Search Results (93)

The object of this study is welded joints of AISI 321 and Ti-6Al-4V, obtained by diffusion welding on developed conical surfaces. The problem of creating bimetallic joints of AISI 321 and Ti-6Al-4V with developed conical contact surfaces, using diffusion welding through an intermediate Electrolytic Tough Pitch Copper (Cu-ETP) copper layer, was solved. The joints were studied using micro-X-ray spectral analysis, microstructural analysis, and mechanical tests. High mutual diffusion of copper and titanium, along with increased concentrations of Cr and V in copper, was detected. The shear strength of the obtained welded joints is 250 MPa and 235 MPa at 30 min and 15 min, respectively, which is higher than the copper layer’s strength (180 MPa). The obtained results are explained by the dislocation diffusion mechanism in the volume of grains and beyond, due to thermal deformations during welding. Under operating conditions of internal pressure and cryogenic temperatures, the strength of the connection is ensured by the entire two-layer structure, and tightness is ensured by a vacuum-tight diffusion connection. The obtained strength of the connection (250 MPa) is sufficient under the specified operating conditions. Analysis of existing solutions in the literature review indicates that industrial application of technology for manufacturing bimetallic adapters from AISI 321 stainless steel and Ti-6Al-4V titanium alloy is limited to butt joints with small geometric dimensions. Studies of the transition zone structure and diffusion processes in bimetallic joints with developed conical contact surfaces enabled determination of factors affecting joint structure and diffusion coefficients. The obtained bimetallic adapters, made of Ti-6Al-4V titanium alloy and AISI 321 stainless steel, can be used to connect titanium high-pressure vessels with stainless steel pipelines. Full article

Rock slopes exhibiting anti-inclined interbedded strata have widespread distribution and complex deformation mechanisms. In this study, we used a physical model test with basal friction to replicate the evolution process of the slope deformation. Digital Image Correlation (DIC) and Particle Image Velocimetry (PIV) methods were used to capture the variation in slope velocity and displacement fields. The results show that the slope deformation is conducted by bending of soft rock layers and accumulated overturning of hard blocks along numerous cross joints. As the faces of the rock columns come back into contact, the motion of the slope can progressively stabilize. Destruction of the toe blocks triggers the formation of the landslides within the toppling zone. The toppling fracture zones form by tracing tensile fractures within soft rocks and cross joints within hard rocks, ultimately transforming into a failure surface which is located above the hinge surface of the toppling motion. The evolution of the slope deformation mainly undergoes four stages: the initial shearing, the free rotation, the creep, and the progressive failure stages. Full article

The torsional stiffness of rehabilitation robot joints is a critical performance determinant, significantly affecting motion accuracy, stability, and user comfort. This paper introduces an innovative traction drive mechanism that transmits torque through friction forces, overcoming mechanical impact issues of traditional gear transmissions, though accurately modeling surface roughness effects remains challenging. Based on fractal theory, this study presents a comprehensive torsional stiffness analysis for advanced traction drive joints. Surface topography is characterized using the Weierstrass–Mandelbrot function, and a contact mechanics model accounting for elastic–plastic deformation of micro-asperities is developed to derive the tangential stiffness of individual contact pairs. Static force analysis determines load distribution, and overall joint torsional stiffness is calculated through the integration of individual contact contributions. Parametric analyses reveal that contact stiffness increases with normal load, contact length, and radius, while decreasing with the tangential load and roughness parameter. Stiffness exhibits a non-monotonic relationship with fractal dimension, reaching a maximum at intermediate values. Overall system stiffness demonstrates similar parameter dependencies, with a slight decrease under increasing output load when sufficient preload is applied. This fractal-based model enables more accurate stiffness prediction and offers valuable theoretical guidance for design optimization and performance improvement in rehabilitation robot joints. Full article

Jointing is inevitable for CFRTP (carbon fiber reinforced thermoplastic) component applications in the automotive industry. In this study, commonly used jointing methods were applied to fasten CFRTP components. Three types of jointing methods. Ultrasonic welding, bolted joints, and adhesive joining, and three types of CFRTP materials, conventional cross-ply, ultra-thin prepreg cross-ply, and sheet molding compounds, were selected. The influence of the jointing methods on mechanical properties and damage patterns under bending load has been investigated. The finite element models were developed to predict the hazardous area and structural stiffness of jointed structures; the simulation results showed good agreement with experimental ones. The results indicate that the ultrasonic welding could reach similar bending stiffness compared to adhesive joining, whereas the stiffness of bolt jointed structures is relatively lower due to the contact separation induced by the bending deformation. Overall, the finite element model results correlated well with the experimental data. Full article

The dynamic response of multi-story steel frames under impact loading exhibits a complex nonlinear behavior. This study develops a three-story, multi-scale spatial steel frame finite element model using ABAQUS 2023 software, and the contact algorithm and material parameters were validated through published drop-weight impact beam tests. A total of 48 impact parameter combinations were defined, covering rational mass–velocity ranges while accounting for column position variations at the first story. Systematic comparisons were conducted on the influence of varying impact parameters on structural dynamic responses. This study investigates deformation damage and progressive collapse mechanisms in spatial steel frames under impact loading. Structural dynamic responses show significant enhancement with increasing impact mass and velocity. As impact kinetic energy increases, the steel frame transitions from localized denting at impact zones to global bending deformation, inducing structural tilting. The steel frame exhibits potential collapse risk under severe impact conditions. Under identical impact energy, corner column impact displacements differ by <1% from edge-middle column displacements, with vertical displacement variations ranging 0–17.6%. The displacement of the first-floor joints of the structure with three spans in the impact direction was reduced by about 50% compared to that with two spans. When designing the structure, it is necessary to increase the number of frame spans in the impact direction to improve the overall stability of the structure. Based on the development of the rotation angle of the beam members during the impact process, the steel frame collapse process was divided into three stages, the elastic stage, the plastic and catenary stage, and the column member failure stage; the steel frame finally collapsed due to an excessive beam rotation angle and column failure. Full article

This paper presents a comprehensive methodology to enable the optimization of an automotive electric axle to reduce noise emissions and improve load distribution. The proposed method consists of the application of two sequential optimization procedures. The first one focuses on the gears’ macro-geometry, based on an objective function that combines the contact ratio, power loss, and center distance. The second one optimizes the micro-geometry of the teeth to reduce the sound pressure generated by tooth impacts. Mechanical stress limits are considered as a constraint in the optimization process. Shafts, joints, and the electric motor are analyzed, taking into account their deformation that influences the dynamics of the entire system. The results of the proposed procedure are verified through experimental measurements and the comparison can be considered successful. Full article

The electro-hydraulic composite intelligent completion technology is one of the most effective ways to solve the efficient development of oil and gas. The development of an electro-hydraulic composite wet joint tool that is compatible with the electro-hydraulic composite intelligent completion system can achieve intelligent control between the upper and lower pipe columns of deepwater oil and gas wells and the pluggable transmission of monitoring signals. This article proposes a new type of electromagnetic coupling electro-hydraulic composite wet joint designed to address the defects of friction damage and poor contact in current wet joint direct contact power transmission. The joint uses claw docking and wireless energy transmission to achieve the composite transmission of hydraulic and electric power. Firstly, we independently designed a DC power supply inverter circuit, rectification circuit, and wireless power transmission coil assembly to form a wireless power transmission system. We also conducted testing and analysis on the wireless power transmission efficiency, which exceeded 60%. When the input voltage was above 80 V, the output power was greater than 60 W, meeting the design requirements. Secondly, the mechanical structure of the new electro-hydraulic signal wet joint tool was optimized and its strength was verified. The simulation results showed that the maximum stress was 891.8 MPa, and the maximum deformation of the wet joint docking overall structure was 0.123 mm. The strength and deformation met the design requirements. The hydraulic and electrical connectivity indoor tests were conducted on the electromagnetic coupling wet joint, and all aspects of transmission were normal, thus forming a design scheme for the underground electromagnetic coupling electro-hydraulic signal wet joint. The wireless transmission type electro-hydraulic signal wet joint designed in this article is of great significance for accelerating the promotion and application process of deepwater intelligent completion systems. Full article

The objective of this study was to develop a musculoskeletal model incorporated with a subject-specific knee joint to predict the tibiofemoral contact force (TFCF) during daily motions. For this purpose, 18 healthy participants were recruited to perform the motion data acquisition using synchronized motion capture and force platform systems, and motion simulation based on an improved musculoskeletal model for five daily activities, including normal walking, stair ascent, stair descent, sit-to-stand, and stand-to-sit. The proposed musculoskeletal model included subject-specific models of bones, cartilages, and meniscus, detailed knee ligaments and muscles, deformable elastic contacts, and multiple degrees of freedom (DOFs) of the knee joint. The prediction accuracy was demonstrated by the good agreements of TFCF curves between the model predictions and in vivo measurements for the five activities (RMSE: 0.216~0.311 BW, R²: 0.928~0.992, and C_E: 0.048~0.141). Based on the validated model, the TFCF on total, medial, and lateral compartments (TFCF_Total, TFCF_Medial, and TFCF_Lateral) during the five daily activities were predicted. For TFCF_Total, the peak force for stair descent or sit-to-stand was the largest, followed by stair ascent or stand-to-sit, and finally normal walking. For TFCF_Medial, stair descent had the largest peak, followed by stair ascent. There were no significant differences between the peak TFCF_Medial values of normal walking, sit-to-stand, and stand-to-sit. For TFCF_Lateral, the peak of sit-to-stand was the largest, followed by stand-to-sit or stair descent, and finally normal walking or stair ascent. This study is valuable for further understanding the biomechanics of a healthy knee joint and providing theoretical guidance for the treatment of knee osteoarthritis (KOA). Full article

Enabling robots to work safely close to humans requires both adherence to safety standards and the development of appropriate strategies to plan and control robot movements in accordance with human movements. Collaboration between humans and robots in a shared environment is a joint activity aimed at completing specific tasks, requiring coordination, synchronisation, and sometimes physical contact, in which each party contributes its own skills and resources. Among the most challenging tasks of human–robot cooperation is the co-transport of deformable materials such as fabrics. This paper proposes a method for generating the trajectory of a collaborative manipulator. The method is designed for the co-transport of materials such as fabrics. It combines a near time-optimal control strategy that ensures responsiveness in following human actions while simultaneously guaranteeing compliance with the safety limits imposed by current regulations. The combination of these two elements results in a viable co-transport solution which preserves the safety of human operators. This is achieved by constraining the path of the robot trajectory with prescribed velocities and accelerations while simultaneously ensuring a near time-optimal control strategy. In short, the robot movement is generated in such a way as to ensure both the tracking of humans in the co-transportation task and compliance with safety limits. As a first attempt to adopt the proposed approach to integrate time-optimal strategies into human–robot interaction, the simulations and preliminary experimental result obtained are promising. Full article

During the excavation process of a Tunnel Boring Machine (TBM), the cutterhead exerts significant torque on the tunnel structure, which potentially causes torsional shear deformation at segment ring joints. Thus, examining the characteristics of torsional shear deformation and the shear-bearing performance of segment joints under construction torque is crucial for the design and safety of segment structures and the construction of TBM tunnels. To achieve this, a refined finite element model of the segment joints was developed to study their torsional shear resistance under varying axial forces and with or without mortise and tenon. Furthermore, the failure modes of bolts and the damage characteristics of segment concrete during torsional shear deformation are analyzed. The results show that the load-bearing process of torsional shear deformation in segment joints consists of three stages: development of the friction at the segment interface (Stage I), development of the bolt force (Stage II), and development of the mortise and tenon force (Stage III). It is noteworthy that axial force is the primary factor in enhancing the torsional shear resistance of the segmental joints. Moreover, as the torsional shear deformation increases, the contact and compression occur between the bolts and the segment bolt holes as well as between the mortise and tenon, leading to the yielding of the bolts and the failure of the concrete at the joints. Consequently, the segment concrete around the mortise and tenon and the bolt hole is prone to cracking and crushing. To prevent shear failure of the bolts, it is recommended that the rotational angle of segment be maintained at less than 0.045°. Full article

The China Bearing Reducer (CBR) is a single-stage cycloid reducer with a compact structure, primarily used in high-precision fields such as robotic joints and Computer Numerical Control (CNC) machine tool turntables, where strict requirements for transmission accuracy are necessary. Tooth modification and manufacturing errors in the cycloid gear are two important factors affecting the transmission accuracy of CBRs. In this paper, the transmission performance of the CBR is studied using a new tooth modification method that considers manufacturing errors. Firstly, the structure of the CBR is introduced, and a new method known as Variable Isometric Sectional Profile Modification (VISPM) is proposed. Secondly, the Tooth Contact Analysis (TCA) model is constructed using the VISPM method, and a method for reconstructing the tooth profile with cycloid tooth profile error based on B-spline curve fitting is proposed. The TCA is carried out with both VISPM and tooth profile error. The influence of the modification parameters on meshing characteristics, such as contact force, contact stress, contact deformation, and transmission error, is analyzed. Thirdly, the optimization of the modification parameters is conducted using Particle Swarm Optimization (PSO) to determine the optimal VISPM and isometric and offset modification (IOM) parameter values. The results indicate that the VSIPM method is superior to the IOM method in enhancing meshing characteristics. A physical prototype of the CBR25 is manufactured using the optimized VISPM and IOM, and the transmission error is tested on an experimental platform. The test results demonstrate that the ETCA method is corrected for cycloid drive analysis. Full article

The contact stiffness of the mechanical joint usually becomes the weakest part of the stiffness for the whole machinery equipment, which is one of the important parameters affecting the dynamic characteristics of the engineering machinery. Based on the three-dimensional Weierstrass–Mandelbrot (WM) function, the novel normal contact stiffness model of the joint with the bi-fractal surface is proposed, which comprehensively considers the effects of elastoplastic deformation of asperity and friction factor. The effect of various parameters (fractal dimension, scaling parameter, material parameter, friction factor) on the normal contact stiffness of the joint is analyzed by numerical simulation. The normal contact stiffness of the joint increases with an increase in the fractal dimension, normal load, and material properties and decreases with an increase in the scaling parameter. Meanwhile, the fractal parameters of the equivalent rough surface of the joint are calculated by the structural function method. The experimental results show that when the load is between 14 and 38 N∙m, the error of the model is within 20%. The normal contact stiffness model of the bi-fractal surface joint can provide a theoretical basis for the analysis of the dynamic characteristics of the whole machine at the design stage. Full article

This article contains an advanced analysis of the properties of solid wire electrical contacts produced by ultrasonic welding, both with and without varnish. The main disadvantage of ultrasonic welding of thin wires is the inability to achieve acceptable peel force and tensile strength, which is mainly due to the deformation and thinning of the wires. This study deals with ultrasonic welding using a ring of thin solid copper wires that minimises the deformation and thinning of the wires. The influence of welding parameters such as energy, pressure and amplitude were systematically analysed. Based on these parameters, the optimum welding programme and control method was determined to weld unvarnished and varnished wires. The investigations included electrical resistance tests, optical microscopy, micro-hardness measurements, peel tests and tensile tests, and the measurement of energy consumption. The results showed no significant differences in microstructure and hardness between varnished and unvarnished joints. Ultrasonic joints of varnished wires achieved lower electrical conductivity (by 38%), lower tensile strength (by 3%) and higher peel strength (by 7%), while the welding process was more sustainable in terms of energy (by 6.6%) and time consumption (without preprocessing). Full article

The article examines the results of testing a series of samples, where the joint operation of wooden elements is ensured by a composite material based on fiberglass. A method for ensuring joint operation is adopted according to the insert scheme on the contact surfaces. The strength and deformation characteristics of the samples are obtained, and the calculated bearing capacity is established. Statistical processing of the obtained parameters is performed. Full article

Machine tool vibrations play a significant role in hindering productivity during machining. The growing vibrations accelerate tool wear and chipping, cause a poor wave surface finish, and may damage the spindle bearing. Some research showed that tribological properties such as friction factors can have obvious influences on the topography of rough surfaces and the nonlinear dynamic characteristics of machine tool systems. Therefore, studying the vibration friction dynamic characteristics on the normal contact stiffness (NCS) of joints of CNC machine tools is absolutely necessary for improving the machining accuracy and precision of the whole system. The study results of NCS of joints of the CNC and the friction coefficient are discussed in this paper. The model of NCS based on fractal parameters was obtained. The models of deformations of the rough surfaces and contact surfaces were deduced. The results showed that the NCS based on the calculation method considering the elastic–plastic deformation of the asperity is much higher in precision than the methods considering only elastic or plastic deformation separately. The observations this paper described suggest that in the CNC machine tools system, higher D and G and higher friction coefficients lead to higher normal contact stresses (NCSs). Full article