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Model-Based Investigation of Machining Systems Characteristics: Static and Dynamic Stability Analysis
KTH, School of Industrial Engineering and Management (ITM), Production Engineering, Machine and Process Technology.ORCID iD: 0000-0001-9185-4607
2008 (English)Licentiate thesis, comprehensive summary (Other academic)
Abstract [en]

The increasing demands for precision and efficiency in machining call for new control strategies for machining systems based on the identification of static and dynamic characteristics under operational conditions. By considering the machining system as a closed-loop system consisting of a machine tool structure and a machining process, the join system characteristics can be analyzed. The capability of a machining system is mainly determined by its static and dynamic stiffness.

The goal of this thesis is to introduce some concepts and methods regarding the identification of machining system stability. Two methods are discussed, one for the static behaviour analysis of a machine tool, and one for dynamic stability of a machining system. Preliminary results are indicating unambiguous identification of capabilities of machining systems static and dynamic characteristics.

The static behaviour of a machine tool is evaluated by use of a loaded double ball bar (LDBB) device. The device reproduces the real interaction between the join system, the machine tool elastic structure and the cutting process. This load is not equivalent to real cutting forces, but it does have a similar effect on the structure. This has been investigated both trough simulation and experimental work.

It is possible to capture the process – ­machine interaction in a machining system by use of the model-based identification approach. The identification approach takes into consideration this interaction and can therefore be used to characterize the machining system under operational conditions. The approach provides realistic prerequisites for in-process machining system testing. The model parameters can be further employed for control and optimization of the cutting process. Using different classification schemes, the model-based identification method is promising for the detection of instability.

Furthermore, it is the author’s belief that a model-based stability analysis approach is needed to exploit the full potential of a model driven parts manufacturing approach.

Place, publisher, year, edition, pages
Stockholm: KTH , 2008. , ix, 62 p.
Series
Trita-IIP, ISSN 1650-1888 ; 08-13
Keyword [en]
Machining systems, modelling
National Category
Engineering and Technology
Identifiers
URN: urn:nbn:se:kth:diva-9754ISBN: 978-91-7415-196-1 (print)OAI: oai:DiVA.org:kth-9754DiVA: diva2:127584
Presentation
2008-12-15, Brinellsalen M312, Brinellvägen 68, KTH, Stockholm, 13:00 (English)
Opponent
Supervisors
Note
QC 20101103Available from: 2008-12-11 Created: 2008-12-09 Last updated: 2010-11-03Bibliographically approved
List of papers
1. Evaluation of machining system static stiffness
Open this publication in new window or tab >>Evaluation of machining system static stiffness
2007 (English)In: Swedish Production Symposium: Gothenburg, Sweden, 2007, 2007Conference paper, Published paper (Refereed)
Abstract [en]

The majority of test methods used for determine a machining systems status, are machine tool oriented and do not take into consideration the characteristics of the machining process. In this paper an evaluation method for determining a machining system static characteristics are discussed. The importance of joint stiffness and damping in elastic structures of machine tool is emphasized. In this context the new type of double ball bar (DBB) is described which applies a preload on the structure, thus creating more realistic conditions for accuracy measurements. Also, for machine capability analysis, the overall elastic structure must be considered, i.e., machine tool-fixture-workpiece-tool holder-tool.

Keyword
Machining system, elastic structure, static stiffness, machining process, accuracy, DBB
National Category
Engineering and Technology
Identifiers
urn:nbn:se:kth:diva-25867 (URN)
Note
QC 20101103Available from: 2010-11-03 Created: 2010-11-03 Last updated: 2011-01-05Bibliographically approved
2. Evaluation of machining system dynamic stiffness
Open this publication in new window or tab >>Evaluation of machining system dynamic stiffness
2007 (English)In: Swedish Production Symposium: Gothenburg, Sweden, 2007, 2007Conference paper, Published paper (Refereed)
Abstract [en]

Today’s test methods are analysing machine tool specific characteristics but leaves out to a great deal the machining process. In this paper an evaluation method for determining machining system dynamic characteristics is discussed. For machine capability analysis, the overall elastic structure must be considered, i.e., machine tool – fixture – workpiece – toolholder – tool. Regarding dynamic behaviour of machining systems, the stability can only be evaluated through the interaction between the two subsystems, elastic structure and cutting process. In order to analyse the join machining system, stochastic discrete models, ARMA models are used to identify the stability of the join system, elastic structure – machining process.

Keyword
Machining system, dynamic stiffness, model based vibration analysis, ARMA models
National Category
Engineering and Technology
Identifiers
urn:nbn:se:kth:diva-25876 (URN)
Note
QC 20101103Available from: 2010-11-03 Created: 2010-11-03 Last updated: 2010-11-03Bibliographically approved
3. Model-based Identification of Dynamic Stability of Machining System
Open this publication in new window or tab >>Model-based Identification of Dynamic Stability of Machining System
2008 (English)In: 1st International Conference on Process Machine Interaction - Proceedings, 2008, 41-52 p.Conference paper, Published paper (Refereed)
Keyword
Machining system, modelling, dynamic stability, in-process identification
National Category
Engineering and Technology
Identifiers
urn:nbn:se:kth:diva-25878 (URN)
Conference
1st International Conference on Process Machine Interaction, Hannover, Germany, 2008
Note
QC 20101103Available from: 2010-11-03 Created: 2010-11-03 Last updated: 2011-11-23Bibliographically approved
4. Loaded double ball bar for capability testing of NC machine tools
Open this publication in new window or tab >>Loaded double ball bar for capability testing of NC machine tools
(English)In: Mechanical systems and signal processing, ISSN 0888-3270, E-ISSN 1096-1216Article in journal (Other academic) Submitted
Abstract [en]

This paper presents a novel test device for the evaluation of the accuracy of NC machine tools. The design concept is similar to a double ball bar (DBB) with the difference that an adjustable load generated by the device can be applied between spindle nose and machine tool table. This load eliminates the play existing in machine tool joints, thus reproducing the testing conditions that exist during machining. Collected data can be used to plot diagrams displaying important aspects of machine tool performance and a number of key figures such as static stiffness may be determined. The data can also be used for trend analysis; to predict any accuracy problems, and further to conduct preventive maintenance instead of emergency calls. The determined static behaviour could also be used to improve digital models for process simulations and compensation of errors caused by deflection.

Keyword
Machine tool testing, loaded double ball bar, static stiffness, trend analysis
National Category
Engineering and Technology
Identifiers
urn:nbn:se:kth:diva-25881 (URN)
Note
QC 20101103Available from: 2010-11-03 Created: 2010-11-03 Last updated: 2017-12-12Bibliographically approved

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Archenti, Andreas

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