Residual stress fluctuates periodically via the workpiece rotation phase during low frequency vibration cutting

The turning process is a standard machining process employed in diverse sectors. However, it produces long continuous chips that can affect the efficiency of the process, accelerate the tooling's wear, or damage the machined surface. As a solution, low frequency vibration cutting synchronizing with the spindle rotation has recently been developed as a new machining method in turning operation. It applies vibrations in the tool feed direction and can synchronously control the applied vibrations and the spindle rotation. It can also effectively divide the long continuous chips generated by the turning process and has the potential to reduce thermo-mechanical load on the tool by periodically enabling the tool to leave the workpiece due to the vibrations. Low frequency vibration cutting, the cutting characteristics of which differ from those of conventional turning, induces residual stresses in the machined surface; however, the properties of these stresses have not yet been studied. Residual stress can have both beneficial and negative effects on the fatigue life of products. While compressive residual stress increases the fatigue life of the product, tensile residual stress facilitates the growth of fine cracks on the product's surface and reduces fatigue life. Therefore, it is important to understand the characteristics of the residual stress developed on a machined surface. In this study, an annealed 0.45% C steel bar was machined via straight turning of the vibration cutting process synchronizing with the spindle rotation, and the residual stress on the finished surface was measured. Particular focus was placed on analyzing the effects of the spindle phase on the characteristics of the residual stress inside the machined surface, especially the effects of the number of vibrations per spindle rotation, D, which is a unique parameter defining the vibration condition. Our results revealed that the residual stress varied depending on the position of the finished surface owing to the change in feed with the spindle phase during the process. Furthermore, D was observed to heavily influence the distribution of the residual stress on the finished surface. By means of adjusting its value, the residual stress value could either fluctuate periodically according to the phase of the workpiece or not fluctuate.     

枪钻低频振动钻削振动问题的研究

概述了枪钻低频振动钻削的加工原理,介绍了国内外的研究和发展状况,指出了该项技术研究所存在的问题,并对今后的研究方向作了展望。     

Analytical time constant design for jerk-limited acceleration profiles to minimize residual vibration after positioning operation in NC machine tools

The positioning operation of the axes of numerically controlled (NC) machine tools is essential before initiating their machining operation. Residual vibration following the positioning operations of the axes deteriorates the cycle time and quality of the machined parts. This study aims to develop a novel acceleration and deceleration design method to suppress the residual vibration during the high-speed positioning of NC machine tools. The proposed method suppresses the vibration by appropriately designing the jerk-limited acceleration profile during acceleration and deceleration. To design the jerk profile, the amplitude map that can represent the relationships between the acceleration parameters and the estimated vibration amplitude is developed. The proposed method suppresses the vibration amplitude without changing the total positioning time. To evaluate the effectiveness of this method, the residual vibration following the high-speed positioning motions was measured and simulated. The results confirm that the proposed method can effectively suppress the residual vibration.     

粘滞阻尼器在蒸汽发生器振动响应中的应用与研究

我国是一个多震国家,核电站关键设备如蒸汽发生器、蒸汽管道等都需要采用主动或者被动控制方式进行减振,以防止在地震灾害中受到破坏。为了提高蒸汽发生器在地震载荷作用下的振动性能,必须对比安装与未安装阻尼器的蒸汽发生器在相同地震载荷下的响应参数,根据对响应的安全校核,验证阻尼器的减振效果是否达到要求。然后根据最优设计理论,计算出最佳阻尼器安装方式,使得蒸汽发生器在给定条件下变形位移最小。分析结果表明,通过优化阻尼器参数和安装位置,能够明显提高蒸汽发生器减振的效果。     

Stabilization of high frequency chatter vibration in fine boring by friction damper

Friction damper has been found successful to prevent high frequency chatter occurring at more than 10,000Hz, and causing problem of reduced tool life in fine boring operation. The new damper is characterized by simple structure that consists of an additional mass attached to the main vibrating structure with small piece of permanent magnet. The principle is straightforward in which Coulomb and viscous frictions dissipate vibration energy at the interface between the damper and main vibrating structure. The damper needs no tuning, and is effective at high frequency. The paper first introduces a typical design of the friction damper with experimental proof by cutting tests of its effectiveness in eliminating the high frequency chatter in fine boring, and assuring normal tool life of the cutting edge. Theoretical and experimental analyses are introduced for understanding the fundamental principle and characteristics of the new damper. The new damper is effective for boring tools, which vibrate at frequency more than 5,000Hz.     

Influence of rotary axis on tool-workpiece loop compliance for five-axis machine tools

This study investigated the influence of the rotary axis of a 5-axis machine tool on the tool-workpiece compliance. The evaluation focused on the influence of the rotation angle and clamping condition of the B axis on the compliance variation. A method was determined to calculate the tool-workpiece compliance in an arbitrary direction from compliances measured using orthogonal triaxial excitations. Then, the tool-workpiece compliance of a 5-axis machine tool was evaluated and displayed using a color map. The compliance map showed that the magnitude of the compliance varied by up to 40% with changes in the B axis rotation angle and its clamping condition. A drastic change in the negative real part of the compliance was also detected in the compliance map. The results of an experimental modal analysis are used to discuss the cause of the compliance variation. The bending mode of the B axis is an important mode because the change in the bending direction due to B axis rotation has a great influence on the direction dependency of the compliance magnitude and the stability limit. A cutting experiment was conducted to verify the correspondence between the evaluated compliance and the vibrational amplitude in a real cutting process. The compliance variation in the compliance map corresponded to the amplitude variation of the vibration in an end milling process. The compliance map revealed that the vibration synchronized with the passing cycle of cutters was decreased by 80% by unclamping the B axis.     

The use of displacement threshold for switching frequency strategy for structural vibration mitigation

This paper presents a study of controllable real-time frequency shift using a fluid pin damper, so called ‘smart pin’, mounted at a beam-column connection. Unlike the stationary frequency shifter, the pin can increase or decrease the rotational stiffness of the connection, leading to an actively adjustable structural frequency due to real-time responses of polarised magneto-rheological (MR) fluid, whose rheological properties can change in milliseconds. The feedback to the pin damper governs the structural frequency changes. To demonstrate this concept, a single storey plane steel frame model with one hinge and one ‘smart pin’ damper, mounted at each beam-column connection and subjected to two scaled earthquake excitations, namely El-Centro 1940 and Northridge 1994, which respectively represent near- and farfield excitations, was tested using the shake table at the University of Technology, Sydney (UTS) structures laboratory, for ‘proof-of-concept’ investigation. Further, the dynamic performance of the model using a proposed switching strategy with a displacement threshold as an indicator for alternately supplied current level (flip-flop) was examined, assuming the earthquake records were known. The results showed some potential use of this control technique for structural vibration mitigation, however, further study to optimize the performance of the switching strategy is still required. An erratum to this article is available at .     

变频调速在机床旋转主运动中的应用

用变频调速和机械变速相结合的方法，在主运动为旋转运动的通用机床中，实现全部恒功率范围内的无级调速。     

三维振动强化抛光振动台变刚度弹性支承调谐固频的探讨

振动强化、抛光技术用于对复杂异型曲面工件进行表面强化、抛光处理。对三维强化、抛光振动台变刚度弹性支承调谐固频的问题进行了探讨。理论分析计算与实验研究表明：这种调谐方式是有效的。     

Dynamic characteristics of spindle with water-lubricated hydrostatic bearings for ultra-precision machine tools

A key component of ultra-precision machine tools is the spindle. The motivation for this study was to improve machining accuracies in precision cutting and grinding by pursuing improvements in the spindle characteristics by designing a sophisticated spindle with water-lubricated hydrostatic bearings. The static bearing stiffness of the developed spindle was investigated in previous studies. In addition to the static bearing stiffness, the dynamic characteristics regarding bearing stiffness also affect significantly on the machining results. In this study, dynamic characteristics of the developed spindle with water-lubricated hydrostatic bearings were investigated via simulations and experiments. Not only bearing dynamics but also rotor dynamics were considered in this study.In the simulation studies, the spindle dynamic characteristics were analysed based on the transfer matrix method. A spindle rotor supported with hydrostatic bearings was represented by discrete sections of the rotor. The mathematical model of transverse linear vibrations of the spindle rotor was derived with distributed parameters for these discretized rotor sections. As a result of the analysis on the amplitude-frequency characteristic, radial displacements of the rotor due to bearing displacement and bending deformation were defined. Then, the frequency characteristics were represented with Nyquist plots. Resonant frequencies and amplitudes formation in the transverse vibration of the rotor were determined. The influence of rotor bending deformations on spindle compliance was assessed. Furthermore, the study examined the influences of the supply pressure of the lubricating fluid, radial clearance and journal diameter of the hydrostatic bearings on the amplitude of the rotor vibration, and the resonance frequency of the system.Furthermore, the dynamic characteristics of the spindle were examined experimentally. The simulation results were in good agreement with the actual spindle dynamics obtained experimentally. The influence of the structural parameters of the rotor and the operating parameters of the bearings on the spindle dynamic characteristics was also determined. It was verified that the amplitude of the vibration of the rotor overhang part was dominantly affected not by bearing stiffness but by bending stiffness of the bearing journal of the front bearing and the length of the rotor overhang.Then it was verified that the resultant displacement of the rotor in the radial direction due to the influence of the bearing characteristics and the structural effect of the rotor is significantly small. Practical recommendations to improve the spindle design in terms of the dynamic characteristics of the spindle with water-lubricated hydrostatic bearings were also derived.     

轴系减振器相位角的频域分析提取技术

为了预防船舶行进过程中减振器性能衰退引起轴系振动过大所带来的危害,提出了船舶轴系减振器相位角频域分析提取算法,使用扭振仪对减振器内外圈扭角速度 进行实时测量,计算减振器的相位角和阻尼系数,分析误差原因,筛除误差较大的数据,将拟合曲线与标准曲线进行对比,判断减振器性能。实船测试结果表明,该算法能准确计算出减振器相位角,拟合曲线精确度高,满足了船舶轴系减振器性能分析的设计要求。     

铁磁构件内外表面裂纹低频漏磁检测技术研究

针对承压设备中铁磁性构件内外壁损伤检测问题,发展了一种低频漏磁检测技术。对低频漏磁信号进行分析处理,提取出的低频漏磁信号的幅值和相位信息,用于铁磁构件内外表面损伤检测与定量评价。通过数值仿真和检测实验,研究了裂纹深度和位置(上表面或下表面)的裂纹对漏磁场特征参数空间分布的影响。结果表明,漏磁信号的幅值特征参数和相位特征参数均可用于铁磁性构件上下表面一定深度范围内裂纹检测及定量表征,但两个参数对不同位置及深度范围内裂纹检测的敏感性不同。当裂纹位于试件上表面时,幅值特征参数对裂纹深度变化更敏感;而当裂纹位于试件下表面时,相位特征参数对裂纹深度变化的敏感性更高。本文研究工作为承压设备中铁磁性构件内外壁损伤检测做了有益探索。     

求解非均质变截面轴扭转振动固有频率的混合状态方法

本文给出了均质等截面轴扭转振动的混合状态方程及其解。对于非均质变截面轴，可以把它划分为很多微段，然后，利用段与段之间的连续条件推出一个传递公式，最后，利用边界条件可将固有频率求出。