Advanced Materials Research Vols. 201-203

Abstract: A new efficient interpolation algorithm for multi-axis linear linkage is proposed in this paper, which uses the principle of DDA algorithm, its function be extended and improved. the left normalized data is used in this algorithm, the maximum amount of movement is used as the basis for the calculation of speed, the efficiency of the interpolation is improved and the uniformity of speed is ensured. At last machining result are presented, which shows that this algorithm is powerful to machine spherical surfaces and planes.

Abstract: Based on viscoplastic Anand’s model, the structural stress of 8×8 InSb infrared focal plane array (IRFPA) detector is systemically analyzed by finite element method, and the impacts of design parameters including indium bump diameters, heights and InSb chip thicknesses on both Von Mises stress and its distribution are discussed in this manuscript. Simulation results show that the maximum stress existing in InSb chip reaches minimum with indium bump diameter 32μm. Under this condition, for the fixed indium height, as the InSb chip thickness reduces from 21µm to 9µm in step of 3µm, Von Mises stress maximum values of InSb chip seems increases gradually, and when the indium bump height reduces from 21µm to 9µm in step of 3µm, its maximum Von Mises stress increase at random increment, do not show certain rules, and indium bump height seems to have a comparable effect on stress value with InSb chip thickness. When indium diameter, height and InSb chip thickness are set to 32µm, 15µm, and 12µm, respectively, the maximal Von Mises value existing in InSb chip reaches minimal value 628MPa, simultaneously the stress distribution at the contacts areas is uniform and concentrated, and this structure is promising to avoid device invalidation.

Abstract: According to the surface integration of laser technology and computer-aided design and computer-aided manufacturing technology (CAD & CAM), a method that is rebuilt surface of three-dimensional facial reconstruction has been explored. A laser scanning system is used to collect the 3D discrete point data of the facial model, which will be cut up by their characteristics and curvature in order to make a 3D face reconstruction. The maximum reconstructive error is 0.2174mm. Application results indicate that the proposed method is quite satisfactory for facial reconstructive surgery, rehabilitation design and plastic surgery.

Abstract: An integrated digital routine is applied in the near net shape manufacturing of marine propeller. Firstly, the 3D CAD file of propeller is created by parametric modeling. Secondly, the propeller casting process is simulated using CAE software, through which an optimized casting scheme is obtained. Thirdly, fabricates the mold using laser rapid prototyping and cast the metal propeller. Finally, evaluate the casting precision performance. CAD, CAE and CAM are integrated in this process. The dimensional accuracy of the final piece is controlled within 1mm and its surface roughness achieves Ra 6.3μm. The result shows that the pattern-less casting of propeller can be achieved by this method, reducing cost and performing high accuracy.

Abstract: The weighing platform of the truck scale is a load-bearer, which is used for bearing a load. Its structure has many forms, in this paper, the finite element analysis of a structure with u-beam which is currently the most widely used for different loading modes, the traditional method of structural analysis of truck scale is to simplily the platform as a simply supported beam. As the model is too simplified, the result of this method will be unreliable and it cannot make part analysis about stress and strain . In this research, ANSYS was used to model, and loaded analysis. Through different loading, get the structure of weighing platform stress distribution and deformation. By analysing,we give reasonable proposals and provide valuable reference for the design and production of truck scale .

Abstract: The application of ultrasonic vibrations superimposed on wire drawing, deep drawing, upsetting and rolling has been developed in the literature. No attempts have ever been made to develop the application of the ultrasonic vibration to blanking process. This paper reports an investigation into the effects of the superimposed ultrasonic vibrations of the die during the blanking process by finite element software DEFORM-2D. The results are compared with the conventional blanking experiment by Hatanaka and Yamaguchi [7] and the simulations are analyzed with various vibration directions, amplitudes and frequencies. The effects of the ultrasonic vibration on the punch load, flow stress and edge profile are systematically studied. The results show ultrasonic vibration can decrease the punch load and improve the quality of edge profile by increasing the vibration amplitudes and frequencies.

Abstract: Five-axis machining, an important processes in precision manufacturing, has been used in defense, aerospace and consumer product industries. Many combinations can be synthesized to generate various five-axis machine tool configurations, in which the linear and rotary axes are normally orthogonal. Since five-axis NC data can only be applied to a specific configuration, the portability of the NC data is inevitably limited. A special purpose five-axis machine with a nonorthogonal linear axis configuration is investigated in this research. The complete analytical equations for NC data are obtained using the homogeneous coordinate transformation matrix and inverse kinematics. A window-based postprocessor system written by Borland C++ Builder was developed according to the proposed algorithm. A roller gear cam was adopted as an example to generate the NC code using the proposed postprocessor system. A trail-cut experiment conducted with this special purpose machine tool confirms the effectiveness of the proposed methodology.

Abstract: In this paper, the thinning rate and die elastic deformation under large forming force are investigated by finite element simulation with experimental validation focused on the problem of coloring rate between die and panel in automotive die manufacturing. The study suggests that when the panel is formed, the thinning rate of panel has little influence on the coloring rate and the die elastic deformation under large forming force is the main influence factor. The definition of high contact pressure area is proposed by the comparison between the simulation and industrial experiment results. The definition greatly benefits the predication of die face coloring rate. The method that die face is compensated reasonably is also proposed. It can reduce the die polishing workloads obviously compared to the traditional method of die face equivalent offset. This paper has a guide for comprehensive understanding the influence factors of coloring rate and greatly reducing the die tryout period.

Abstract: In view of present problems that interior information of H-beam in multi-pass hot rolling process is not clear enough, an integrated simulation system with automatic design and analysis is developed based on ABAQUS Scripting Interface. Architecture of simulation system is designed according to the process of rough rolling, and several key problems are illustrated in the paper. The reliability of the system is verified through the forming simulation of H-beam H250x125. The system is very helpful for experienced mill designers who are unfamiliar with finite element analysis to test new section designs through virtual hot rolling trials.

Abstract: To accelerate the development of new product, one important method is to use the information of the existed products. In this paper, Fuzzy C-Means clustering method (FCM) is proposed to retrieve the desired model in the given model database. In the retrieval process, first, the shape distribution histograms of the model are established and transformed into the proper format of FCM. Then, the shape distribution histograms of the model are served as inputs of FCM and classified into several groups by this algorithm. Last, all the models that belong to the classification of the query model are returned as the retrieval results. To validate the proposed method, a case study is presented. The results show that the result of proposed method is better than that of Shape Distribution. Thus, this method is suitable for 3D mechanical models retrieval.