Optimal Control for Static Stiffness and Thermal Sensitivity of a Hexapod Machine Tool

Beneath many conceptual advantages, parallel kinematic manipulators suffer some disadvantages which complicate their operation as machine tool. One of them is their inhomogeneous stiffness characteristic within the workspace, another is the high thermal sensitivity of their static accuracy due to the large strut lengths. Both properties, stiffness and thermal sensitivity, depend strongly on the configuration of the manipulator. As for machining purposes only five degrees of freedom are necessary, the 6th axis can be utilized to choose an optimal configuration with respect to stiffness or thermal sensitivity. In this contribution, an optimization method based on Jacobian matrix analysis is introduced and demonstrated for a model of the hexapod milling machine HEXACT. (© 2005 WILEY-VCH Verlag GmbH & Co. KGaA, Weinheim)     

Comparative study of cable parallel manipulators with and without hybrid-driven planar five-bar mechanism

Cable parallel manipulators (CPMs) relay on cables instead of rigid links to support and manipulate the end-effector. The CPMs are required not only for operations with lower inertia and high payload, but also for output with greater flexibility. The paper is devoted to present and analyze a cable parallel manipulator with and without hybrid-driven planar five-bar mechanism (HDPM). The cable parallel manipulator with the HDPM combines positive features of both the cable parallel manipulator and the HDPM. Comparative study of kinematics and dynamics of the CPMs with and without HDPM are studied. Drive torques and drive powers are given to compare the load carrying capacity of the two manipulators, and workspace, stiffness performance, singularity analysis are also carried out. Simulation examples are presented to demonstrate the CPMs with and without HDPM and their mechanics performance.     

A influência do peso próprio na otimização topológica de estruturas elásticas 2D – via técnica numérica Smooth Evolutionary Structural Optimization (SESO)

This paper deals with topology optimization in plane elastic‐linear problems considering the influence of the self weight in efforts in structural elements. For this purpose it is used a numerical technique called SESO (Smooth ESO), which is based on the procedure for progressive decrease of the inefficient stiffness element contribution at lower stresses until he has no more influence. The SESO is applied with the finite element method and is utilized a triangular finite element and high order. This paper extends the technique SESO for application its self weight where the program, in computing the volume and specific weight, automatically generates a concentrated equivalent force to each node of the element. The evaluation is finalized with the definition of a model of strut‐and‐tie resulting in regions of stress concentration. Examples are presented with optimum topology structures obtaining optimal settings.     

Modelling of Wave Propagation using Spectral Finite Elements

For the analysis of wave propagation at high frequencies, the spectral finite element method (SFEM) is under investigation. In contrast to the conventional finite element method high-order shape functions are used. They are composed of Lagrange polynomials with nodes at the Gauß-Lobatto-Legendre points. The Gauß-Lobatto-Legendre integration scheme is applied in order to obtain a diagonal mass matrix. So, the resulting system equations can be solved efficiently. In the numerical examples, spectral finite elements with shape functions of different order are applied to a plane strain problem. The numerical examples cover structures without and with stiffness discontinuities. It is shown that the results agree well with analytical solutions. (© 2010 Wiley-VCH Verlag GmbH & Co. KGaA, Weinheim)     

Dynamic analysis of cable-driven parallel manipulators with time-varying cable lengths

In conventional researches, cables of cable-driven parallel manipulators are treated as simple linear elements that can only work in tension. This results in the fact that the effect of cable dynamics on the positioning precision of the end-effector is not adequately taken into account. To overcome this shortcoming, a dynamic model for cable-driven parallel manipulators with cables of slowly time-varying length is presented in this paper. The partial differential equation characterizing the dynamics of a cable with varying-length is deduced, and converted into ordinary differential equations through spatial discretization by finite difference approximation. Then, the dynamic model for cable-driven parallel manipulators is achieved considering the relationship between the motion of the end-effector and the cable end force, in which the degrees of freedom of cables and the end-effector are all involved. Two numerical examples are demonstrated to validate the dynamic model, and also show that it is necessary to take into consideration the cable dynamics for manipulators of long-span cables.     

Analytical modeling of chatter stability using multi-dimensional approach

Machining is one of the most common manufacturing processes in industry due to its high flexibility and ability to produce parts which excellent quality. Chatter, a type of self excited vibrations arising in metal cutting operations, is a major limitation in machining resulting in poor quality and reduced productivity. Under certain conditions, the cutting process may become unstable yielding oscillations with high amplitudes and cutting forces. Stability analysis of the dynamic cutting process can be used to determine chatter-free machining conditions with high material removal rate. Usually, one dimensional models are used for stability analysis of machining. However, based on the geometry of the actual machining process, multi-directions would have to be used for accurate modeling of the process dynamics and the stability. In this presentation, multi directional models for turning and milling processes are presented. The effects of multi directional process mechanics on the stability are demonstrated by applications. (© 2008 WILEY-VCH Verlag GmbH & Co. KGaA, Weinheim)     

Implementation and computational aspects of a 3D elastic wave modelling by PUFEM

This paper presents an enriched finite element model for three dimensional elastic wave problems, in the frequency domain, capable of containing many wavelengths per nodal spacing. This is achieved by applying the plane wave basis decomposition to the three-dimensional (3D) elastic wave equation and expressing the displacement field as a sum of both pressure (P) and shear (S) plane waves. The implementation of this model in 3D presents a number of issues in comparison to its 2D counterpart, especially regarding how S-waves are used in the basis at each node and how to choose the balance between P and S-waves in the approximation space. Various proposed techniques that could be used for the selection of wave directions in 3D are also summarised and used. The developed elements allow us to relax the traditional requirement which consists to consider many nodal points per wavelength, used with low order polynomial based finite elements, and therefore solve elastic wave problems without refining the mesh of the computational domain at each frequency. The effectiveness of the proposed technique is determined by comparing solutions for selected problems with available analytical models or to high resolution numerical results using conventional finite elements, by considering the effect of the mesh size and the number of enriching 3D plane waves. Both balanced and unbalanced choices of plane wave directions in space on structured mesh grids are investigated for assessing the accuracy and conditioning of this 3D PUFEM model for elastic waves.     

Geometrically nonlinear analysis with a 4-node membrane element formulated by the quadrilateral area coordinate method

Recently, a 4-node quadrilateral membrane element AGQ6-I, has been successfully developed for analysis of linear plane problems. Since this model is formulated by the quadrilateral area coordinate method (QACM), a new natural coordinate system for developing quadrilateral finite element models, it is much less sensitive to mesh distortion than other 4-node isoparametric elements and free of various locking problems that arise from irregular mesh geometries. In order to extend these advantages of QACM to nonlinear applications, the total Lagrangian (TL) formulations of element AGQ6-I was established in this paper, which is also the first time that a plane QACM element being applied in the implicit geometrically nonlinear analysis. Numerical examples of geometrically nonlinear analysis show that the presented formulations can prevent loss of accuracy in severely distorted meshes, and therefore, are superior to those of other 4-node isoparametric elements. The efficiency of QACM for developing simple, effective and reliable serendipity plane membrane elements in geometrically nonlinear analysis is demonstrated clearly.     

Una formulación de mínimo peso con restricciones en tensión en optimización topológica de estructuras

Optimum design of structures has been traditionally focused on the analysis of shape and dimensions optimization problems. However, more recently a new discipline has emerged: the topology optimization of the structures. This discipline states innovative models that allow to obtain optimal solutions without a previous definition of the type of structure being considered. These formulations obtain the optimal topology and the optimal shape and size of the resulting elements. The most usual formulations of the topology optimization problem try to obtain the structure of maximum stiffness. These approaches maximize the stiffness for a given amount of material to be used. These formulations have been widely analyzed and applied in engineering but they present considerable drawbacks from a numerical and from a practical point of view. In this paper the author propose a different formulation, as an alternative to maximum stiffness approaches, that minimizes the weight and includes stress constraints. The advantages of this kind of formulations are crucial since the cost of the structure is minimized, which is the most frequent objective in engineering, and they guarantee the structural feasibility since stresses are constrained. In addition, this approach allows to avoid some of the drawbacks and numerical instabilities related to maximum stiffness approaches. Finally, some practical examples have been solved in order to verify the validity of the results obtained and the advantages of the proposed formulation.     

A BE based finite element for crack propagation processes

A boundary element based finite macro element for the simulation of 3D crack propagation in the framework of linear elastic fracture mechanics is presented. While the major part of the numerical model is discretized with finite elements, a small domain containing the crack is meshed with boundary elements. By means of the Symmetric Galerkin BEM a stiffness formulation for the cracked BE domain is obtained which enables a direct FEM/BEM coupling. All necessary operations for the crack propagation are carried out within this boundary element based finite macro element and exploit the potential of the boundary integral formulation. (© 2008 WILEY-VCH Verlag GmbH & Co. KGaA, Weinheim)     

Semi‐analytical integration of the 8‐node plane element stiffness matrix using symbolic computation

The semi‐analytical integration of an 8‐node plane strain finite element stiffness matrix is presented in this work. The element is assumed to be super‐parametric, having straight sides. Before carrying out the integration, the integral expressions are classified into several groups, thus avoiding duplication of calculations. Symbolic manipulation and integration is used to obtain the basic formulae to evaluate the stiffness matrix. Then, the resulting expressions are postprocessed, optimized, and simplified in order to reduce the computation time. Maple symbolic‐manipulation software was used to generate the closed expressions and to develop the corresponding Fortran code. Comparisons between semi‐analytical integration and numerical integration were made. It was demonstrated that semi‐analytical integration required less CPU time than conventional numerical integration (using Gaussian‐Legendre quadrature) to obtain the stiffness matrix. © 2005 Wiley Periodicals, Inc. Numer Methods Partial Differential Eq, 2006     

Analytical elastostatic stiffness modeling of parallel manipulators considering the compliance of the link and joint

This paper discusses the analytical elastostatic stiffness modeling of parallel manipulators (PMs) considering the compliance of the link and joint. The proposed modeling is implemented in three steps: (1) the limb constraint wrenches are formulated based on screw theory; (2) the strain energy of the link and the joint is formulated using material mechanics and a mapping matrix, respectively, and the concentrated limb stiffness matrix corresponding to the constraint wrenches is obtained by summing the strain energy of the links and joints in the limb; and (3) the overall stiffness matrix is assembled based on the deformation compatibility equations. The strain energy factor index (SEFI) is adopted to describe the influence of the elastic components on the stiffness performance of the mechanism. Matrix structural analysis (MSA) using Timoshenko beam elements is applied to obtain analytical expressions for the compliance matrices of different joints through a three-step process: (1) formulate the element stiffness equation for each element; (2) extend the element stiffness equation to obtain the element contribution matrix, allowing the extended overall stiffness matrix to be obtained by summing the element contribution matrices; and (3) determine the stiffness matrices of joints by extracting the node stiffness matrix from the extended overall stiffness matrix and then releasing the degrees of freedom of twist. A comparison with MSA using Euler–Bernoulli beam elements demonstrates the superiority of using Timoshenko beam elements. The 2PRU-UPR PM is presented to illustrate the effectiveness of the proposed approach. Finally, the global SEFI and scatter matrix are used to identify the elastic component with the weakest stiffness performance, providing a new approach for effectively improving the stiffness performance of the mechanism.     

TWO-GRID DISCRETIZATION SCHEMES OF THE NONCONFORMING FEM FOR EIGENVALUE PROBLEMS

This paper extends the two-grid discretization scheme of the conforming finite elements proposed by Xu and Zhou （Math. Comput., 70 （2001）, pp.17-25） to the nonconforming finite elements for eigenvalue problems. In particular, two two-grid discretization schemes based on Rayleigh quotient technique are proposed. By using these new schemes, the solution of an eigenvalue problem on a fine mesh is reduced to that on a much coarser mesh together with the solution of a linear algebraic system on the fine mesh. The resulting solution still maintains an asymptotically optimal accuracy. Comparing with the two-grid discretization scheme of the conforming finite elements, the main advantages of our new schemes are twofold when the mesh size is small enough. First, the lower bounds of the exact eigenvalues in our two-grid discretization schemes can be obtained. Second, the first eigenvalue given by the new schemes has much better accuracy than that obtained by solving the eigenvalue problems on the fine mesh directly.     

Fully homomorphic SIMD operations

At PKC 2010 Smart and Vercauteren presented a variant of Gentry’s fully homomorphic public key encryption scheme and mentioned that the scheme could support SIMD style operations. The slow key generation process of the Smart–Vercauteren system was then addressed in a paper by Gentry and Halevi, but their key generation method appears to exclude the SIMD style operation alluded to by Smart and Vercauteren. In this paper, we show how to select parameters to enable such SIMD operations. As such, we obtain a somewhat homomorphic scheme supporting both SIMD operations and operations on large finite fields of characteristic two. This somewhat homomorphic scheme can be made fully homomorphic in a naive way by recrypting all data elements separately. However, we show that the SIMD operations can be used to perform the recrypt procedure in parallel, resulting in a substantial speed-up. Finally, we demonstrate how such SIMD operations can be used to perform various tasks by studying two use cases: implementing AES homomorphically and encrypted database lookup.     

Dynamic modeling of a Stewart platform using the generalized momentum approach

Dynamic modeling of parallel manipulators presents an inherent complexity, mainly due to system closed-loop structure and kinematic constraints.In this paper, an approach based on the manipulator generalized momentum is explored and applied to the dynamic modeling of a Stewart platform. The generalized momentum is used to compute the kinetic component of the generalized force acting on each manipulator rigid body. Analytic expressions for the rigid bodies inertia and Coriolis and centripetal terms matrices are obtained, which can be added, as they are expressed in the same frame. Gravitational part of the generalized force is obtained using the manipulator potential energy. The computational load of the dynamic model is evaluated, measured by the number of arithmetic operations involved in the computation of the inertia and Coriolis and centripetal terms matrices. It is shown the model obtained using the proposed approach presents a low computational load. This could be an important advantage if fast simulation or model-based real-time control are envisaged.     

Domain decomposition iterative procedures for solving scalar waves in the frequency domain

The propagation of dispersive waves can be modeled relevantly in the frequency domain. A wave problem in the frequency domain is difficult to solve numerically. In addition to having a complex–valued solution, the problem is neither Hermitian symmetric nor coercive in a wide range of applications in Geophysics or Quantum–Mechanics. In this paper, we consider a parallel domain decomposition iterative procedure for solving the problem by finite differences or conforming finite element methods. The analysis includes the decomposition of the domain into either the individual elements or larger subdomains ( of finite elements). To accelerate the speed of convergence, we introduce relaxation parameters on the subdomain interfaces and an artificial damping iteration. The convergence rate of the resulting algorithm turns out to be independent on the mesh size and the wave number. Numerical results carried out on an nCUBE2 parallel computer are presented to show the effectiveness of the method. Received October 30, 1995 / Revised version received January 10, 1997     

Measuring the closeness to singularities of a planar parallel manipulator using geometric algebra

A new index for measuring the closeness to the singularities of parallel manipulators using geometric algebra is proposed in this paper. Constraint wrenches acting on the moving platform of a parallel manipulator are derived using the outer product and dual operations. Removing the redundant constraint wrenches, a singularity polynomial is obtained when the coefficient of the outer product of all the non-redundant constraint wrenches equals zero. A singularity surface can be drawn using the singularity polynomial. Similarly, an approximate singularity polynomial and approximate singularity surface can be obtained by imposing a threshold to the singular polynomial. Then the singularity volume is calculated as the space between singularity surface and approximate singularity surface. The new index is derived by calculating the ratio of the non-singularity workspace volume (the workspace volume minus the singularity volume) to the workspace volume. The proposed index is coordinate-free and has a clear geometrical and physical interpretation. This index can be a basis for selecting structural parameters, path planning and mechanism design.     

Micromechanically motivated finite element model for ferroelectric ceramics

Ferroelectric ceramics exhibit significant coupled electromechanical phenomena that have been widely employed in sensor and actuator applications. In regular finite element models dealing with electromechanical plane problems, each grain needs to be subdiscretized by many triangular or quadrilateral elements for required accuracy. This problem can be overcome by a polygonal finite element approach where each grain is modelled by a single finite element without compromising on the results. In this paper, a polygonal finite element approach has been employed to understand the anisotropic response of the ferroelectric ceramics in their piezoelectric region. (© 2009 Wiley-VCH Verlag GmbH & Co. KGaA, Weinheim)     

MPM simulations of high-speed machining of Ti6Al4V titanium alloy considering dynamic recrystallization phenomenon and thermal conductivity

Ti6Al4V titanium alloy is often used in the aircraft industry due to its good strength and toughness etc. However, it is very difficult to simulate high speed machining of titanium alloy using the finite element method (FEM). The reason is that the high speed, large deformation and high strain rate of metal material at high temperature etc. will lead to the element distortions and other numerical difficulties. In contrast with FEM, material point method (MPM) has the advantage of simulating extreme large deformation, fracture and impact problems. Therefore, it is specially suitable for dealing with high speed cutting process. In many existing researches about the high speed cutting process using Johnson−Cook constitutive model, the material dynamic recrystallization softening effect under high pressure and high temperature has not been considered. For this, three modified Johnson−Cook constitutive models for Ti6Al4V titanium alloy are adopted and the parameters for these models were obtained by the split Hopkinson pressure bar (SHPB) test considering the critical strain values, high-temperature range and dynamic recrystallization phenomenon. Furthermore, to ensure the numerical accuracy, the transient heat conduction algorithm is employed in MPM implementation. Finally, comparison and discussion are carried out between the experimental and the simulation data, which show that the high speed cutting process can be better simulated using the modified Johnson−Cook constitutive models.     

Transverse cracks in cross-ply laminates. 1. Stress analysis

During service loading of cross-ply laminates, transverse cracks occur in plies. The cracks parallel to the fiber direction are extended over the full thickness of transverse plies and often cross the entire test specimen width. It is widely recognized that the changes of laminate thermomechanical constants, caused by the transverse cracking of composite laminates, can be significant. Theoretical stress analysis in the cross-ply laminates in the vicinity of cracks is performed using numerical (FE) and analytical methods. The effect of transverse cracks on the degradation of elastic properties will be discussed in Part 2 [1]. Approximate analytical micromechanical models based on shear lag predictions, variational analysis, and numerical 2D finite element calculations were verified in their predictive abilities. The three variational models used are based on the principle of minimum complementary energy and have different degrees of accuracy with respect to the stress assumptions used (Hashin's, 2D 0° and 2D 0°/90° models). Using FEM, the plane stress and strain state were analyzed. The effect of material properties and layer thickness on the stress distribution in a 90° layer was evaluated by varying the crack spacing. The crack opening displacement (COD), normalized with respect to the far field strain, is proposed as a measure of reduction of the mechanical properties. Since the CODs are rather insensitive to the crack spacing (crack density) in a wide region, they will be used in modeling the stiffness reduction in these laminates [1].Translated from Mekhanika Kompozitnykh Materialov, Vol. 33, No. 6, pp. 796–820, November–December, 1997.