Search Results (529)

Blade tip leakage vortex (TLV) is a critical phenomenon in hydraulic machinery, which can significantly affect the internal flow characteristics and deteriorate the hydraulic performance. In this paper, the blade tip leakage flow and TLV characteristics in a novel dishwasher pump were investigated. The correlation between the vorticity distribution in various directions and the leakage vortices was established within a rotating coordinate system. The results show that the TLV in a composite impeller can be categorized into initial and secondary leakage vortices. The initial leakage vortex originates from the evolution of two corner vortices that initially form at different locations within the blade tip clearance. This vortex induces pressure fluctuations at the impeller inlet; its shedding is identified as the primary contributor to localized energy loss within the flow passage. These findings provide insights into TLVs in complex pump geometries and provide solutions for future pump optimization strategies. Full article

Analyzing the two-phase flow behavior in bearing lubrication is crucial for understanding friction and wear mechanisms, optimizing lubrication design, and improving bearing operational efficiency and reliability. However, the complexity of oil–air two-phase flow in high-speed bearings poses significant research challenges. Currently, there is a lack of comparative studies employing different simulation strategies to address this issue, leaving a gap in evidence-based guidance for selecting appropriate simulation approaches in practical applications. This study begins with a comparative analysis between experimental and simulation results to validate the reliability of the adopted simulation approach. Subsequently, a comparative evaluation of different simulation methods is conducted to provide a scientific basis for relevant decision-making. Evaluated from three dimensions—adaptability to rotational speed conditions, research focuses (oil distribution and power loss), and computational economy—the findings reveal that FVM excels at medium-to-high speeds, accurately predicting continuous oil film distribution and power loss, while MPS, leveraging its meshless Lagrangian characteristics, demonstrates superior capability in describing physical phenomena under extreme conditions, albeit with higher computational costs. Economically, FVM, supported by mature software ecosystems and parallel computing optimization, is more suitable for industrial design applications, whereas MPS, being more reliant on high-performance hardware, is better suited for academic research and customized scenarios. The study further proposes that future research could adopt an FVM-MPS coupled approach to balance efficiency and precision, offering a new paradigm for multi-scale lubrication analysis in bearings. Full article

This paper presents a novel dynamic modeling framework for gantry crane systems based on the cart double pendulum with dual cables (CDPD) model. The CDPD model systematically incorporates the effects of dual suspension cables, equalizer beams, and closed-chain kinematic constraints, enabling an accurate simulation of both symmetric and asymmetric lifting scenarios. Utilizing Kane’s method, the model efficiently handles redundant coordinates and holonomic constraints, resulting in a compact and numerically robust formulation. Validation results demonstrate strict energy conservation and consistency with traditional models in limiting cases. The proposed approach provides a unified and extensible foundation for the advanced analysis, control, and optimization of large-scale gantry crane operations. Full article

Rehabilitation devices such as actuated lower-limb exoskeletons can provide essential mobility assistance for pediatric patients with gait impairments. Enhancing their control systems under conditions of user variability and dynamic disturbances remains a significant challenge, particularly in active-assist modes. This study presents a human-in-the-loop control architecture for a pediatric lower-limb exoskeleton, combining outer-loop admittance control with robust inner-loop trajectory tracking via a non-singular terminal sliding-mode (NSTSM) controller. Designed for active-assist gait rehabilitation in children aged 8–12 years, the exoskeleton dynamically responds to user interaction forces while ensuring finite-time convergence under system uncertainties. To enhance adaptability, we augment the inner-loop control with a twin delayed deep deterministic policy gradient (TD3) reinforcement learning framework. The actor–critic RL agent tunes NSTSM gains in real-time, enabling personalized model-free adaptation to subject-specific gait dynamics and external disturbances. The numerical simulations show improved trajectory tracking, with RMSE reductions of 27.82% (hip) and 5.43% (knee), and IAE improvements of 40.85% and 10.20%, respectively, over the baseline NSTSM controller. The proposed approach also reduced the peak interaction torques across all the joints, suggesting more compliant and comfortable assistance for users. While minor degradation is observed at the ankle joint, the TD3-NSTSM controller demonstrates improved responsiveness and stability, particularly in high-load joints. This research contributes to advancing pediatric gait rehabilitation using RL-enhanced control, offering improved mobility support and adaptive rehabilitation outcomes. Full article

Accurate oil debris analysis and wear monitoring of a gearbox are essential to ensure its stable and reliable operation. Element types of wear debris and their changes in the lubrication oil of the gearbox can be monitored by spectral analysis. However, it is still difficult to identify wear parts of the gearbox due to the complex composition of elements of wear debris. An improved multi-variable grey prediction model by incorporating a multi-objective genetic algorithm (MOGA-GM(1, N)) is proposed to evaluate weight coefficients of element concentrations of wear debris in the lubrication oil of the gearbox. Moreover, a wear growth rate of each element in the lubrication oil is proposed as an index for oil debris analysis to analyze the multi-variable correlation between the common element of iron (Fe) and other related elements of wear parts of the gearbox. Oil debris analysis of the gearbox is conducted on optimal weight coefficients of related elements to the common element Fe using the MOGA-GM(1, N) model. Wear experiment results verify feasibility of the proposed oil debris analysis method. Full article

Studying nonlinear oscillations in mechanical systems is fundamental to understanding complex dynamic behavior in engineering applications. While classical analytical methods remain valuable for systems with limited complexity, they become increasingly inadequate when nonlinearities are strong and geometrically induced, as in the case of large-amplitude oscillations. This paper presents a combined numerical and experimental investigation of a mechanical system composed of two coupled pendulums, exhibiting significant nonlinear behavior due to elastic deformation throughout their motion. A mathematical model of the system was developed using the MatLab/Simulink ver.6.1 environment, considering gravitational, inertial, and nonlinear elastic restoring forces. One of the major challenges in accurately modeling such systems is accurately representing damping, particularly in the absence of dedicated dampers. In this work, damping coefficients were experimentally identified through decrement measurements and incorporated into the simulation model to improve predictive accuracy. The simulation outputs, including angular displacements, velocities, accelerations, and phase trajectories over time, were validated against experimental results obtained via high-precision inertial sensors. The comparison shows a strong correlation between numerical and experimental data, with minimal relative errors in amplitude and frequency. This research represents the first stage of a broader study aimed at analyzing forced and parametrically excited oscillations. Beyond validating the model, the study contributes to the design of a robust experimental framework suitable for further exploration of nonlinear dynamics. The findings have practical implications for the development and control of mechanical systems subject to dynamic loads, with potential applications in automation, vibration analysis, and system diagnostics. Full article

To address the issues of large errors, low accuracy, and time-consuming simulations in finite element (FE) models of tapping processes, which hinder the identification of optimal structural parameters, this study integrates FE simulation with experimental testing to optimize the structural parameters of spiral taps specifically designed for stainless steel. Initially, single-factor experiments were conducted to analyze the influence of mesh parameters on experimental outcomes, leading to the identification of optimal mesh coefficients. Subsequently, the accuracy of the FE tapping simulation model was validated by comparing trends in axial force, torque, and chip morphology between simulations and actual tapping experiments. Orthogonal experimental design combined with entropy weight analysis and range analysis was then employed to conduct FE simulations. The results indicated that the optimal structural parameter combination is a helix angle of 43°, cone angle of 19°, and cutting edge relief amount of 0.18 mm. Finally, based on this combination, optimized spiral taps were manufactured and subjected to comparative performance testing. The results demonstrated significant improvements: the average maximum axial force decreased by 33.22%, average maximum torque decreased by 13.41%, average axial force decreased by 38.22%, and average torque decreased by 24.87%. Error analysis comparing corrected simulation results with actual tapping tests revealed axial force and torque error rates of 5.04% and 0.24%, respectively. Full article

The two-stage proportional valve is a key control component in heavy-duty equipment, where its signal-flow characteristics critically influence operational performance. This study proposes an innovative flow characteristic regulation method using variable-gain feedback grooves. Unlike conventional throttling notch optimization, the core mechanism actively adjusts pilot–main valve mapping through feedback groove shape and area gain adjustments to achieve the desired flow curves. This approach avoids complex throttling notch issues while retaining the valve’s high dynamics and flow capacity. Mathematical modeling elucidated the underlying mechanism. Subsequently, trapezoidal and composite feedback grooves are designed and investigated via simulation. Finally, composite feedback groove spools tailored to construction machinery operating conditions are developed. Comparative experiments demonstrate the following: (1) Pilot–main mapping inversely correlates with area gain; increasing gain enhances micro-motion control, while decreasing gain boosts flow gain for rapid actuation. (2) This method does not significantly increase pressure loss or energy consumption (measured loss: 0.88 MPa). (3) The composite groove provides segmented characteristics; its micro-motion flow gain (2.04 L/min/0.1 V) is 61.9% lower than conventional valves, significantly improving fine control. (4) Adjusting groove area gain and transition point flexibly modifies flow gain and micro-motion zone length. This method offers a new approach for high-performance valve flow regulation. Full article

Compared to spiral bevel gear drives with localized conjugation, line contact spiral bevel gears possess a significantly larger meshing area, theoretically achieving full tooth surface contact and substantially enhancing load capacity. To accurately support the root strength calculation and parameter design of line contact spiral bevel gear drives, this paper presents a theoretical analysis and experimental study of the root bending stress of gear pairs. First, based on the analysis of the meshing characteristics of line contact spiral bevel gear pairs, the load distribution along the contact lines is investigated. Using the slicing method, the load distribution characteristics along the contact line are obtained, and the load sharing among multiple tooth pairs during meshing is further studied. Then, by applying a cantilever beam bending stress model, the root bending stress on such a gear drive is calculated. A root bending moment distribution model is proposed based on the characteristics of the line load distribution previously obtained, from which a formula for calculating root bending stress is derived. Finally, static-condition experiments are conducted to test the root bending stress. The accuracy of the proposed calculation method is verified through experimental testing and finite element analysis. The results of this study provide a foundation for designing lightweight and high-power-density spiral bevel gear drives. Full article

Downwind wind turbines offer potential for reduced blade loads and lighter designs, yet systematic aeroelastic comparisons against upwind configurations remain limited, especially for multi-megawatt scales. This study conducts comprehensive OpenFAST simulations of the IEA 15 MW reference turbine in both configurations, contextualized against smaller turbines (2.1, 5, and 10 MW). Scaling trends reveal that, with the increase in turbine size, the disadvantage of the downwind turbine (higher flapwise and edgewise fatigue load) is gradually disappearing and even becomes an advantage. However, downwind configurations amplify tower base loads significantly. These results highlight scalable benefits for blade loads but underscore critical trade-offs requiring tower reinforcement. Optimizing rotor-nacelle mass distribution emerges as a key pathway to mitigate tower penalties while leveraging blade-load alleviation for larger downwind turbines. Full article

The paper provides an analysis of the energy efficiency of the swing drive system of hydraulic excavators, which integrally includes a hydraulic motor and a planetary reducer. The indicator of the drive’s energy efficiency is determined based on the efficiency of the hydraulic motor and the planetary reducer. The efficiency of the hydraulic motor is defined as a function of the specific flow, pressure, and the number of revolutions of the hydraulic motor. The efficiency of the reducer is determined using structural analysis of planetary gearboxes and the moment method. As an example, the results of a comparative analysis of the energy efficiency of the swing drive of a tracked hydraulic excavator, weighing 16,000 kg and having a bucket volume of 0.6 m³, are presented. From the set of possible generated variant solutions of the drive, obtained through the synthesis process based on the required torque and platform rotation speed, two extreme drive variants were selected for the analysis. In the first configuration, a hydraulic motor characterized by a low specific flow is combined with a three-stage reduction gear featuring a higher overall transmission ratio, whereas the second configuration integrates a high-specific-flow hydraulic motor with a two-stage reduction gear of a lower transmission ratio. The obtained results of the comparative analysis of the drive’s energy efficiency are presented depending on the change in the required torque and the rotational speed of the platform. Full article

Duplex ball bearings are common components in space satellite mechanisms, and their behaviour impacts the overall performance and reliability of these systems. During rocket launches, these bearings suffer high vibrational loads, making their dynamic response essential for their survival. To predict the dynamic behaviour under vibration, simulations and experimental tests are performed. However, published models for space applications fail to capture the variations observed in test responses. This study presents a multi-degree-of-freedom nonlinear multibody model of a hard-preloaded duplex space ball bearing, particularized for this work to the case in which the outer ring is attached to a shaker and the inner ring to a test dummy mass. The model incorporates the Hunt and Crossley contact damping formulation and employs quaternions to accurately represent rotational dynamics. The simulated model response is validated against previously published axial test data, and its response under step, sine, and random excitations is analysed both in the case of radial and axial excitation. The results reveal key insights into frequency evolution, stress distribution, gapping phenomena, and response amplification, providing a deeper understanding of the dynamic performance of space-grade ball bearings. Full article

Hydraulic support (Hs) is an important support equipment in coal mining. With the continuous increase in coal mining intensity, stricter technical specifications have been put forward for the effectiveness of Hs. Hs is always in a dynamic coupling state with the surrounding rock. Investigating its dynamic adaptation characteristics in relation to surrounding rock is of great significance for improving its performance. In this work, a numerical analysis model of the ‘support–surrounding rock’ coupling system was established by taking the Hs (type ZZ 17000/33/72D) in the Kouzidong coal mine as an example and using explicit dynamic analysis software Ls-dyna R12. The dynamic response and pressure distribution characteristics of the hydraulic ‘support–surrounding rock’ coupling system under different mining heights and load conditions were investigated. The key vulnerable connection components of the Hs and their critical connection unit instability conditions were identified. These findings provide a theoretical basis for the structural optimization of four-column Hs, which will be beneficial in promoting the improvement of its load-bearing stability. Full article

Additive manufacturing (AM) has been gaining increased traction in the manufacturing industry due to its ability to fabricate prototypes and end use parts in low volumes at a much lower cost compared to conventional manufacturing processes. There has been research to select an AM process appropriate for fabricating particular parts. However, there is little extant research to select appropriate AM machines even though there is a growing number of AM machines with interesting topologies, structures, and systems. This paper proposes a methodology that aims to assist Technical Experts in selecting a machine for Fused Filament Fabrication (FFF). The methodology is built around a weighted Technique for Order of Preference by Similarity to Ideal Solution (TOPSIS), which uses the concept of relative closeness and attribute weights to rank the machines. The paper uses Monte Carlo simulations for sensitivity analysis to evaluate the impact of randomizing attribute scoring, perturbing weights assigned, and probability distributions used to model human decision variability. The methodology and the sensitivity analysis were applied to three case studies, with five FFF machines and seven attributes, and top machines ranked for a specific part were found to be largely robust. Full article