05 March 2026, Volume 62 Issue 5
    

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  • WANG Guoqing, CHEN Jincun, YUAN Weijia, LIU Qi, HU Runzhi, WANG Guodong, HUANG Sihan
    Journal of Mechanical Engineering. 2026, 62(5): 1-11. https://doi.org/10.3901/JME.260223
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    China’s aerospace manufacturing has gone through research and development dominated phase, development and production mixed phase, and now is entering a new phase of mass customization production driven by normalized high density emission of aerospace products, which calls for a new manufacturing mode that can simultaneously meet the major national strategy and the characteristics of China's aerospace industry. This article analyzes the direction of transformation and development in aerospace manufacturing, proposes the new aerospace manufacturing model named as final assembly pull, which the basic connotation and main characteristics are elaborated. This study proposes an implementation framework that includes four aspects: overall manufacturing control, efficient flexible assembly, complete supply chain management, and network collaborative manufacturing. It is committed to building a new aerospace product manufacturing system, achieving efficient collaboration among multi-level, multi legal person manufacturing enterprises across different regions, different networks, and different systems, improving the ability to deliver high-quality, efficient, and low-cost aerospace products, and cultivating new quality productivity in aerospace industry. The proposal of the aerospace final assembly pull manufacturing model could provide important support for the completion of major aerospace missions and the transformation and upgrading of the aerospace industry.
  • YANG Zehao, DONG Wei, HUANG Sihan, YIN Yanchao, DONG Liyang, ZHENG Zujie
    Journal of Mechanical Engineering. 2026, 62(5): 12-25. https://doi.org/10.3901/JME.260224
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    Production scheduling remains a perpetual research hotspot in industry, serving as a critical metronome for the efficient operation of production lines. With the continuous evolution of intelligent manufacturing, smart production scheduling has emerged as a cutting-edge frontier. Multi-source stochastic disturbances, such as production task variations, the coupling of manufacturing resources, and others, pose a significant challenge in balancing scheduling efficiency and accuracy during dynamic production. To address this challenge, a real-time scheduling simulation optimization method based on digital twin (DT) and reinforcement learning (RL) is proposed. DT technology is used to construct high-fidelity models of production lines, establishing a hierarchical and high-fidelity virtual production simulation environment. An improved Q-Learning algorithm is developed to establish a scheduling optimization agent, incorporating triple state space reconstruction, a multi-dimensional reward function, and a dual exploration strategy to mitigate the curse of dimensionality and the robustness limitations inherent in traditional algorithms. Furthermore, a hierarchical execution control architecture is established based on perception-decision-execution loop throughout the production simulation process to achieve deep fusion between the DT and the intelligent simulation agent. A case study focusing on aerospace product final assembly line is provided to demonstrate the effectiveness of the proposed method. The result shows that the execution distances yielded by five other classical scheduling rules are 6.38% to 16.50% higher than those of the proposed method, signifying a substantial improvement in manufacturing resource collaborative efficiency.
  • TIAN Shichen, ZHANG Chunjiang, GAO Liang, LI Xinyu
    Journal of Mechanical Engineering. 2026, 62(5): 26-36. https://doi.org/10.3901/JME.260225
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    In practical production, due to the complex assembly process and diverse configuration requirements, the final assembly pulling production driven by orders is often adopted in the delivery of large and complex products, which are processed in distributed job shops first and assembled into final products in an assembly factory. Additionally, with the increasing global attention to sustainable development, green and energy-saving production has become the focus of enterprises and academia. Therefore, the distributed assembly job-shop scheduling problem with variable machine speed is investigated. To minimize the maximum completion time and the total energy consumption, a non-dominated sorting genetic algorithm II with variable neighborhood search is proposed. In the local search period of the algorithm, several machine speed adjustment strategies are designed to reduce maximum completion time and total energy consumption respectively, and the local search strategies based on critical path is used to optimize the operation sequencing problem. A large number of experiments are carried out on four groups of instances with different scales to verify the effectiveness of the proposed algorithm, which demonstrate that the adopted framework and the designed local search strategies effectively improve the scheduling scheme.
  • LI Jiwei, ZHANG Jian, REN Xiaoyu, CHEN Haojie
    Journal of Mechanical Engineering. 2026, 62(5): 37-48. https://doi.org/10.3901/JME.260226
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    The complex products is experiencing trends of increasing production scale, higher levels of customization, and shorter production cycles, requiring more efficient scheduling techniques to enhance production efficiency and meet future development needs. However, the final assembly pull production mode for complex products requires the collaboration of multiple workshops. Its characteristics, including large scale, abundant resources, and complex process logic, result in existing multi-workshop scheduling models and methods being inadequate to meet the demands in terms of solution quality and response speed. To address this issue, a multi-workshop collaborative scheduling model for complex product with final assembly pull is constructed, considering both internal constraints and coupling constraints across workshops. Based on this model and considering the characteristics of different workshops, a niche-based ensemble genetic programming with multiple priority rule sets is proposed to construct a more effective scheduling strategy by generating multiple scheduling priority rule sets. Additionally, a complementary priority rule set update mechanism is constructed to enhance the effectiveness of the generated priority rule sets, and a multi-workshop sequencing decoding mechanism is designed to obtain a complete multi-workshop scheduling solution. Through an analysis of real-world scenarios, a dataset based on the PSPLIB standard is constructed, and a comparative study with the latest genetic programming and manually designed priority rules, along with ablation experiments, is conducted to thoroughly validate the advantages of the proposed algorithm.
  • SHI Yihan, ZHANG Xu, ZHUANG Cunbo, LIU Jinshan, WANG Jiaxiu, SUN Liansheng
    Journal of Mechanical Engineering. 2026, 62(5): 49-60. https://doi.org/10.3901/JME.260227
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    In the assembly pull production mode, the discrete manufacturing workshop, which is characterized by decentralized production tasks, flexible equipment layout, and complex processes, serves as the core carrier of the multi-factory(shop) production mode. However, the dynamic drift of bottleneck units in both temporal and spatial dimensions has become a critical challenge that limits the improvement of production efficiency and resource utilization. Thus, investigating the bottleneck prediction problem in discrete workshops is crucial for enhancing overall production efficiency in multi-factory settings. To address this, a spatiotemporal network prediction model integrating dual attention mechanisms, CNN-LSTM-DAM (Convolutional neural network-long short term memory-dual attention mechanism), is proposed. First, a composite definition-based bottleneck identification model is constructed, considering the multi-attribute coupling of bottleneck units. Second, the identified historical quasi-bottleneck data are input into the spatial feature perceiver integrated with CNN and spatial attention mechanism, as well as the temporal feature perceiver integrated with LSTM and state attention mechanism, as auxiliary data to further enhance the model's ability to capture spatial and temporal information in production sequence data. Finally, through ablation experiments, the proposed model is compared with other LSTM variants, such as gated recurrent unit (GRU) and bidirectional long short term memory (BiLSTM). The results verify the model's accuracy and effectiveness in predicting bottleneck units and their drift trends within a given time delay.
  • XU Hongwei, LIU Lilan, ZHANG Jie, QIN Wei, XING Hongwen, WANG Wei, LIU Siren, Lü Youlong
    Journal of Mechanical Engineering. 2026, 62(5): 61-73. https://doi.org/10.3901/JME.260228
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    To address key challenges in aviation intelligent manufacturing, such as low data-knowledge collaboration efficiency, difficulties in tracing assembly deviation sources, lagging process parameter optimization, and insufficient virtual-real interactive verification, this study proposes an AI twin control methodology framework with industrial large models as the cognitive engine, and constructs a digital twin closed-loop control framework covering the entire "perception-diagnosis-decision-verification" process. Through networked associative modeling of knowledge graphs, semantic fusion and dynamic reasoning of multi-source heterogeneous data are realized, an industrial large model corpus for aviation manufacturing is established, and a professional knowledge base with autonomous evolution capabilities is formed. An industrial large model algorithm library for multi-scenario intelligent decision closed-loops is developed: Bayesian causal inference is used to analyze multi-level coupled causes of assembly deviations; incremental ensemble learning is integrated to achieve dynamic evolution prediction of multi-source coupled deviations; and transfer reinforcement learning is applied to break through the bottleneck of cross-scenario parameter optimization. Finally, a virtual-real bidirectional driven verification closed-loop is built using digital twin technology. Verification results based on the fuselage panel assembly of a certain type of civil aircraft show that the proposed method significantly improves the automatic assembly accuracy of stringers, with the one-time assembly and adjustment success rate of stringers increased by 24% compared with traditional methods. It also enables real-time inspection of drilling and riveting quality, achieving an accuracy rate of 98% in identifying continuous drilling and riveting defects. By constructing and evolving a domain-specific knowledge base, this study deeply drives the full-process closed-loop from deviation causal tracing to twin verification, and realizes a paradigm shift in manufacturing decision-making from experience-driven to model cognition-driven.
  • HUANG Ming, HUANG Sihan, CHEN Jianpeng, DONG Wei, WANG Baicun, RUAN Bing, GAO Yunpeng, WANG Guoxin, YAN Yan
    Journal of Mechanical Engineering. 2026, 62(5): 74-87. https://doi.org/10.3901/JME.260229
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    With the rapid development of the new energy vehicle industry and the rise of diversified market demand and customization trends, an emerging island assembly mode has been introduced to address the lack of flexibility in the traditional automotive assembly line. Moreover, the frequent occurrence of uncertain events, such as emergency order insertion, severely restricts the stability and productivity of automotive final assembly in the actual assembly environment. Therefore, based on practical needs, dynamic scheduling optimization of island assembly lines under uncertain disturbances is conducted. First, a mixed-integer nonlinear programming model is formulated with the dual objectives of minimizing the maximum completion time and the order change index. Secondly, a multi-objective dueling double deep Q-network (MO-D3QN) is designed to solve this model. In this framework, state indicators and action scheduling rules are developed based on the features of assembly islands, assembly processes, assembly products, and production transportations in the island assembly scenario. Continuous immediate reward function components are constructed separately for dual optimization objectives, and reward aggregation is implemented by the weighted-sum scalarization method. Then, through the learning training for MO-D3QN network model to realize the selection of the optimized scheduling rules in different environment states. Finally, the computational experiment is conducted on three scaled instances. The results show that MO-D3QN outperforms the single scheduling rule, random selection strategy, and classical DQN, thereby verifying its effectiveness and competitiveness.
  • ZHENG Xiaohu, CAO Lijun, LIU Xiaojia, DU Siqi, WU Wenqiang, ZHANG Jie, DING Siyi
    Journal of Mechanical Engineering. 2026, 62(5): 88-99. https://doi.org/10.3901/JME.260230
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    To address the challenges of integrating multi-source heterogeneous data and inefficient association and tracing of quality issues in the assembly process of aerospace products, this study proposes a knowledge graph-based quality tracing method. By constructing a knowledge graph encompassing critical scenarios including logistics and hoisting, cable network conductivity, and comprehensive testing, we integrate structured and unstructured data to achieve cross-process semantic association and deep reasoning of data. The approach combines YOLOv8 and DeepSORT algorithms for real-time object detection and behavior analysis in logistics/hoisting scenarios, while employing the K-nearest neighbors (KNN) algorithm for anomaly detection in cable network conductivity and comprehensive testing scenarios. A collaborative reasoning mechanism of "anomaly-cause-solution" is established through the knowledge graph, breaking through the data silo limitations of traditional quality tracing methods and providing interpretable support for quality issue localization and root cause analysis in product assembly. Case validation demonstrates that this method effectively resolves data silo issues in aerospace product assembly, enhances the accuracy and efficiency of anomaly localization and quality tracing, and offers technical support for intelligent quality management in complex assembly scenarios.
  • WANG Guodong, LIU Jingtao, ZHAO Qin, WANG Hongjun
    Journal of Mechanical Engineering. 2026, 62(5): 100-116. https://doi.org/10.3901/JME.260231
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    The aerospace large-scale complex equipment products have diverse types and high complexity. The existing scientific research and production mode focuses on vertical integration, trial production and batch production mixed line production, which leads to difficulties in horizontal collaboration and insufficient batch production capacity. By analyzing the characteristics of mixed line production and final assembly of aerospace equipment products, based on the manufacturing model driven by aerospace final assembly, a unified data model, collaborative mechanism, and standard specifications are established to build a cross enterprise, horizontally penetrating unified collaborative platform for final assembly plants, component factories, and raw material factories. General assembly plants at all levels rely on collaborative platforms to release a complete set of KBOM (kitting BOM) for final assembly. Supporting plants use the collaborative platform to associate and deliver multi-dimensional data such as physical objects, product certificates, QR codes, etc., and use digital pull dashboards to display real-time panoramic data of the entire chain of supporting plants. Explore key technologies such as the technical architecture and security protection of a collaborative platform for aerospace equipment research and production based on cross heterogeneous networks, data standards and routing transmission mechanisms based on heterogeneous collaborative scenarios, and model-based lightweight transmission and parsing mechanisms for a complete collaborative environment, forming a aerospace “main supply collaboration” model with multi-level assembly plants as the fulcrum of the industry chain. Carry out application practices in typical aerospace assembly plants, component plants, and parts factories, streamline the open and collaborative aerospace manufacturing industry chain characterized by lean, digital, networked, and intelligent processes, enhance the overall management level of the supply chain, and promote collaborative innovation and ecological development of the pull production industry chain.
  • GU Lianrui, GUO Guoqiang, JIANG Renzheng, WU Tiange, KE Shuai, KONG Zhixue, ZHAO Huan
    Journal of Mechanical Engineering. 2026, 62(5): 117-132. https://doi.org/10.3901/JME.260232
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    In the aerospace field, the structural design of high-speed aircraft has high requirements for structural weight and surface protection performance. To ensure accuracy, grinding processing is usually necessary. However, manual grinding relies on experience and the working environment is harsh. Industrial robots, with their high applicability, strong flexibility, low cost and easy programming, not only improve production efficiency and product quality, but also reduce labor costs and labor intensity. ity. The latest research progress of robot grinding technology for thin-walled and complex structure coatings is reviewed, with a focus on grinding path planning, force-position hybrid control technology, and their collaborative methods. Polishing path planning includes path generation and discretization methods, such as traditional algorithms like the equal parameter line method and the equal residual height method, as well as intelligent optimization methods. For the force-position hybrid control technology, the aspects such as control methods, control strategies and control devices are discussed. Collaborative methods of force-position hybrid control and path planning are also explored, including data sharing mechanisms, joint optimization algorithms, and model predictive control. For the force-position hybrid control technology, aspects such as control methods, control strategies, and control devices are discussed. The collaborative methods of force-position hybrid control and path planning were also discussed, including data sharing mechanism, joint optimization algorithm and model predictive control, aiming to maintain the tracking of the target path while ensuring the stability of control force and motion. Through the collaboration of path planning and force-position hybrid control technology, the processing quality and efficiency of robot grinding can be greatly improved, and the engineering applicability of robot grinding technology can be expanded.
  • ZHANG Tao, HE Jiahao, SHI Yongping, ZHAO Ping, WANG Jian, WANG Wei
    Journal of Mechanical Engineering. 2026, 62(5): 151-167. https://doi.org/10.3901/JME.260234
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    Accurate dynamic models are crucial for the control and safety of collaborative robots in human–robot interaction tasks, and the core of this research is dynamic model parameter identification. Inaccurate modelling of friction terms in dynamic models can lead to poor robot control, stability, and motion accuracy. To address this issue, a modified Stribeck friction model is proposed, which adds acceleration and velocity terms to better fit the nonlinearities in the dynamic model. First, a robot dynamic model with joint friction terms is established using the Lagrangian method, and divided into linear and nonlinear components. Using a six-degree-of-freedom collaborative robot platform, third-order Fourier series signals are used as joint trajectory inputs. The collected data is processed and filtered to establish an experimental dataset for parameter identification. Finally, this dataset is used to identify the dynamic model parameters. The linear component is identified using the constrained iteratively reweighted least squares method, while the nonlinear component is identified using the density-based spatial clustering of applications with noise (DBSCAN) and the grey wolf optimization-cuckoo search hybrid optimization algorithm (GWO-CS). Experimental results show that the improved Stribeck friction model can accurately fit the nonlinear terms of joint friction. Compared with the traditional Coulomb–viscous friction model and the standard Stribeck model, the root mean square error (RMSE) of the joint torque is greatly reduced, effectively improving the parameter identification accuracy of the collaborative arm dynamics model.
  • LIN Song, DAI Jiansheng, SONG Yifeng, WANG Hongguang, YUAN Bingbing
    Journal of Mechanical Engineering. 2026, 62(5): 168-181. https://doi.org/10.3901/JME.260235
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    To address the challenge of traditional wheeled mobile robots adapting to curved surfaces with variable curvatures, a reconfigurable wheeled mobile robot with the ability to adapt to variable-curvature surfaces by leveraging the advantage of reconfigurable mechanisms in having multiple motion modes is proposed. Firstly, the motion plane of the robot’s wheel-leg branch chain is defined, and the mapping relationship between the motion of the reconfigurable trunk and the attitude of the magnetic wheels is established. Furthermore, based on the normal vector of the motion plane of the wheel-leg branch chain, an attitude ruled surface in four-dimensional space is constructed. The Gaussian mapping is used to characterize the angle change of the normal vector of the magnetic wheels, revealing the variation law between the normal vector angle and the surface curvature, thus theoretically verifying the robot’s ability to adapt to variable curvatures. Moreover, based on the finite displacement screw theory, the motion screws of the reconfigurable trunk and the wheel-leg branch chain are established respectively. Combined with the rolling constraint model of the magnetic wheels on the curved surface, a constrained kinematic model of the robot in the curved surface environment is constructed. Finally, experiments on the physical prototype show that the robot can move flexibly on variable-curvature surfaces by adjusting the attitude of the reconfigurable trunk, verifying its surface adaptability and the rationality of the kinematic model.
  • MENG Xiangfei, TAN Guodong, DUAN Xuechao, XIAO Jiaxuan, YAO Bin
    Journal of Mechanical Engineering. 2026, 62(5): 182-191. https://doi.org/10.3901/JME.260236
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    The kinematic characteristics of parallel-driven antenna pedestals are complex, and their constraint conditions are highly coupled, presenting significant challenges in modeling and parameter optimization. This research fully exploits the high consistency between the pitch motion characteristics of the antenna pedestals and the crank-slider mechanism, establishing a kinematic mapping model between the antenna pedestals and the crank-slider mechanism. This approach transforms the study of the antenna pedestals into the study of the crank-slider mechanism. By conducting multiple solution recognition and singular analysis on the crank-slider mechanism, feasible forward and inverse solutions and singular positions of the antenna pedestals are identified. Combined with the kinematic mapping model, the impact of singular configurations outside the workspace on the structural stiffness of the antenna pedestals is explored. Furthermore, a systematic backtracking algorithm suitable for such mechanisms is designed to optimize structural parameters, significantly reducing the weight of the antenna pedestal structure and improving the utilization rate of circular orbits.
  • SUN Peng, GE Menghu, RUI Chao, CAO Likang, CHEN Bo, WANG Jianbin, LI Yanbiao
    Journal of Mechanical Engineering. 2026, 62(5): 192-203. https://doi.org/10.3901/JME.260237
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    To enhance the speed and accuracy of dynamic parameter identification for bipedal robotic legs based on hybrid mechanisms, an integrated parameter identification method is proposed, which combines an improved excitation trajectory optimization technique with the Ivy algorithm (IVYA). Initially, the parallel joints in the robotic leg are simplified into equivalent serial joints, and a linearized single-leg dynamic model is established using the Newton–Euler method. Compared with traditional methods, this research proposes the first integration of joint space utilization constraints into excitation trajectory optimization, addressing the optimization efficiency issues arising from the compact joint space of hybrid serial-parallel mechanisms, and successfully designs excitation trajectories. A dynamic parameter identification experiment is conducted on a 5-DOF robotic leg with a hybrid mechanism. Joint angle and current data are collected via sensors, and after filtering, the IVYA algorithm is employed for parameter estimation. The prediction results obtained using IVYA are compared with those derived from the least squares method. Experimental results indicate that the excitation trajectory optimized under joint space utilization constraints improves the optimization speed by 17% and exhibits negligible condition number error. Moreover, compared with the least squares method, the RMS errors between the actual torques and the predicted torques for the five joints obtained using the IVYA-based dynamic model are lower, with the average RMS error reduced by 13.42% and the maximum RMS error decreased by 2.68 N•m. These findings confirm the effectiveness of the proposed integrated identification method, providing a theoretical basis for precise model-based control of hybrid robots.
  • ZHANG Zihao, YAO Qin, CHEN Zhirong, SUN Junxian, HUANG Jiale
    Journal of Mechanical Engineering. 2026, 62(5): 204-214. https://doi.org/10.3901/JME.260238
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    To improve the transmission performance of the recirculating planetary roller screw mechanism (RPRSM), structural modification of key components is essential. Addressing the accuracy limitations of conventional linear compensation strategies, a mathematical model of load distribution between the annular teeth of the roller and the threads of the screw and nut is established. Based on the deformation compatibility and the stiffness matrix, the discrete modification values of the roller’s annular teeth are derived. A fitting function model is then constructed according to the distribution characteristics of these values, and the Levenberg-Marquardt algorithm is employed to optimize the fitting coefficients and obtain the optimal modification curve. Furthermore, a multi-parameter coupled cooperative modification strategy is proposed, considering the effects of the flank angles of the screw, roller, and nut, as well as the profile radius of the roller tooth, on the peak contact stress. The theoretical model is validated by comparing the load distribution and peak contact stress before and after modification through finite element analysis. The results indicate that the modification curve, based on a quadratic polynomial model, causes the load distribution coefficients on the nut and screw sides to converge to 0.998-1.001 and 0.995-1.003, respectively. Moreover, the cooperative modification strategy significantly reduces the average contact stress on both sides of the roller by 35.55% and 32.93%, while maintaining uniform load distribution.
  • GUO Shihang, WANG Shenlong, HOU Jinhui, LI Yongge
    Journal of Mechanical Engineering. 2026, 62(5): 215-229. https://doi.org/10.3901/JME.260239
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    The rapid development and widespread application of underwater soft robots are of significant importance for fields such as ocean exploration, military applications, and industrial production. However, most existing underwater soft robots rely on single actuators for single-degree-of-freedom (SDOF) motion or multiple actuators for multi-degree-of-freedom (MDOF) motion, increasing system complexity. In response, a novel soft robot fish capable of MDOF underwater motion and driven by a single magnetic actuator is presented. The magnetic actuator consists of a magnet, coil, and PET dorsal fin, while the power supply, control, and actuation systems are integrated within a soft silicone fish body to withstand harsh environments. By applying positive and negative direct currents at specific frequencies, the actuator drives the dorsal fin to provide thrust for diving. The rolling motion of the fish induces periodic deformation of the pectoral silicone fins, disturbing the water flow to propel the fish forward. Steering is achieved by adjusting the duty cycle of the dorsal fin’s driving voltage. Based on the Lagrange method, the roll motion equation of a robotic fish is established. The actual motion trajectory of the pectoral fins is simulated using a mechanical wave function. Furthermore, the dynamic models for the diving and forward motions of the robotic fish are developed by integrating the Newton-Euler formulation with the Morrison equation. Experimental data are employed to determine model parameters and validate the accuracy of the proposed models. A series of experiments—including tests on forward swimming, diving, and turning—demonstrates the fish’s MDOF underwater performance. The robotic fish achieves a forward swimming speed of 0.77 BL/s, a diving speed of 0.26 BL/s, and a minimum turning radius of 1.30 BL. Additionally, it withstands low temperatures, confirmed through tests at 2.7 ℃. This robotic fish design holds potential for flexible intelligent devices and provides new insights into soft robot design for ocean exploration.
  • ZHAO Penghao, LIU Jianhua, GONG Hao, WANG Xingjie
    Journal of Mechanical Engineering. 2026, 62(5): 230-243. https://doi.org/10.3901/JME.260240
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    In order to accurately characterize the dynamic performance of joint interface, a precise sub-regional virtual material equivalent modeling approach is proposed based on fractal contact theory and semi-analytical method, considering uneven contact pressure of joint interface. Firstly, the contact pressure of a joint interface is equivalent to a polynomial function, and the joint interface was divided into several sub-regions according to pressure distribution, so that the pressure within each sub-region is approximately uniform. Secondly, considering the micro morphology of the rough surface in each sub-region, W-M function is used to solve elastic-plastic deformation of asperities in sub-regions. With the purpose of accurately calculate the contact stiffness of sub-regions, a semi-analytical method is developed, so that the dimensionless contact area of rough surface under elastic-plastic deformation can be solved. Next, based on the fractal contact theory, the contact stiffness of sub-regions is calculated, and the equivalent virtual material parameters of sub-regions are derived. By weighting the nominal contact area of sub-regions, the equivalent virtual material parameters of whole joint interface are obtained. Finally, a modal test platform is built up, and a finite element model containing equivalent virtual material parameters is established. The result is compared with the equivalent virtual material parameters obtained through uniform pressure distribution and regardless of the microscopic morphology of rough surface. The accuracy and reliability of the modeling method proposed in this paper are verified through the analysis of experimental and simulation results.
  • YAO Sibo, LUO Zhong, ZHOU Shenghao, XU Chunyang, ZHANG Hongwei, ZHAO Jiang
    Journal of Mechanical Engineering. 2026, 62(5): 244-252. https://doi.org/10.3901/JME.260241
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    Axisymmetric vectoring exhaust nozzle for aero-engine is one of the key components for achieving thrust vectoring conversion capability due to its ability to achieve 360 ° vector deflection. At present, in nozzle design and dynamic research, most consider the joint friction coefficient to be constant. However, the friction coefficient often has a time-varying effect, which leads to problems such as joint wear or sticking in the actual working process of the mechanism due to dynamic changes in friction force and unreasonable design. Therefore, based on the measured data of material level friction experiments, a dynamic friction coefficient model considering time-varying effect is first proposed. Then, an Axisymmetric Vectoring Exhaust Nozzle dynamic model is established to obtain the load and motion boundary conditions of the key components of the roller-bushing. On this basis, the influence of time-varying effect on the friction characteristics of the roller-bushing. is analyzed. The results show that the time-varying effect of friction coefficient has a more significant impact on the friction force at the beginning of operation, and should be carefully considered in mechanism design.
  • ZHANG Chunlin, XIAO Yunlü, QIN Yi, LUO Jun, YUAN Shujin, HAO Yaodong, WU Fei
    Journal of Mechanical Engineering. 2026, 62(5): 253-262. https://doi.org/10.3901/JME.260242
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    The magnetic field modulated permanent magnet adjustable-speed driver (MFM-PMASD) is a novel dual-rotor magnetic transmission system that combines the topological configurations of permanent magnet synchronous machines and magnetic gears. It enables wide-range continuously variable speed regulation through frequency conversion control. In this study, the MFM-PMASD is designed, and the physical mechanism of magnetic field modulation is analytically derived, establishing the relationships among the pole-pair numbers and rotational speeds of the stator winding, modulator ring rotor, and permanent magnet rotor. Analytical solutions for the air-gap flux density and the torque of the inner/outer rotors are obtained using the equivalent magnetic circuit method. Finite element simulations in ANSYS Maxwell are employed to analyze the air-gap flux density distribution, harmonic components, and speed regulation characteristics under various operating conditions. Four critical structural parameters affecting torque transmission performance are investigated. Simulation results demonstrate that selecting permanent magnet rotors and stator windings with opposite parity in pole numbers significantly reduces torque ripple. To achieve high torque output with minimal torque pulsation, the optimal pole arc coefficient of the permanent magnets is determined to be 0.75-0.8. Furthermore, the torque transmission performance is optimized when the width ratio of the modulator’s permeable segments is 0.5 and the ratio of permanent magnet thickness to physical air gap is 2. A prototype is manufactured, and experimental results validate the accuracy of the theoretical model while confirming the advantages of the MFM-PMASD in wide speed regulation range and high control precision. This work provides theoretical guidance for optimizing the design of MFM-PMASDs and achieving precise speed regulation under variable load conditions.
  • WU Jinhui, CHEN Yongchang, WU Yanan, HAO Huiqian, YUAN Xiang, TAO Yourui
    Journal of Mechanical Engineering. 2026, 62(5): 263-273. https://doi.org/10.3901/JME.260243
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    To achieve visual monitoring and virtual debugging of reflector antennas, a high-fidelity digital twin system construction method is proposed based on the multi-domain unified modeling of the mechanical, electrical and control systems, and model parameter identification. First, the electrical model, machine model and control model of the azimuth and pitch joints are respectively constructed, and then coupled to build the multi-domain unified model according to information transmission and energy conversion laws. Then, the motion control system, data acquisition system and the Unity virtual monitoring system of the antenna physical entity are established to monitor operational status of the antenna physical entity in real-time, and collect the motion data and send to the upper computer in real-time. The dynamic parameters of the antenna's mechanical system are identified based on the motion data, and the parameters of the control and motor models are also updated, so that the real-time motion status of the physical antenna is accurately mapped by the multi-domain unified digital twin model. Finally, the motion performance of reflector antenna is virtually debugged based on the multi-domain unified digital twin model on a 0.9
  • LIU Jingxu, LU Yongjie, WANG Jianxi, JIA Yunchao, LI Haoyu
    Journal of Mechanical Engineering. 2026, 62(5): 274-286. https://doi.org/10.3901/JME.260244
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    The analysis of dynamic behavior characteristics of vibratory rollers is the basis of parameter decision research of intelligent compaction system. However, the dynamic response characteristics under different excitation parameters and the change mechanism between different compaction stages have not been fully studied. Based on viscoelastic-plastic subgrade, a nonlinear coupling dynamic model of vibratory rollers-subgrade with 3 degrees of freedom is established in this study. By analyzing the amplitude characteristics of roller in different compaction States, the calculation index of roller compaction ability is put forward. Combined with the two-parameter bifurcation of drum, the influence of nonlinear vibration response of drum on compaction ability under different excitation parameters is studied. The results show that low excitation frequency and high excitation force are suitable for initial compaction. This is beneficial to increase the compaction capacity of the drum. In the later stage of compaction, it is appropriate to choose higher excitation frequency and smaller excitation force. This is beneficial to improve the uniformity of roller compaction amplitude and avoid vibration jumping. Non-single-cycle roller has higher compaction ability, but it may increase the impact of roller on subgrade. The calculation method of compaction capacity in this study provides a theoretical basis for the decision of excitation parameters of intelligent compaction system from the perspective of dynamics.
  • ZHAO Wei, CHANG Jiajun, WEI Qingsong, WU Jiamin, YE Chunsheng, HUANG Shuangjun
    Journal of Mechanical Engineering. 2026, 62(5): 287-296. https://doi.org/10.3901/JME.260245
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    The high efficiency of binder jetting technology (BJAM) and the better high temperature resistance of alumina (Al2O3) provided advantages for the fabrication of the turbine blade casting core, however, the lower mechanical performance of BJAM Al2O3 ceramic was hard to meet the application standard of cores. To solve the above problems, this study proposed the introduction of silicon nitride (Si3N4) and vacuum infiltration of silicon sol to realize the performance improvement of Al2O3 ceramic core. Effects of Si3N4 contents (0%-20%, wt%) and silica sol on the porosity, dimensional shrinkage, mircostructure, and mechanical performance are systematically investigated. Results show that the optimal generation content of mullite and sialon compounds by the chemical reaction between Si3N4 and Al2O3 could improve the comprehensive performance of ceramic when the content of Si3N4 and sintering parameters are 10% and 1500℃ for 4h, and the relative density and bending strength respectively reached 51.62% and 21.2MPa compared with the 0% Al2O3 ceramic, but the dimensional shrinkage of X–, Y–, and Z–axis are increased to 4.55%, 5.36%, and 6.21%. When all Al2O3–Si3N4 ceramics are initially sintered and vacuum infiltrated with silicon sol after the second sintering, the porosity and bending strength had been further improved by the generation of mullite by the reaction between Al2O3and silicon sol, and the corresponding optimal values are 39.77%/34.8MPa (e.g., 0 wt%Si3N4–Al2O3infiltration sample) and 41.28%/37.9MPa (e.g., 10 wt.%Si3N4–Al2O3infiltration sample), which indicated that doping Si3N4 and vacuum infiltrating silica sol could obviously improve the comprehensive properties of Al2O3 ceramics, and laid a theoretical foundation for fast and low–cost preparation of ceramic cores.
  • YANG Yinru, GAO Hang, TIAN Yachuang, LIU Jianbao
    Journal of Mechanical Engineering. 2026, 62(5): 297-305. https://doi.org/10.3901/JME.260246
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    Thermoplastic carbon fiber composites have been widely used in fields such as aerospace and navigation because of their low density, high strength, corrosion resistance, and good plasticity. Ultrasonic welding has been proven to be one of the effective methods for conventional thermoplastic carbon fiber composites to achieve joint. Still, it is challenging to realize ultrasonic welding of poly(phthalazinone ether)resin/carbon fiber composites with a glass transition temperature of more than 280 ℃. In response to the ultrasonic welding requirements of the 0°/90° continuous stacking preparation process of this thermoplastic carbon fiber composite material, ultrasonic welding experiments on overlapping layers with three typical different fiber directions are carried out. The macro and micro structures of the ultrasonic welding interface and the bonding behavior of the ultrasonic welding interface are analyzed, revealing the influence of ultrasonic welding process parameters on the connection strength of this thermoplastic carbon fiber composite material. The key to improving the high strength of ultrasonic welding is to achieve the mutual embedding of laminated fibers under high pressure and welding heat is clarified. The research work provides reliable process parameters for ultrasonic welding of 0°/90° continuous stacking production line of the newly developed thermoplastic composite material.
  • SU Yonglei, YIN Daozhi, ZHANG Zhifei, DING Zhi
    Journal of Mechanical Engineering. 2026, 62(5): 306-318. https://doi.org/10.3901/JME.260247
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    In the field of vehicle lightweight design, mega-casting components have attracted significant attention due to integrated characteristics and involvement of multidisciplinary issues. Lightweight design methodology for such mega-casting components to achieve global lightweight design under multidisciplinary performance constraints is systematically established. For continuous body structures without natural boundaries, a subsystem partitioning strategy that considers the nonlinear characteristics of collisions is proposed, and model reduction techniques are employed to significantly improve computational efficiency while ensuring analysis accuracy. A compromise programming approach is used to normalize static and dynamic performance objectives and construct a comprehensive objective function. An objective decision sequence calculation method based on the performance information of the initial design state is proposed, which combines the Analytic Hierarchy Process to determine the subjective and objective combined weighting coefficients for sub-objective synthesis, and guides the design of strengthening rib effectively with topology optimization technology. A parameterized method was developed for casting components with variable thickness structures, and key thickness variables affecting multiple properties were identified through relative sensitivity analysis and the entropy-weighted TOPSIS method. The best surrogate model was selected to conduct optimization using the differential evolution algorithm, achieving a balanced approach to multi-disciplinary performance and global lightweight. The weight was reduced by a total of 5.0 kg. The lightweight method offers a robust theoretical and practical foundation, which is useful for reducing complex system models and optimizing the design of mega-casting components.
  • LI Jiacheng, LU Kun, XI Xiang, SHI Yan, SUN Jiangkun, WU Xuezhong, XIAO Dingbang
    Journal of Mechanical Engineering. 2026, 62(5): 319-328. https://doi.org/10.3901/JME.260248
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    Micro hemispherical resonator gyroscope (μHRG) is one of the most high-precision micro electromechanical system (MEMS) gyroscope at present, which has the significant advantages of high quality factor, good impact resistance and small size. Low-damage and high-precision mechanical tuning is one of the key technologies to improve the performance of micro-hemispherical resonant gyroscopes. Due to the large initial frequency split of the μHRG, mechanical tuning will produce a lot of dust, and preliminary mechanical tuning is needed before coating to facilitate subsequent cleaning. In view of the abnormal sensitivity to shell surface mass stiffness and decoupling of mass stiffness in specific regions of shell surface, a mechanical tuning method based on ion beam etching of the shell surface of the micro hemisphere resonantor is proposed. The problem of large frequency split of the uncoated resonator is solved. The influence of the shell surface tuning model on the frequency split of the resonant structure is analyzed by theory and simulation, and the position of the tuning center area and the tuning are determined. In addition, for the detection of the frequency split of the uncoated MHR, a planar interdigitated electrode test system is established to accurately identify the frequency split size and stiffness axis direction of the resonantor. Finally, ion beam trimming experiment is designed to verify the proposed method. The frequency split of a uncoated micro-hemispherical resonator is reduced to less than 100 mHz, considerably improves the gyroscope’s performance.
  • CHEN Xiaotong, LI Zhonghao, YANG Min, KONG Xianggang, LIU Mingzheng, LI Benkai, MA Xiao, CUI Xin, DAMBATTA Y S, YU Zhenwei, WANG Guang, LI Changhe
    Journal of Mechanical Engineering. 2026, 62(5): 329-346. https://doi.org/10.3901/JME.260249
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    Diamond micro-grinders can rapidly and precisely remove bone tissue in the lesion area, which has been widely applied in orthopedic surgery. However, the technical problems of low spreading wettability at the micro-grinding tool/bone interface and high grinding temperature exist in normal saline spray cooling, which easily causes thermal damage to biological bone tissue. Learning from the principle of water capture and directional transport of desert beetles, constructing biomimetic desert beetle micro-grinding tools is expected to solve the technical bottleneck of thermal damage in bone micro-grinding. Based on this, the dynamic mechanism of droplets on the surface of biomimetic desert beetle hydrophilic/hydrophobic micro-grinding tools is first studied. The droplet spreading mechanism under the synergistic effect of surface energy and Laplace pressure is revealed, and the droplet spreading radius model at the biomimetic micro-grinding tool/bone interface under the influence of factors such as wettability gradient and temperature gradient is constructed. Then, the droplet spreading experiment on the surface of biomimetic micro-grinding tools is carried out to explore the spreading morphology of droplets on the surface of micro-grinding tools, and the droplet spreading radius model on the surface of micro-grinding tools is verified with an average error of 10.34%. Finally, the bone micro-grinding experiment is carried out to explore the influence trends and mechanisms of the bone grinding experimental parameters of biomimetic micro-grinding tools on the grinding temperature. The results show that the biomimetic micro-grinding tools can increase the droplet spreading area and reduce the micro-grinding temperature. It aims to provide theoretical guidance and technical support for reducing the grinding temperature of biological bone micro-grinding.
  • LIU Peiru, WEI Fanan, YAO Ligang, LIU Xiaomin
    Journal of Mechanical Engineering. 2026, 62(5): 347-356. https://doi.org/10.3901/JME.260250
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    Conductive polymer hydrogels are extensively utilized in energy storage, flexible electronics, and bioelectronics because of their inherent conductivity and biocompatibility. Currently, the production of most conductive polymer hydrogels relies on conventional two-dimensional (2D) technologies. This includes techniques such as printing, casting, and lithography. These manufacturing processes are cumbersome, expensive, and often yield low resolution in three-dimensional (3D) structures. These limitations impede the application and innovation of polymer hydrogels in electronic conduction. To address these challenges, we proposed a novel composite ink that demonstrates excellent printability for computer-controlled cross-scale extrusion ink direct writing (DIW). This ink was subsequently transformed into a high-performance conductive hydrogel through crosslinking and acid post-treatment. The modified 3D-printed hydrogel exhibits a conductivity of 62 S/m in the gel state and 311 S/m in the dry gel state, with a strain exceeding 210%. By optimizing the printing parameters to accommodate inks of varying viscosities, we created a hydrogel flexible inductor with tensile properties and a multi-layer structure designed for radio signal transmission. Furthermore, due to its excellent biocompatibility and stable molecular structure, this hydrogel holds significant potential for applications in implantable electronic engineering.
  • JIANG Kai, LIU Zhifeng, CHENG Qiang, CHEN Chuanhai, ZHANG Tao
    Journal of Mechanical Engineering. 2026, 62(5): 357-373. https://doi.org/10.3901/JME.260251
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    During the initial phase of machine tool design and manufacturing, accurate prediction of dynamic characteristics is essential for ensuring the reliability of high-end CNC equipment. However, conventional multi-body dynamics and finite element methods encounter substantial challenges in effectively and precisely analyzing the system's dynamic performance, owing to its substantial scale and intricate structural complexity. Moreover, this type of machine tool incorporates numerous nonlinear bolted joints, whose influence cannot be neglected. To study the dynamic characteristics of the heavy-duty machine tool-foundation system(HDMTFS), considering the influence of bolted joints, the spatial hinge transfer matrix of stiffness in X, Y, Z, Rx, Ry and Rz directions is introduced. Based on the transfer matrix method for the multi-body system(MSTMM), a dynamic model of the HDMTFS that is more in line with engineering is established. The model enables comprehensive analysis of both the machine tool system’s free vibration characteristics and the impact of performance degradation in critical bolted joints on the overall dynamic behavior. By identifying system vulnerabilities, it provides essential theoretical foundations for reliability-oriented design of bolted connections in the heavy-duty machine tool.
  • GAN Lei, WANG Chengjun, LI Lei, XU Hongmeng, WU Jun, HUANG Haihong
    Journal of Mechanical Engineering. 2026, 62(5): 374-389. https://doi.org/10.3901/JME.260252
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    Monitoring the part quality variation is essential to avoid defects and resource waste for green manufacturing achievement. However, it is difficult to obtain accurate images, vibration, pressure distribution, and other data for the accurate monitoring of the forming quality of stamping parts due to the closed mold and noisy production environment. Existing efforts indicated that the part thickness variation ratio varies quantitatively with process energy, which is the accumulation of punch force over the stamping depth, and it is easy to collect and anti-interference. In this context, a stamping process energy map is proposed to characterize the thickness variation ratio by color and its intensity. The stamping depth and process energy are set as the horizontal and vertical coordinates of the map, respectively. A data interpolation technique is applied to interpolate the measured thickness variation ratio data located in the map. Considering the limitation of finite measurement data on the accuracy of interpolation data, a data spatial blending strategy that weights and blends the interpolated and simulated thickness variation ratio data to fill and color the map followed by the quality zone division according to the threshold curve of thickness variation ratio. To validate the effectiveness, the map was applied to form a downscaling part of a car door. The mean absolute percentage error of the monitored thickness variation ratio was within 5%. The crack and wrinkle identification accuracy is up to 90.63%. The results of applying the map to stamping process control showed a 14.56% reduction in the maximum thinning ratio of the part, which effectively prevents cracking. The proposed stamping process energy map assisted in accurate part quality monitoring and quality improvement in stamping.
  • ZHAO Mingjie, LU An, HUANG Liang, JIANG Lihong, LI Jianjun, GUO Zhenghua
    Journal of Mechanical Engineering. 2026, 62(5): 390-398. https://doi.org/10.3901/JME.260253
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    The hot deformation behavior of the material is affected by many parameters, which leads to complex microstructure evolution law and difficulty in the control of flow behavior. Therefore, the effects of austenitizing temperature, deformation temperature, and strain rate on the flow behavior and microstructure evolution of 300M steel are studied based on Gleeble-3500 equipment. The results show that the effect of austenitizing temperature on the flow behavior of 300M steel is more complex than that of deformation temperature and strain rate. With the increase of austenitizing temperature, the flow stress of 300M steel changes little before the peak strain, and decreases first and then increases after the peak strain. Based on microstructure analysis, it is found that dynamic recrystallization progresses more fully with the increase of deformation temperature, the decrease of strain rate and austenitizing temperature. The effect of austenitizing temperature on the progress of dynamic recrystallization is mainly ascribed to the fine grain size induced by low austenitizing temperature. In order to accurately describe the coupling effects of austenitizing temperature, deformation temperature, strain rate and strain on the flow stress response, the polynomial of grain size before deformation is introduced into the Hensel-Spittel model, and the constitutive model of 300M steel modified by Hensel-Spittel model is established. The prediction accuracy of the established model reaches 0.997 27. The above study lays a theoretical foundation for accurately predicting and controlling the hot deformation behavior of 300M steel.
  • LIU Changyong, WU Huaian, LI Chen, HUANG Kehao, LIU Zhiyuan, CHEN Zhangwei, ZHANG Lei
    Journal of Mechanical Engineering. 2026, 62(5): 399-407. https://doi.org/10.3901/JME.260254
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    A four-axis multi-material simultaneous 3D printing based on rotating nozzle is proposed. A print head with three nozzle micro-holes is introduced to print three types of materials simultaneously. In addition, a rotation motion freedom is introduced to avoid the overlapping and interference of the three materials during the printing process. Based on this idea, a multi-material extrusion print head and four-axis simultaneous printing machine are developed. Pluronic F127 is selected as the material to test the printing process and inks with appropriate rheological properties are prepared. The effects of printing pressures, scanning velocity, and layer thickness are investigated. The printing parameters are optimized and multi-material structures with good shapes and geometries are obtained. Furthermore, the printing process is validated by printing various complex geometries. The four-axis multi-material simultaneous 3D printing process proposed in this study can be utilized to fabricate multi-material functional devices in one-step, and push forward the applications of 3D printing in the fabrication of complex functional multi-material devices.
  • SHU Zhengtao, ZHAO Kang, GAO Liang, LI Hao
    Journal of Mechanical Engineering. 2026, 62(5): 408-418. https://doi.org/10.3901/JME.260255
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    To achieve parameterized modeling of hollow lattice structures and to overcome the issues of low efficiency and accuracy in optimizing isotropic properties, an optimization design method for hollow isotropic lattice structures is proposed. By introducing the level set implicit modeling method, the signed distance function of the basic solid microstructure is constructed. Then a parameterized geometric model of the hollow lattice is established through Boolean subtraction operations. The elastic properties of the microstructure are calculated using homogenization methods. Whereafter a database of hollow lattice samples and a Kriging surrogate model are constructed to achieve high-precision and efficient prediction of elastic properties. An optimization mathematical model for hollow isotropic lattice structures is established, and a genetic algorithm is introduced to achieving rapid optimization of microstructural isotropic properties at a specific volume fraction. Six types of hollow isotropic lattice configurations are studied and compression tests are conducted, verifying structural isotropic properties. Numerical results demonstrate that the proposed method can effectively realize the parameterized design of hollow lattice structures, and significantly reduce the cost of isotropic property optimization while ensure computational accuracy.
  • ZHANG Bing, ZHANG Houchao, SUN Mingze, LI Hongke, ZHU Xiaoyang, XU Quan, ZHAO Jiawei, LAN Hongbo
    Journal of Mechanical Engineering. 2026, 62(5): 419-433. https://doi.org/10.3901/JME.2600256
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    Large-size transparent glass heaters (TGHs) with de-icing, de-fogging, and de-frosting functions are widely used in windshields, glass curtain walls, and display coolers. However, existing technologies for fabricating high-performance TGHs on large-size, non-flat glass substrates suffer from poor uniform consistency, low efficiency, and high cost, which constrain their widespread industrialized applications. To address these challenges, a novel additive and subtractive composite fabrication process combining electric field-assisted vertical jet critical contact printing, wet etching and electroplating is proposed. By regulating the taper of the Taylor cone and combining the proposed vertical melt-jet critical contact printing mode, the printing height is increased (maximum printing height of 0.7 mm), and uniform and consistent polycaprolactone (PCL) mask printing is this method has been demonstrated to be effective even when the substrate exhibits a flatness error of more than 0.28 mm, and the utilisation of a low-cost hot-melt PCL printing material serves to address the issue of nozzle clogging that can occur over extended periods. Subsequent to this, the combination of wet etching (a subtractive process) and plating (an additive process) has been shown to facilitate the efficient and cost-effective fabrication of metal grids. Large-size TGHs (300 mm×300 mm) fabricated in combination with optimised process parameters exhibit a line width variation of less than 1.5 μm, a line resistance variation of less than 0.3 Ω, and a line resistance of only 0.39 Ω/mm at 95.73% transmittance, and demonstrate uniform electrical heating performance. The resistance change was found to be less than 0.7% after scratch, adhesion and ultrasonic tests, less than 5% after acid and alkali corrosion tests, and less than 16.8% after 72 h high temperature and high humidity tests. The proposed method provides a solution with good prospects for industrialised applications for the low-cost, high-efficiency, and batch production of large-size TGHs with high transmittance and high conductivity.
  • BAI Zhaoruo, HUANG Kanghua, TANG Mingjun, FENG Shulong, FENG Feng, ZHANG Jianfu, FENG Pingfa, ZHANG Xiangyu
    Journal of Mechanical Engineering. 2026, 62(5): 434-442. https://doi.org/10.3901/JME.260257
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    As a common stress concentration detail in the aircraft structure, the chamfer of bearing hole is prone to fatigue cracks when subjected to complex alternating loads, affecting the service life of the aircraft. Because of its small size and tilt angle, the hole chamfer is difficult to strengthen with conventional methods, and usually accompanied with low machining precision. A high- precision high-speed ultrasonic peening access is adopted for improving the surface performance of hole chamfer. The kinematics for hole chamfer ultrasonic peening machining through theoretical model is developed to study the surface generation mechanism of the machining process. Moreover, the effects of preload depth, spindle speed, strengthening time on surface integrity are analyzed. The best machining parameters are chosen for 45 steel hole chamfer. It was found that the high-speed ultrasonic peening process can efficiently reduce the surface roughness of the chamfer surface, form hardened layer in the subsurface, and introduce compressive residual stress at the same time. The results prove that the high-speed ultrasonic peening method can be applied on the hole chamfer for its considerable improvement on surface integrity.