Diagnostics-based Approach to Vibration Surveillance during High Speed Milling of Flexible Details

The paper concerns vibration surveillance during ball end milling of curved flexible details and considering assurance of parameters of a modal subsystem. Here is explained dynamic analysis of non-stationary vibrating system, from which are separated subsystems: modal, structural and connective. Minimising vibration level by matching the spindle speed to optimal phase shift has been employed. Two alternatives of the approach have been developed. The first one is based on generalised condition of optimum spindle speed and relates to diagnosis of chatter vibration with only one detected frequency. The second approach concerns a few harmonic components having different frequencies. Obtained results of production experiments proved a meaning of the approaches. (© 2009 Wiley-VCH Verlag GmbH & Co. KGaA, Weinheim)     

Spindle Speed Variation for the Suppression of Regenerative Chatter

Summary. A phenomenon commonly encountered during machining operations is chatter. It manifests itself as a vibration between workpiece and cutting tool, leading to poor dimensional accuracy and surface finish of the workpiece and to premature failure of the cutting tool. A chatter suppression method that has received attention in recent years is the spindle speed variation method, whereby greater widths of cut are achieved by modulating the spindle speed continuously. By adapting existing mathematical techniques, a perturbative method is developed in this paper to obtain finite-dimensional equations in order to systematically study the mechanism of spindle speed variation for chatter suppression. The results indicate both modest increase of stability and complex nonlinear dynamics close to the new stability boundary. The method developed in this paper can readily be applied to any other system with time-delay characteristics.     

Vibration surveillance during milling of flexible details with a use of the optimal control

The paper concerns vibration surveillance during ball end milling of curved flexible details. Here is explained dynamic analysis of non-stationary vibrating system, from which are separated subsystems: modal, structural and connective. An assessment of coincidence of the calculation model results with those from investigation on milling machine is performed. Ball end milling of flexible details is observed very frequently in case of modern machining centres. It is obvious that tool-workpiece relative vibration plays principal role during cutting process. The most important task is to create a FE-model of machined flexible detail and obtain its good correlation with the results of experimental modal analysis. (© 2009 Wiley-VCH Verlag GmbH & Co. KGaA, Weinheim)     

Adaptive network-based fuzzy inference system with leave-one-out cross-validation approach for prediction of surface roughness

The prediction of surface roughness is a challengeable problem. In order to improve the prediction accuracy in end milling process, an improved approach is proposed to model surface roughness with adaptive network-based fuzzy inference system (ANFIS) and leave-one-out cross-validation (LOO-CV) approach. This approach focuses on both architecture and parameter optimization. LOO-CV, which is an effective measure to evaluate the generalization capability of mode, is employed to find the most suitable membership function and the optimal rule base of ANFIS model for the issue of surface roughness prediction. To find the optimal rule base of ANFIS, a new “top down” rules reduction method is suggested. Three machining parameters, the spindle speed, feed rate and depth of cut are used as inputs in the model. Based on the same experimental data, the predictive results of ANFIS with LOO-CV are compared with the results reported recently in the literature and ANFIS with clustering methods. The comparisons indicate that the presented approach outperforms the opponent methods, and the prediction accuracy can be improved to 96.38%. ANFIS with LOO-CV approach is an effective approach for prediction of surface roughness in end milling process.     

A contribution to the mathematical analysis of variable spindle speed machining

It has been observed that the critical depth of cut in single-point machining can be increased by continuously varying the spindle speed.Several more experimentally oriented analyses have confirmed this observation. Theoretical models have been set up but in general do not confirm the experimentally obtained results.The analysis presented here, although starting from a different point of view, confirms some of the work by Sexton et al. It further yields detailed supplementary information, particularly concerning the nature of the chatter vibration under variable spindle speed and the dependence of the process on the amplitude of the speed variation. These results are illustrated by some specific experimental evidence.     

基于卷积神经网络的智能制造过程质量异常诊断

针对现有方法在智能制造过程中诊断能力有限和识别精度不高的问题,提出了一种与智能制造过程相适应的基于卷积神经网络的质量异常诊断模型。首先建立基于实时数据的过程质量图谱,以精准表达制造过程运行状态。其次,构建用于识别质量图谱的卷积神经网络诊断模型。最后,利用滑动窗口取值的方式对当前过程运行状态进行动态诊断,并通过某球磨过程验证了所提方法的有效性与实用性。结果表明,所提方法优于传统浅层模型,能够有效的对过程异常状态进行识别与诊断。     

Effects of bearing clearance on the chatter stability of milling process

In the present study, the influences of the bearing clearance, which is a common fault for machines, to the chatter stability of milling process are examined by using numerical simulation method. The results reveal that the presence of bearing clearance could make the milling process easier to enter the status of chatter instability and can shift the chatter frequency. In addition, the spectra analysis to vibration signals obtained under the instable milling processes show that the presence of bearing clearance could introduce more frequency components to the vibration responses but, however, under both the stable and instable milling processes, the generated frequency components will not violate the ideal spectra structures of the vibration responses of the milling process, which are usually characterized by the tooth passing frequency and its associated higher harmonics for the stable milling process and by the complex coupling of the tooth passing frequency and the chatter frequency for the instable milling process. This implies that, even under the case with bearing clearance fault, the stability of the milling process can still be determined by viewing the frequency spectra of the vibration responses. Moreover, the phenomena of the chatter frequency shift and the generation of more components provide potential ways to detect the bearing clearance in machines.     

Use of the time-of-flight mass spectrometer to study the volatile products from mechanical degradation of polymers in a vibration grinder

Problems about the use of the mass-spectrometry method to study the compositions and kinetics of evolution of volatile products formed during the process of mechanical degradation of polymers in a vibration grinder are examined. A vibration ball mill was directly connected to the vacuum chamber of a time-of-flight mass analyzer. By use of this method, mass spectra of the volatile products evolved during vibration grinding of samples of polymethyl methacrylate, polytetrafluoroethylene, polyethylene, and poly-α-methylstyrene have been obtained. The possibility of studying the kinetics of evolution of volatile products as a function of the amplitude and duration of grinding has been shown in the case of polymethyl methacrylate and of polytetrafluoroethylene.     

Study on frequency response and bifurcation analyses under primary resonance conditions of micro-milling operations

Avoidance of resonance in fluctuation of milling tool is vital for reaching excellence quality and performance of the cutting operation. The cutting tool in resonance condition vibrates with considerable magnitude that causes to increase milling tool wear and manufacturing prices. Analytical study of primary resonances and bifurcation behavior of a micro-milling process, including structural nonlinearities, gyroscopic moment, rotary inertia, velocity-dependent process damping, static and dynamic chip thickness, is chief aim of this article. The milling tool is modeled as a 3-D spinning cantilever beam that is motivated by cutting forces. To get the analytical solution for frequency response function and bifurcation behavior of the system under primary resonances, the method of multiple scales is operated on converted ordinary differential equations that are obtained by applying assumed modes method on nonlinear partial differential equations of tool vibration. The effects of different process parameters and nonlinear terms on the frequency response of the tool tip oscillations are examined. In addition, the effects of detuning parameter and damping ratio on the bifurcation and behavior of the limit cycle under primary resonances are examined. The results shows that these parameters are the bifurcation parameters and Neimark, symmetry breaking, flip, and period-3 bifurcations occur when the detuning parameter is varied.     

Delay equations with fluctuating delay related to the regenerative chatter I: reduced bifurcation equation

The mathematical models representing machine tool chatter dynamics have been cast as differential equations with delay. The suppression of regenerative chatter by spindle speed variation is attracting increasing attention. In this paper, we study nonlinear delay differential equations with periodic delays which models the machine tool chatter with continuously modulated spindle speed. The explicit time-dependent delay terms, due to spindle speed modulation, are replaced by state dependent delay terms by augmenting the original equations. The augmented system of equations is autonomous and has two pairs of pure imaginary eigenvalues without resonance. The reduced bifurcation equation is obtained by making use of Lyapunov–Schmidt Reduction method.     

Fracture toughness investigations on UHPC by spalling tests

Ultra High Performance Concrete (UHPC) is defined as a new generation of concrete which shows improved performance and higher strength than traditional concrete. This allows to realize slender and much more durable structures and in this way significantly reduces the required resources. Despite its huge potential in construction, technical information about this new type of material is still limited. This contribution presents investigations on the dynamic mechanical behavior and properties of UHPC specimens by spalling experiments. Two different recipes were used to compare the properties. Due to the special specimen geometry (slender cylindrical) a flowable consistency was required to enable a sufficient degassing of the mixtures. For the test, a Split Hopkinson Pressure Bar (SHPB) has been modified and used. A high speed photograph system was focused on the fragmentation process during the test. On the basis of these experiments the dynamic E-moduli as well as the dynamic tensile strength of the UHPC specimens were determined. By observation of the specific crack patterns on each tested specimen and corresponding times, the dynamic fracture energy is calculated. Numerical simulations also were performed and compared to the experimental result. It is concluded that the dynamic tensile strength of the UHPC increases at higher strain rates. The results of the current study provide technical information about fracture and dynamic behavior of UHPC and the obtained values could be used for future computational models. (© 2014 Wiley-VCH Verlag GmbH & Co. KGaA, Weinheim)     

浅水亚临界航速舰船水压场计算方法研究

基于浅水波动势流理论和薄船假定,建立了浅水亚临界航速舰船水压场理论数学模型．采用有限差分方法,对浅水亚临界航速舰船水压场分布特征进行了数值计算．分析了航道岸壁、Froude数、色散效应对舰船水压场的影响,利用虚拟长度法改善了计算结果．通过与源汇分布法、Fourier积分变换法以及实验结果进行比对,验证了所建立的舰船水压场数学模型和计算方法的正确性．     

A surveillance of structural oscillations of industrial robots using optimal control at energy performance index

Here is considered vibration of non-stationary carrying system of the IRb-6 robot. For a use of vibration surveillance an algorithm of modal control at energy performance index in the frequency domain has been applied. Purpose of the algorithm proposed is to minimise vibration amplitude of manipulating ends, and thus – to increase capacity of modern robot lines as well as, improve accuracy and repeatability of robot positioning. (© 2009 Wiley-VCH Verlag GmbH & Co. KGaA, Weinheim)     

非线性系统动态响应的数值计算方法

文[9]曾将一种模态综合技术推广到非线性系统的动态响应分析,应用于线性子结构具有非线性连接件耦合系统的振动分析.本文进一步把模态综合技术推广到各子结构具有非线性特性大型复杂结构的动态分析.文末给出的算例表明本方法具有良好的精确度和很高的计算效率.     

变速度轴向运动粘弹性梁的动态稳定性

研究速度变化的轴向运动粘弹性梁在亚谐波共振及组合共振范围内的参数振动．通过平均法,在运动参数激励频率为2倍固有频率或为两阶固有频率之和附近时得到了自治的常微分方程组．在参数激励频率和激励振幅平面上,可以找到由于共振而产生的失稳区域,并应用数值方法验证了理论推导结果的正确性．分析了粘弹性阻尼,速度和预紧张力对失稳区域的影响．粘弹性阻尼使得共振失稳区域减小,而速度和预紧张力使共振失稳区域在频率-振幅平面上发生漂移．     

Practical stabilization for piecewise-affine systems: A BMI approach

We propose in this paper, a systematic switching practical stabilization method for PWA switched systems around an average equilibrium. For these systems, the main difficulty comes from the fact that to end in BMI formulation, it is necessary to represent the system in an augmented state space but a restricted one. However, the derived stabilizing conditions are not tractable as BMI in the restricted domain. We will present a method that overcomes this difficulty and drives asymptotically system states into a ball centered on the desired non-equilibrium reference. The efficiency of this practical stabilization method is showed by the ball smallness and the good robustness against disturbances. The design control searches for a single Lyapunov-like function and an appropriate continuous state space partition to satisfy stabilizing properties. Therefore, the method constitutes a simple systematic state feedback computation; it may be useful for on-line applications. As a direct application, satisfactory simulation results are obtained for two illustrative examples, a Buck-Boost converter and a multilevel one. Due to their functioning nature, these devices constitute good examples of switched systems. They are electrical circuits controlled by switches to produce regulated outputs despite the load disturbances and power supply irregularities.     

Heavy Ball Flexible GMRES Method for Nonsymmetric Linear Systems

Flexible GMRES (FGMRES) is a variant of preconditioned GMRES, which changes preconditioners at every Arnoldi step. GMRES often has to be restarted in order to save storage and reduce orthogonalization cost in the Arnoldi process. Like restarted GMRES, FGMRES may also have to be restarted for the same reason. A major disadvantage of restarting is the loss of convergence speed. In this paper, we present a heavy ball flexible GMRES method, aiming to recoup some of the loss in convergence speed in the restarted flexible GMRES while keep the benefit of limiting memory usage and controlling orthogonalization cost. Numerical tests often demonstrate superior performance of the proposed heavy ball FGMRES to the restarted FGMRES.     

Stochastic semidiscretization method: Second moment stability analysis of linear stochastic periodic dynamical systems with delays

In this paper, an efficient numerical approach is presented, which allows the analysis of the moment dynamics, stability, and stationary behavior of linear periodic stochastic delay differential equations. The method leads to a high dimensional stochastic mapping with periodic statistical properties, from which the periodic first and second moment mappings are derived. The application of the method is demonstrated first through the analysis of the stochastic delay Mathieu equation. Then a practical case study, where the effect of spindle speed variation on the stability and the resulting surface quality of turning operations is investigated.     

考虑车辆限速区间的危险品运输网络优化

由于危险品在运输过程中存在极大的危害性,为了降低危险品运输风险,政府可以通过对不同路段设置不同的限速区间来引导危险品运输车辆的路径选择,从而导致不同的运输网络总风险和鲁棒成本。首先基于车辆限速区间的方法,构建了危险品运输网络优化的双层规划模型,上层规划以最大运输网络总风险值最小化为目标,下层规划以危险品运输企业的鲁棒成本最小化为目标;然后,设计了粒子群优化算法求解了该模型;最后,通过两个算例验证了模型和算法的有效性。计算结果表明政府部门运用车辆限速区间的方法不仅能够非常有效地降低危险品运输网络总风险,而且更具有鲁棒性和现实可操作性。