Simulation-Based Stability Analysis of a Thin-Walled Cylinder During Turning with Improvements Using an Adaptronic Turning Chisel

Open access

Simulation-Based Stability Analysis of a Thin-Walled Cylinder During Turning with Improvements Using an Adaptronic Turning Chisel

The dynamics of the turning process of a thin-walled cylinder in manufacturing is modeled using flexible multibody system theory. The obtained model is time varying due to workpiece rotation and tool feed and retarded, due to repeated cutting of the same surface. Instabilites can occur due to these consecutive cuts that must be avoided in practical application because of the detrimental effects on workpiece, tool and possibly the machine. Neglecting the small feed, the stability of the resulting periodic system with time-delay can be analyzed using the semi-discretization method.

The use of an adaptronic tool holder comprising actuators and sensors to improve the dynamic stability is then investigated. Different control concepts, two collocated and two model-based, are implemented in simulation and tuned to increase the domain of stable cutting. Cutting of a moderately thin workpiece exhibits instabilities mainly due to tool vibration. In this case, the stability boundary can be significantly improved. When the instability is due to workpiece vibration, the collocated concepts fail completely. Model based concepts can still obtain some improvements, but are sensitive to modeling errors in the coupling of workpiece and tool.

Tobias S. A.: Machine-Tool Vibration. London, Blackie and Sons, 1965.

Shabana A. A.: Dynamics of Multibody Systems. Cambridge, Cambridge University Press, 1998.

Insperger T., Stépán G.: Semi-Discretization Method for Delayed Systems. International Journal for Numerical Methods in Engineering, Vol. 55, pp. 503-518, 2002.

Ambrósio J., Gonçalves J.: Complex Flexible Multibody Systems with Application to Vehicle Dynamics. Multibody System Dynamics, Vol. 6, No. 2, pp. 163-182, 2001.

Kienzle O.: Die Bestimmung von Kräften und Leistungen an spanenden Werkzeugen und Werkzeugmaschinen (in German). Zeitschrift des Vereines Deutscher Ingenieure, Vol. 94, pp. 299-305, 1952.

Paucksch E., Holsten S., LinßM., Tikal F.: Zerspantechnik (in German). Wiesbaden: Vieweg+Teubner, 2008.

Budak E., Altintas Y.: Analytical Prediction of Chatter Stability in Milling - Part I: General Formulation. ASME Journal of Dynamic Systems, Measurement, and Control, Vol. 120, pp. 22-30, 1998.

Henninger C., Eberhard P.: Computation of Stability Bounds for Milling Processes with Parallel Kinematic Machine Tools. Journal of Systems and Control Engineering, Vol. 223, No. 1, pp. 117-129, 2009.

Henninger C., Eberhard P.: Analysis of Dynamic Stability for Milling Processes with Varying Workpiece Dynamics. PAMM Proceedings in Applied Mathematics and Mechanics, Vol. 8, No. 1, pp. 10367-10368, 2008.

Hale J. K., Lunel S. M. V.: Introduction to Functional Differential Equations. New York, Springer, 1993.

Bayly V. B., Davies M. A., Halley J. E., Pratt J. R.: Stability Analysis of Interrupted Cutting with Finite Time in Cut. In Proceedings of the ASME Manufacturing Engineering Division, Vol. 11, pp. 989-996, 2000.

Bayly P. V., Halley J. E., Mann B. P., Davies M. A.: Stability of Interrupted Cutting by Temporal Finite Element Analysis. ASME Journal of Manufacturing Sciences and Engineering, Vol. 125, No. 2, pp. 220-225, 2003.

Insperger T., Stépán G.: Updated Semi-Discretization Method for Periodic Delay-Differential Equations with Discrete Delay. International Journal for Numerical Methods in Engineering, Vol. 61, pp. 117-141, 2004.

Henninger C.: Methoden zur simulationsbasierten Analyse der dynamischen Stabilität von Fräsprozessen (in German). Dissertation, Schriften aus dem Institut für Technische und Numerische Mechanik der Universität Stuttgart, Band 15. Aachen, Shaker Verlag, 2009.

Heisel U., Kang C.: Model-based Form Error Compensation in the Turning of Thin-walled Cylindrical Parts. Production Engineering Research and Development, Vol. 5, No. 2, pp. 151-158, 2010.

Ast A., Eberhard P.: Control Concepts for a Machine Tool with an Adaptronic Actuator. In C. Bottasso; P. Masarati; L. Trainelli (Eds.) Proc. of the ECCOMAS Thematic Conference on Multibody Dynamics, Milano, Italy, 2007.

Ast A., Braun S., Eberhard P., Heisel U.: An Adaptronic Approach to Active Vibration Control of Machine Tools with Parallel Kinematics. Production Engineering Research and Development, Vol. 3, pp. 207-215, 2009.

Preumont A.: Vibration Control of Active Structures. Dordrecht, Kluwer, 2002.

Gawronski W. K.: Advanced Structural Dynamics and Active Control of Structures. New York, Springer, 2004.

Zhou K., Doyle J., Glover K.: Robust and Optimal Control. Upper Saddle River, Prentice Hall, 1996.

Skogestad S., Postlethwaite I.: Multivariable Feedback Control: Analysis and Design. Chichester, John Wiley & Sons, 2nd. Edn., 2005.

Archive of Mechanical Engineering

The Journal of Committee on Machine Building of Polish Academy of Sciences

Journal Information

CiteScore 2016: 0.44

SCImago Journal Rank (SJR) 2016: 0.162
Source Normalized Impact per Paper (SNIP) 2016: 0.459

Cited By


All Time Past Year Past 30 Days
Abstract Views 0 0 0
Full Text Views 116 116 10
PDF Downloads 52 52 8