Vibration analysis of rail grinding using a twin-wheel grinder

Grinding is the final process of machining a rail. Conventionally, the rail’s surfaces are ground by a single-wheel grinder. The vibrations caused by the grinding process can greatly influence the final surface roughness and dimensional accuracy of the rail. This research investigates performance achieved by using two grinding wheels simultaneously and symmetrically on two opposite surfaces of a rail. In practical terms, the feed force from the two grinding wheels cannot be aligned perfectly, and the imbalance and/or imperfect roundness of the grinding wheels will certainly result in vibrations during the grinding process. This study applies an impedance method to determine rail vibration and the grinding instability, such as chatter caused by feed force misalignment and grinding wheel imbalance. When compared to conventional single-wheel grinding, the results indicate twin-wheel grinding reduces rail vibration, leading to low incidence of grinding chatter and better grinding performance. However, feed force misalignment between the two grinding wheels can lead to increased chatter, and both resonance and chatter may occur at lower grinding speeds as feed force misalignment increases. Results also show that feed force misalignment has a greater effect on rail vibration and chatter than imbalance asynchronization between the two grinding wheels.     

Chatter in a transverse grinding process

In transverse grinding, the wheel moves along the workpiece, which induces unique grinding dynamics. To understand these dynamic phenomena, specifically the grinding chatter, a new dynamical model of the process is proposed, in which the wheel position is assumed to be quasi-static since the transverse wheel velocity is small. From the stability and bifurcation analyses of the chatter vibration, it appears that the dynamics of the process is governed by the quasi-static interactions. Moreover, the obtained results also show that the wheel and workpiece chatters are quite different, having continuous and intermittent characters respectively.     

Chatter detection in band sawing based on discriminant analysis of sound features

In the paper chatter detection in band sawing is considered as a signal processing and classification problem. A multi-sensory experimental setup was established on an industrial band saw including sound, acceleration and cutting force, and measurements. Based on an experimental analysis sound signal is shown to be the most appropriate for chatter detection, therefore a sound-based online chatter detection method is proposed. The method consists of a sound signal pre-processing with Short-Time Fourier Transform, extraction of features in frequency space with optimal threshold and application of Quadratic Discriminant Analysis for chatter detection. The proposed method tested with twofold cross validation yields over 96% success of chatter detection.     

A cantilever beam chattering against a stop

Contact chatter or bouncing of a cantilever beam with the free end pressed against a stop was studied. The problem was treated according to the Bernoulli-Euler beam theory and the resulting integral equation was solved by the small time increment technique. Deflections, contact force and chatter were calculated. The number of modes included in the solution, which depends on the fixed contact stiffness, was found to have a great effect on the fine details of chatter, but to have little effect on the overall pattern of chatter or the deflection. Deflections were measured photographically by using a multiflash strobe light and the chatter was measured with an oscilloscope. The overall chatter pattern and the deflection agreed with the calculated values remarkably well. Finally, an approximate method was developed by using kinetic energies based on the beam theory and contact open or closure times based on an equivalent mass-spring system. Kinetic energies for vibrational modes other than the fundamental mode for a propped cantilever beam (clamped-supported) were assumed to be damped out rapidly. Deflections, and the chatter pattern, based on this approximate method agreed well with the observed values. The time for the chatter to stop was also calculated, and it agreed reasonably well with the measured time.     

Dynamics of regenerative chatter and internal resonance in milling process with structural and cutting force nonlinearities

In this paper, internal resonance and nonlinear dynamics of regenerative chatter in milling process is investigated. An extended dynamic model of the peripheral milling process including both structural and cutting force nonlinearities is presented. Closed form expressions for the nonlinear cutting forces are derived through their Fourier series components. In the presence of the large vibration amplitudes, the loss of contact effect is included in this model. Using the multiple-scales approach, analytical approximate response of the delayed nonlinear system is obtained. Considering the internal resonance dynamics (i.e. mode coupling), the energy transfer between the coupled x–y modes is studied. The results show that during regenerative chatter under specific cutting conditions, one mode can decay. Furthermore, it is possible to adjust the rate at which the x-mode (or y-mode) decays by implementation of the internal resonance. Therefore, under both internal resonance and regenerative chatter conditions, it is possible to suppress the undesirable vibration of one mode (direction) in which accurate surface finish is required. Under the steady-state motion, jump phenomenon is investigated for the process with regenerative chatter under various cutting conditions. Moreover, the effects of structural and cutting force nonlinearities on the stability lobes diagram of the process are investigated.     

In-process roughness measurement on moving surfaces

A new optical technique, which utilises the combined effects of interference and light scattering, was developed for surface roughness measurements. This paper presents the technique applicable to extracting the roughness of moving surfaces under high rotational speeds up to 3.7 m/s. The applicability of the technique to in-process roughness measurement was demonstrated with a cylindrical grinding process.     

Optical testing of hard disks

A device and methodology for surface testing of hard disk blanks are presented. A beam of laser light is scanned in a spiral pattern across the disk, and surface defects are diagnosed from the modulation of the scattered light. Since acceptable polish marks also scattered significant levels of light, it was necessary to make use of the directional characteristics of the scattered light in the disk test device.     

Fuzzy stability analysis of regenerative chatter in milling

During machining, 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. Consequently it is desirable to predict, and hence avoid the onset of this instability. Regenerative chatter is a function of empirical cutting coefficients, and the structural dynamics of the machine-tool system. There can be significant uncertainties in the underlying parameters, so the predicted stability limits do not necessarily agree with those found in practice. In the present study, fuzzy arithmetic techniques are applied to the chatter stability problem. It is first shown that techniques based upon interval arithmetic are not suitable for this problem due to the issue of recursiveness. An implementation of fuzzy arithmetic is then developed based upon the work of Hanss and Klimke. The arithmetic is then applied to two techniques for predicting milling chatter stability: the classical approach of Altintas, and the time-finite element method of Mann. It is shown that for some cases careful programming can reduce the computational effort to acceptable levels. The problem of milling chatter uncertainty is then considered within the framework of Ben-Haim's information-gap theory. It is shown that the presented approach can be used to solve process design problems with robustness to the uncertain parameters. The fuzzy stability bounds are then compared to previously published data, to investigate how uncertainty propagation techniques can offer more insight into the accuracy of chatter predictions.     

Stability improvement and regenerative chatter suppression in nonlinear milling process via tunable vibration absorber

In this paper, a tunable vibration absorber set (TVAs) is designed to suppress regenerative chatter in milling process (as a semi-active controller). An extended dynamic model of the peripheral milling with closed form expressions for the nonlinear cutting forces is presented. The extension part of the cutting tool is modeled as an Euler–Bernoulli beam with in plane lateral vibrations (x–y directions). Tunable vibration absorbers in x–y directions are composed of mass, spring and dashpot elements. In the presence of regenerative chatter, coupled dynamics of the system (including the beam and x–y absorbers) is described through nonlinear delay differential equations. Using an optimal algorithm, optimum values of the absorbers' position and their springs' stiffness in both x–y directions are determined such that the cutting tool vibration is minimized. Results are compared for both linear and nonlinear models. According to the results obtained, absorber set acts effectively in chatter suppression over a wide range of chatter frequencies. Stability limits are obtained and compared with two different approaches: a trial and error based algorithm and semi-discretization method. It is shown that in the case of self-excited vibrations, the optimum absorber improves the process stability. Therefore, larger values of depth of cut and consequently more material removal rate (MRR) can be achieved without moving to unstable conditions.     

Squeal and chatter phenomena generated in a mountain bike disc brake

This paper examines squeal and chatter phenomena generated experimentally in mountain bike disc brakes. There are two kinds of frictional self-excited vibrations in the bike disc brakes, called squeal with frequency of 1 kHz and chatter with frequency of 500 Hz. In order to reproduce the squeal and chatter, a bench test apparatus using an actual bike was set up to determine the associated frequency characteristics experimentally. The results show the frequencies to be independent of pad temperature and disc rotating speed. Squeal is shown to be in-plane vibration in the direction of the disc surface which is caused by the frictional characteristics having negative slope with respect to the relative velocity in the vibrating system, which includes brake unit, spokes and hub. Chatter is generated within a limited high temperature region. Again, it is frictional vibration in which the squeal and out-of-plane vibration of the disc due to Coulomb friction combine through the internal resonance relation between in-plane and out-of-plane nonlinear vibration caused by the temperature increase of the disc during braking.     

On-line conveyor belts inspection based on machine vision

Under the background that mining conveyor belts are prone to failure in operation, the on-line fault detection technique based on machine vision for conveyor belts is investigated. High-brightness linear light sources arranged to a vaulted shape provide light for a line-array CCD camera to capture high-quality belt images. A fast image segmentation algorithm is proposed to deal belt images on-line. The algorithm for detecting longitudinal rip and belt deviation which are serious threat to the mine safety production from binary belt images is presented. Then, an on-line visual belt inspection system is developed. The laboratory testing results testify the validity of the visual inspection system.     

Chatter suppression by parametric excitation: Model and experiments

Chatter vibration leads to challenges in precise machining due to its harmful effect on productivity and surface quality. In this study, a chatter suppression method based on parametric excitation was developed. The effect of parametric excitation on self-excited vibration was investigated based on a model of a van der Pol-Mathieu-Duffing oscillator with a time delay. It reveals that there can be a zero solution for the oscillator under the effect of parametric excitation, while it is impossible to have a stable zero equation without parametric excitation. The stability of a parametrically excited vibration system regarding the regenerative effect in the cutting processes was studied by the averaging method. The stability analysis shows that parametric excitation with an appropriate frequency and large amplitude has a chatter suppression effect no matter whether the waveform is a sinusoidal wave, square wave or triangular wave. To validate the effect of parametric excitation for chatter suppression, experiments were conducted based on a magnetorheological (MR) fluid-controlled boring bar, which can generate high-frequency parametric excitation based on the quick response of the MR fluid. Cutting experiments with an excitation current of different waveforms and diverse frequencies show that chatter can be significantly suppressed by the effect of parametric excitation.     

HDP-HSMM的磨削声发射砂轮钝化状态识别*

在高精度金属材料磨削加工中,刀具即砂轮的状态对加工效率和加工质量具有重要的影响。钝化程度较高的砂轮不适于加工精密工件,需提前预警并修整更换砂轮。该文提出一种通过磨削声发射信号来检测砂轮钝化状态的方法。首先,对于采集到的信号进行小波软阈值降噪。然后,将其分割成多个有重叠的帧,并提取每帧信号的8个特征组成声发射数据集。最后,通过分层Dirichlet过程-隐半马尔可夫模型来建立声发射数据集和不同的砂轮钝化状态之间的非线性关系,旨在识别砂轮钝化状态。结果表明,上述检测方法能有效识别砂轮的不同钝化状态并能对整个加工过程中的砂轮钝化程度进行自动划分,其在测试数据集上的准确率达到93.7%,可以为实际工业应用提供理论指导。     

Efficient evaluation of process stability in milling with Spindle Speed Variation by using the Chebyshev Collocation Method

Chatter is a vibrational problem affecting machining operations, which may cause bad surface quality and damages to the machining system. In recent decades, several techniques for avoiding chatter onset were developed. Among other techniques, the continuous modulation of spindle speed during the cutting process (also called Spindle Speed Variation – SSV) has been demonstrated to be very effective for reducing the chance of chatter onset. However, spindle speed modulation parameters should be adequately chosen before machining, in order to effectively increase the material removal rate. In this perspective, chatter prediction algorithms play a crucial role, since they allow a preventive evaluation of process stability for any given spindle speed regime. State of the art algorithms for chatter prediction in milling with SSV are characterized by extremely long computation times, hindering their practical application in industry. In this paper, an innovative and fast algorithm for chatter prediction in milling with SSV, based on the Chebyshev Collocation Method, is presented. The algorithm was successfully compared with a state of the art algorithm – the Semi Discretization Method – in different experimental configurations and cutting conditions. The results showed that the new method is generally more accurate and from ten to one thousand times faster than the Semi Discretization Method.     

Sound propagation in complicated industrial enclosures

I.IntroductionInordcrtocfficlcntlyprcdictandcontro1thenoiseinindustria1enclosurcs,manypeoplehavestudicdmathmodclsforsoundpropagationinindustria1enclosurcs.Butsofar,thereisnosatisfactoryrcsult.Inthepast,a1mostal1studieswcrercstrictedtoidealemptyindustrialcnc1osurcs,andonlyafewofthcm['-']concerncdtheinfluenceofobstac1cswithinthemodel.Thcscmodc1strcattheobstac1eeffcctsbythemethod-ofimagesandcanonIybeusedtoregu-larhexahcdronroomswhcreobstaclcsareassumedtobedistributesuniformIy.Ondet'sartic1el'],…     

Surface plasmon polariton scattering by small ellipsoid particles

Scattering of surface plasmon polaritons (SPP’s) by small ellipsoid particles placed near a dielectric–metal interface is theoretically considered. Using the Green’s function formalism and the dipole approximation, we consider the differential and total scattering cross-sections associated with the SPP-to-SPP scattering as well as with the SPP scattering into waves propagating away from the interface, analyzing the influence of system parameters. As an example, scattering cross-sections of differently shaped gold spheroid particles placed near an air–gold interface are evaluated at the light wavelength of 800 nm. It is shown that the differential and total cross-sections depend strongly upon the particle-to-surface distance, the ratio between the major and minor axes and their orientation with respect to both the interface and the direction of SPP incidence. Implications of the obtained results to the design of SPP micro-optical components are also discussed.     

Height distribution on a rough plane and specularly diffracted light amplitude are Fourier transform pair

In this report we show that the amplitude of specularly diffracted light from a plane rough surface as a function of incident angle cosine is Fourier transform of the height distribution on the surface. Therefore, an even height distribution function, which is the case for many rough surfaces, can be obtained by measuring the specularly diffracted light intensities. Also, it is observed that for polychromatic illumination the spectrum of the specularly diffracted light is modified and the modification depends on roughness, incident angle, and wavelength. It is also shown that, for a fixed incident angle, the height distribution on the rough plane is Fourier transform of the spectral modifying function. Experimental studies on some surfaces of different roughnesses, prepared by grinding sheet-glasses by powders of different grain sizes, show that the corresponding height distributions are Gaussian and the rms heights obtained by the two approaches are quite consistent.     

Polarization controlled couplings of surface plasmon with asymmetrical nanoslit pairs

Light-driven surface plasmons offer an opportunity to ultrafast information processing combining the compactness of electric circuits with the bandwidth of photonic networks. For practical applications, the efficient and controllable conversion from signal light to surface plasmons is essential. This leads to the recent developments in the polarization controlled couplings of surface plasmons. Currently, most works only tailor the orientation and arrangement of nanoslits to control the launching of surface plasmons. In this paper, we consider both the orientation and size of each slit in a one-dimensional array of nanoslit dimers. We first realize the unidirectional propagation of surface plasmons with designed wavefronts. Next, the unidirectional coupling and bi-directional coupling of surface plasmons are realized for a pair of orthogonal polarizations, respectively. This is quite different from the conventional opposite propagating surface plasmons excited by two orthogonal polarizations. The manipulation of both orientation and size of nanoslits allows additional freedom in the photon-plasmon conversions.     

基于镜像焦面检测对准标记的套刻性能原位测量技术

套刻性能是现代高精度步进扫描投影光刻机的重要性能指标之一。提出了一种基于镜像焦面检测对准标记(简称“镜像焦面检测对准标记”)的光刻机套刻性能原位测量技术。该技术通过对曝光在硅片上的镜像焦面检测对准标记图形进行光学对准,利用标记图形对准位置与理想位置偏差实现套刻性能的原位检测。实验结果表明该技术在进行套刻误差的精确测量的同时还可以全面、定量地计算影响光刻机单机套刻误差的场内参量及场间参量。与目前套刻性能原位测量技术相比,该技术有效地避免了测量精度对轴向像质限制的依赖,简化了光刻机整机性能检测的过程。     

Dynamics of stainless steel turning: Analysis by flicker-noise spectroscopy

We use flicker-noise spectroscopy (FNS), a phenomenological method for the analysis of time and spatial series operating on structure functions and power spectrum estimates, to identify and study harmful chatter vibrations in a regenerative turning process. The 3D cutting force components experimentally measured during stainless steel turning are analyzed, and the parameters of their stochastic dynamics are estimated. Our analysis shows that the system initially exhibiting regular vibrations associated with spindle rotation becomes unstable to high-frequency noisy oscillations (chatter) at larger cutting depths. We suggest that the chatter may be attributed to frictional stick-and-slip interactions between the contact surfaces of cutting tool and workpiece. We compare our findings with previously reported results obtained by statistical, recurrence, multifractal, and wavelet methods. We discuss the potential of FNS in monitoring the turning process in manufacturing practice.