机床非线性颤振的描述函数分析

本文采用描述函数方法分析机床的非线性颤振.以描述函数刻划切削过程复杂的非线性特性,并将非线性振动分析所依赖的复平面推广到三维空间进行稳定性分析。从而求出颤振振幅和颤振频率。该法不仅可揭示切削过程等效刚度系数和等效阻尼系数的变化,而且还可考察各切削参数对颤振频率和振幅的影响.结果表明,描述函数方法是分析机床颤振这个极其复杂的非线性系统的一个有效的手段.     

Stability analysis of a thin-walled cylinder in turning operation using the semi-discretization method

In this work, the stability of a flexible thin cylindrical workpiece in turning is analyzed. A process model is derived based on a finite element representation of the workpiece flexibility and a nonlinear cutting force law. Repeated cutting of the same surface due to overlapping cuts is modeled with the help of a time delay. The stability of the so obtained system of periodic delay differential equations is then determined using an approximation as a time-discrete system and Floquet theory. The time-discrete system is obtained using the semi-discretization method. The method is implemented to analyze the stability of two different workpiece models of different thicknesses for different tool positions with respect to the jaw end. It is shown that the stability chart depends on the tool position as well as on the thickness.     

Stability analysis for milling process

In this article, the stability of a milling process is studied by using a semi-discretization method. The model of the workpiece–tool system includes loss-of-contact effects between the workpiece and the tool and time-delay effects associated with the chip-thickness variation. In addition, feed-rate effects are also considered. The governing system of equations is a non-autonomous, delay-differential system with time-periodic coefficients. Stability of periodic orbits of this system is studied to predict the onset of chatter and numerical evidence is provided for period-doubling bifurcations and secondary Hopf bifurcations. Stability charts generated using the semi-discretization method are found to compare well with the corresponding results obtained through time-domain simulations.     

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.     

A Mechanics Based Model for Study of Dynamics of Milling Operations

A unified mechanics based model with multiple degrees of freedom is developed and numerically simulated to study workpiece-tool interactions during milling of ductile workpieces with helical tools. A refined orthogonal cutting model is used at each section of the tool, and the milling forces are determined by using a spatial integration scheme along the axis of the tool. Both regenerative and loss of contact effects are considered in determining the cutting forces, which makes the model well suited for a wide range of milling operations. The model also allows for partial engagement of a tool with a workpiece, which is an important feature needed for milling operations with helical tools. Time domain simulations are carried out by using the developed model to predict the stability boundaries in the space of the tool spindle speed and the axial depth of cut. Poincaré sections are used to determine loss of stability from period-one motions to other motions such as two-period quasiperiodic motions, as a control parameter is varied.     

数控机床电机散热温度场的数值模拟研究

电机作为数控机床的核心部件,其性能影响着机床主轴系统的精度、电机效率和使用寿命.因此,合理设计高速电机的结构使其处于最佳的温度场,了解电机在运行过程中各空气区域内的速度及温度分布非常重要.本文以某机床的电机定转子作为研究对象,利用CFD软件对转子通风道的设计方案进行数值模拟,通过数值模拟分析电机内部的流场温度场及流场分布.根据模拟结果进行优化设计,在转子和定子之间进行单排孔和双排孔的优化方案设计,通过温度分布确定最佳设计方案,为电机转子通风道的散热优化设计提供有意义的参考.     

Parallel algorithms for panel methods

A parallel algorithm for the solution of potential flow problems using the panel method of Hess and Smith and conjugate and bi-conjugate gradient techniques is presented. Analysis of the parallelism for the matrix. solvers shows the algorithms to have scalable properties as the problem size grows indefinitely large. Speed-up and efficiency values are presented along with experimental and theoretical values for the optimum number of processors for maximum speed-up. It is envisaged that the parallel techniques presented here have applications using other boundary integral methods for solving engineering problems of a more complex nature.     

Estimating Critical Hopf Bifurcation Parameters for a Second-Order Delay Differential Equation with Application to Machine Tool Chatter

Nonlinear time delay differential equations are well known to havearisen in models in physiology, biology and population dynamics. Theyhave also arisen in models of metal cutting processes. Machine toolchatter, from a process called regenerative chatter, has been identifiedas self-sustained oscillations for nonlinear delay differentialequations. The actual chatter occurs when the machine tool shifts from astable fixed point to a limit cycle and has been identified as arealized Hopf bifurcation. This paper demonstrates first that a class ofnonlinear delay differential equations used to model regenerativechatter satisfies the Hopf conditions. It then gives a precisecharacterization of the critical eigenvalues on the stability boundaryand continues with a complete development of the Hopf parameter, theperiod of the bifurcating solution and associated Floquet exponents.Several cases are simulated in order to show the Hopf bifurcationoccurring at the stability boundary. A discussion of a method ofintegrating delay differential equations is also given.     

聚晶金刚石刀具加工强化复合地板时的切削性能及磨损机理研究

通过对聚晶金刚石刀具加工A1203表层强化复合地板的试验研究，分析了金刚石粒度对聚品金刚石刀具切削性能的影响以及刀具的磨损机理。结果表明：随着金刚石粒度的增大，聚晶金刚石刀具的耐磨性能增强；聚晶金刚石刀具在加工过程中的磨损机理主要表现为具有疲劳磨损特征的沿品断裂及局部解理断裂．品间微裂纹是导致聚晶金刚石刀具磨损的主要因素．     

Stability and resonance of micro-machined gyroscope under nonlinearity effects

Resonance frequency for a micro-gyroscope plays an extremely significant role since the driving frequency is accordingly tuned so that the best sensitivity and resolution can be achieved. In practice, the micro-gyroscope is usually driven into resonance to retain its superior angular rate detection capability. However, the embedded nonlinearity effect upon the micro-gyroscopic dynamics may not only deteriorate the stability around the vicinity of operation point, but also alter the initially-designed resonance frequencies so that the angular rate detection performance of the micro-gyroscope is dramatically degraded. Hence, the nonlinearities, mainly resulting from flexure springs and electrostatic force, are both taken into account to construct the nonlinear dynamic model of the micro-gyroscope in our work at first. Secondly, the instability region of the proposed micro-gyroscope under different driving frequency and natural frequencies, which tends to be drifted due to mechanical fatigue and temperature rise, is unveiled. In order to catch the insight of slight variation of system parameters, the nonlinear dynamic equation is analyzed by using multiple scales method to outstand the influence of the variation of driving moment. Thirdly, the external resonance and non-resonant hard excitation of the micro-gyroscope—totally five types—are both theoretically studied. It is interesting to find that the resonance frequencies and resonant magnitude are both changed accordingly if either the driving frequency or the magnitude of driving moment is tuned via control loop for the sake of considering more stability or better performance. Finally, the chaotic behavior of the micro-gyroscope is numerically inspected by bifurcation diagrams and verified that the sense mode and drive mode have the similar orbits for transitions across distinct patterns of dynamic motion of the presented micro-gyroscope.     

Stability analysis of a substructured model of the rotating beam

One of the most well-known situations in which nonlinear effects must be taken into account to obtain realistic results is the rotating beam problem. This problem has been extensively studied in the literature and has even become a benchmark problem for the validation of nonlinear formulations. Among other approaches, the substructuring technique was proven to be a valid strategy to account for this problem. Later, the similarities between the absolute nodal coordinate formulation and the substructuring technique were demonstrated. At the same time, it was found the existence of a critical angular velocity, beyond which the system becomes unstable that was dependent on the number of substructures. Since the dependence of the critical velocity was not so far clear, this paper tries to shed some light on it. Moreover, previous studies were focused on a constant angular velocity analysis where the effects of Coriolis forces were neglected. In this paper, the influence of the Coriolis force term is not neglected. The influence of the reference conditions of the element frame are also investigated in this paper.     

Singularity Curves of a Parallel Pointing System

This paper studies a parallel pointing system used in aerospace applications for orientating parabolic antennas. In the literature [6, 7], the position analysis of this device has been already solved in closed form, whereas simple and efficient tools to address singularities distribution are still lacking. In this paper, its velocity analysis is addressed, and a singularity locus analytic expression, containing the manipulator geometric parameters and the end-effector orientation parameters, is derived. Moreover, it is shown that the determined singularity locus can be represented by curves (singularity curves) on a Cartesian plane having the generalized coordinates of the mechanism on the coordinate axes. Finally, an example showing the use of the proposed relationships is given and discussed.     

基于电子万能试验机的新型压杆稳定实验装置

本文介绍了一种基于电子万能试验机开发的新型压杆稳定实验装置。该装置利用电子万能试验机自身传感设备,通过测量压杆两端受力与绘制端部轴向位移曲线来确定压杆失稳荷载。装置包括上、中、下三个约束部分与压杆试样部分,可实现两端固支、两端铰支、一端固支一端铰支和一端固支一端自由等4种不同端部约束型式,并且能够施加中部固支约束与压杆初始偏心。本文同时讨论了两种铰支型式,即刀刃铰支与轴承铰支对测试精度的影响。实验表明,轴承铰支测量精度比刀刃铰支高。该套装置的整体测量精度高,与理论值的相对误差最高为2%。     

Nonlinear Dynamics and Stability of a Two D.O.F. Elastic/Elasto-Plastic Model System

The local and global nonlinear dynamics of a two-degree-of-freedom model system is studied. The undeflected model consists of an inverted T formed by three rigid bars, with the tips of the two horizontal bars supported on springs. The springs exhibit an elasto-plastic response, including the Bauschinger effect. The vertical rigid bar is subjected to a conservative (dead) or non-conservative (follower) force having static and periodic components. First, the method of multiple scales is used for the analysis of the local dynamics of the system with elastic springs. The attention is focused at modal interaction phenomena in weak excitation at primary resonance and in hard sub-harmonic excitation. Three different asymptotic expansions are utilised to get a structural response for typical ranges of excitation parameters. Numerical integration of the governing equations is then performed to validate results of asymptotic analysis in each case. A full global nonlinear dynamics analysis of the elasto-plastic system is performed to reveal the role of plastic deformations in the stability of this system. Static 'force-displacement' curves are plotted and the role of plastic deformations in the destabilisation of the system is discussed. Large-amplitude non-linear oscillations of the elasto-plastic system are studied, including the influence of material hardening and of static and sinusoidal components of the applied force. A practical method is proposed for the study of a non-conservative elasto-plastic system as a non-conservative elastic system with an 'equivalent' viscous damping. This revised version was published online in July 2006 with corrections to the Cover Date.     

Development of a parallel computational fluid dynamics algorithm on a hypercube computer

One of the main factors limiting the widespread use of computational fluid dynamics codes for engineering design is their very large requirements both in terms of computer memory and CPU time. Distributed memory parallel computers offer both the potential for a dramatic improvement in cost/performance over conventional supercomputers and the scalability to large numbers of processors that is required if performance beyond that of current supercomputers is to be achieved. As part of an evaluation to explore the potential of such machines for computational fluid mechanics applications, a concurrent algorithm for the solution of the Navier-Stokes equations has been developed and demonstrated on a hypercube parallel computer. The algorithm is based on a domain decomposition of a well-established serial pressure correction algorithm. The algorithm is demonstrated on both a 32-node scalar and eight-node vector Intel iPSC/2 for complicated two-dimensional laminar and turbulent flow problems with different grid sizes and numbers of processors. Speed-ups relative to a single processor of 12.9 with 16 processors and 20.2 with 32 processors are achieved on a scalar iPSC/2, demonstrating the parallel efficiency of the algorithm. Measured performance on a 32-node scalar iPSC/2 exceeds one-sixth that of a Cray X-MP running the original serial algorithm. The performance of the algorithm on an eight-node vector iPSC/2 exceeds that of the larger scalar hypercube and is about one-fifth that of the Cray X-MP. With cost/performance more than 10 times better than the Cray, these results dramatically show the cost effectiveness of vector hypercubes for this class of fluid mechanics algorithm.     

Stability and coupled dynamics of three-dimensional dual inverted flags

Fluid–structure interaction of an inverted flag, which has a free leading edge and a clamped trailing edge, has drawn attention recently because of its novel properties such as divergence stability, a low stability threshold, and large-amplitude flapping motion. In this study, the stability and flapping behaviors of dual inverted flags with finite height are investigated for a side-by-side arrangement, and their noticeable characteristics are compared to those of dual conventional flags. The critical velocity at which the inverted flags break the equilibrium of a straight configuration reduces monotonically when a gap distance between the two flags becomes smaller and an aspect ratio becomes larger, which is also predicted by our linear stability analysis using simple theoretical models of two-dimensional flags and slender flags. After bifurcation, in addition to the synchronized in-phase and out-of-phase modes commonly observed in dual conventional flags, a novel attached mode appears which is mainly observed for small gap distance and small aspect ratio. In this non-linear mode, the leading edges of the two inverted flags touch each other on a midline, and the deformed inverted flags maintain static equilibrium. In a non-linear flapping regime, a new mechanism of a mode transition from an out-of-phase mode to an in-phase mode is identified, which is allowed by the collision of the two flags flapping with large amplitude.     

刀具变形的在线散斑检测

散斑照相，防震要求低，光路简单，所需曝光时间短，符合连续激光对动态测量的要求。本文利用散斑照相法，测量了机床刀具的动态切削过程，并利用逐点分析和全场分析方法，分析了所拍摄的散斑图，得到了不同车速和不同切削用量条件下的位移场、应力场     

Stability Region Control for a Parametrically Forced Mathieu Equation

We exhibit common features of how the size of parametric regions of stability for the Mathieu equation can be enlarged. The paper shows that the mechanisms for these changes via parametric forcing follow the pattern established earlier for the Arnold circle map which provides a discrete model for external forcing. The various types of behaviour of the standard Mathieu equation for a given set of parameters can be classified as having either (i) all solutions bounded, (ii) at least one unbounded solution, or (iii) periodic solutions of period -/-2 or -/-4. The marginal case (iii) forms the boundary of the regions of stability and instability. We consider a parametric method for changing the shapes of the stability regions and show how maximally stable regions can be produced.     

机床非线性颤振的分段线性化及其数学模型

通过引入非线性调制环节N(S),本文实现了非线性颤振的分段线性化,建立了统一的切削动力学系统模型。这一模型使线性颤振理论、非线性颤振理论趋于统一,并使超声振动切削抑制颤振的机理从理论上得到解释。