForm. The materials are made from SPC270F with thickness 1.4 mm. and the initial diameter of 280 mm. The brake booster requires totally 9 production processes, including the sheet blanking, in the manufacture. Failure has found in the 4th draw in which cracking occurs at the bottom of cylinder. The material property assumed to be anisotropic, behaved according to Ludwik’s equation, and deformed rigid-plastic, which followed Hill’s yielding surface. The deformation for Forming Limit Diagram (FLD) was predicted by Keeler equation. Punch and die were assumed to be rigid during simulation. In this work, the process improvement focus mainly on the smallest change in die design which no lubricant required during the drawing processes. From the predicted results, the recommended punch diameter for the 1st draw should be extended to 111.4 mm while the new design for die’s diameter in the 1st draw is as large as 103 mm. However, punch’s height and its radius need to be varied in order to prevent the wrinkle as well. Since there is a little change in the new design while no more lubrication is required during the draw process, its can be improved in quality of finish product, cost reduction in lubricant consuming as well as the machining time to make a new punch.
Authors: Chun Xiang Wang, Fan Juan Meng, Jing Qiang Zhang
Abstract: In order to obtain 3D solid model of an Oerlikon system’s prolate epicycloidal bevel gear by full generating processing, the solid modeling method for the gear was studied in Pro/E. First, Drawing benchmark circles (base on the circle and reference circle as well as tip circle and root circle)and involute tooth profile of virtual equivalent gears of both large end and small end of the real gear, and then an intercepted segment of prolate epicycloid which has the same trend to the tooth and is controlled by prolate epicycloidal equations is projected to the surface of the gear’s root cone for the sake of getting tooth curve along axial direction. In the end, along the tooth curve and on the root cone conducting a variable cross section solid scanning to tooth shaped cross section, a complete gear tooth will be gained and at last model establishing will be finished. This method provided digital basis for optimization design, reverse design and rapid prototyping of this kind of gear, and so its design efficiency is improved.
Authors: Mei Nan Chen, Wen Hui Tang, Bo Yang, Xing Jun Hu
Abstract: The objective of this research is to design a set of front and rear wings that can help maximize the down-force to enhance the aerodynamic performance of 2011 Jilin University Formula SAE racing car in dynamic events. In this research, computational fluid dynamics analysis is used for the design of the front and rear wings. Based on a given vehicle body styling, twenty sets of front wing and rear wing profile are investigated, the influence of the endplate shape on the wing aerodynamic performance is also investigated, and one plan was chosen as final design, which is suitable for the vehicle at a relatively low speed (70km/h). The CFD analysis results show that the suitable front wing and rear wing will enhance the aerodynamic performance of the racing car significantly.
Authors: Cai Xia Zhao, Fei Tang, Shu Zhe Li, Xiao Hao Wang
Abstract: Corner radius end mill, whose cutting capability is mostly affected by the relief surface, is a kind of highly effective end mill [1]. So a novel mathematical model of relief surface curve about corner radius end mill, which is verified with a five-axis computer numerical control (CNC) grinding machine and simulated based on a system CAM, is derived and presented in the paper. According to the proposed tool coordinates system and the mechanical coordinate of the machine, the relative motion between the cup wheel and the tool is determined. In order to obtain an accurate relief curve when machining, the model of a cup wheel edge is also introduced. The coordinates of grinding point when grinding relief surface are calculated. With the input data of the corner radius end geometry, wheels geometry, wheel setting and machine setting, the NC code is generated automatically from the program. Then the code is used to simulate in 3 Dimension before actual machining. Finally, the NC code will be used for machining in the CNC grinding machine. The roundness of the round corner in the final product is very well, means this model is effective.
Authors: Wahab Saidin, Noraniah Kassim, Yusri Yusof, Zainul Ahmad Rajion
Abstract: This paper presents the research on manufacturing for full denture components. The aim is to develop a new manufacturing procedure for the removal full denture by integrating the techniques used in the Advanced Manufacturing Technology (AMT). The 3D-ATOS scanning system was used to obtain the surface data of the denture teeth sets, the edentulous models and the rims for patient. The surface quality of the digitized images was further refined by using Geomagic Studio 10 and the complete model of the denture components were prepared using Solid Work CAD application tool. A set of library for teeth was developed in the CAD system which includes the reference lines and points for setup and assembly process. The master models of the full denture were produced using MJM rapid prototyping system. The full denture was fabricated using acrylic resin (Vertex Castavaria) material using vacuum casting technique. The finish denture was then tested on patient and found satisfactory with good fitting accuracy as compared to the conventional denture. The use of vacuum casting procedure also has improved about 30% flexural strength as compared to the conventional technique (compression flask).
Authors: Han Wu Liu, Shan Ping Zhan, Yun Hui Du, Peng Zhang
Abstract: According to the principle and the type of the oil pipeline corrosion, we use the square wave of wide spectrum, strong signal transmission capability and a certain duty ratio as the excitation source of the pulsed eddy current. The finite element analysis software ANSYS is used to establish a three-dimensional finite element model of the pipeline corrosion defects by applying the boundary conditions of square wave excitation to simulate the distributions of current and induced magnetic field in the pipeline under various defect volumes. It can solve the induced voltage variation with time on detection coil, and can accomplish the finite element analysis and the nondestructive testing about the pipeline internal corrosion defects with the insulation layer and the protection layer. The results of the study show: When there is no corrosion defect in the pipeline, the electric current in the pipeline is basically even distribution. The magnetic field is distributed for the symmetrical vortex shape from head to foot, and it has not obviously gather phenomenon. When there are some corrosion defects in the pipeline, the electric current forms partial symmetrical vortex shape in both sides of the corrosion defect, and it is obviously assembled in the defect place. The simulation results of the different size defects show that the maximum magnetic field strength and the maximum current value increase with the defect depth increasing, while the output voltage decreases with the defect depth increasing. By extracting the induced voltage signals on the detection coil in a certain excitation condition, the quantitative detection of the pipeline corrosion defects can be achieved.
Authors: Qun Zhang Tu, Long Qin, Jv Ying Dai
Abstract: The principle of stereoscopic display technology,the software and hardware framework for single-channel passive stereoscopic display and the simulation software Delmia are introduced in this paper. Certain shafting components serve as an example to realize the effect of passive stereoscopic display and disassembly simulation in Delmia, which is helpful for teaching and training about equipments maintenance
Authors: Zhi Jian Gou, Hai Ying Yu, Yong Kang Niu, Yan Chao Xie
Abstract: With the continuous development of industrial robot application, it becomes very important for the solution of reachable space in the designing and applicating process. But the traditional theory calculation method is complex. When solving the reachable space of new kind of robot, we only draw lessons from the theory and need to change more. So a simple and convenient method is needed in theory field. This paper proposes a method that combine Matlab with SimDesigner to solve 6-DOF Robot reachable space, and takes ABB-1400 as an example to explain the solution of 6-DOF Robot reachable space. It could attain the full reachable space by add sine motion function reasonably to every joint, and obtain the solution of robot reachable space speedly.

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