On nonlinear cutting response and tool chatter in turning operation

Tool chatter in turning process is addressed with a new perspective. Turning dynamics is investigated using a 3D model that allows for simultaneous workpiece-tool deflections in response to the exertion of nonlinear regenerative force. The workpiece is modeled as a system of three rotors, namely, unmachined, being machined and machined, connected by a flexible shaft. Such a configuration enables the workpiece motion relative to the tool and tool motion relative to the machining surface to be three-dimensionally established as functions of spindle speed, instantaneous depth-of-cut, material removal rate and whirling. The equations of motion for the model are coupled through the nonlinear cutting force. The model is explored along with its 1D counterpart, which considers only tool motions and disregards workpiece vibrations. Different stages of stability for the workpiece and the tool subject to the same cutting conditions are studied. Numerical simulations reveal diverse, oftentimes inconsistent, tool behaviors described by the two models. Most notably, observations made with regard to the inconsistency in describing machining stability limits raise the concern for using 1D models to obtain stability charts.     

Chaotic vibrations in a regenerative cutting process

We have analysed vibrations generated in an orthogonal cutting process. Using a simple one degree of freedom model of the regenerative cutting, we have observed the complex behaviour of the system. In presence of a shaped cutting surface, the nonlinear interaction between the tool and a workpiece leads the to chatter vibrations of periodic, quasi-periodic or chaotic type depending on system parameters. To describe the profile of the surface machined by the first pass we used a harmonic function. We analysed the impact phenomenon between the tool and a workpiece after their contact loss.     

Stabilization and destabilization in non-conservative gyroscopic systems

Stability of a linear autonomous non-conservative system in presence of potential, gyroscopic, dissipative, and nonconservative positional forces is studied. The cases when the non-conservative system is close to a gyroscopic system or to a circulatory one, are examined. It is known that the marginal stability of gyroscopic and circulatory systems can be destroyed or improved up to asymptotic stability due to action of small non-conservative positional and velocity-dependent forces. The present contribution shows that in both cases the boundary of the asymptotic stability domain of the perturbed system possesses singularities such as “Dihedral angle” and “Whitney umbrella” that govern stabilization and destabilization. Approximations of the stability boundary near the singularities and estimates of the critical gyroscopic and circulatory parameters are found in an analytic form. In case of two degrees of freedom these estimates are obtained in terms of the invariants of matrices of the system. As an example, the asymptotic stability domain of the modified Maxwell-Bloch equations is investigated with an application to the stability problems of gyroscopic systems with stationary and rotating damping, such as the Crandall gyropendulum, tippe top and Jellet's egg. An instability mechanism in a system with two degrees of freedom, originating after discretization of models of a rotating disc in frictional contact and possessing the spectral mesh in the plane ‘frequency’ versus ‘angular velocity’, is described in detail and its role in the disc brake squeal problem is discussed. (© 2008 WILEY-VCH Verlag GmbH & Co. KGaA, Weinheim)     

Nonlinear dynamics of a machining system with two interdependent delays

The dynamics of turning by a tool head with two rows, each containing several cutters, is considered. A mathematical model of a process with two interdependent delays with the possibility of cutting discontinuity is analyzed. The domains of dynamic instability are derived, and the influence of technological parameters on system response is presented. The numeric analysis show that there exists specific conditions for given regimes in which one row of cutters produces an intermittent chip form while the other row produces continuous chips. It is demonstrated that the contribution of parametric excitation by shape roughness of an imperfect (unmachined) cylindrical workpiece surface is not substantial due to the special filtering properties of cutters that are uniformly distributed circumferentially along the tool head.     

The stability of linear periodic Hamiltonian systems under non-Hamiltonian perturbations

A definition of strong stability and strong instability is proposed for a linear periodic Hamiltonian system of differential equations under a given non-Hamiltonian perturbation. Such a system is subject to the action of periodic perturbations: an arbitrary Hamiltonian perturbation and a given non-Hamiltonian one. Sufficient conditions for strong stability and strong instability are established. Using the linear periodic Lagrange equations of the second kind, the effect of gyroscopic forces and specified dissipative and non-conservative perturbing forces on strong stability and strong instability is investigated on the assumption that the critical relations of combined resonances are satisfied.     

Hopf bifurcation for delay differential equation with application to machine tool chatter

In the machining process, unstable self-excited vibrations known as regenerative chatter can occur, causing excessive tool wear or failure, and a poor surface finish on the machined workpiece, hence the relevant measures must be taken to predict and avoid this phenomenon of instability. In this paper, we propose a weakly nonlinear model with square and cubic terms in both structural stiffness and regenerative terms, to represent self-excited vibrations in machining. It is proved that Hopf bifurcation exists when bifurcation parameter equals a critical value, a formula for determining the direction of the Hopf bifurcation and the stability of bifurcating periodic solutions are given by using the normal form method and center manifold theorem. Numerical simulations show excellent agreement with the theoretical results.     

大位移Timoshenko转轴三维耦合动力学分析

对于高速柔性转轴,综合考虑滑移、弯曲、剪切变形、旋转惯性、陀螺效应和动不平衡等因素,运用Timoshenko旋转梁理论,给出弹性体空间运动的一般性描述,通过Hamilton原理建立弯曲-扭转-轴向三维耦合非线性动力学方程,应用参数摄动方法和假设振型方法进行化简,并用数值模拟分析了轴向刚性滑移、剪切变形、截面尺寸和转速等因素对转轴动力学响应的影响。     

On the instability of elastic shells as the manifestation of internal resonance

A large number of internal resonances, sensitivity to small imperfections and to a small external non-conservative action are characteristic for a number of elastic shells subjected to conservative forces. It is shown that, in combination, these three features result in dynamic instability of a system, that manifests itself in the existence of a solution of the explosive instability type when the deviation from the equilibrium state becomes infinitely large in a finite time. A simple method is proposed to calculate the ultimately allowable load by which one should be guided in designing structures containing thin shells. This load calculated by a linear model corresponds to the appearance of the first internal resonance in the system. The results are illustrated by well-known experimental facts.     

Dynamic modeling and analysis of rotating FG beams for capturing steady bending deformation

A dynamic analysis of rotating functionally gradient (FG) beams is presented for capturing the steady bending deformation by using a novel floating frame reference (FFR) formulation. Usually, the cross section of bending beams should rotate round the point at the neutral axis while centrifugal inertial forces are supposed to act on centroid axis. Due to material inhomogeneity of FG beams, centroid and neutral axes may be in different positions, which leads to the eccentricity of centrifugal forces. Thus, centrifugal forces can be divided into three componets: transverse component, axial component and force moment acting on the points of the neutral axis, in which transverse component and force moment can make the beam produce the steady bending deformation. However, this speculation has not been presented and discussed in existing literatures. To this end, a novel FFR formulation of rotating FG beams is especially developed considering centroid and neutral axes. The FFR and its nodal coordinates are used to determine the displacement field, in which kinetic and elastic energies can be accurately formulated according to centroid and neutral axes, respectively. By using the Lagrange's equations of the second kind, the nonlinear dynamic equations are derived for transient dynamics problems of rotating FG beams. Simplifying the nonlinear dynamic equations obtains the equilibrium equations about inertial and elastic forces. The equilibrium equations can be solved to capture the steady bending deformation. Based on the steady bending state, the nonlinear dynamic equations are linearized to obtain eigen-frequency equations. Transient responses obtained from the nonlinear dynamic equations and frequencies obtained from the eigen-frequency equations are compared with available results in existing literatures. Finally, effects of material gradient index and angular speed on the steady bending deformation and vibration characteristics are investigated in detail.     

Magneto-Structural analysis of rotating electrical machines

The vibrations of the stator core of a rotating electrical machine induce acoustic noise. These oscillations of the stator yoke are excited of the force density due to the magnetic field in the air gap. This requires a transient magnetic field analysis coupled with a dynamic mechanical analysis. Coupling these two different physical fields results in a high numerical effort and usually one direction of the interaction is disregarded. This paper presents a method to calculate the vibrations of a stator core under design operating conditions. For this purpose, harmonic electromagnetic excitation forces have been calculated in a linear magnetic field analyses using the finite element method. The resulting forces have been applied to a linear structural dynamic FE model in the frequency domain. The results of the calculations are harmonic velocities specified by amplitude and phase from the structural surface of the stator core. (© 2016 Wiley-VCH Verlag GmbH & Co. KGaA, Weinheim)     

双层柱壳在流场中辐射声场压力的解析解

应用Donnell壳体理论,对加强内外壳体的横向构件,利用交界面的变形协调条件,等价为作用在壳体上的反力和反力矩,把双层柱壳振动辐射声场压力的求解,归结为求解结构动力方程、流场Helmholtz方程、流体和结构交界面上连续性条件组成的声-流体-结构的耦合振动方程.通过复杂的求解方法,可直接求得双层柱壳近场声压.     

The stability of the boundary layer on a compliant rotating disc

The boundary layer over a infinite rotating disc is 3D and offinite depth. The breakdown and eventual transition of flowover the surface is preceded by the emergence of crossflow vorticesthat are stationary with respect to the disc. These result froman inviscid instability mechanism associated with an inflexionpoint within the boundary layer's velocity profile or a mechanisminduced by the balance between viscous and Coriolis forces.It has been seen in past studies that compliance can substantiallypostpone the onset of transition, therefore the aim of thisresearch is to investigate whether compliance can be used asa useful tool to do so here. We use numerical and asymptoticmethods to predict possible behaviour by calculating growthrates and producing neutral solutions for the wave number andorientation of both inviscid and viscous modes. The resultsobtained suggest that the inviscid mode of instability willbe stabilized by compliance but the viscous mode will be greatlydestabilized.     

Implementation of a cohesive zone model for the investigation of the dynamic behavior of a rotating shaft with a transverse crack

The influence of a transverse crack on the vibration of a rotating shaft has been at the focus of attention of many researchers. The knowledge of the dynamic behavior of cracked shaft has helped in predicting the presence of a crack in a rotor. Here, the changing stiffness of the cracked shaft is investigated based on a cohesive zone model. This model is developed for mode-I plane strain and accounts for triaxiality of the stress state explicitly by using basic elastic-plastic constitutive relations. Then, the proposed numerical solution is compared to the switching crack model, which is based on linear elastic fracture mechanics. The cohesive zone model is implemented in finite element techniques to predict and to analyse the dynamic behavior of cracked rotor system. Timoshenko beam theory is used to model the discrete shaft under the effect of gravity, unbalance force and gyroscopic effect. The analysis includes the cohesive function for describing the breathing crack and the reduction of the second moment of area of the element at the location of the crack. (© 2010 Wiley-VCH Verlag GmbH & Co. KGaA, Weinheim)     

Vibration reduction in ultrasonic machine to external and tuned excitation forces

The dynamic response of mechanical and civil structures subject to high-amplitude vibration is often dangerous and undesirable. Sometimes controlled vibration is desirable as in ultrasonic machining (USM). Ultrasonic machining (USM) is the removal of material by the abrading action of grit-loaded liquid slurry circulating between the workpiece and a tool vibrating perpendicular to the workface at a frequency above the audible range. A high-frequency power source activates a stack of magnetostrictive material, which produces a low-amplitude vibration of the toolholder. This motion is transmitted under light pressure to the slurry, which abrades the workpiece into a conjugate image of the tool form. This can be achieved via passive and active control methods. In this paper, multi-tool techniques are used in the ultrasonic machining via reducing the vibration in the tool holder and providing reasonable amplitudes for the tools represented by the absorbers. The coupling of the tool holder and absorbers simulating ultrasonic cutting process are investigated. This leads to a multi-degree-of-freedom system subject to external and tuned excitation forces. Multiple scale perturbation method is applied to obtain the solution up to the second order approximation. Different resonance cases are reported and studied numerically. The stability of the system is investigated applying both phase-plane and frequency response techniques. The effects of the different parameters of the absorbers on the system behavior are studied numerically. Comparison with the available published work is reported.     

A priori error analysis of two force-based atomistic/continuum models of a periodic chain

The force-based quasicontinuum (QCF) approximation is a non-conservative atomistic/continuum hybrid model for the simulation of defects in crystals. We present an a priori error analysis of the QCF method, applied to a one-dimensional periodic chain, that is valid for an arbitrary interaction range, large deformations, and takes coarse-graining into account. Our main tool in this analysis is a new concept of atomistic stress. Moreover, we formulate a new atomistic/continuum coupling mechanism based on coupling stresses instead of forces and extend the a priori analysis to this new method. We show that the new method has several theoretical advantages over the original QCF method.     

Stability analysis of an open cracked rotor with the anisotropic rotational damping in rotating operation

The damping effects with the distinction of stationary damping and the anisotropic rotating damping on the dynamic stability of the rotating rotor with an open crack on the surface of the shaft is studied. The motion equations of the cracked rotor system are formed by Lagranges principal. Different from previous studies, the anisotropic system with the multi periodical varied coefficients is simplified by the moving frame method such that the stability analysis based on the root locus method can be applied. The corresponding Campbell diagram, decay rate plot and roots locus plot are derived to prove the destabilizing influence of both the rotational damping and the varied anisotropy ratio of the rotating damping. The effects of anisotropy of stiffness on the decisions of the critical range are also presented. The result with theoretical precision would not only generally provide practical applicability to crack detection and instability control of the heavy loading turbo-machinery system, but also give the suggestion that, the increased proportion and the aggravated anisotropy of the rotational damping due to the crack of the fatigue rotor should been taken into consideration on the modeling of cracked rotor system.     

Thermoactive vibration control of shafts

Flexible long‐span rotating shafts exhibit flutter instability conditioned by internal friction in bending at high rotation speeds. Under usual working conditions a shaft may be additionally subjected to external excitations related to unbalance forcing or edge bearing movements. Flutter occurs at angular speeds exceeding the lowest natural frequency of the shaft as a nonrotating beam. Thus, externally excited resonances mostly appear in the subcritical speed zone although they can interact with flutter vibration as well. The present paper is concerned with resonant vibration control of shafts based on application of thermoactive SMA components in composite shaft structures, as conceptually shown in [1]. The well known unique properties of SMAs consisting in huge changes of the elastic modulus and its loss factor as results of a reversible martensitic phase transformation under slight temperature variations [2] promise to control shaft vibrations through temperature‐induced modal modifications of the structure. The main resonance of a simply supported rotating shaft is considered to be controlled by open‐loop SMA activation. Efficiency of thermoactive vibration control is analysed and a concept of an intelligent self‐controlled shaft structure is introduced. Geometric nonlinearity is assumed in modelling and computer simulations to show the thermoactive resonance suppression including the case when both externally excited and flutter vibrations interact.     

Flexural Vibrations of Shafts with Delaminations

The purpose of this theoretical work is to present a general model of laminated rotating shaft with circumferential delaminations. The shaft is treated as a thin‐walled composite cylindrical shell. The delamination of constant width is parallel to the shell reference surface and it covers the entire circumference. The edge delamination is modeled by changing the effective reduced stiffnesses of debonded parts. The stabilizing effect of external damping and destabilizing effect of internal damping are taken into account in the dynamic stability analysis. The influence of the relative delamination length and configuration on the critical angular velocity of shaft is shown.     

Stabilitätsbetrachtungen im Ljapunowschen Sinn bei rotierenden,einfach besetzten Wellen unter periodischer Belastung

Summary Stability problems of rotating shafts are usually solved by linearization without investigating the influence of nonlinearity, and in most cases persistant disturbances are not taken into account. The present paper makes a contribution to these questions. For this purpose a shaft with one disk under different boundary conditions and periodic loading is considered. If the mass of the shaft is neglected a system with two degrees of freedom has to be treated. Therefore application of Liapunov's ideas and its generalizations is possible. Stability can be determined easily by linear approximation after introducing damping forces.     

Size-dependent dynamic analysis of rectangular nanoplates in the presence of electrostatic,Casimir and thermal forces

In the present study by considering the small-scale effects, the dynamic instability of fully clamped and simply supported nanoplates is studied in the attendance of electrostatic, Casimir as well as thermal forces. To this end, by applying the nonlocal elasticity theory of Eringen along with the classical plate theory, the dynamic equilibrium equation of nanoplates is obtained by incorporating the in-plane thermal and transverse intermolecular distributed loads. The solution of the obtained nonlinear governing equation is done using the Galerkin method and the dynamic pull-in instability voltage of the nanoplates is compared with the available experimental results. Finally, the simultaneous effects of thermal force as well as nonlocal parameter on the dynamic response of nanoplates are examined in the presence of Casimir force in detail.