Application of bolt joints dynamic parameters identification in machine tools based on partially measured frequency response functions

This paper presents a method to identify the bolt joints dynamic parameters based on partially measured frequency response functions (FRFs) and demonstrates its application in machine tools. Basic formulas are derived to identify the joint dynamic properties based on the substructuring method and an algorithm to estimate the unmeasured FRFs is also developed. The identification avoids direct inverse calculation to the frequency response function matrix, and its validity is demonstrated by comparing the simulated and measured FRFs of the assembled free-free steel beams with a bolt joint. An approach is put forward to apply the identification in machine tools by constructing structures assembled of substructures and joint structures to substitute the bolt joints in machine tools and assuring the contact conditions unchanged. The identification of the bed-column bolt joint in a vertical machining center is provided to describe the application procedure and show the feasibility of the proposed approach

Prediction of machining accuracy based on geometric error estimation of tool rotation profile in five-axis multi-layer flank milling process

In five-axis multi-layer flank milling process, the geometric error of tool rotation profile caused by radial dimension error and setup error has great influence on the machining accuracy. In this work, a new comprehensive error prediction model considering the inter-layer interference caused by tool rotation profile error is established, which incorporates a pre-existing prediction model dealing with a variety of errors such as geometric errors of machine tool, workpiece locating errors, and spindle thermal deflection errors. First, a series of tool contact points on the tool swept surface in each single layer without overlapping with others are calculated. Second, the position of the tool contact points on the overlapped layers is updated based on the detection and calculation of inter-layer interferences. Third, all evaluated tool contact points on the final machined surface are available for completing the accuracy prediction of the machined surface. A machining experiment has been carried out to validate this prediction model and the results show the model is effective

Customization design method for complex product systems based on a meta-model

In order to effectively reuse the design knowledge of product family life cycle development and support holistic and rapid individual product design, this article presents a new meta-model-based systemic customization design method for complex product systems within a product-pedigree. The proposed method aims to synthetically analyze the common and adaptive customer demands and product features of a product-pedigree of complex product systems and to quickly respond to the changing demands based on knowledge accumulation in the field of customization design. The key to implement such a method is (1) to construct a product-pedigree-oriented product meta-model with a four-layered architecture where it is possible to achieve a high degree of abstraction of product and (2) to develop a special technique for configuring the meta-model of the complex product systems. We have tested the proposed method with the rapid design of product-pedigree of a high-speed train’s bogies as an illustrative example. In this work, a rapid customization design prototype system has been developed and applied to the design of a high-speed train’s bogie to illustrate how to construct a product meta-model and how to conduct configuration design on different layers and variant design for generating new products

Collaborative simulation method with spatiotemporal synchronization process control

When designing a complex mechatronics system, such as high speed trains, it is relatively difficult to effectively simulate the entire system’s dynamic behaviors because it involves multi-disciplinary subsystems. Currently, a most practical approach for multi-disciplinary simulation is interface based coupling simulation method, but it faces a twofold challenge: spatial and time unsynchronizations among multi-directional coupling simulation of subsystems. A new collaborative simulation method with spatiotemporal synchronization process control is proposed for coupling simulating a given complex mechatronics system across multiple subsystems on different platforms. The method consists of 1) a coupler-based coupling mechanisms to define the interfacing and interaction mechanisms among subsystems, and 2) a simulation process control algorithm to realize the coupling simulation in a spatiotemporal synchronized manner. The test results from a case study show that the proposed method 1) can certainly be used to simulate the sub-systems interactions under different simulation conditions in an engineering system, and 2) effectively supports multi-directional coupling simulation among multi-disciplinary subsystems. This method has been successfully applied in China high speed train design and development processes, demonstrating that it can be applied in a wide range of engineering systems design and simulation with improved efficiency and effectiveness

A hyper-heuristic based ensemble genetic programming approach for stochastic resource constrained project scheduling problem

In project scheduling studies, to the best of our knowledge, the hyper-heuristic collaborative scheduling is first-time applied to project scheduling with random activity durations. A hyper-heuristic based ensemble genetic programming (HH-EGP) method is proposed for solving stochastic resource constrained project scheduling problem (SRCPSP) by evolving an ensemble of priority rules (PRs). The proposed approach features with (1) integrating the critical path method into the resource-based policy class to generate schedules; (2) improving the existing single hyper-heuristic project scheduling research to construct a suitable solution space for solving SRCPSP; and (3) bettering genetic evolution of each subpopulation from a decision ensemble with three different local searches in corporation with discriminant mutation and discriminant population renewal. In addition, a sequence voting mechanism is designed to deal with collaborative decision-making in the scheduling process for SRCPSP. The benchmark PSPLIB is performed to verify the advantage of the HH-EGP over heuristics, meta-heuristics and the single hyper-heuristic approaches

Research on priority rules for the stochastic resource constrained multi-project scheduling problem with new project arrival

The resource constrained multi-project scheduling problem (RCMPSP) is a general and classic problem, which is usually considered and solved in a deterministic environment. However, in real project management, there are always some unforeseen factors such as one or more new project arrivals that give rise to intermittent changes in the activity duration (or stochastic duration) of the current project in execution by inserting the new project. This study takes two practical factors in terms of stochastic duration of project activities and new project arrivals waiting for insertion into account of the problem space to form a stochastic resource constrained multi-project scheduling problem with new project arrivals (SRCMPSP-NPA). Based on the benchmark of the PSPLIB (Project Scheduling Problem Library), a new data set is built and 20 priority rules (PRs) are applied to solve the problem and their performances are analyzed. In addition, a heuristic hybrid method is designed for solving the problem timely by dividing the entire scheduling process into multi-state scheduling problems solved by the corresponding rules separately. This approach has been verified by experiments and its performance is better than that of a single rule in most situations

Application of bolt joints dynamic parameters identification in machine tools based on partially measured frequency response functions

This paper presents a method to identify the bolt joints dynamic parameters based on partially measured frequency response functions (FRFs) and demonstrates its application in machine tools. Basic formulas are derived to identify the joint dynamic properties based on the substructuring method and an algorithm to estimate the unmeasured FRFs is also developed. The identification avoids direct inverse calculation to the frequency response function matrix, and its validity is demonstrated by comparing the simulated and measured FRFs of the assembled free-free steel beams with a bolt joint. An approach is put forward to apply the identification in machine tools by constructing structures assembled of substructures and joint structures to substitute the bolt joints in machine tools and assuring the contact conditions unchanged. The identification of the bed-column bolt joint in a vertical machining center is provided to describe the application procedure and show the feasibility of the proposed approach

How to model and implement connections between physical and virtual models for digital twin application

Digital twin (DT) is a virtual mirror (representation) of a physical world or a system along its lifecycle. As for a complex discrete manufacturing system (DMS), it is a digital model for emulating or reproducing the functions or actions of a real manufacturing system by giving the system simulation information or directly driven by a real system with proper connections between the DT model and the real-world system. It is a key building block for smart factory and manufacturing under the Industry 4.0 paradigm. The key research question is how to effectively create a DT model during the design stage of a complex manufacturing system and to make it usable throughout the system's lifecycle such as the production stage. Given that there are some existing discussions on DT framework development, this paper focuses on the modeling methods for rapidly creating a virtual model and the connection implementation mechanism between a physical world production system at a workshop level and its mirrored virtual model. To reach above goals, in this paper, the discrete event system (DES) modeling theory is applied to the three-dimension DT model. First, for formally representing a manufacturing system and creating its virtual model, seven basic elements: controller, executor, processor, buffer, flowing entity, virtual service node and logistics path of a DMS have been identified and the concept of the logistics path network and the service cell is introduced to uniformly describe a manufacturing system. Second, for implementing interconnection and interaction, a new interconnection and data interaction mechanism between the physical system and its virtual model for through-life applications has been designed. With them, each service cell consists of seven elements and encapsulates input/output information and control logic. All the discrete cells are constructed and mapped onto different production-process-oriented digital manufacturing modules by integrating logical, geometric and data models. As a result, the virtual-physical connection is realized to form a DT model. The proposed virtual modeling method and the associated connection mechanism have been applied to a real-world workshop DT to demonstrate its practicality and usefulness