A novel ensemble method based on SBLMD-ANN-MOPSO approach for predicting the milling stability regimes

In recent decades, lots of work has been done to mitigate self excited vibration effects in milling operations. Still, a robust methodology is yet to be developed that can suggest stability bounds pertaining to higher metal removal rate (MRR). In the present work, experimentally acquired acoustic signals in milling operation have been computed using a modified Local Mean Decomposition (SBLMD) technique in order to cite tool chatter features. Further, three artificial neural network (ANN) training algorithms viz. Resilient Propagation (RP), Conjugate Gradient-Based (CGP) and Levenberg-Marquardt Algorithm (LM) and two activation functions viz. Hyperbolic Tangent Sigmoid (TANSIG) and Log Sigmoid (LOGSIG) has been used to train the acquired chatter vibration and metal removal rate data set. Over-fitting or under-fitting issues may arise from the random selection of a number of hidden neurons. The solution to these problems is also proposed in this paper. Among these training algorithms and activation functions, a suitable one has been selected and further invoked to develop prediction models of chatter severity and metal removal rate. Finally, Multi-Objective Particle Swarm Optimization (MOPSO) has been invoked to optimize developed prediction models for obtaining the most favourable range of input parameters pertaining to stable milling with higher productivity.

A Perturbation Approach for Lateral Excited Vibrations of a Beam-like Viscoelastic Microstructure Using the Nonlocal Theory

In this paper, we investigate the lateral vibration of fully clamped beam-like microstructures subjected to an external transverse harmonic excitation. Eringen’s nonlocal theory is applied, and the viscoelasticity of materials is considered. Hence, the small-scale effect and viscoelastic properties are adopted in the higher-order mathematical model. The classical stress and classical bending moments in mechanics of materials are unavailable when modeling a microstructure, and, accordingly, they are substituted for the corresponding effective nonlocal quantities proposed in the nonlocal stress theory. Owing to an axial elongation, the nonlinear partial differential equation that governs the lateral motion of beam-like viscoelastic microstructures is derived using a geometric, kinematical, and dynamic analysis. In the next step, the ordinary differential equations are obtained, and the time-dependent lateral displacement is determined via a perturbation method. The effects of external excitation amplitude on excited vibration are presented, and the relations between the nonlocal parameter, viscoelastic damping, detuning parameter, and the forced amplitude are discussed. Some dynamic phenomena in the excited vibration are revealed, and these have reference significance to the dynamic design and optimization of beam-like viscoelastic microstructures.

Method of Experimentally Identifying the Complex Mode Shape of the Self-Excited Oscillation of a Cantilevered Pipe Conveying Fluid

The dynamics of a flexible cantilevered pipe conveying fluid have been researched for several decades. It is known that the flexible pipe undergoes self-excited vibration when the flow speed exceeds a critical speed. This instability phenomenon is caused by nonconservative forces. From a mathematical point of view, the system has a characteristic of non-selfadjointness and the linear eigenmodes can be complex and non-orthogonal to each other. As a result, such a mathematical feature of the system is directly related to the instability phenomenon. In this study, we propose a method of experimentally identifying the complex mode from experimentally obtained time histories and decomposing the linear mode into real and imaginary components. In nonlinear analysis, we show that the nonlinear effects of practical systems on the mode in the steady-state selfexcited oscillation are small. The real and imaginary components identified using the proposed method for experimental steady-state self-excited oscillations are compared with those obtained in the theoretical analysis, thus validating the proposed identification method.

Design of Regenerative Flutter Stability Detection System in Machine Tool Cutting

Cutting chatter is a strong relative vibration between cutting tool and work piece in machining process, which will reduce cutting quality and cutting efficiency, and shorten the service life of cutting tool and machine tool. As long as cutting is carried out in production, vibration will occur, and chatter is a strong self-excited vibration between machining work piece and cutting tool. Flutter problem will occur in almost all cutting processes, which will cause a series of problems such as the reduction of dimensional accuracy of machined work pieces, tool damage and so on. In the dynamic design and dynamic analysis of machine tool structure, in order to evaluate and improve the ability of machine tool to resist chatter, and to select the cutting conditions without chatter, it is necessary to judge the cutting stability of machine tool. How to improve the advanced technology of manufacturing industry is an important topic for manufacturing researchers, and the research on the detection of cutting chatter stability has important practical significance for promoting the development of cutting manufacturing industry to high-end technology.

Experimental study on vertical vibration characteristics of medium-low speed maglev vehicle when standing still on steel beams

Levitation stability is the very basis for the dynamic operation of Electromagnetic Suspension (EMS) medium-low speed maglev trains (MSMT). However, self-excited vibration tends to occur when the vehicle is standing still above the lightweight lines, which remains a major constraint to the promotion of medium-low speed maglev technology. In order to study the vertical vibration characteristics of the coupled system of MSMT when it is standing still above lightweight lines, levitation tests were carried out on two types of steel beams: steel beam and active girder of the turnout, with a newly developed maglev vehicle using levitation frames with mid-set air spring. Firstly, modal tests were carried out on the steel beam to determine its natural vibration characteristics; secondly, the acceleration signals and the dynamic displacement signals of the air spring obtained at each measurement point were analyzed in detail in both the time and frequency domains, and the vertical ride comfort was assessed by means of the calculated Sperling index. Subsequently, theoretical explanations were given for the occurrence of self-excited vibration of coupled system from the perspective of the vehicle-to-guideway vibration energy input. Results show that the eigen frequencies of the vehicle on the steel beam and the turnout are 9.65 Hz and 2.15 Hz, respectively, the former being close to the natural frequency of the steel beam while the latter being close to the natural frequency of the air spring suspension system, thus causing the self-excited vibration of the coupled system. It is recommended to either avoid the main eigen frequencies of the coupled system or to increase the damping of the corresponding vibration modes to guarantee a reliable coupled system for its long-term performance. These results may provide valuable references for the optimal design of medium-low speed maglev systems.

Noise Characteristics of Tungsten Circular Blade During Sawing of Medium Density Fiberboard

This work deals with the noise generated from sawing processes of medium density fiberboard, where special attention was given to the changes in sawing noise at different cutting conditions when using circular saws with varied radial slots. The experimental results gave the following insights: The noise level in idling is positively related to the spindle speed. According to the noise power spectra, whistling noise is found during sawing processes, which is mainly caused by self-excited vibration of saw, and it had directivity. Furthermore, the radial slots have a different positive contribution to the noise reduction during idling, but has limited effect on the noise in cutting. In order to reduce the noise pollution induced by sawing, it was proposed to use circular saws with radial slots and copper plugged in its bottom for sawing of medium density fiberboard, in respect to low noise level and avoiding whistling noise.

Investigation of friction noise properties of M50 matrix curved microporous channel composites filled with Sn-Ag-Cu

PurposeThis paper aims to investigate the friction noise properties of M50 matrix curved microporous channel composites filled with solid lubricant Sn-Ag-Cu (MS). Design/methodology/approachPure M50 (MA) and MS are prepared by selective laser melting and vacuum-pressure infiltration technology. The tribological and friction noise properties of MA and MS are tested through dry sliding friction and then the influential mechanism of surface wear sate on friction noise is investigated by analyzing the variation law of noise signals and the worn surface characteristics of MS. FindingsExperimental results show that the friction noise sound pressure level of MS is only 75.6 dB, and it mainly consists of low-frequency noise. The Sn-Ag-Cu improves the surface wear state, which reduces self-excited vibration of the interface caused by fluctuation of friction force, leading to the decrease of friction noise. Originality/valueThis investigation is meaningful to improve the tribological property and suppress the friction noise of M50 bearing steel.