Advances in Engineering Design and Optimization

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Authors: Xin Li Tian, Zhao Li, Xiu Jian Tang, Fang Guo, Ai Bing Yu
Abstract: Tool edge radius has obvious influences on micro-cutting process. It considers the ratio of the cutting edge radius and the uncut chip thickness as the relative tool sharpness (RST). FEM simulations of orthogonal cutting processes were studied with dynamics explicit ALE method. AISI 1045 steel was chosen for workpiece, and cemented carbide was chosen for cutting tool. Sixteen cutting edges with different RTS values were chosen for analysis. Cutting forces and temperature distributions were calculated for carbide cutting tools with these RTS values. Cutting edge with a small RTS obtains large cutting forces. Ploughing force tend to sharply increase when the RTS of the cutting edge is small. Cutting edge with a reasonable RTS reduces the heat generation and presents reasonable temperature distributions, which is beneficial to cutting life. The force and temperature distributions demonstrate that there is a reasonable RTS range for the cutting edge.
Authors: Ping Zhao, Hong Wei Fan, Jia Jie Chen, Ju Long Yuan, Bing Hai Lv, Qian Fa Deng
Abstract: To improve the sphericity and processing uniformity of precision ball, Simulations and analysis of the mechanism Position Deviation of Rotated Dual-Plates Lapping on precise Sphere, it can be indicated that mechanism Position Deviation (down plate axial deviation and down plate radial deviation) have little disadvantageous influence on sphericity and processing uniformity.
Authors: Jun Liu, Gang Ming Wang, Bao Shou Sun
Abstract: Thin-walled slender tubes are produced by injection molding, where there might be defects such as short shot, excessive warpage and uneven temperature distribution. In this paper, injection process analysis was carried out. The 3D modeling technology of Pro/E established a solid model of thin-walled slender tube. MPI (Moldflow Plastics Insight) was used for executing injection molding flow simulation. Gate location and gate number was optimized. Filling system and cooling system of the combined cavity was optimized by analysis of flow, cool and warp. The results can be used for supplying reliable data of mold designing and manufacturing, reducing the engineering mold trial time, decrease the manufacturing cost. The configuration and dimensions of the injection gate can be determined by the computer program before the molds are actually manufactured. The potential defects were forecasted. Therefore, the designers can quickly optimize the mold design.
Authors: Bao Shou Sun, Zhe Chen, Bo Qin Gu, Xiao Diao Huang
Abstract: The optimization algorithm of MUD-RBFNN-GA was proposed in this article. An injection molding process optimization model of multi-factor and multi-objective was also researched. The multiple uniform designs of experiment was applied to optimize the processing parameters. During this process, the RBF neural network was established, where the melt temperature, mold temperature and packing pressure were taken as the inputs, and warpage, area of air-traps and weld-line length as the outputs, and the Moldflow simulation analysis was used to obtain the output values. By combining the algorithm with genetic algorithm and global optimization in the networks, we can get the optimal process parameters. The results show that the multi-objective optimization based on MUD-RBFNN-GA is practically applicable, and it can reduce the molding defects effectively.
Authors: Bao Shou Sun, Zhe Chen, Bo Qin Gu, Xiao Diao Huang
Abstract: To optimize injection molding warpage, this paper applies the uniform design of experiment method to search for the optimal injection molding processing parameters. The warpage. simulation analysis is accomplished by emplying Moldflow software. The melt temperature, mold temperature, injection time and packing pressure are regarded as processing parameters, and processing parameters are optimized through establishing a regression equation, and the optimization result and influence factors are analyzed. The results show that uniform design of experiment can reduce number of experiments used effectively and the quality of the product is greatly improved by the optimization method.
Authors: Xiao Chun Wang, Ke Jian Shi
Abstract: In this paper we proposed an "Inside & Outside" design method which is suitable for small and medium–sized enterprises to solve the problems that small and medium–sized enterprises usually meet with non-design and tough design. The meaning as well as the principles of this method was explained in detail, meanwhile the process to find out the production opportunities in a short time for small and medium–sized enterprises with the provided method was discussed. Finally, a case study on the improvement of a specific product was analyzed so as to be an illustrated-example.
Authors: Jing Ling Zhou, Jian Chun Chen, Guo Qing Wu, Xiao Yang Chen
Abstract: An intelligent control system for ceramics ball rolling contact fatigue test rig based on LabVIEW was designed. The system consists of four functional blocks, which are data acquisition block, signal processing block, state recognition block and diagnosis decision-making block. The data in the test process such as load, vibration, speed, fatigue life and so on, are collected and recorded automatically. This system can alarm or shutdown once the test rig state is abnormal or the truncate time is satisfied. By using wavelet transform and other methods in the vibration signal processing and analysis, the failure parts can be detected accurately according to the spectral characteristics and the fault characteristic frequency of the parts. The intelligent control system has practical advantages. The high precision, fast response, low cost, accurate judgment and convenience manipulation are very desirable for ceramics ball rolling contact fatigue experiment.
Authors: Hui Feng Jiao, Jian Zhong Fu, Yong He, Xiao Lei Deng
Abstract: Surface roughness is the most important index of product surface in grinding. Bayesian network model was built about process parameters and surface roughness. The network parameters were learned by grinding workpieces with a CNC surface grinding machine tool. The experiments for giving grinding parameters on Bayesian network prediction model have shown good results.
Authors: Li Ping Zhao, Yi Yong Yao, Da Min Xu
Abstract: In the modern manufacturing mode, product is often manufactured by multi-enterprise, so effective and dynamic tracking for process quality information is the precondition to realize product quality control in distributed enterprises. Aiming at these demands, a dynamic tracking method for inter-enterprise quality information based on process quality BOM (PQ-BOM) was put forward in this paper. PQ-BOM was employed as the carrier and organization form of process quality information. With the formal definition of PQ-BOM, structure information and process information included in PQ-BOM were mapped to three-layer process model. The process BOM is dynamically updated with the process change, thus the in-time and history quality information tracking is achieved by dynamically reconfigured PQ-BOM. Finally, the application of proposed method has been described in detail.
Authors: Chang He Li, Zhen Lu Han, Jing Yao Li
Abstract: In the grinding process, grinding fluid is delivered for the purposes of chip flushing, cooling, lubrication and chemical protection of work surface. Hence, the conventional method of flood delivering coolant fluid by a nozzle in order to achieve high process performance purposivelly. However, hydrodynamic fluid pressure can be generated ahead of the grinding zone due to the wedge effect between wheel peripheral surface and part surface. In this paper, a theoretical fluid velocity field modeling is presented for flow of coolant fluid of wedge-shaped gap in flood delivery surface grinding, which is based on navier-stokes equation and continuous formulae. The numerical simulation results showed that the velocity in the x direction was dominant and the side-leakage in the y direction existed. The velocity in the z direction was smaller than the others because of the assumption of laminar flow. The smaller the gap is, the larger the velocity in the x direction. The magnitude of the velocity is also proportional to the surface velocity of the wheel.

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