Search Results (14)

The instantaneous contact zone in robotic abrasive belt grinding involves highly coupled thermo-mechanical interactions between abrasive grains and the workpiece material. Acoustic Emission (AE) signals generated during this process are inherently nonlinear and nonstationary, posing challenges for accurate process monitoring and mechanistic understanding. To address this, this study introduces an innovative AE signal processing framework designed to elucidate the robotic grinding mechanism for Ti-6Al-4V (TC4) titanium alloy. An improved Completely Complementary Ensemble Empirical Mode Decomposition (CCEEMD) algorithm, building upon Empirical Mode Decomposition (EMD), is developed to precisely extract intrinsic mode functions (IMFs) from raw AE data. Subsequently, a novel denoising algorithm utilizing noise statistical characteristics effectively removes invalid noise from the robotic machining system. Validation through robotic grinding experiments on TC4 workpieces successfully established quantifiable relationships between extracted AE features and the underlying grinding mechanism. Significantly, implementing this methodology contributed to extending the effective service life of a structured abrasive belt by approximately 20% while increasing machining efficiency by approximately 12%. This work presents a novel methodology combining improved CCEEMD and statistical denoising for AE analysis in robotic grinding, providing a robust link between AE signatures and material removal mechanisms, ultimately enabling quantitative process optimization. Full article

On-load tap changers (OLTCs) are critical components of power transformers. In recent years, condition monitoring technologies for OLTCs based on vibration signals have attracted increasing research interest. However, practical applications still face several challenges, including background noise interference, insufficient characterization of transient signals, signal complexity, difficulty in detecting subtle anomalies, and ambiguous associations between fault modes and signal features. To address these issues, this paper proposes an OLTC acoustic fingerprint feature recognition method based on multidimensional phase-space trajectory analysis. First, an OLTC fault simulation platform was established, in which typical mechanical faults—such as fastener loosening, contact wear, and insufficient spring energy storage—were physically simulated. Corresponding vibration signals were then acquired under different operating conditions. Considering the independence of vibration characteristics at different locations of the distribution transformer, a blind source separation method based on endpoint detection was employed to separate OLTC vibration signals from the operational noise of the transformer body. Given the nonlinear and chaotic characteristics of OLTC vibration signals, phase-space reconstruction was introduced for signal analysis. Based on the reconstructed phase space, characteristic patterns and geometric feature parameters corresponding to different mechanical states of the OLTC were extracted. Furthermore, a two-dimensional membership function was constructed using the phase-space trajectories, and fuzzy inference based on predefined fuzzy rules was applied to compute representative feature parameters. A feature parameter database was subsequently established to enable OLTC condition identification. Experimental results demonstrate that the proposed diagnostic model can effectively classify and identify OLTC fault conditions using vibration signals, achieving an average classification accuracy exceeding 91.25%. The proposed method provides an effective non-intrusive approach for online monitoring and mechanical fault diagnosis of OLTCs without interrupting normal transformer operation. Full article

In comparison to internal combustion engines, which usually have low frequency, broadband excitations, in electric vehicles, tonal excitations from the electric drivetrain are noticeable and disturbing. As the acoustic and structural dynamic behavior, often referred to as noise, vibration, and harshness (NVH), strongly influences customers’ quality perceptions, optimizing it is a key challenge in development. This study investigates the influence of static rotor–stator eccentricity on the NVH behavior of an electric drivetrain using a transient elastic multibody simulation (eMBS) model incorporating non-linear gear meshing, bearing contact, and electromagnetic forces. The analysis identifies the 36th order excitation of the electric machine as the dominant source, leading to a maximum total acceleration level of 152 dB. Two specific excitation directions were found to reduce this amplitude most effectively. However, varying the amount of static eccentricity in these directions resulted in only minor vibration reductions (<1.5 dB). The findings indicate that the symmetric mode shapes of the cylindrical housing govern the response, indicating that addressing the excitability of housing modes by developing asymmetric housing designs could offer a more effective approach for NVH optimizations of electric drivetrains. Full article

Shale oil and gas reservoirs are characterized by low porosity and low permeability. The development of ultra-long horizontal wells can significantly increase reservoir contact area and enhance single-well production. Shale formations exhibit distinct bedding structures, high formation pressure, high rock hardness, and strong anisotropy. These characteristics result in poor drillability, slow drilling rates, and high costs when drilling horizontally, severely restricting efficient development. Therefore, accurately predicting the drillability of shale gas wells has become a major challenge. Currently, most scholars rely on a single parameter to predict drillability, which overlooks the coupled effects of multiple factors and reduces prediction accuracy. To address this issue, this study employs drillability experiments, mineral composition analysis, positional analysis, and acoustic transit-time tests to evaluate the effects of mineral composition, acoustic transit time, bottom-hole confining pressure, and formation drilling angle on the drillability of horizontal well reservoirs, innovatively integrating multiple parameters to construct a nonlinear model and introducing three intelligent optimization algorithms (PSO, AOA-GA, and EBPSO) for the first time to improve prediction accuracy, thus breaking through the limitations of traditional single-parameter prediction. Based on these findings, a nonlinear regression prediction model integrating multiple parameters is developed and validated using field data. To further enhance prediction accuracy, the model is optimized using three intelligent optimization algorithms: PSO, AOA-GA, and EBPSO. The results indicate that the EBPSO algorithm performs the best, followed by AOA-GA, while the PSO algorithm shows the lowest performance. Furthermore, the model is applied to predict the drillability of Well D4, and the results exhibit a high degree of agreement with actual measurements, confirming the model’s effectiveness. The findings support optimization of drilling parameters and bit selection in shale oil and gas reservoirs, thereby improving drilling efficiency and mechanical penetration rates. Full article

Thin-walled connection structures are commonly used in the hot-end components of aerospace vehicles. Large deflection nonlinear responses and fatigue failure occur due to their discontinuous mass distribution and prominent cross-sectional changes under the action of complex thermal, aerodynamic, and noise loads. A thermoacoustic fatigue test was carried out to obtain the acoustic and vibration responses and fatigue life changes of the connection structure under heat flow conditions in engineering applications. The high-temperature acoustic fatigue test system of aviation thin-walled structures was used, taking the high-temperature alloy thin-walled plate-load-bearing frame bolted connection structure as the research object. As a result, the vibration response and fatigue life under different thermoacoustic loads were obtained. The contact finite element method was used to simulate the connection pre-tightening force, and the coupled finite element/boundary element method was used to calculate the acoustic and vibration response of the heat flow conditions. The changing rules of the frequency response peak value at the critical point of the thin-walled connection structure under the effects of different temperature fields, fluid fields, and sound fields were obtained through the processing and analysis of the calculation results. Considering the structural vibration fatigue damage mechanism, this study employed an improved rainflow counting method to compute the rainflow circulation matrix (RFM) and rainflow damage matrix (RFD) of the vibration stress time history at critical points within the structure framework. Said method was combined with Miner’s linear cumulative damage theory to estimate the fatigue life under various thermal-fluid-acoustic coupled loads. A comprehensive analysis validates the accuracy of the established numerical simulation calculation model in identifying critical connection points within structures subjected to pre-tightening forces. This model effectively characterizes thermal, aerodynamic, and acoustic loads on high-temperature alloy thin-walled-load-bearing frame bolted connection structures. It delineates the relationship between vibration response and fatigue life while assessing the impact of three distinct load parameters. Full article

Acoustic sensing systems play a critical role in identifying and determining weak sound sources in various fields. In many fault warning and environmental monitoring processes, sound-based sensing techniques are highly valued for their information-rich and non-contact advantages. However, noise signals from the environment reduce the signal-to-noise ratio (SNR) of conventional acoustic sensing systems. Therefore, we proposed novel nonlinear gradient-coiling metamaterials (NGCMs) to sense weak effective signals from complex environments using the strong wave compression effect coupled with the equivalent medium mechanism. Theoretical derivations and finite element simulations of NGCMs were executed to verify the properties of the designed metamaterials. Compared with nonlinear gradient acoustic metamaterials (Nonlinear-GAMs) without coiling structures, NGCMs exhibit far superior performance in terms of acoustic enhancement, and the structures capture lower frequencies and possess a wider angle acoustic response. Additionally, experiments were constructed and conducted using set Gaussian pulse and harmonic acoustic signals as emission sources to simulate real application scenarios. It is unanimously shown that NGCMs have unique advantages and broad application prospects in the application of weak acoustic signal sensing, enhancement and localization. Full article

There are some limitations when conventional ultrasonic testing methods are used for testing early damage in metal parts. With the continuous development of acoustics and materials science, nonlinear ultrasonic nondestructive testing technology has been used for testing of early damage in metal materials. In order to better understand the basic theory and research progress of the nonlinear ultrasonic testing technology, the classical nonlinear ultrasonic theoretical models, including the dislocation monopole model, dislocation dipole model, precipitate-dislocation pinning model, and contact nonlinear ultrasonic theory-microcrack model, are analyzed in depth. This paper introduces the application and research progress of nonlinear ultrasonic detection technology, which is derived from different acoustic nonlinear effects, such as higher harmonic, wave mixing and modulation, sub-harmonic, resonance frequency spectrum analysis, and non-linear ultrasonic phased array imaging. The key technologies and problems are summarized to provide a reference for the further development and promotion of nonlinear ultrasonic non-destructive testing technology. Full article

Bolted joints are fundamental to numerous structural components in engineering practice. Nevertheless, their failure or even their loosening can lead to insufficient performance and reduced structural safety. This study presents a theoretical development and experimental investigation into nonlinear guided-wave mixing for integrity monitoring of bolted joints in plates. Combinational harmonics generated due to nonlinear Lamb wave mixing and contact acoustic nonlinearity at the bolted joints were used to evaluate the applied torque level in the joint. The area of the power spectral density in the region of the sum combinational harmonic bandwidth is found to be highly correlated to the applied torque level at the joint. Moreover, the effect of the number of cycles and thus the time duration of the excitation is investigated. The results show that the combinational harmonics remain robust for different numbers of cycles in detecting bolt loosening. The findings presented in this study also provide physical insight into the phenomena of nonlinear Lamb wave mixing for evaluating applied torque in bolted joints, and the results help further advance the use of nonlinear guided waves for damage detection. Full article

The response of the quartz crystal microbalance (QCM, also: QCM-D for “QCM with Dissipation monitoring”) to loading with a diverse set of samples is reviewed in a consistent frame. After a brief introduction to the advanced QCMs, the governing equation (the small-load approximation) is derived. Planar films and adsorbates are modeled based on the acoustic multilayer formalism. In liquid environments, viscoelastic spectroscopy and high-frequency rheology are possible, even on layers with a thickness in the monolayer range. For particulate samples, the contact stiffness can be derived. Because the stress at the contact is large, the force is not always proportional to the displacement. Nonlinear effects are observed, leading to a dependence of the resonance frequency and the resonance bandwidth on the amplitude of oscillation. Partial slip, in particular, can be studied in detail. Advanced topics include structured samples and the extension of the small-load approximation to its tensorial version. Full article

A challenge in the field of material science and concrete technology is to associate material properties and behavior with changes in internal microstructure. A fundamental issue for planning, implementation, and quality control of construction projects is the fundamental understanding of the hardening process in freshly poured cement-based materials. Shortly after the mixing process, cementitious materials exhibit a substantial damping effect on ultrasonic wave propagation along with low-pulse velocity. The way a wave reflects and diffuses in the volume of a solid material can provide important information about internal heterogeneities. An important application of the wave propagation technique is the determination of layers within the material distinguished by unlike elastic properties. During the hardening process, the ultrasonic wave propagation exhibits a noticeable sensitivity at the point of phase change of the material, that is, the critical point at which the state of the suspension transforms from liquid to solid state. After that point, there is a continuous increase of pulse velocity and ultrasonic signal amplitude. The solidification point is of practical importance since at this point the load-bearing capacity of the composite material and its long-term behavior are based on the connectivity of the solid phase. This study aims to develop a nondestructive tool to monitor freshly poured cement-paste composites at early stages, during the hydration process, by means of nonlinear elastic waves. The measurement setup combined a contact ultrasonic transducer with a noncontact optical detection system, in which the principle of operation is based on the Doppler effect. This methodology enabled us to assess the amplitudes of harmonic vibrations of an acoustic wave propagating through the material with a specific fundamental frequency. This enabled the evaluation of important material properties, such as minute changes in the internal microstructure of fresh concrete during hardening, the evolution of nonlinearity parameters that relate to higher-order elastic constants of the material, as well as the ultrasonic wave velocity. Full article

In this paper, characterization of the orientation of a microcrack is quantitatively investigated using the directivity of second harmonic radiated by the secondary sound source (SSS) induced by the nonlinear interaction between an incident ultrasonic transverse wave (UTW) and a microcrack. To this end, a two-dimensional finite element (FE) model is established based on the bilinear stress–strain constitutive relation. Under the modulation of contact acoustic nonlinearity (CAN) to the incident UTW impinging on the microcrack examined, the microcrack itself is treated as a SSS radiating the second harmonic. Thus, the directivity of the second harmonic radiated by the SSS is inherently related to the microcrack itself, including its orientation. Furthermore, the effects of the stiffness difference between the compressive and tensile phases in the bilinear stress–strain model, and the UTW driving frequency, as well as the radius of the sensing circle on the SSS directivity are discussed. The FE results show that the directivity pattern of the second harmonic radiated by the SSS is closely associated with the microcrack orientation, through which the microcrack orientation can be characterized without requiring a baseline signal. It is also found that the SSS directivity varies sensitively with the driving frequency of the incident UTW, while it is insensitive to the stiffness difference between the compressive and tensile phases in the bilinear stress–strain model and the radius of the sensing circle. The results obtained here demonstrate that the orientation of a microcrack can be characterized using the directivity of the SSS induced by the interaction between the incident UTW and the microcrack. Full article

Steel wires are widely used as raw materials for spring valves in engines. Considering the quality and safety issues of their structure, there is a demand to develop nondestructive inspection approaches to detect initial damages in steel. In this study, nonlinear ultrasonic-guided waves generated by an electromagnetic acoustic transducer (EMAT) were used to inspect the defects in steel wires. As one of the noncontact testing methods, the use of EMAT has significant advantages to decrease the nonlinearity induced by instruments and transducer contact condition. The principles of design and manufacturing of EMAT are first introduced. The fundamental theory of nonlinear guided waves is also briefly discussed in this investigation. Phase-matched guided wave modes were generated and measured by using EMAT. Variations of acoustic nonlinearity corresponding to existing defects in specimens were obtained. A scanning electron microscope (SEM) was used to check the existence of microdefects in specimen. The results indicate that the use of EMAT can be an effective means to generate and measure nonlinear ultrasonic-guided waves for inspection of microdefects. Full article

Ultrasonic guided waves (UGWs) have attracted attention in the nondestructive testing and structural health monitoring (SHM) of multi-wire cables. They offer such advantages as a single measurement, wide coverage of the acoustic field, and long-range propagation ability. However, the mechanical coupling of multi-wire structures complicates the propagation behaviors of guided waves and signal interpretation. In this paper, UGW propagation in these waveguides is investigated theoretically, numerically, and experimentally from the perspective of dispersion and wave structure, contact acoustic nonlinearity (CAN), and wave energy transfer. Although the performance of all possible propagating wave modes in a multi-wire cable at different frequencies could be obtained by dispersion analysis, it is ineffective to analyze the frequency behaviors of the wave signals of a certain mode, which could be analyzed using the CAN effect. The CAN phenomenon of two mechanically coupled wires in contact was observed, which was demonstrated by numerical guided wave simulation and experiments. Additionally, the measured guided wave energy of wires located in different layers of an aluminum conductor steel-reinforced cable accords with the theoretical prediction. The model of wave energy distribution in different layers of a cable also could be used to optimize the excitation power of transducers and determine the effective monitoring range of SHM. Full article

Compared with conventional linear ultrasonic inspection methods, which are sensitive only to severe defects, nonlinear ultrasonic inspection methods are better for revealing micro-cracks in thin plates. However, most nonlinear ultrasonic inspection methods have only been experimentally investigated using bulk or Rayleigh waves. Numerical studies, especially numerical simulations of Lamb ultrasonic waves, have seldom been reported. In this paper, the interaction between nonlinear S0 mode Lamb waves and micro-cracks of various lengths and widths buried in a thin metallic plate was simulated using the finite element method (FEM). The numerical results indicate that after interacting with a micro-crack, a new wave-packet was generated in addition to the S0 mode wave-packet. The second harmonics of the S0 mode Lamb waves and the new wave-packet were caused by nonlinear acoustic effects at the micro-crack. An amplitude ratio indicator is thus proposed for the early detection of buried micro-cracks. Full article