scholarly journals Design Optimization of a Compact Double-Ended-Tuning-Fork-Based Resonant Accelerometer for Smart Spindle Applications

Micromachines ◽  
2019 ◽  
Vol 11 (1) ◽  
pp. 42
Author(s):  
Yu-Hsuan Chen ◽  
Wei-Chang Li ◽  
Xi-Wen Xiao ◽  
Chieh-Cheng Yang ◽  
Chien-Hao Liu
Keyword(s):  
High Speed ◽  
Tuning Fork ◽  
Intelligent Manufacturing ◽  
Low Noise ◽  
Modulation Scheme ◽  
Chatter Detection ◽  
Machining Processes ◽  
Element Analysis ◽  
Out Of Plane ◽  
Resonant Accelerometer

With the rapid developments of the Industrial Era 4.0, numerous sensors have been employed to facilitate and monitor the quality of machining processes. Among them, accelerometers play an important role in chatter detection and suppression for reducing the tool down-time and increasing manufacturing efficiency. To date, most commonly seen accelerometers have relatively large sizes such that they can be installed only on the housing of spindles or the surfaces of workpieces that may not be able to directly capture actual vibration signals or obstruct the cutting process. To address this challenge, this research proposed a compact, wide-bandwidth resonant accelerometer that could be embedded inside high-speed spindles for real-time chatter monitoring and prediction. Composed of a double-ended tuning fork (DETF), a proof mass, and a support beam, the resonant accelerometer utilizes the resonance frequency shift of the DETF due to the bending motions of the structure during out-of-plane accelerations as the sensing mechanism. The entire structure based on commercially available quartz tuning forks (QTFs) with electrodes for symmetric-mode excitations. The advantages of this structure include low noise and wide operation bandwidth thanks to the frequency modulation scheme. A theoretical model and finite element analysis were conducted for designs and optimizations. Simulated results demonstrated that the proposed accelerometer has a size of 9.76 mm × 4.8 mm × 5.5 mm, a simulated sensitivity of 0.94 Hz/g, and a simulated working bandwidth of 3.5 kHz. The research results are expected to be beneficial for chatter detection and intelligent manufacturing.

Analysis and Research of High Speed Milling of Thin-Walled Bracket Part Based on UG NX

2010 ◽  
Vol 129-131 ◽  
pp. 256-260
Author(s):  
Yi Shu Hao ◽  
Chuang Hai ◽  
Xin Xing Zhu
Keyword(s):  
High Speed ◽  
Three Dimensional ◽  
Structural Features ◽  
Milling Process ◽  
Analysis Method ◽  
Three Dimensional Model ◽  
Machining Processes ◽  
Element Analysis ◽  
High Speed Milling ◽  
Tool Paths

Treating high speed milling theory as the guidance, this paper researched high speed milling process of bracket part based on UG NX. Combined with the structural features of bracket part, three dimensional model is built by UG NX CAD and machining processes are worked out after analysis. UG CAM module was applied to fabricate tool paths. At last, finite element analysis method is introduced to study the processing deformation by UG NX NASTRAN module, based on which measures to restrain processing deformations is advanced and processing sequences are optimized.

Based on Pro/E High Speed Milling of Thin-Walled Stents of Research

2011 ◽  
Vol 295-297 ◽  
pp. 2487-2491
Author(s):  
Jian Qiang Wang
Keyword(s):  
High Speed ◽  
Three Dimensional ◽  
Structural Features ◽  
Milling Process ◽  
Analysis Method ◽  
Three Dimensional Model ◽  
Machining Processes ◽  
Element Analysis ◽  
High Speed Milling ◽  
Tool Paths

Treating high speed milling theory as the guidance, this paper researched high speed milling process of bracket part based on Pro/E. Combined with the structural features of bracket part, three dimensional model is built by Pro/E and machining processes are worked out after analysis. Pro/E module was applied to fabricate tool paths. At last, finite element analysis method is introduced to study the processing deformation by Pro/E module, based on which measures to restrain processing deformations is advanced and processing sequences are optimized.

Measuring Tool-Chip Interface Temperatures

1986 ◽  
Vol 108 (2) ◽  
pp. 101-104 ◽  
Author(s):  
J. P. Kottenstette
Keyword(s):  
High Speed ◽  
Spectral Band ◽  
Radiation Detectors ◽  
Low Noise ◽  
True Temperature ◽  
Machining Processes ◽  
Light Pipe ◽  
Narrow Band Filter ◽  
Metal Chips ◽  
Measuring Tool

A two-color pyrometer was developed for monitoring the surface temperature of metal chips formed during high-speed machining processes. Optical access to the tool-chip interface was obtained by cementing a plastic light pipe into a 1/16-in. (1.6-mm) hole milled through the carbide tool insert. The light pipe serves to transmit radiation falling on the rake face of the insert to radiation detectors located elsewhere. Radiation captured by the light pipe is passed through a lens-beam splitter combination and imaged on two identical photodiode detectors. The diodes have integral operational amplifiers to achieve high detectivity and low-noise operation. Each photodiode is masked by an interference type narrow-band filter having spectral bandpass frequencies chosen to match the point where the emittance of several metals is constant for all temperatures. Thus, the temperature of the chip stream monitored by the diodes is a function of the intensity measured for each spectral band at the same instant in time. The functional relationship between true temperature and the ratio of signal amplitudes (the calibration curve) was established for pyrometer over the interval 1000–1750 K using standard laboratory methods.

Research on MFBD Modeling Method for a Gantry Machining Center Beam Components

2011 ◽  
Vol 188 ◽  
pp. 487-492 ◽  
Author(s):  
Q.J. Yang ◽  
D.N. Li ◽  
L.L. Kong ◽  
K. Li
Keyword(s):  
Machine Tool ◽  
Machine Tools ◽  
High Speed ◽  
Modeling Method ◽  
Ball Screw ◽  
Machining Processes ◽  
Element Analysis ◽  
Machining Center ◽  
Body Dynamics ◽  
Multi Body

In modern machining processes, Gantry Machining Center is one of the most important machine tools. Moreover, beam components directly relate to the overall performance. From multi-body simulation (MBS) and finite element analysis (FEA) respectively, the paper discusses current state of the multi-body dynamics modelling of the machine tool components in domestic and overseas. In this paper, We adopt a method, the multi-flexible body dynamics(MFBD) modeling method for machine tool transmission components (linear guidance and ball screw drives) in software Recurdyn, to create the conditions for MFBD simulation analysis of the beam components system. Much more, it provides a way of MFBD modelling for machine tools components in both the high-speed and high-performance.

Performance analysis of magnetic gear with Halbach array for high power and high speed

2020 ◽  
Vol 64 (1-4) ◽  
pp. 959-967
Author(s):  
Se-Yeong Kim ◽  
Tae-Woo Lee ◽  
Yon-Do Chun ◽  
Do-Kwan Hong
Keyword(s):  
Permanent Magnet ◽  
Eddy Current ◽  
High Power ◽  
High Speed ◽  
Torque Ripple ◽  
Eddy Current Loss ◽  
Element Analysis ◽  
Current Loss ◽  
Halbach Array ◽  
Magnetic Gear

In this study, we propose a non-contact 80 kW, 60,000 rpm coaxial magnetic gear (CMG) model for high speed and high power applications. Two models with the same power but different radial and axial sizes were optimized using response surface methodology. Both models employed a Halbach array to increase torque. Also, an edge fillet was applied to the radial magnetized permanent magnet to reduce torque ripple, and an axial gap was applied to the permanent magnet with a radial gap to reduce eddy current loss. The models were analyzed using 2-D and 3-D finite element analysis. The torque, torque ripple and eddy current loss were compared in both models according to the materials used, including Sm2Co17, NdFeBs (N42SH, N48SH). Also, the structural stability of the pole piece structure was investigated by forced vibration analysis. Critical speed results from rotordynamics analysis are also presented.

Tribological and dynamical analysis of a brake pad with multiple blocks for a high-speed train

2019 ◽  
Vol 234 (11) ◽  
pp. 1771-1788
Author(s):  
YK Wu ◽  
JL Mo ◽  
B Tang ◽  
JW Xu ◽  
B Huang ◽  
...  
Keyword(s):  
High Speed ◽  
Wear Behavior ◽  
Dynamical Analysis ◽  
Brake Disc ◽  
Brake Pad ◽  
High Speed Train ◽  
Brake Squeal ◽  
Element Analysis ◽  
Single Block ◽  
Middle Ring

In this research, the tribological and dynamical characteristics of a brake pad with multiple blocks are investigated using experimental and numerical methods. A dynamometer with a multiblock brake pad configuration on a brake disc is developed and a series of drag-type tests are conducted to study the brake squeal and wear behavior of a high-speed train brake system. Finite element analysis is performed to derive physical explanations for the observed experimental phenomena. The experimental and numerical results show that the rotational speed and braking force have important influences on the brake squeal; the trends of the multiblock and single-block systems are different. In the multiblock brake pad, the different blocks exhibit significantly different magnitudes of contact stresses and vibration accelerations. The blocks located in the inner and outer rings have higher vibration acceleration amplitudes and stronger vibration energies than the blocks located in the middle ring.

scholarly journals Research on Performance Test System of Space Harmonic Reducer in High Vacuum and Low Temperature Environment

Machines ◽  
2020 ◽  
Vol 9 (1) ◽  
pp. 1
Author(s):  
Jing Wang ◽  
Zhihua Wan ◽  
Zhurong Dong ◽  
Zhengguo Li
Keyword(s):  
Low Temperature ◽  
High Speed ◽  
Performance Test ◽  
High Reliability ◽  
High Vacuum ◽  
Test System ◽  
Low Noise ◽  
Speed Ratio ◽  
Space Harmonic ◽  
Temperature Environment

The harmonic reducer, with its advantages of high precision, low noise, light weight, and high speed ratio, has been widely used in aerospace solar wing deployment mechanisms, antenna pointing mechanisms, robot joints, and other precision transmission fields. Accurately predicting the performance of the harmonic reducer under various application conditions is of great significance to the high reliability and long life of the harmonic reducer. In this paper, a set of automatic harmonic reducer performance test systems is designed. By using the CANOpen bus interface to control the servo motor as the drive motor, through accurately controlling the motor speed and rotation angle, collecting the angle, torque, and current in real time, the life cycle test of space harmonic reducer was carried out in high vacuum and low temperature environment on the ground. Then, the collected data were automatically analyzed and calculated. The test data of the transmission accuracy, backlash, and transmission efficiency of the space harmonic reducer were obtained. It is proven by experiments that the performance data of the harmonic reducer in space work can be more accurately obtained by using the test system mentioned in this paper, which is convenient for further research on related lubricating materials.

Dynamic Analysis of DVG 850 High-Speed Machining Center

2012 ◽  
Vol 487 ◽  
pp. 203-207
Author(s):  
Gong Xue Zhang ◽  
Xiao Kai Shen
Keyword(s):  
High Speed ◽  
Simulation Analysis ◽  
Response Analysis ◽  
Improved Method ◽  
Analysis Software ◽  
Element Analysis ◽  
Harmonic Response ◽  
Machining Center ◽  
Calculation Results ◽  
Harmonic Response Analysis

Purpose, with the application of workbench finite element analysis software, get the analysis results of DVG 850 high-speed vertical machining center via the modal analysis and harmonic response analysis. Use the calculation results for reference, put forward the improved method, and prove the credibility of the simulation analysis by testing DVG 850 prototype.

scholarly journals Optimization of Air Gap Length and Capacitive Auxiliary Winding in Three-Phase Induction Motors Based on a Genetic Algorithm

Energies ◽  
2021 ◽  
Vol 14 (15) ◽  
pp. 4407
Author(s):  
Mbika Muteba
Keyword(s):  
Genetic Algorithm ◽  
Design Process ◽  
Power Factor ◽  
High Speed ◽  
High Efficiency ◽  
Air Gap ◽  
Element Analysis ◽  
Three Phase ◽  
High Torque ◽  
Cage Induction Motor

There is a necessity to design a three-phase squirrel cage induction motor (SCIM) for high-speed applications with a larger air gap length in order to limit the distortion of air gap flux density, the thermal expansion of stator and rotor teeth, centrifugal forces, and the magnetic pull. To that effect, a larger air gap length lowers the power factor, efficiency, and torque density of a three-phase SCIM. This should inform motor design engineers to take special care during the design process of a three-phase SCIM by selecting an air gap length that will provide optimal performance. This paper presents an approach that would assist with the selection of an optimal air gap length (OAL) and optimal capacitive auxiliary stator winding (OCASW) configuration for a high torque per ampere (TPA) three-phase SCIM. A genetic algorithm (GA) assisted by finite element analysis (FEA) is used in the design process to determine the OAL and OCASW required to obtain a high torque per ampere without compromising the merit of achieving an excellent power factor and high efficiency for a three-phase SCIM. The performance of the optimized three-phase SCIM is compared to unoptimized machines. The results obtained from FEA are validated through experimental measurements. Owing to the penalty functions related to the value of objective and constraint functions introduced in the genetic algorithm model, both the FEA and experimental results provide evidence that an enhanced torque per ampere three-phase SCIM can be realized for a large OAL and OCASW with high efficiency and an excellent power factor in different working conditions.

scholarly journals Study on the High-Speed Milling Performance of High-Volume Fraction SiCp/Al Composites

Materials ◽  
2021 ◽  
Vol 14 (15) ◽  
pp. 4143
Author(s):  
Youzheng Cui ◽  
Shenrou Gao ◽  
Fengjuan Wang ◽  
Qingming Hu ◽  
Cheng Xu ◽  
...  
Keyword(s):  
High Speed ◽  
Large Scale ◽  
Volume Fraction ◽  
Simulation Analysis ◽  
Cutting Temperature ◽  
High Volume ◽  
Cutting Parameters ◽  
High Volume Fraction ◽  
High Wear Resistance ◽  
Element Analysis

Compared with other materials, high-volume fraction aluminum-based silicon carbide composites (hereinafter referred to as SiCp/Al) have many advantages, including high strength, small change in the expansion coefficient due to temperature, high wear resistance, high corrosion resistance, high fatigue resistance, low density, good dimensional stability, and thermal conductivity. SiCp/Al composites have been widely used in aerospace, ordnance, transportation service, precision instruments, and in many other fields. In this study, the ABAQUS/explicit large-scale finite element analysis platform was used to simulate the milling process of SiCp/Al composites. By changing the parameters of the tool angle, milling depth, and milling speed, the influence of these parameters on the cutting force, cutting temperature, cutting stress, and cutting chips was studied. Optimization of the parameters was based on the above change rules to obtain the best processing combination of parameters. Then, the causes of surface machining defects, such as deep pits, shallow pits, and bulges, were simulated and discussed. Finally, the best cutting parameters obtained through simulation analysis was the tool rake angle γ0 = 5°, tool clearance angle α0 = 5°, corner radius r = 0.4 mm, milling depth ap = 50 mm, and milling speed vc= 300 m/min. The optimal combination of milling parameters provides a theoretical basis for subsequent cutting.

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