Yang Tian, Dacian Tomus, Aijun Huang and Xinhua Wu
Selective laser melting (SLM) process is an additive manufacturing method that uses computer-aided design to fabricate complex components layer-by-layer. Surface roughness is one…
Abstract
Purpose
Selective laser melting (SLM) process is an additive manufacturing method that uses computer-aided design to fabricate complex components layer-by-layer. Surface roughness is one of the primary drawbacks of SLM process; hence, the purpose of this paper is to present a parametric study and optimisation of fundamental parameters, including scan power, speed, inclined angle and layer thickness on surface roughness during selective laser melting of Hastelloy X.
Design/methodology/approach
Parametric significance on surface finish was analysed using analysis of variance and response surface methodology. General agreement between predicted and measured values was achieved. Surface characteristics of both up-skin and down-skin with various angles were covered within the investigated range.
Findings
Both experimental and statistical analysis showed that surface roughness of up-skin was primarily influenced by scan power, inclined angle and layer thickness while down-skin was more affected by the former two factors. Melt pool shape and staircase size were found to determine the up-skin surface, whereas attached particles were responsible for down-skin surface roughness.
Originality/value
As per our understanding, this manuscript provides valuable insight into the surface quality problem of SLM, which is a very critical issue for up-grading the process for manufacturing real components. This manuscript helps promote improved knowledge and understanding of the attributes and capabilities of this rapidly evolving 3D printing technology. Moreover, it establishes usable processing window and helps obtain optimal conditions, thus offering useful information to professionals working in this field. By combining experiments with statistical analysis, both practice and theory relevant to SLM process are further developed.
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Yang Tian, Dacian Tomus, Aijun Huang and Xinhua Wu
Limited research has attempted to reveal the different modes of the melt pool formation in additive manufacturing. This paper aims to study the mechanisms of surface roughness…
Abstract
Purpose
Limited research has attempted to reveal the different modes of the melt pool formation in additive manufacturing. This paper aims to study the mechanisms of surface roughness formation, especially on the aspect of melt pool formation which determine the surface profile and consequently significantly influence the surface roughness.
Design/methodology/approach
In this study, the conditions under which different modes of melt pool formation (conduction mode and keyhole mode) occur for the case of as-fabricated Hastelloy X using direct metal laser solidification (DMLS) are derived and validated experimentally. Top surfaces of uni-directionally built samples under various processing conditions are cut, grinded, polished and etched to reveal their individual melt pool morphologies. Similarly, up-skin (slope angle < 90°) and down-skin (slope angle > 90°) melt pool morphologies are also investigated to compare the differences. Surface tension gradients and resultant Marangoni flow, which dominate the melt flow in the melt pool, is also calculated to help better evaluate the melt pool shape forming.
Findings
Two types of melt pool formation modes are dominating in DMLS: conduction mode and keyhole mode. Melt pool formed by conduction mode generally has an aspect ratio of 1:2 (depth vs width) and is in elliptical shape. Appropriate selection of scanning laser power and speed are required to maintain a low characteristic length and width ratio to prevent ballings. Melt pool formed by keyhole mode has an aspect ratio of 1:1 or less. High-energy contour promotes formation of key-hole-shaped melt pool which fills the gaps between layers and smoothens the up-skin surface roughness. Low-energy contour scan is necessary for down-skin surface to form small melt pool profiles and achieve low Ra.
Originality/value
This paper provides valuable insight into the origins of surface quality problem of DMLS, which is a very critical issue for upgrading the process for manufacturing real components. This paper helps promote the understanding of the attributes and capabilities of this rapidly evolving three-dimensional printing technology and allow appropriate control of processing parameters for successful fabrication of components with sound surface quality.
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Zhigang Wang, Aijun Li, Lihao Wang, Xiangchen Zhou and Boning Wu
The purpose of this paper is to propose a new aerodynamic parameter estimation methodology based on neural network and output error method, while the output error method is…
Abstract
Purpose
The purpose of this paper is to propose a new aerodynamic parameter estimation methodology based on neural network and output error method, while the output error method is improved based on particle swarm algorithm.
Design/methodology/approach
Firstly, the algorithm approximates the dynamic characteristics of aircraft based on feedforward neural network. Neural network is trained by extreme learning machine, and the trained network can predict the aircraft response at (k + 1)th instant given the measured flight data at kth instant. Secondly, particle swarm optimization is used to enhance the convergence of Levenberg–Marquardt (LM) algorithm, and the improved LM method is used to substitute for the Gauss Newton algorithm in output error method. Finally, the trained neural network is combined with the improved output error method to estimate aerodynamic derivatives.
Findings
Neither depending on the initial guess of the parameters to be estimated nor requiring numerical integration of the aircraft motion equation, the proposed algorithm can be used for unstable aircraft and is successfully applied to extract aerodynamic derivatives from both simulated and real flight data.
Research limitations/implications
The proposed method requires iterative calculation and can only identify parameters offline.
Practical implications
The proposed method is successfully applied to estimate aircraft aerodynamic parameters and can also be used as a new algorithm for other optimization problems.
Originality/value
In this study, the output error method is improved to reduce the dependence on the initial value of parameters and expand its application scope. It is applied in aircraft aerodynamic parameter identification together with neural network.
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Hongshi Lu, Li Aijun, Wang Changqing and Zabolotnov Michaelovitch Yuriy
This paper aims to present the impact analysis of payload rendezvous with tethered satellite system and the design of an adaptive sliding mode controller which can deal with mass…
Abstract
Purpose
This paper aims to present the impact analysis of payload rendezvous with tethered satellite system and the design of an adaptive sliding mode controller which can deal with mass parameter uncertainty of targeted payload, so that the proposed cislunar transportation scheme with spinning tether system could be extended to a wider and more practical range.
Design/methodology/approach
In this work, dynamical model is first derived based on Langrangian equations to describe the motion of a spinning tether system in an arbitrary Keplerian orbit, which takes the mass of spacecraft, tether and payload into account. Orbital design and optimal open-loop control for the payload tossed by the spinning tether system are then presented. The real payload rendezvous impact around docking point is also analyzed. Based on reference acceleration trajectory given by optimal theories, a sliding mode controller with saturation functions is designed in the close-loop control of payload tossing stage under initial disturbance caused by actual rendezvous error. To alleviate the influence of inaccurate/unknown payload mass parameters, the adaptive law is designed and integrated into sliding mode controller. Finally, the performance of the proposed controller is evaluated using simulations. Simulation results validate that proposed controller is found effective in driving the spinning tether system to carry payload into desired cislunar transfer orbit and in dealing with payload mass parameter uncertainty in a relatively large range.
Findings
The results show that unideal rendezvous manoeuvres have significant impact on in-plane motion of spinning tether system, and the proposed adaptive sliding mode controller with saturation functions not only guarantees the stability but also provides good performance and robustness against the parameter and unstructured uncertainties.
Originality/value
This work addresses the analysis of actual impact on spinning tether system motion when payload is docking with system within tolerated docking window, rather than at the particular ideal docking point, and the robust tracking control of deep-space payload tossing missions with the spinning tether system using the adaptive sliding mode controller dealing with parameter uncertainties. This combination has not been proposed before for tracking control of multivariable spinning tether systems.
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Rooh ul Amin and Aijun Li
The purpose of this paper is to present μ-synthesis-based robust attitude trajectory tracking control of three degree-of-freedom four rotor hover vehicle.
Abstract
Purpose
The purpose of this paper is to present μ-synthesis-based robust attitude trajectory tracking control of three degree-of-freedom four rotor hover vehicle.
Design/methodology/approach
Comprehensive modelling of hover vehicle is presented, followed by development of uncertainty model. A μ-synthesis-based controller is designed using the DK iteration method that not only handles structured and unstructured uncertainties effectively but also guarantees robust performance. The performance of the proposed controller is evaluated through simulations, and the controller is also implemented on experimental platform. Simulation and experimental results validate that μ-synthesis-based robust controller is found effective in: solving robust attitude trajectory tracking problem of multirotor vehicle systems, handling parameter variations and dealing with external disturbances.
Findings
Performance analysis of the proposed controller guarantees robust stability and also ensures robust trajectory tracking performance for nominal system and for 15-20 per cent variations in the system parameters. In addition, the results also ensure robust handling of wind gusts disturbances.
Originality/value
This research addresses the robust performance of hover vehicle’s attitude control subjected to uncertainties and external disturbances using μ-synthesis-based controller. This is the only method so far that guarantees robust stability and performance simultaneously.
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Muhammad Taimoor, Li Aijun and Rooh ul Amin
The purpose of this paper aims to investigate an effective algorithm for different types of disturbances rejection. New dynamics are designed based on disturbance. Observer-based…
Abstract
Purpose
The purpose of this paper aims to investigate an effective algorithm for different types of disturbances rejection. New dynamics are designed based on disturbance. Observer-based sliding mode control (SMC) technique is used for approximation the disturbances as well as to stabilize the system effectively in presence of uncertainties.
Design/methodology/approach
This research work investigates the disturbances rejection algorithm for fixed-wing unmanned aerial vehicle. An algorithm based on SMC is introduced for disturbances rejection. Two types of disturbances are considered, the constant disturbance and the sinusoidal disturbance. The comprehensive lateral and longitudinal models of the system are presented. Two types of dynamics, the dynamics without disturbance and the new dynamics with disturbance, are presented. An observer-based algorithm is presented for the estimation of the dynamics with disturbances. Intensive simulations and experiments have been performed; the results not only guarantee the robustness and stability of the system but the effectiveness of the proposed algorithm as well.
Findings
In previous research work, new dynamics based on disturbances rejection are not investigated in detail; in this research work both the lateral and longitudinal dynamics with different disturbances are investigated.
Practical implications
As the stability is always important for flight, so the algorithm proposed in this research guarantees the robustness and rejection of disturbances, which plays a vital role in practical life for avoiding any kind of damage.
Originality/value
In the previous research work, new dynamics based on disturbances rejection are not investigated in detail; in this research work both the lateral and longitudinal dynamics with different disturbances are investigated. An observer-based SMC not only approximates the different disturbances and also these disturbances are rejected in order to guarantee the effectiveness and robustness.
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Aijun Zhang, Xinxin Li, Pibo Ma, Ying Xiong and Gaoming Jiang
Realistic geometric description is essential for simulating physical properties of warp-knitted velvet fabrics, which are widely used for home-textiles and garments. The purpose…
Abstract
Purpose
Realistic geometric description is essential for simulating physical properties of warp-knitted velvet fabrics, which are widely used for home-textiles and garments. The purpose of this paper is to provide an approach to the description of patterned piles and propose a customized simulation model to realize highly real-time simulation of warp-knitted velvet fabrics in three dimensions.
Design/methodology/approach
Based on knitting technology and structure features, a mathematical model to qualify forming possibility of piles is conducted by assessing underlaps of pattern bars and pile ground bars. When the pile areas and ground areas are classified, a three-dimensional (3D) space coordinate is built, of which the z-axis is divided into equal spaces to form certain multi-layer textured slices. Color and transparency of piles on each textured slice can be computed and generated by mapping to 3D geometrical grid layers with particular mapping relationship. Moreover, piles’ deflection and spatial collision are also taken into account to make sure high uniformity with real fabrics.
Findings
According to the models built, a simulator special for warp-knitted patterned velvet fabrics is programed via Visual C++ and the models are proven practical and easily implemented by comparing simulated effect of one sample with real fabric.
Research limitations/implications
Because of present limited research, 3D simulation of patterned velvet fabrics knitted on double-needle bar Raschel machine as well as 3D shadow effect will be studied in the further research.
Practical implications
The paper includes implications for designing patterned velvet products and shows convenience to instantly see finished effect without sampling on machine.
Originality/value
This paper fulfills a featured simulation method for warp-knitted patterned velvet fabrics in 3D dimensions for the first time.
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Zhiwei Li, Dingding Li, Yulong Zhou, Haoping Peng, Aijun Xie and Jianhua Wang
This paper aims to contribute to the performance improvement and the broader application of hot-dip galvanized coating.
Abstract
Purpose
This paper aims to contribute to the performance improvement and the broader application of hot-dip galvanized coating.
Design/methodology/approach
First, the ability to provide barrier protection, galvanic protection, and corrosion product protection provided by hot-dip galvanized coating is introduced. Then, according to the varying Fe content, the growth process of each sublayer within the hot-dip galvanized coating, as well as their respective microstructures and physical properties, is presented. Finally, the electrochemical corrosion behaviors of the different sublayers are analyzed.
Findings
The hot-dip galvanized coating is composed of η-Zn sublayer, ζ-FeZn13 sublayer, δ-FeZn10 sublayer, and Γ-Fe3Zn10 sublayer. Among these sublayers, with the increase in Fe content, the corrosion potential moves in a noble direction.
Research limitations/implications
There is a lack of research on the corrosion behavior of each sublayer of hot-dip galvanized coating in different electrolytes.
Practical implications
It provides theoretical guidance for the microstructure control and performance improvement of hot-dip galvanized coatings.
Originality/value
The formation mechanism, coating properties, and corrosion behavior of different sublayers in hot-dip galvanized coating are expounded, which offers novel insights and directions for future research.
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Lina Qiu, Jin Tian, Weiwei Zhang, Aijun Gong and Weiyu Zhao
Sulfate-reducing bacteria (SRB) are recognized by scholars as the most important class of bacteria leading to corrosion of metal materials. It is important to use the properties…
Abstract
Purpose
Sulfate-reducing bacteria (SRB) are recognized by scholars as the most important class of bacteria leading to corrosion of metal materials. It is important to use the properties of microorganisms to inhibit the growth of SRB in the corrosion protection of metal materials and to protect the environment.
Design/methodology/approach
In this work, the behavior of anaerobic Thiobacillus denitrificans (TDN) intracellular enzyme inhibition of SRB corrosion of EH36 steel was investigated with electrochemical impedance spectroscopy, biological detection technology and X-ray photoelectron spectroscopy.
Findings
Results showed that the SRB crude intracellular enzyme affected the corrosion behavior of EH36 steel greatly and the purified TDN intracellular enzyme inhibits SRB intracellular enzyme corrosion to EH36 steel.
Originality/value
A perfect enzyme activity inhibition mechanism will provide theoretical guidance for the selection and application of anticorrosion microorganisms, which is of scientific significance in the field of microbial anticorrosion research.
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Keywords
Muhammad Taimoor, Li Aijun, Rooh ul Amin and Hongshi Lu
The purpose of this paper is to design linear quadratic regulator (LQR) based Luenberger observer for the estimation of unknown states of aircraft.
Abstract
Purpose
The purpose of this paper is to design linear quadratic regulator (LQR) based Luenberger observer for the estimation of unknown states of aircraft.
Design/methodology/approach
In this paper, the LQR-based Luenberger observer is deliberated for autonomous level flight of unmanned aerial vehicle (UAV) which has been attained productively. Various modes like phugoid and roll modes are exploited for controlling the rates of UAV. The Luenberger observer is exploited for estimation of the mysterious states of the system. The rates of roll, yaw and pitch are used as an input to the observer, while the remaining states such as velocities and angles have been anticipated. The main advantage of using Luenberger observer was to reduce the cost of the system which has been achieved lucratively. The Luenberger observer proposes sturdiness at the rate of completion to conquest over the turmoil and insecurities to overcome the privileged recital. The FlightGear simulator is exploited for the endorsement of the recital of the Luenberger observer-based autopilot. The level flight has been subjugated lucratively and has been legitimated by exploiting the FlightGear simulator. The authenticated and the validated results are offered in this paper. Microsoft Visual Studio has been engaged as a medium between the MATLAB and FlightGear Simulator.
Findings
The suggested observer based on LQR ensures the lucrative approximation of the unknown states of the system as well as the successful level flight of the system. The Luenberger observer is used for approximation of states while LQR is used as controller.
Originality/value
In this research work, not only the estimation of unknown states of both longitudinal and lateral model is made but also the level flight is achieved by using those estimated states and the autopilot is validated by using the FlightGear, while in most of the research work only the estimation is made of only longitudinal or lateral model.