Spectral analysis of malfunction mode in endmilling

For the investigation of the chatter modes, the power spectrum of the parametric time series model was adopted and analyzed at several mixed conditions of different revolution. This paper describes a methodology for an application of several time series such asAR (forward-backward, burg, least square, Yule Walker, geometric lattice, instrumental variable),ARX (least square, instrumental variable),ARMAX, ARMA, Box Jenkins, Output Error. To estimate the chatter mode using their spectral analysis their results were compared with one another. As a result, it was proven that several time series methods can be used for chatter mode estimation. Among them, theARX, ARMAX and instrumental variable methods (iv4) are more desirable and reliable than the other algorithm for the exact calculation of the chatter mode in endmilling. Among three cutting forces, the z direction cutting force,Fz, has more powerful characteristics of chatter occurring than the cutting forces,Fx andFy, in the sense that weak mode is calculated exactly and there is no shifted or pseudo mode in the estimated power spectra of endmilling forces.     

Gyroscopic and mode interaction effects on micro-end mill dynamics and chatter stability

This paper investigates the gyroscopic and mode interaction effects on the micro-end mill dynamics and the stability behavior due to regenerative chatter. A high-speed spindle system for micro-milling is modeled using finite elements. The transfer functions and the mode shapes are studied to gain a deep insight into the dynamic characteristics. The experimentally identified chatter states and operational vibration modes are given to verify the analytical results. It is shown that, due to the small rotary inertia of the micro-end mill, the gyroscopic effect considered in the inertial frame is less significant despite high rotational speeds. The mode interaction strongly affects the dynamics and the chatter stability. Moreover, piezoelectric elements are applied to in-process excitation in order to identify the transfer behavior of the micro-end mill in the operating state.     

微铣削再生颤振动力学建模及稳定性分析

再生颤振是制约微铣削加工效率和加工质量的主要因素.以微铣削加工为研究对象,建立了考虑再生效应的微铣削颤振系统动力学模型和颤振稳定域解析模型,通过模态实验获得机床-刀具系统的频响函数,在此基础上综合使用铣削稳定性判据进行数值分析,获得了颤振稳定域解析解.最后进行了颤振稳定性加工实验,实验结果与仿真结果吻合良好,验证了建立的微铣削颤振系统动力学模型和颤振稳定域解析模型的正确性.     

Enhanced meta-modelling technique for analysis of mode crossing, mode veering and mode coalescence in structural dynamics

In this paper, an enhanced meta-modelling procedure for the approximation of structural eigenfrequencies and eigenvectors is introduced. The procedure allows for correct prediction of the modal parameters in case of mode crossing, veering, and coalescence phenomena that can be observed when variations of the structural parameters occur. The procedure overcomes the erroneous approximation of these phenomena which results from a direct approximation of the modal parameters. The methodology is based on the response surface approximation of the structural matrices and on the concept of modal reduction. A comparison with a direct response surface approximation of the eigenfrequencies shows a considerable improvement in the accuracy as it is presented for a finite element frame structure.     

薄壁零件高速铣削振动试验与分析

切削速会加强振动随针对薄壁零件在高速铣削加工过程中存在的振动问题,为有效抑制加工振动,采用单因素试验,对每齿进给量、度、工彳车径向轴向切深、径向切深等加工参数进行了研究。试验结果显示：每齿进给量并不是越小越好;转速过高过低都振动：切深增随轴向切深增大振动增强;随径向切深增大振动逐渐减弱,较大轴向切深下,径向切深小于1mm时,大而增强。综合数据优选：薄壁零件高速铣削时,每齿进给量在0．1～0．15mm之间;转速在11000—14000r／min之间;较小的轴向切深和较大径向切深会有效抑制加工振动。     

斜齿轮精确建模及有限元模态分析

通过三维造型软件UG实现渐开线斜齿轮的精确建模。采用有限元方法,研究斜齿轮的固有振动特性,分析斜齿 轮的主要振动类型,所得结论反映了斜齿轮的动力学性能,为振动响应求解做了必要的准备。     

考虑犁切力的微铣削颤振稳定域建模与分析

以微结构铣削加工为研究对象,建立了微观尺度下考虑犁切效应的铣削动态铣削力模型和颤振稳定域解析模型。在微铣削加工实验的基础上,对应于刀齿的每一个瞬时转角,对微铣削颤振稳定域进行了时域求解,进而研究了犁切-剪切机制对微铣削颤振稳定域的影响。实验结果表明犁切效应对微细铣削过程的加工不稳定现象没有显著的影响。     

Identification of bearing dynamics under operational conditions for chatter stability prediction in high speed machining operations

Chatter is a major problem causing poor surface finish, low material removal rate, machine tool failure, increased tool wear, excessive noise and thus increased cost for machining applications. Chatter vibrations can be avoided using stability diagrams for which tool point frequency response function (FRF) must be determined accurately. During cutting operations, due to gyroscopic moments, centrifugal forces and thermal expansions bearing dynamics change resulting in tool point FRF variations. In addition, gyroscopic moments on spindle–holder–tool assembly cause separation of modes in tool point FRF into backward and forward modes which will lead to variations in tool point FRF. Therefore, for accurate stability predictions of machining operations, effects of operational conditions on machine tool dynamics should be considered in calculations. In this study, spindle bearing dynamics are identified for various spindle rotational speeds and cutting forces. Then, for a real machining center, tool point FRFs under operating conditions are determined using the identified speed dependent bearing dynamics and the mathematical model proposed. Moreover, effects of gyroscopic moments and bearing dynamics variations on tool point FRF are examined separately. Finally, computationally determined tool point FRFs using revised bearing parameters are verified through chatter tests.     

Stochastic analysis of Poisson impact series using discrete form,spectrum analysis and time correlation

A stochastic model based on Poisson impact series is developed from a random pulse train model. Using the discrete form of the expectation function, first- and second-order time correlation functions are generated. Then, the force and power spectral density functions are generated by the Fourier transform of the first- and second-order correlation functions, respectively. Experimental force and power spectra are compared with those from the developed model and an existing model using single, multiple and ensemble averaged impact samples. Overlapping and consistent matching occur in most of the regions in these comparisons. The effects of noise and pulse shape deviation are discussed. It is shown theoretically and experimentally that the signal-to-noise ratio increases with the impaction rate. Using ensemble averages of a 100 samples, the impact magnitude and its arrival time is validated to be Gaussian and Uniformly distributed. The signal-to-error ratio increases with the number of ensemble averages. The established model is utilised to carry out modal tests of a space truss. Comparing modal parameters, such as mode shapes, natural frequencies, and damping ratios, consistent matching is observed with those obtained from the random noise test.     

时序分析在电主轴热误差建模中的应用

针对电主轴热误差基于三点法测量和建模中忽略径向热倾角误差的问题,采用五点法对主轴热误差进行测量,建立基于时序分析的热误差自回归滑动平均混合模型ARIMA。通过引用单位根检验算法实现对热误差序列的平稳性判定,运用自相关/偏自相关函数完成模型的高效识别;利用信息准则解决热误差模型的定阶问题,结合Yule-Walker方程实现自回归参数以及滑动平均参数的求解,从而提高了模型的预测精度及泛化能力,设定了模型的预测优度评价标准。电主轴热误差模型蕴含轴向伸长及径向热倾角,更符合实际,模型可更准确地描述主轴热误差空间位姿状态。通过电主轴热误差建模的应用实例,验证了所提测量及建模方法的有效性。     

Three-dimensional stability prediction and chatter analysis in milling of thin-walled plate

Stability lobe diagram can be used for selecting proper milling parameters to perform chatter-free operations and improve productivity during milling of thin-walled plates. This paper studies the machining stability in milling of thin-walled plates and develops a three-dimensional stability lobe diagram of the spindle speed, tool position, and axial depth of cut. The workpiece-holder system is modeled as a 2-degree-of-freedom system considering that the tool system is much more rigid than the thin-walled plate, and dynamic equations of motion described for the workpiece-holder system are solved numerically in time domain to compute the dynamic displacements of the thin-walled plate. Statistical variances of the dynamic displacements are then employed as a chatter detection criterion to acquire the stability lobe diagram. The experimentally obtained stability limits correspond well with the predicted stability limits. In addition, influence of feed rate on stability limits is also investigated. By performing frequency analysis of the measured cutting forces to judge if chatter occurs, it is found that feed per tooth has little influence on the stability limits. However, feed per tooth impacts the machined surface quality. The results show that the surface quality drops by increasing feed per tooth.     

Detecting transition to chatter mode in peakless tool turning by monitoring vibration and acoustic emission signals

Stability of a peakless tool turning on slender shafts was studied under conditions of low- and high-magnitude vibrations by registering and short-time Fourier transformation (STFT) processing of acoustic emission (AE) and vibration acceleration (VA) signals. Both VA and AE signals have been registered in three positions of the cutting tool on the workpiece and for different shaft diameters. Both amplitude- and frequency-dependent AE and VA characteristics were obtained and analyzed for overall process signal length as well as for single frames. It was shown that power spectrum characteristic could be used for monitoring the fast-occurring changes in the cutting process stability. A criterion of the cutting process stability based on the power spectrum has been offered.     

Multiple failure mode reliability modeling and analysis in failure crack propagation based on time-varying copula

The fatigue failure of crack structure is influenced by fracture failure and static strength failure in the process of its growth. And the correlation characteristics between them change with the crack growth, which brings difficulties to safety assessment. To solve this problem, we propose a reliability model of failure crack propagation (FCP) based on time-varying copula. Meanwhile, a dynamic parameter estimation is put forward to build the time-varying copula. First, a flexible mixed copula model was constructed, by means of linear weighted model, to describe the nonlinear dependence among failure modes. Then the time-varying correlation parameters of copula were obtained by maximum likelihood estimation and least square polynomial fitting. Therefore, the dynamic parameter estimation of copula was realized, and then we used the built time-varying copula model to solve the reliability of joint failure. Finally, a numerical example was provided to illustrate the feasibility and application of the built time-varying copula model.     

产品族建模的关键技术

结合产品数字化快速设计系统研究、开发和应用经验，对产品数字化系统的重要环节产品族建模的关键技术——QFD技术、模块化设计技术、GT技术、设计知识的表达技术、用户化界面技术进行了总结、研究和探讨。     

An efficient approach for milling dynamics modeling and analysis with varying time delay and cutter runout effect

An efficient approach for milling stability and surface location error (SLE) prediction with varying time delay and cutter runout effect is presented in this paper. Firstly, based on the tooth trochoid motion, the paper proposes a varying time delay model during cutter/workpiece engagement with taking cutter runout into account, establishes a milling dynamic model under arbitrary feed direction, and then derives the state transition matrix in one cutter rotation period by using the Cotes numerical integration formula. The milling stability of the dynamics system are obtained by using Floquet theory. According to the fixed point theory, the displacement response of the dynamic system and the method for solving the SLE are both developed. Later, a series of numerical and experimental works are conducted. The numerical verification shows that the proposed method can achieve a faster convergence rate and higher calculation efficiency than other previous methods. Meanwhile, the prediction of stability and SLE are in good agreement with the experimental results, and have a high accuracy for stability prediction when cutter runout and varying time delay considered. In the end, the numerical studies show that the milling stability and SLE strongly depends on the actual milling conditions, including milling parameters, cutter runout, cutter geometric parameters, and asymmetric structural dynamic parameters, which are helpful for milling process optimization.     

Image processing for chatter identification in machining processes

Identifying chatter or intensive self-excited relative tool–workpiece vibration is one of the main challenges in the realization of automatic machining processes. Chatter is undesirable because it causes poor surface finish and machining accuracy, as well as reducing tool life. The identification of chatter is performed by evaluating the surface roughness of a turned workpiece undergoing chatter and chatter-free processes. In this paper, an image-processing approach for the identification of chatter vibration in a turning process was investigated. Chatter is identified by first establishing the correlation between the surface roughness and the level of vibration or chatter in the turning process. Images from chatter-free and chatter-rich turning processes are analyzed. Several quantification parameters are utilized to differentiate between chatter and chatter-free processes. The arithmetic average of gray level G _a is computed. Intensity histograms are constructed and then the variance, mean, and optical roughness parameter of the intensity distributions are calculated. The surface texture analysis is carried out on the images using a second-order histogram or co-occurrence matrix of the images. Analysis is performed to investigate the ability of each technique to differentiate between a chatter-rich and a chatter-free process. Finally, a machine vision system is proposed to identify the presence of chatter vibration in a turning process.     

高效铣削中的振动控制策略

从理论上讲,提高切削速度和进给速度能极大地提高铣削加工的生产效率,但这将会导致振动产生,对加工零件的加工精度、表面粗糙度、刀具与机床使用寿命以及加工周期等都产生负面影响。究其原因,是在通常高效率铣削中,每个切削刃将会在加工表面留下由于振动产生的波形痕迹。如当有一些波形痕迹是由第3齿切削刀留下的,它是在消除了第1齿切削刃留下的波形痕迹之后,     

Breakthrough of regenerative chatter modeling in milling by including unexpected effects arising from tooling system deflection

Self-excited anomalous vibrations called chatter affected milling operations since the beginning of the industrial era. Chatter is responsible for bad surface quality of the machined part and it may severely damage machining system elements. Although the significant advances of recent years, state of the art dynamic models are not yet able to completely explain chatter onset even when some conventional cutting tools are applied for conventional milling operations. In this work, a more general model of regenerative chatter is presented. The model takes into account some additional degrees of freedom and cutting forces which are neglected in the classical approach. By so doing, a more accurate representation of milling dynamics is obtained, especially when considering large diameter cutters. An improved mathematical formulation of regenerative cutting forces is provided with respect to a very recent publication where the new model has been first outlined. This approach allows ?45 % of computation time. Moreover, here a new, independent, and stronger experimental validation is provided, where the new model successfully predicts an increase of about +(50 ÷ 100) % of the stability boundaries with respect to the classical prediction, thus showing the potential breakthrough of the new approach.     

动力学仿真中的子系统建模技术研究

针对目前复杂机械系统动力学仿真软件建模效率偏低、模型无法重用、用户起点高等缺点,对复杂机械系统动力学仿真中的子系统建模技术进行了研究.提出了多级子系统的坐标切换方法,设计了子系统模型的接口方案,并提出了子系统的装配算法和面向子系统装配的参数化求解算法.在算法研究的基础上,开发了子系统建模组件和汽车子模型库,并集成于动力学仿真分析平台InteDyna.通过与某汽车企业合作,将InteDyna应用于多款车型的整车动力学仿真分析和实车试验,验证了子系统建模技术的有效性与可靠性.