Dynamics of a stainless steel turning process by statistical and recurrence analyses

This paper explores the cutting force oscillations. Forces have been measured during the stainless steel turning. We provide the results of standard statistical analysis of the corresponding time series together with their recurrence properties. We claim that the system, which initially exhibits regular vibrations, is unstable to chaotic oscillation for some fairly larger cutting depths. This characteristic transition in the cutting dynamics can be monitored by recurrences and could have the important implications to design a new control procedure.     

Understanding root cause of stick–slip vibrations in deep drilling with drag bits

In search for the root cause of stick–slip, a mode of torsional vibrations of a drilling assembly, a linear stability analysis of coupled axial–torsional vibrations has been carried out. It has been shown that in a rotary drilling system with axial and torsional degree of freedom two distinct modes of self-excited vibrations are present: axial and torsional. These axial (torsional) modes of vibrations are due to resonance between the cutting forces acting at the bit and the axial (torsional) natural modes of drillstring vibrations. It has been demonstrated that although axial and torsional modes of vibrations do affect each other the underlying mechanisms driving these modes of vibrations are completely different. In particular, the only driving mechanism of the axial vibrations is the regenerative effect, while there are two distinct mechanisms that drive the torsional vibrations: (i) the cutting action of the bit, and (ii) the wearflat/rock interaction. Moreover, in the case of the torsional vibrations the regenerative effect plays only a secondary role. The results of the present study indicate that the axial compliance can play a stabilizing role. In particular, the stabilizing role of the axial compliance increases as the ratio of the torsional to the axial natural frequency of the drillstring vibrations decreases.     

Active control of time-delay in cutting vibration

The system dynamics of turning processes can be described by a delay differential equation. How to improve the stability and suppress the vibration of cutting is of an interesting topic. In this paper, a multiple time-delay controller is developed based on discrete optimal control method for the turning vibrations control. Numerical simulations are carried out to verify the efficiency of the controller. Results indicate the designed controller can suppress the cutting vibration efficiently and improve the stability of the cutting processes. The influence of designed time-delay and sampling time on the control performance is also discussed.     

Nonlinear Dynamics and Stability of a Machine Tool Traveling Joint

In this work, we investigate the nonlinear dynamics and stability of a machine tool traveling joint. The dynamical system considered includes contacting elements of a lathe joint and the cutting process where the onset of instability is governed by mode coupling. The equilibrium equations of the dynamical system yield a unique fixed point that can change its stability via a Hopf bifurcation. The unstable domain is primarily governed by the cutting tool location, the contact stiffness of the joint and the depth of material to be removed. Self excited vibrations due to a mode coupling instability evolve around the unstable fixed point and one or more limit cycles may coexist in the statically unstable domain. Stability and accuracy of the approximate analytical solutions are analyzed by applying Floquet analysis. Perturbation of the dynamical system with weak periodic excitation results with periodic and aperiodic solutions.     

The identification of the vibration control system parameters designed for continuous miner machines

The Continuous Miner machines are exposed to time dependent loads during normal operation of the rock cutting process. These loads cause vibrations, which have a negative influence on the whole structure of the machine. This phenomenon can be eliminated by applying passive or active vibration control systems (VCS). Generally these systems are coupled with additional elements, which provide dispersion or transfer energy. The energy thus acquired can also reinforce the intended function such as rock cutting operation in the case of mining machines. The objective of this paper is to present the method of numerical identification of VCS parameters for Continuous Miner machines. The main function of the presented system is to reduce displacement of cutting drum by using elastic element joined to machine chassis and applying appropriate algorithm of control of the angular velocity of cutting drum. The method described improves efficiency of mining and increases durability of machine. In order to determine mechanical and control parameters of VCS the genetic algorithm optimisation method conjugated with numerical modal analysis was used. Finally the transient dynamic analysis was performed for the full-scale model of Continuous Miner in order to verify VCS in normal working condition.     

Impact Dynamics in Milling of Thin-Walled Structures

The development of reliable high-speed spindles and motioncontrol systems has led to an increase in the industrial use ofhigh-speed milling. One of the primary applications of this newtechnology is the manufacture of thin-walled aluminum components foraircraft. The flexibility of the tools and workpieces, the high spindlefrequencies, and the inherent impact nonlinearities in the millingprocess can lead to complicated dynamic tool-workpieceinteractions. An experiment was constructed to study the vibrations ofa thin-walled part during milling. Time series, power spectra,autocorrelations, auto-bispectra, and phase portraits were examined.From this data, it is inferred that stiffness and damping nonlinearitiesdue to the intermittent cutting action have a pronounced effect on thedynamics of the workpiece. Delay space reconstructions and pointwisedimension calculations show that the associated motions arecharacterized by a fractal geometry. The auto-bispectra suggestquadratic phase coupling among the spectral peaks associated with thecutter frequency. A mechanics-based model with impact-nonlinearities wasdeveloped to explain the observed results. The predicted results agreewell with the experimental observations. The model predictions indicatethat aperiodic motions are possible over a large range ofcontrol-parameter values. These analytical and experimental results haveimplications for the prediction and control of vibrations in milling.     

Interaction between torsional and lateral vibrations in flexible rotor systems with discontinuous friction

In this paper, we analyze the interaction between friction-induced vibrations and self-sustained lateral vibrations caused by a mass-unbalance in an experimental rotor dynamic setup. This study is performed on the level of both numerical and experimental bifurcation analyses. Numerical analyses show that two types of torsional vibrations can appear: friction-induced torsional vibrations and torsional vibrations due to the coupling between torsional and lateral dynamics in the system. Moreover, both the numerical and experimental results show that a higher level of mass-unbalance, which generally increases the lateral vibrations, can have a stabilizing effect on the torsional dynamics, i.e. friction-induced limit cycling can disappear. Both types of analysis provide insight in the fundamental mechanisms causing self-sustained oscillations in rotor systems with flexibility, mass-unbalance and discontinuous friction which support the design of such flexible rotor systems.     

Self-excited stick–slip oscillations of drill bitsOscillations stick–slip auto-entretenues d'un outil de forage

This Note studies the self-excited stick–slip oscillations of a rotary drilling system with a drag bit, using a discrete model which takes into consideration the axial and torsional vibration modes of the bit. Coupling between these two vibration modes takes place through a bit-rock interaction law which accounts for both frictional contact and cutting processes at the bit-rock interface. The cutting process introduces a delay in the equations of motion which is ultimately responsible for the existence of self-excited vibrations, exhibiting stick–slip oscillations under certain conditions. To cite this article: T. Richard et al., C. R. Mecanique 332 (2004).     

Fast parametrically excited van der Pol oscillator with time delay state feedback

We investigate the effect of a fast vertical parametric excitation on self-excited vibrations in a delayed van der Pol oscillator. We use the method of direct partition of motion to derive the main autonomous equation governing the slow dynamic in the vicinity of the trivial equilibrium. Then, we apply the multiple scales method on this slow dynamic to derive a second-order slow flow system describing the modulation of slow dynamic. In particular we analyze the slow flow to obtain the effect of a fast excitation on the regions in parameter space where self-excited vibrations can be eliminated. We have shown that in the case where the time delay and the feedback gains are imposed, fast vertical parametric excitation can be an alternative to suppress undesirable self-excited vibrations in a delayed van der Pol oscillator.     

Effect of normal vibrations of a flat horizontal heater on the second boiling crisis

The effect of normal vibrations of a flat horizontal heater on the second boiling crisis is considered within the framework of the hydrodynamic theory of boiling crises. The critical heat flux is estimated by characteristics of growth of the most dangerous disturbances destroying the liquid-vapor interface. As the vibration intensity increases, the interface can be destroyed either owing to the Rayleigh-Taylor instability or by virtue of parametrically excited disturbances with wavelengths corresponding to resonance zones. In the domain of parameters where the parametric instability in the first resonance zone is the most dangerous factor, it is possible to significantly reduce the critical heat flux, as compared with the value corresponding to the case with no vibrations. With a further increase in vibration intensity, the critical heat flux increases as a whole. The nonmonotonic character of the critical heat flux as a function of vibration intensity allows an effective control of the critical heat flux whose value can be made higher or lower than the value in the case without vibrations. __________ Translated from Prikladnaya Mekhanika i Tekhnicheskaya Fizika, Vol. 47, No. 4, pp. 88–97, July–August, 2006.     

Infinite dimensional slow modulations in a well known delayed model for cutting tool vibrations

We apply the method of multiple scales (MMS) to a well-known model of regenerative cutting vibrations in the large delay regime. By “large” we mean the delay is much larger than the timescale of typical cutting tool oscillations. The MMS up to second order, recently developed for such systems, is applied here to study tool dynamics in the large delay regime. The second order analysis is found to be much more accurate than the first order analysis. Numerical integration of the MMS slow flow is much faster than for the original equation, yet shows excellent accuracy in that plotted solutions of moderate amplitudes are visually near-indistinguishable. The advantages of the present analysis are that infinite dimensional dynamics is retained in the slow flow, while the more usual center manifold reduction gives a planar phase space; lower-dimensional dynamical features, such as Hopf bifurcations and families of periodic solutions, are also captured by the MMS; the strong sensitivity of the slow modulation dynamics to small changes in parameter values, peculiar to such systems with large delays, is seen clearly; and though certain parameters are treated as small (or, reciprocally, large), the analysis is not restricted to infinitesimal distances from the Hopf bifurcation.     

Influence of the resonator angular displacements in a hemispherical resonator gyro on the coupling between the working and beam-type vibrations

In [1], we have studied how the coupling between the working and beam type vibrations of the resonator affects the hemispherical resonator gyro operation. We show that such a coupling arises if the resonator is unbalanced. The beam type vibrations are considered as translational displacements of the resonator hemisphere in the plane orthogonal to the symmetry axis. In the present paper, we take into account the fact that the hemisphere translational displacement is accompanied by its rotation about the axis perpendicular to the displacement line. We show that in this case a more accurate balancing of the resonator is required to eliminate the coupling between the two vibration modes.     

Vibrations of mechanical systems with energy dissipation hysteresis

A phenomenological approach which we refer to as kinematic is proposed to describe hysteresis; according to this approach, the force and kinematic parameters of a mechanical system are related by a first-order ordinary differential equation. The right-hand side is chosen in the class of functions ensuring the asymptotic approach of the solution to the curves of the enveloping (limit) hysteresis cycle of steady-state vibrations. The coefficients of the equation are identified by experimental data for the enveloping cycle. The proposed approach permits describing the hysteresis trajectory under the conditions of unsteady vibrations with an arbitrary starting point inside the region of the enveloping cycle. As an example, we consider the problem on forced vibrations of a pendulum-type damper of low-frequency vibrations.     

A review of development and implementation of an active nonlinear vibration absorber

Summary We present an account of an implementation of an active nonlinear vibration absorber that we have developed. The control technique exploits the saturation phenomenon that is known to occur in quadratically-coupled multi-degree-of-freedom systems subjected to primary excitation and possessing a two-to-one internal resonance. The technique is based on introducing an absorber and coupling it with the structure through a sensor and an actuator, where the feedback and control signals are quadratic. First, we consider the case of controlling the vibrations of a single-degree-of-freedom system. We develop the equations governing the response of the closed-loop system and use the method of multiple scales to obtain an approximate solution. We investigate the performance of the control strategy by studying its steady-state and transient characteristics. Additionally, we compare the performance of the quadratic absorber with that of a linear absorber. Then, we present theoretical and experimental results that demonstrate the versatility of the technique. We design an electronic circuit to emulate the absorber and use a variety of sensors and actuators to implement the active control strategy. First, we use a motor and a potentiometer to control the vibration of a rigid beam. We develop a plant model that includes Coulomb friction and demonstrate that the closed-loop system exhibits the saturation phenomenon. Second, we extend the strategy to multi-degree-of-freedom systems. We use PZT ceramics and strain gages to suppress vibrations of flexible steel beams when subjected to single- and simultaneous two-mode excitations. Third, we employ Terfenol-D, a nonlinear actuator, and accelerometers to control the vibrations of flexible beams. In all instances, the technique is successful in reducing the response amplitude of the structures. Received 3 May 1999; accepted for publication 3 June 1999     

Nonlinear dynamics of a regenerative cutting process

We examine the regenerative cutting process by using a single degree of freedom nonsmooth model with a friction component and a time delay term. Instead of the standard Lyapunov exponent calculations, we propose a statistical 0-1?test analysis for chaos detection. This approach reveals the nature of the cutting process signaling regular or chaotic dynamics. For the investigated deterministic model, we are able to show a transition from chaotic to regular motion with increasing cutting speed. For two values of time delay showing the different response, the results have been confirmed by the means of the spectral density and the multiscaled entropy.     

An influence of temperature on reconstructed middle ear with shape memory prosthesis

In the paper idea of reconstructed middle ear with a prosthesis made of shape memory alloy is proposed. The new design of shape memory prosthesis is used to enable adjusting its length to individual patient’s needs which is a novel contribution of the paper. In order to make a proper fit of prosthesis, a surgeon has to adjust its size and position by cutting step by step classical prosthesis. It takes time of a operation and enlarges a period of patient’s esthesia. Therefore, a shape memory prosthesis (SMP) is proposed to shorten operation time and improve fitting through precisely selected length. A reconstructed middle ear is modelled as a two degree of freedom system with nonlinear shape memory element. Finding advisable periodic and undesirable a periodic and irregular behaviour in various temperature is the main aim of the paper. Results of the study should give an answer whether SMP can be useful in medical practice and should also explain dynamics of the middle ear with SMP. The properties of the shape memory prosthesis, in the form of helical spring, are described here by a polynomial dependence. Firstly, free vibrations are investigated and equilibrium points, next forced vibrations are studied under different parameters of external excitations and temperature range. Bifurcation analysis and stability of periodic solutions are performed in order to reveal the system behaviour. Finally, interesting dynamical findings of chaotic vibrations pure regular and regular oscillations with fluctuation are presented. However, from practical point of view only harmonic response of the stapes is advisable. That can be achieved at the normal temperature of a human body only for small excitation amplitude.     

Chaotic vibrations in high-speed milling

A large number of literatures are devoted to the stability of the milling process and various control methods for chatter suppression. But chaotic dynamics beyond the stable region has not been considered extensively. Moreover, modeling issues for chaotic motion need more challenge for accurate prediction of its complex dynamical behavior. This paper presents a detailed two-degree-of-freedom mechanics based model for the study of chaotic vibrations in milling. Segmental multiple regenerative effect that is the principle feature of nonlinear vibrations in milling processes besides two state dependent time delays has been considered. Exact geometrical formulation of multiple regenerative effects by considering simultaneously different numbers of delayed tool positions over the cutting zone is presented for the first time. Phase portrait, bifurcation diagram, largest Lyapunov exponent, and surface profile were calculated for a given machine tool and workpiece parameters. The simulation results show positive values of the largest Lyapunov exponent corresponding to the existence of chaos in high-speed milling operations. Also, investigation of the machined surface of the workpiece formed by the helical mill demonstrates an irregular pattern on the surface.     

Elastic bending vibrations of a rod carrying electric current

In [1] a dispersion relation for the vibrations of an elastic rod of circular cross section with an electric current flowing over its surface was obtained, and a detailed study was made of the particular case of axially symmetric vibrations. The present paper is devoted to an examination of the longwave bending vibrations of elastic rods with an electric current flowing over their surface. These vibrations are of special interest since they have the lowest frequency and hence the last stability.     

Eigenfrequencies of the three dimensional euler-bernoulli beam system with dissipative joints

In this paper, we will compute the transfer matrices to find the eigenfrequencies for the vibrations of the general non-collinear Euler-Bernoulli or Timoshenko beam structure with dissipative joints. We will allow the structure to be three dimensional, and thus we must consider all types of vibrations simultaneously, including longitudinal and torsional vibrations. The general structure considered will consist of any number of beams joined end to end to form a chain. Many different kinds of dampers are allowed, even within the same structure. We also will allow different materials within the structure as well as different beam widths. We then will show that asymptotic estimates can be used to find the eigenfrequencies approximately.     

Criticality of Hopf bifurcation in state-dependent delay model of turning processes

In this paper the non-linear dynamics of a state-dependent delay model of the turning process is analyzed. The size of the regenerative delay is determined not only by the rotation of the workpiece, but also by the vibrations of the tool. A numerical continuation technique is developed that can be used to follow the periodic orbits of a system with implicitly defined state-dependent delays. The numerical analysis of the model reveals that the criticality of the Hopf bifurcation depends on the feed rate. This is in contrast to simpler constant delay models where the criticality does not change. For small feed rates, subcritical Hopf bifurcations are found, similar to the constant delay models. In this case, periodic orbits coexist with the stable stationary cutting state and so there is the potential for large amplitude chatter and bistability. For large feed rates, the Hopf bifurcation becomes supercritical for a range of spindle speeds. In this case, stable periodic orbits instead coexist with the unstable stationary cutting state, removing the possibility of large amplitude chatter. Thus, the state-dependent delay in the model has a kind of stabilizing effect, since the supercritical case is more favorable from a practical viewpoint than the subcritical one.