科创中国

There have been various theoretical attempts by researchers worldwide to link up different scales of plasticity studies from the nano-, micro- and macro-scale of observation, based on molecular dynamics, crystal plasticity and continuum mechanics. Very few attempts, however, have been reported in ultra-precision machining studies. A mesoplasticity approach advocated by Lee and Yang is adopted by the authors and is successfully applied to studies of the micro-cutting mechanisms in ultra-precision machining. Traditionally, the shear angle in metal cutting, as well as the cutting force variation, can only be determined from cutting tests. In the pioneering work of the authors, the use of mesoplasticity theory enables prediction of the fluctuation of the shear angle and micro-cutting force, shear band formation, chip morphology in diamond turning and size effect in nano-indentation. These findings are verified by experiments. The mesoplasticity formulation opens up a new direction of studies to enable how the plastic behaviour of materials and their constitutive representations in deformation processing, such as machining can be predicted, assessed and deduced from the basic properties of the materials measurable at the microscale.

Straight-line compliant mechanisms are important building blocks to design a linear-motion stage,which is very useful in precision applications.However,only a few configurations of straight-line compliant mechanisms are applicable.To construct more kinds of them,an approach to design large-displacement straight-line flexural mechanisms with rotational flexural joints is proposed,which is based on a viewpoint that the straight-line motion is regarded as a compromise of rigid and compliant parasitic motion of a rotational flexural joint.An analytical design method based on the Taylor series expansion is proposed to quickly obtain an approximate solution.To illustrate and verify the proposed method,two kinds of flexural joints,cross-axis hinge and leaf-type isosceles-trapezoidal flexural(LITF)pivot are used to reconstruct straight-line flexural mechanisms.Their performances are obtained by analytic and FEA method respectively.The comparisons of the results show the accuracy of the approach.Both examples show that the proposed approach can convert a large-deflection flexural joint into approximate straight-line mechanism with a high linearity that is higher than 5 000within 5 mm displacement.This can lead to a new way to design,analyze or optimize straight-line flexure mechanisms.

Influence of geometric and cutting parameters of cemented carbide cutting tool on reliability of cutting tool has become more and more mature,yet influence of its physical and material parameters on reliability is still blank.In view of this,cutting test and fatigue crack growth test of YT05 cemented carbide cutting tool are conducted to measure such data as the original crack size,growth size,times of impact loading,number and time of cutting tool in failure,and stress distribution of cutting tool is also obtained by simulating cutting process of tools.Mathematical models on dynamic reliability and dynamic reliability sensitivity of cutting tool are derived respectively by taking machining time and times of impact loading into account,thus change rules of dynamic reliability sensitivity to physical and material parameters can be obtained.Theoretical and experimental results show that sensitive degree on each parameter of tools increases gradually with the increase of machining time and times of impact loading,especially for parameters such as fracture toughness,shape parameter,and cutting stress.This proposed model solves such problems as how to determine the most sensitive parameter and influence degree of physical parameters and material parameters to reliability,which is sensitivity,and can provide theoretical foundation for improving reliability of cutting tool system.

In design of flexure mechanism, diminishing the parasitic-motion is a key point to improve the accuracy. However, most of existing topics concentrate on improving the accuracy of linear-motion flexure mechanisms via compensating the parasitic error, but few research the multi-dimensional flexure mechanisms. A general design principle and method for high-precision flexure mechanisms based on the parasitic-motion compensation is presented, and the proposed method can compensate the parasitic rotation in company with translation, or the parasitic translation in company with rotation, or both. The crucial step for the method is that the parasitic motion of a flexure mechanism is formulated and evaluated in terms of its compliance. The overall compliance matrix of a general flexure mechanism is formulated by using screw theory firstly, then the criteria for the parasitic motions is introduced by analyzing the characteristics of the resultant compliance matrix as well as with aid of the concept of instantaneous rotation center. Subsequently, a compliance-based compensation approach for reducing parasitic-motion is addressed as the most important part. The design principles and procedure are further discussed to help with improving the accuracy of flexure mechanisms, and case studies are provided to illustrate this method. Finally, an analytical verification is provided to demonstrate that the symmetry design philosophy widely used in flexure design can effectively improve accuracy in terms of the proposed method. The proposed compensation method can be well used to diminish the parasitic-motion of multi-dimensional flexure mechanisms.

Existing biped robots mainly fall into two categories: robots with left and right feet and robots with upper and lower feet. The load carrying capability of a biped robot is quite limited since the two feet of a walking robot supports the robot alternatively during walking. To improve the load carrying capability, a novel biped walking robot is proposed based on a 2-UPU+2-UU parallel mechanism. The biped walking robot is composed of two identical platforms(feet) and four limbs, including two UPU(universal-prismatic-universal serial chain) limbs and two UU limbs. To enhance its terrain adaptability like articulated vehicles, the two feet of the biped walking robot are designed as two vehicles in detail. The conditions that the geometric parameters of the feet must satisfy are discussed. The degrees-of-freedom of the mechanism is analyzed by using screw theory. Gait analysis, kinematic analysis and stability analysis of the mechanism are carried out to verify the structural design parameters. The simulation results validate the feasibility of walking on rugged terrain. Experiments with a physical prototype show that the novel biped walking robot can walk stably on smooth terrain. Due to its unique feet design and high stiffness, the biped walking robot may adapt to rugged terrain and is suitable for load-carrying.

Condition based maintenance(CBM) issues a new challenge of real-time monitoring for machine health maintenance. Wear state monitoring becomes the bottle-neck of CBM due to the lack of on-line information acquiring means. The wear mechanism judgment with characteristic wear debris has been widely adopted in off-line wear analysis; however, on-line wear mechanism characterization remains a big problem. In this paper, the wear mechanism identification via on-line ferrograph images is studied. To obtain isolated wear debris in an on-line ferrograph image, the deposition mechanism of wear debris in on-line ferrograph sensor is studied. The study result shows wear debris chain is the main morphology due to local magnetic field around the deposited wear debris. Accordingly, an improved sampling route for on-line wear debris deposition is designed with focus on the self-adjustment deposition time. As a result, isolated wear debris can be obtained in an on-line image, which facilitates the feature extraction of characteristic wear debris. By referring to the knowledge of analytical ferrograph, four dimensionless morphological features, including equivalent dimension, length-width ratio, shape factor, and contour fractal dimension of characteristic wear debris are extracted for distinguishing four typical wear mechanisms including normal, cutting, fatigue, and severe sliding wear. Furthermore, a feed-forward neural network is adopted to construct an automatic wear mechanism identification model. By training with the samples from analytical ferrograph, the model might identify some typical characteristic wear debris in an on-line ferrograph image. This paper performs a meaningful exploratory for on-line wear mechanism analysis, and the obtained results will provide a feasible way for on-line wear state monitoring.

During hard cutting process there is severe thermodynamic coupling effect between cutting tool and workpiece, which causes quenching effect on finished surfaces under certain conditions. However, material phase transformation mechanism of heat treatment in cutting process is different from the one in traditional process, which leads to changes of the formation mechanism of damaged layer on machined workpiece surface. This paper researches on the generation mechanism of damaged layer on machined surface in the process of PCBN tool hard cutting hardened steel Cr12 Mo V. Rules of temperature change on machined surface and subsurface are got by means of finite element simulation. In phase transformation temperature experiments rapid transformation instrument is employed, and the effect of quenching under cutting conditions on generation of damaged layer is revealed. Based on that, the phase transformation points of temperature under cutting conditions are determined. By experiment, the effects of cutting speed and tool wear on white layer thickness in damaged layer are revealed. The temperature distribution law of third deformation zone is got by establishing the numerical prediction model, and thickness of white layer in damaged layer is predicted, taking the tool wear effect into consideration. The experimental results show that the model prediction is accurate, and the establishment of prediction model provides a reference for wise selection of parameters in precise hard cutting process. For the machining process with high demanding on surface integrity, the generation of damaged layer on machined surface can be controlled precisely by using the prediction model.

Published studies in regard to coupler systems have been mainly focused on the manufacturing process or coupler strength issues. With the ever increasing of tonnage and length of heavy haul trains, lateral in-train forces generated by longitudinal in-train forces and coupler rotations have become a more and more significant safety issue for heavy haul train operations. Derailments caused by excessive lateral in-train forces are frequently reported. This article studies two typical coupler systems used on heavy haul locomotives. Their structures and stabilizing mechanism are analyzed before the corresponding models are developed. Coupler systems models are featured by two distinct stabilizing mechanism models and draft gear models with hysteresis considered. A model set which consists of four locomotives and three coupler systems is developed to study the rotational behavior of different coupler systems and their implications for locomotive dynamics. Simulated results indicate that when the locomotives are equipped with the type B coupler system, locomotives can meet the dynamics standard on tangent tracks; while the dynamics performance on curved tracks is very poor. The maximum longitudinal in-train force for locomotives equipped with the type B coupler system is 2000 kN. Simulations revealed a distinct trend for the type A coupler system. Locomotive dynamics are poorer for the type A case when locomotives are running on tangent tracks, while the dynamics are better for the type A case when locomotives are running on curved tracks. Theoretical studies and simulations carried out in this article suggest that a combination of the two types of stabilizing mechanism can result in a good design which can significantly decrease the relevant derailments.

Most gait studies of multi-legged robots in past neglected the dexterity of robot body and the relationship between stride length and body height.This paper investigates the performance of a radial symmetrical hexapod robot based on the dexterity of parallel mechanism.Assuming the constraints between the supporting feet and the ground with hinges,the supporting legs and the hexapod body are taken as a parallel mechanism,and each swing leg is regarded as a serial manipulator.The hexapod robot can be considered as a series of hybrid serial-parallel mechanisms while walking on the ground.Locomotion performance can be got by analyzing these equivalent mechanisms.The kinematics of the whole robotic system is established,and the influence of foothold position on the workspace of robot body is analyzed.A new method to calculate the stride length of multi-legged robots is proposed by analyzing the relationship between the workspaces of two adjacent equivalent parallel mechanisms in one gait cycle.Referring to service region and service sphere,weight service sphere and weight service region are put forward to evaluate the dexterity of robot body.The dexterity of single point in workspace and the dexterity distribution in vertical and horizontal projection plane are demonstrated.Simulation shows when the foothold offset goes up to 174 mm,the dexterity of robot body achieves its maximum value 0.164 4 in mixed gait.The proposed methods based on parallel mechanisms can be used to calculate the stride length and the dexterity of multi-legged robot,and provide new approach to determine the stride length,body height,footholds in gait planning of multi-legged robot.

The existing researches on singularity of parallel mechanism are mostly limited to the property and regularity of singularity locus and there is no further research into the geometric relationship between uncontrolled kinematic screw and parallel mechanism in singularity.A 3UPS-S parallel mechanism is presented which fulfils 3-DOF in rotation.The regularity of nutation angle singularity is analyzed based on the Jacobian matrix,and the singularity surface of 3UPS-S parallel mechanisms is obtained.By applying the concept of reciprocal product in screw theory,the singular kinematic screw is derived when 3UPS-S parallel mechanism is in singularity.The geometric relationship between singular kinematic screw and singular configuration of 3UPS-S parallel mechanism is investigated by using programs in MATLAB.It is revealed that there are two kinds of situation.Firstly,the three limbs of 3UPS-S parallel mechanism intersect the singular kinematic screw in space simultaneously;Secondly,two limbs cross the singular kinematic screw while the third limb parallels with that screw.It is concluded that the nutation angle singularity of 3UPS-S parallel mechanism belongs to the singular linear complexes.This paper sheds light into and clarifies the geometric relationship between singular kinematic screw and singular configuration of 3UPS-S parallel mechanism.