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Suppressing tool chatter with novel multi-layered nanostructures of carbon based composite coatings
KTH, Skolan för industriell teknik och management (ITM), Industriell produktion, Maskin- och processteknologi. (MMS)ORCID-id: 0000-0002-4677-7005
KTH, Skolan för industriell teknik och management (ITM), Industriell produktion, Maskin- och processteknologi.
Visa övriga samt affilieringar
2015 (Engelska)Ingår i: Journal of Materials Processing Technology, ISSN 0924-0136, E-ISSN 1873-4774, Vol. 223, s. 292-298Artikel i tidskrift (Refereegranskat) Published
Abstract [en]

Multi-layered nanostructured Cu and Cu-CNx composites synthesized by plasma-enhanced chemical vapour deposition were applied in the clamping area of a milling tool to suppress regenerative tool chatter. Scanning electron microscopy analysis showed a multi-layered nanostructure with excellent conformality, i.e. coating is not only uniform on planar surfaces but also around corners of the substrate. Cu:CuCNx nanostructured multilayers with thicknesses of approximately 0.5:1.6 mu m were obtained. With a diameter of 20 mm, the milling tool performed slotting processes at an overhang length of 120 mm. Modal analysis showed that a coating, with a thickness of approximately 300 mu m, can add sufficient damping without losing stiffness of the tool, to increase the critical stability limit by 50% or 100% depending on cutting direction.

Ort, förlag, år, upplaga, sidor
2015. Vol. 223, s. 292-298
Nyckelord [en]
Milling, Tool regenerative chatter, Metal matrix composites, Nano-structures, Internal friction damping, Plasma enhanced chemical vapour deposition (PECVD)
Nationell ämneskategori
Produktionsteknik, arbetsvetenskap och ergonomi Nanoteknik Kompositmaterial och -teknik
Identifikatorer
URN: urn:nbn:se:kth:diva-170666DOI: 10.1016/j.jmatprotec.2015.03.043ISI: 000356106600031Scopus ID: 2-s2.0-84929497633OAI: oai:DiVA.org:kth-170666DiVA, id: diva2:840139
Forskningsfinansiär
EU, Europeiska forskningsrådet, 260048, 608800
Anmärkning

QC 20150707

Tillgänglig från: 2015-07-07 Skapad: 2015-07-03 Senast uppdaterad: 2017-12-04Bibliografiskt granskad
Ingår i avhandling
1. High dynamic stiffness nano-structured composites for vibration control: A Study of applications in joint interfaces and machining systems
Öppna denna publikation i ny flik eller fönster >>High dynamic stiffness nano-structured composites for vibration control: A Study of applications in joint interfaces and machining systems
2015 (Engelska)Doktorsavhandling, sammanläggning (Övrigt vetenskapligt)
Abstract [en]

Vibration control requires high dynamic stiffness in mechanical structures for a reliable performance under extreme conditions. Dynamic stiffness composes the parameters of stiffness (K) and damping (η) that are usually in a trade-off relationship. This thesis study aims to break the trade-off relationship.

After identifying the underlying mechanism of damping in composite materials and joint interfaces, this thesis studies the deposition technique and physical characteristics of nano-structured HDS (high dynamic stiffness) composite thick-layer coatings. The HDS composite were created by enlarging the internal grain boundary surface area through reduced grain size in nano scale (≤ 40 nm). The deposition process utilizes a PECVD (Plasma Enhanced Chemical Vapour Deposition) method combined with the HiPIMS (High Power Impulse Magnetron Sputtering) technology. The HDS composite exhibited significantly higher surface hardness and higher elastic modulus compared to Poly(methyl methacrylate) (PMMA), yet similar damping property. The HDS composites successfully realized vibration control of cutting tools while applied in their clamping interfaces.

Compression preload at essential joint interfaces was found to play a major role in stability of cutting processes and a method was provided for characterizing joint interface properties directly on assembled structures. The detailed analysis of a build-up structure showed that the vibrational mode energy is shifted by varying the joint interface’s compression preload. In a build-up structure, the location shift of vibration mode’s strain energy affects the dynamic responses together with the stiffness and damping properties of joint interfaces.

The thesis demonstrates that it is possible to achieve high stiffness and high damping simultaneously in materials and structures. Analysis of the vibrational strain energy distribution was found essential for the success of vibration control.

Ort, förlag, år, upplaga, sidor
Stockholm: KTH Royal Institute of Technology, 2015. s. ix, 71
Serie
TRITA-IIP, ISSN 1650-1888
Nyckelord
Vibration control, High dynamic stiffness, Metal matrix composite, Nano structures, Plasma enhanced chemical vapour deposition (PECVD), High power impulse magnetron sputtering (HiPIMS), Adiabatic, Machining, Regenerative tool chatter
Nationell ämneskategori
Nanoteknik Produktionsteknik, arbetsvetenskap och ergonomi Kompositmaterial och -teknik Fusion, plasma och rymdfysik Kemi Bearbetnings-, yt- och fogningsteknik Teknisk mekanik
Forskningsämne
Industriell produktion
Identifikatorer
urn:nbn:se:kth:diva-176869 (URN)978-91-7595-740-1 (ISBN)
Disputation
2015-12-01, M311, Brinellvägen 68, KTH, Stockholm, 10:00 (Engelska)
Opponent
Handledare
Forskningsfinansiär
EU, FP7, Sjunde ramprogrammet, 608800EU, FP7, Sjunde ramprogrammet, 260048VINNOVA, E!4329VINNOVA, HydroMod
Tillgänglig från: 2015-11-11 Skapad: 2015-11-10 Senast uppdaterad: 2015-11-11Bibliografiskt granskad
2. Estimation of Machining System Dynamic Properties - Measurement and Modelling
Öppna denna publikation i ny flik eller fönster >>Estimation of Machining System Dynamic Properties - Measurement and Modelling
2017 (Engelska)Doktorsavhandling, sammanläggning (Övrigt vetenskapligt)
Abstract [en]

Dynamic characteristics of machining systems are analysed for improved understanding of both structural and process properties. The thesis stresses the use of testing methods under operational like conditions as these are more representative of closed loop systems, such as machining systems, as compared to conventional testing methods.

The test instrument proposed is a contactless excitation and response system, developed for testing of machine tool spindles under load and with rotating spindle. The instrument uses electromagnetic excitation and displacement sensors for analysis of rotating milling tools subject to load. A graphical tool for displaying and analysing rotor displacement was developed in conjunction with this.

A modelling procedure for both off-line and on-line estimation of dynamic properties of mechanical structure and process information is presented. The proposed auto-regressive moving average models enable calculation of operational dynamic parameters and they can be estimated in a recursive manner, thus enabling real-time monitoring. The discrimination between stable and unstable processes, both in turning and milling, was performed by analysing the damping obtained from the operational dynamic parameters.

Ort, förlag, år, upplaga, sidor
Stockholm: Kungliga Tekniska högskolan, 2017. s. 57
Serie
TRITA-IIP, ISSN 1650-1888 ; 17-02
Nyckelord
Machining system, Operational dynamic parameters, Displacement map, Contactless excitation and response system
Nationell ämneskategori
Produktionsteknik, arbetsvetenskap och ergonomi
Forskningsämne
SRA - Produktion; Industriell produktion
Identifikatorer
urn:nbn:se:kth:diva-204579 (URN)978-91-7729-323-1 (ISBN)
Disputation
2017-04-28, F3, Lindstedtsvägen 26, Stockholm, 10:00 (Engelska)
Opponent
Handledare
Forskningsfinansiär
VINNOVA
Anmärkning

QC 20170330

Tillgänglig från: 2017-03-30 Skapad: 2017-03-28 Senast uppdaterad: 2017-03-30Bibliografiskt granskad

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