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.     

Evolution of the resonance vibrations of an oscillator with dry friction

We study the problem of free and forced vibrations of a mechanical system modeling the functioning of seismic isolation systems of “kinematic foundation” type in the case when the sliding friction damper is not centrally located. We determine the damping characteristics in the case of free vibrations and the critical values of the damping parameter for the case of forced vibrations. For the case of resonance vibrations with one degree of freedom we establish the relation of the increase in the amplitude of the vibrations to time at subcritical values of the friction. Translated fromDinamicheskie Sistemy, Vol. 11, 1992.     

Forced vibrations of an oscillator in the presence of dry friction

We study the vibrations of an oscillator with two degrees of freedom in the presence of dry friction. We compare the nature of the damping of the free oscillations in a straight line with the general case. For the forced vibrations we determine the way in which the critical values of friction at which there exist periodic motions depend on the parameters of external action in resonance mode.Translated fromDinamicheskie Sistemy, No. 6, 1987, pp. 49–54.     

On the Effect of Contact Compliance on Vibrational Smoothing of Dry Friction

High-frequency vibrations may be utilized in order to smooth the characteristics of dry friction at low sliding velocities and, consequently, quench undesired friction induced phenomena. Many studies have been published so far, most of them using classical Coulomb friction models and yielding compact results. Unfortunately, the agreement with related experimental results is insufficient. As the Coulomb model overestimates the smoothing effect, improved modelling seems to be necessary. Based on Dahl's friction model, the effect of longitudinal and transverse high-frequency vibrations on a 1-DoF-friction oscillator is investigated here. Accounting for contact compliance, a reduction of the smoothing effect is observed. (© 2015 Wiley-VCH Verlag GmbH & Co. KGaA, Weinheim)     

A new shimmy model

Shimmy is a phenomenon of intense angular self-excited vibrations of the wheels of a carriage. Such self-excited vibrations present a serious threat to traffic safety, which accounts for the great interest of researchers in this phenomenon. The problem is of highest importance for the front wheels of aircraft. Usually, the deformation of pneumatic tires is considered to be the main factor responsible for shimmy. Without challenging this thesis, we nevertheless note that this is not the only factor. The shimmy phenomenon can be observed in everyday life in the case of various carriages that often have nothing to do with pneumatics if the wheels are rigid. Below we will show that the theory of polycomponent dry friction fully explains the shimmy phenomenon for absolutely rigid wheels and, hence, is at least one of the factors responsible for shimmy in the general case. The reason why researchers have not taken dry friction into account when explaining shimmy is that the theory of this kind of friction has not been well developed; at the same time one has failed to explain shimmy in the framework of other existing theories.     

A Wave-Based Approach to Adaptively Control Self-Excited Vibrations in Drill-Strings

Due to their small diameter-to-length-ratio, drill-strings are vulnerable to torsional vibrations. Moreover, the string is exposed to unknown or uncertain time-variant and nonlinear loads (e.g. friction with falling friction characteristics, contact with the borehole, differential sticking), which can result in severe torsional vibrations and stick-slip. The control law for the boundary controller at the top drive of the string needs to adapt to those unknown loads in order to stabilize the vibrations. The torsional vibrations of a drill-string are governed by the wave equation. Analytical solutions and control laws are often based on a separation of the dynamics into a time- and a space-dependent part (modal representation). Here, we decompose the vibrations into two traveling waves according to the D'Alembert solution, using only few measurements along the string. The wave which travels up the string is then compensated by the actuator at the top drive. With this compensation, the upward-traveling wave is no longer reflected back into the string and vibration energy is absorbed, thus stabilizing the torsional vibrations. (© 2010 Wiley-VCH Verlag GmbH & Co. KGaA, Weinheim)     

Simulation of friction phenomena between randomly rough elastic surfaces

Friction induced vibrations are a widely studied field in which the friction coefficient is one of the most important parameters. Measurements show that the friction coefficient underlies stochastic fluctuations. To gain more knowledge about the friction coefficient a finite element study is carried out in order to simulate the friction forces. The Bowden-Tabor model is implemented which calculates the friction force as the force which is needed to shear apart contact areas hold together by welding or adhesion. The dependency of the friction value on sliding velocity and normal pressure can be determined with this model. Different realization are studied and the stochastic properties of the friction value such as mean value, standard deviation, amplitude spectrum and correlation coefficient can be calculated depending on the roughness of the surface. (© 2011 Wiley-VCH Verlag GmbH & Co. KGaA, Weinheim)     

Hysteretic Friction of a Sliding Rubber Element

Friction, especially friction of elastomers, can cause acoustic problems like noise, squeal and comfort drawbacks like vibrations and wear. Therefore, rubber friction affects the function of many products in technical applications, e.g. seals, belts and tires. It can be classified according to different physical phenomena like adhesion, hysteresis, cohesion and viscous friction, see [3]. The topic of this paper is hysteresis friction of rubber that is caused by the energy dissipation due to internal material damping during the process of deformation. The deformation itself occurs during the sliding of a rubber element across the micro‐scaled asperities of a rough surface. In this paper, the sliding process of a rubber element over real surfaces is simulated in time domain and compared to experiments. (© 2004 WILEY‐VCH Verlag GmbH & Co. KGaA, Weinheim)     

Modeling of cutting force prediction in machining high-volume SiCp/Al composites

Variations in cutting forces significantly influence the tool wear and part quality in machining high-volume SiC-particle-reinforced aluminum matrix (SiCp/Al) composites. Properties of the reinforcement SiC particles, such as size and volume fraction, contribute to the change in the cutting forces. This paper presents a cutting force model based on the geometrical and mechanical nature of the tool and workpiece, considering the effect of the SiC reinforcement particles. The cutting force is predicted as three components (F_z, F_x, and F_y) and the resultant cutting force F_τs. The cutting force was considered to generate three deformed zones: (a) shear deformed zone, (b) friction deformed zone on the chip–tool interface, (c) plow deformed zone. The effect of SiC reinforcement particles on friction deformed zone is analyzed emphatically. The friction force from friction deformed zone was obtained by calculating the sliding friction force and rolling friction force. To verify the feasibility and validity of the predicted model of cutting force, cutting experiments were performed with different combinations of cutting speed, feed rate, depth of cut, and tool nose radius. The predicted cutting force values demonstrate good agreement with the measured experimental cutting force values in most cutting conditions. The average percentages of the prediction error were 1.93%, 6.20%, and 10.48% for the F_z, F_x, and F_y components, respectively, thus proving the validity and accuracy of the predicted model of cutting forces.     

Efficient Calculation of Tread Block Vibrations

A model is presented that allows to calculate the dynamics of tyre tread blocks. The numerical efficiency is achieved by the combination of static and important modal ansatz functions, also known as Hurty/Craig/Bampton transformation. Nonlinear single point contacts provide the contact forces and consider the surface roughness. The non-smooth friction characteristic is approximated an arctan function and a parameter study of the slope parameter is conducted. Typical stickslip limit cycles of the tread block are shown. These phenomena can have a part in the tyre/road noise. Experimental results qualitatively agree with the modelled tread block vibrations. (© 2006 WILEY-VCH Verlag GmbH & Co. KGaA, Weinheim)     

Identification of chaos in a cutting process by the 0–1 test

We have examined the cutting process by using a two degrees of freedom non-smooth model with a friction component. Instead of the standard Lyapunov exponent treatment a statistical ‘0–1’ test based on the asymptotic properties of a non-harmonic Brownian motion chain has been successively applied to reveal the nature of the cutting process. In this test we calculated the control parameter K which is approaching asymptotically to 0 or 1 for regular and chaotic motions, respectively. The presented approach is independent on the integration procedure as we defined a characteristic distance between the points forming the time series used in the test separately.     

On the Influence of High-Frequency Excitation on Systems with Dynamic Friction

By imposing high-frequency vibrations to a system, the characteristics of dry friction for low sliding velocities can be smoothed and, consequently, undesired friction induced phenomena such as stick-slip motion can be quenched. Many studies have been published so far, most of them focussing on the reduction of friction between metal surfaces and using classical Coulomb friction models. Within this contribution the effect of high-frequency excitation on dry friction taking into account dynamic friction models will be discussed. To this end, the friction law suggested by Dahl is used and the resulting friction characteristics are compared to those obtained for the classical Coulomb friction model. Using Dahl's friction model, a reduction of the smoothing effect is observed. (© 2014 Wiley-VCH Verlag GmbH & Co. KGaA, Weinheim)     

The Vibrational Behavior of Bladed Disks in Consideration of Friction Damping and Contact Elasticity

Rotating turbine blading is subjected to fluctuating gas forces during operation that cause blade vibrations. One of the main tasks in the design of turbomachinery blading is the reduction of the vibration amplitudes of the blades to avoid high resonance stresses that could damage the blading. The vibration amplitudes of the blades can be reduced significantly to a reasonable amount by means of friction damping devices such as underplatform dampers. In the case of blade vibrations, relative displacements between the friction damping devices and the neighboring blades occur and friction forces are generated that provide additional damping to the structure due to the dry friction energy dissipation. In real turbomachinery applications, spatial blade vibrations caused by a complex blade geometry and distributed excitation forces acting on the airfoil accur. Therefore, a three dimensional model including an appropriate spatial contact model to predict the generalized contact forces is necessary to describe the vibrational behavior of the blading with sufficient accuracy, see [1] and [2]. In this paper the contact model presented in [2] is extended to include also local deformations in the contacts between underplatform dampers and the contact surfaces of the adjacent blades. The additional elasticity in the contact influences the resonance frequency of the coupled bladed disk assembly. (© 2005 WILEY-VCH Verlag GmbH & Co. KGaA, Weinheim)     

Self-excited vibrations of deformable multibody systems due to friction: Explanation with the help of two point masses and a belt

The aim of this paper is to present the results of the investigations of the ability of self-excited vibrations due to friction in a planar simplified mechanical model, with a constant coefficient of friction. The Hurwitz criteria is used for the stability analysis and the determination of the critical value of the coefficent of friction. (© 2012 Wiley-VCH Verlag GmbH & Co. KGaA, Weinheim)     

Analysis of lumped models with contact and friction

We consider two mathematical models that describe the vibrations of spring-mass-damper systems with contact and friction. In the first model, both the contact and frictional boundary conditions are described with subdifferentials of nonconvex functions. In the second model, the contact is modeled with a Lipschitz continuous function, and the restitution force is described by a differential equation involving a Volterra integral term. The two models lead to second-order differential inclusions with and without an integral term, in which the unknowns are the positions of the masses. For each model, we prove the existence of a solution by using an abstract result for first-order differential inclusions in finite dimensional spaces. For the second model, in addition, we prove the uniqueness of the solution by using a fixed point argument. Finally, we provide examples of systems with contact and friction conditions for which our results are valid.     

Analysis of lumped models with contact and friction

We consider two mathematical models that describe the vibrations of spring-mass-damper systems with contact and friction. In the first model, both the contact and frictional boundary conditions are described with subdifferentials of nonconvex functions. In the second model, the contact is modeled with a Lipschitz continuous function, and the restitution force is described by a differential equation involving a Volterra integral term. The two models lead to second-order differential inclusions with and without an integral term, in which the unknowns are the positions of the masses. For each model, we prove the existence of a solution by using an abstract result for first-order differential inclusions in finite dimensional spaces. For the second model, in addition, we prove the uniqueness of the solution by using a fixed point argument. Finally, we provide examples of systems with contact and friction conditions for which our results are valid.     

Nonlinear dynamics of regenerative cutting processes—Comparison of two models

Understanding the nonlinear dynamics of cutting processes is essential for the improvement of machining technology. We study machine cutting processes by two different models, one has been recently introduced by Litak [Litak G. Chaotic vibrations in a regenerative cutting process. Chaos, Solitons & Fractals 2002;13:1531–5] and the other is the classic delay differential equation model. Although chaotic solutions have been found in both models, well known routes to chaos, such as period-doubling or quasi-periodic motion to chaos are not observed in either model. Careful analysis shows that the chaotic motion from the Litak’s model has sharper spectral peaks, a smaller correlation dimension and a smaller value for the largest positive Lyapunov exponent. Implications to the control of chaos in cutting processes are discussed.     

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)