The rotational speed of the agitator is one of the important parameters that affect the grinding efficiency of the vertical stirred mill. Increasing the speed will improve the grinding effect, but it will increase energy consumption, and determining a reasonable speed setting is a system issue. The effects of different speeds on energy consumption, product particle size, and grinding efficiency were analyzed in this study. An experimental vertical stirred mill was used to grind iron ore, and five different speed parameters from 175 rpm to 350 rpm were set as variables. It was found that increasing the rotational speed will increase the grinding effect, but it will trigger more energy consumption. A new evaluation index to comprehensively reflect the grinding efficiency of the mill, which was defined as the ability of a mill to grind the same product per unit of time and energy consumption, was proposed. The grinding efficiency was calculated when the particle size of iron ore powder decreased to −45, −38, and −28 μm at different speeds. It can be seen that the growth rate of energy consumption is faster than that of the percentage of particle size, which leads to a continuous decrease in grinding efficiency with the increase in rotational speed. If high processing capacity is pursued within a certain period of time, high speed can be chosen, but it will result in energy loss. On the contrary, the low speed can be chosen, if considering grinding economy.

Biological structures have excellent mechanical performances including lightweight, high stiffness, etc. However, these are difficult to apply directly to some given complex structures, such as automobile frame, control arm, etc. In this study, a novel bionic design method for skeleton structures with complex features is proposed by the bio-inspired idea of “main-branch and sub-branch”. The envelope model of a given part is established by analyzing the structural functions and working conditions, and the load path is extracted by the load-transferred law as the structural main-branch. Then, the selection criterion of bionic prototype is established from three aspects: load similarity, structural similarity and manufacturability. The cross-sections with high similarities are selected as the structural sub-branch. Finally, the multi-objective size optimization is carried out and a new model is established. The bionic design of a control arm is carried out by the method: structural main-branch is obtained by the load path analysis and structural sub-branch is occupied by the fish-bone structure. The design result shows that the structural stiffness is increased by 62.3%, while the weight is reduced by 24.75%. The method can also be used for other fields including automobile, aerospace and civil engineering.

Lattice structure is more and more widely used in engineering by replacing solid structure. But its mechanical performances are constrained by the external shape if the unit cells are directly filled in the design domain, and the traditional topology optimization methods are difficult to give the explicitly mechanical guidance for the distribution of internal unit cells. In this paper, a novel design and optimization method of variable-density lattice structure is proposed in order to simultaneously optimize the external shape and the internal unit cells. First of all, the envelope model of any given structure should be established, and the load paths need to be visualized by the theory of load path. Then, the design criteria of external shape are established based on the principle of smoother load paths in the structure. An index of load flow capacity is defined to indicate the load paths density and to control the density distribution of unit cells, and a detailed optimization strategy is given. Finally, three examples of a cantilever plate, an L-shaped bracket and a classical three-point bending beam are used to verify the method. The results show that the models designed by the proposed method have better mechanical performances, lower material usage and less printing time.

There are alternating impact loads for the diesel engine cylinder block. The topology optimization of the extreme single‐working condition cannot guarantee its overall mechanical performance, and the traditional multiworking condition optimization has the problem that the weight coefficients are difficult to determine. Thus, a multiobjective topology optimization method based on analytic hierarchy process is proposed. Firstly, the static, dynamic characteristics and structure efficiency are calculated by the finite element analysis which indicates the direction of topology optimization for the cylinder block. The hierarchical structure model of topology optimization, including 12 weighting coefficients, is constructed considering static multiworking condition stiffness and dynamic multiorder natural frequency. The comprehensive evaluation function for the cylinder block is established by the compromise programming method and the weight coefficients are determined based on analytic hierarchy process. The optimization mathematical model is established and the multiobjective topology optimization of the cylinder block is carried out. The optimization results show that the proposed method can take into account structural multiworking condition performance, which has obvious advantages over the single objective topology optimization. The simulation results show that the static and dynamic characteristics are improved to some extent and the overall mechanical performance of the new model is more uniform with a 5.22% reduction in weight. It shows that the topology structure of the cylinder block is more reasonable.

A windlass driven heavy duty multifunctional billet tong was designed for large-scale forging and casting to reduce the number of auxiliary material handling devices in manufacturing workshops. To improve its mechanical performance and safety, a novel multi-objective topology optimization method for its curved arm is proposed in this paper. Firstly, the influence of different open angles and working frequencies for the curved arm was simplified to a multi-objective optimization problem. A comprehensive evaluation function was constructed using the compromise programming method, and a mathematical model of multi-objective topology optimization was established. Meanwhile, a radar chart was employed to portray the comparative measures of working conditions, the weight coefficient for each working condition was determined based on the corresponding enclosed areas, combining the stress indices, the displacement indices and the frequency indices of all working conditions. The optimization results showed that the stiffness and strength of the curved arm can be improved while its weight can be reduced by 10.77%, which shows that it is feasible and promising to achieve a lightweight design of the curved arm of a billet tong. The proposed method can be extended to other equipment with complex working conditions.

As the main load-bearing structure of heavy machine tools, cranes, and other high-end equipment, the large-scale box structures usually bear moving loads, and the results of direct topology optimization usually have some problems: the load transfer skeleton is difficult to identify and all working conditions are difficult to consider comprehensively. In this paper, a layout design method of stiffened plates for the large-scale box structures under moving loads based on multiworking-condition topology optimization is proposed. Based on the equivalent principle of force, the box structures are simplified into the main bending functional section, main torsional functional section, and auxiliary functional section by the magnitude of loads and moments, which can reduce the structural dimension and complexity in topology optimization. Then, the moving loads are simplified to some multiple position loads, and the comprehensive evaluation function is constructed by the compromise programming method. The mathematical model of multiworking-condition topology optimization is established to optimize the functional sections. Taking a crossbeam of superheavy turning and milling machining center as an example, optimization results show that the stiffness and strength of the crossbeam are increased by 17.39% and 19.9%, respectively, while the weight is reduced by 12.57%. It shows that the method proposed in this paper has better practicability and effectiveness for large-scale box structures.