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A Computational Framework for Control of Machining System Capability: From Formulation to Implementation
KTH, School of Industrial Engineering and Management (ITM), Production Engineering, Machine and Process Technology.ORCID iD: 0000-0001-9185-4607
2011 (English)Doctoral thesis, comprehensive summary (Other academic)
Abstract [en]

Comprehensive knowledge and information about the static and dynamic behaviour of machine tools, cutting processes and their interaction is essential for machining system design, simulation, control and robust operation in safe conditions. The very complex system of a machine tool, fixture and cutting tools during the machining of a part is almost impossible to model analytically with sufficient accuracy. In combination with increasing demands for precision and efficiency in machining call for new control strategies for machining systems. These strategies need to be based on the identification of the static and dynamic stability under both the operational and off-operational conditions. To achieve this it is necessary to monitor and analyze the real system at the factory floor in full production. Design information and operational data can then be linked together to make a realistic digital model of a given machining system. Information from such a model can then be used as input in machining simulation software to find the root causes of instability.

The work presented in this thesis deals with the static and dynamic capability of machining systems. The main focus is on the operational stability of the machining system and structural behaviour of only the machine tool, as well.

When the accuracy of a machining system is measured by traditional techniques, effects from neither the static stiffness nor the cutting process are taken into account. This limits the applicability of these techniques for realistic evaluation of a machining system’s accuracy. The research presented in this thesis takes a different approach by introducing the concept of operational dynamic parameters. The concept of operational dynamic parameters entails an interaction between the structural elements of the machining systems and the process parameters. According to this concept, the absolute criterion of damping is used to evaluate the dynamic behaviour of a machining system. In contrast to the traditional theory, this methodology allows to determine the machining system's dynamic stability, in real time under operating conditions. This framework also includes an evaluation of the static deformations of a machine tool.  In this context, a novel concept of elastically linked system is introduced to account for the representation of the cutting force trough an elastic link that closes the force loop. In addition to the elastic link which behaves as a static element, a dynamic non-contact link has been introduced. The purpose is to study the non-linear effects introduced by variations of contact conditions in joints due to rotational speed.

Place, publisher, year, edition, pages
Stockholm: KTH Royal Institute of Technology , 2011. , xv, 97 p.
Series
Trita-IIP, ISSN 1650-1888 ; 11:11
Keyword [en]
Machining system, Stability, Statistical Dynamics, Elastic Linked System (ELS), Operational Dynamic Parameters (ODP), Loaded Double Ball Bar (LDBB), Virtual Machining System Engine (VMSE), Contactless Excitation and Response System (CERS).
National Category
Production Engineering, Human Work Science and Ergonomics
Research subject
SRA - Production
Identifiers
URN: urn:nbn:se:kth:diva-48824ISBN: 978-91-7501-162-2 (print)OAI: oai:DiVA.org:kth-48824DiVA: diva2:458645
Public defence
2011-12-05, F3, Lindstedtsvägen 26, KTH, Stockholm, 09:00 (English)
Opponent
Supervisors
Funder
XPRES - Initiative for excellence in production research
Note
QC 20111123Available from: 2011-11-23 Created: 2011-11-23 Last updated: 2012-06-19Bibliographically approved
List of papers
1. 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
2. Model-Based Identification of Manufacturing Processes Operational Dynamic Parameters
Open this publication in new window or tab >>Model-Based Identification of Manufacturing Processes Operational Dynamic Parameters
2009 (English)In: The Annals of Univeritym of Galati / [ed] V. Paunoiu, Galati, 2009Conference paper, Published paper (Refereed)
Place, publisher, year, edition, pages
Galati: , 2009
Series
The Annals of Univerity of Galati, ISSN 1221-4566
Keyword
Machining, Stability, ARMA, Modelling, Classification
Research subject
SRA - Production
Identifiers
urn:nbn:se:kth:diva-27996 (URN)
Conference
Newtech 2009
Funder
XPRES - Initiative for excellence in production research
Note
QC 20110110Available from: 2011-01-04 Created: 2011-01-04 Last updated: 2011-11-23Bibliographically approved
3. Recursive estimation of operational dynamic parameters in milling using acoustic signal
Open this publication in new window or tab >>Recursive estimation of operational dynamic parameters in milling using acoustic signal
2010 (English)In: International Conference on Process Machine Interactions / [ed] Y. Altintas, Vancouver, 2010Conference paper, Published paper (Refereed)
Abstract [en]

The key concept of the identification procedure in this paper is to find a feature of the measured random response (sound pressure) that can be used to discriminate between stable and unstable process-machine interaction (PMI) in milling. The dynamic condition of the machining system is represented by the operational dynamic parameters (ODP), which refer to the contribution of the structural vibration modes and process vibration modes resulting during machining system operation. It is shown that the sound pressure level acquired by a microphone, located in the machine’s working area, is able to follow rapid changes in the process dynamics and therefore may be used as input in the recursive estimation scheme. The primary contribution of this paper lies within the formulation and implementation of recursive parametric models for the study of the real-time dynamics of a face milling operation PMI. A comparison between the experimental, simulated, and identified results is outlined.

Place, publisher, year, edition, pages
Vancouver: , 2010
Keyword
Milling, stability, recursive estimation, operational dynamic parameters
National Category
Engineering and Technology
Research subject
SRA - Production
Identifiers
urn:nbn:se:kth:diva-27790 (URN)
Conference
2nd International Conference on Process Machine Interactions, 10-11 June, 2010, Vancouver BC, Canada
Projects
FFI Robust maskinbearbetning
Funder
XPRES - Initiative for excellence in production research
Note
QC 20110126Available from: 2011-01-26 Created: 2010-12-31 Last updated: 2011-11-23Bibliographically approved
4. Recursive estimation of machine tool structure dynamic properties
Open this publication in new window or tab >>Recursive estimation of machine tool structure dynamic properties
2010 (English)In: CIRP International Conference on High Performance Cutting, / [ed] Tojiro Aoyama, Yoshimi Takeuchi, Gifu, 2010, 365-370 p.Conference paper, Published paper (Refereed)
Abstract [en]

In today’s highly competitive environment there is a need for fast and accurate methods to assess the capability of manufacturing units. The traditional estimation of the dynamic properties of machine tools is usually time consuming and assumes time-invariant properties. This paper introduces a method for analyzing machine tool structure dynamic properties by recursive estimation of modal and operational parameters. A contact-less excitation system and a specially designed tool were employed to enable spindle speed sweep. The primary contribution of this paper lies within the formulation and implementation of recursive parametric models for tracking the time-varying dynamic properties of a machine tool structure.

Place, publisher, year, edition, pages
Gifu: , 2010
Series
CIRP High Performance Cutting, 4
Keyword
High speed machine tool, Spindle, Recursive estimation, Modal parameters, Operational dynamic parameters, Contact-less excitation system
National Category
Engineering and Technology
Research subject
SRA - Production
Identifiers
urn:nbn:se:kth:diva-27789 (URN)978-4-915698-03-3 (ISBN)
Conference
4th CIRP International Conference on High Performance Cutting, 24-26 October, 2010, Nagaragawa Convention Center, Gifu, Japan
Projects
FFI Robust maskinbearbetning
Funder
XPRES - Initiative for excellence in production research
Note
QC 20110126Available from: 2011-01-26 Created: 2010-12-31 Last updated: 2012-04-13Bibliographically approved
5. Manufacturing resource modelling for model driven operation planning
Open this publication in new window or tab >>Manufacturing resource modelling for model driven operation planning
Show others...
2010 (English)In: Process Machine Interactions (PMI): Vancouver, Canada, June 10-11, 2010 / [ed] Prof. Y. Altintas, University of British Columbia, 2010Conference paper, Published paper (Refereed)
Abstract [en]

Models of manufacturing resources as machine tools, fixtures and cutting tools contribute to efficient and simplified operation planning. With operation planning domain concept, defined in ontology and used during modelling of coherent ISO 10303-214 conforming data models of manufacturing resources, stable implementation solutions are ensured while capable of representing current manufacturing resources and resources developed in the future. Using similarities between different types of resources, a unified modelling approach may be applied independent of the type of object. Information classes as interfaces, kinematics, performance and behavior are identified and related to corresponding construct of the standardized product generic schema. With the common representation of shared information between applications domains as operation planning, maintenance and factory layout design, presented result contributes to set the basis for a digital factory used in virtual manufacturing to continuously improve the production system.

 

Keyword
Modelling, Computer Aided Process Planning (CAPP), Manufacturing resource data
National Category
Production Engineering, Human Work Science and Ergonomics Computer and Information Science
Research subject
SRA - Production
Identifiers
urn:nbn:se:kth:diva-27788 (URN)978-0-9866331-0-2 (ISBN)
Conference
CIRP 2nd International Conference on Process Machine Interactions
Projects
Feature Based Operation Planning, Vinnova FFI Program (Strategic Vehicle Research and Innovation Initiative)Robust Machining, Vinnova FFI Program (Strategic Vehicle Research and Innovation Initiative)Digital factory building blocks, Vinnova FFI Program (Strategic Vehicle Research and Innovation Initiative)
Funder
XPRES - Initiative for excellence in production research
Note

QC 20110105

Available from: 2010-12-30 Created: 2010-12-30 Last updated: 2013-05-14Bibliographically approved
6. Virtual machining system engine for validation of realtime identification schems
Open this publication in new window or tab >>Virtual machining system engine for validation of realtime identification schems
2011 (English)Conference paper, Published paper (Refereed)
Abstract [en]

The aim of this paper is to introduce a novel methodology, based on a finite element (FE) computation engine for validating of real-time identification schemes applied in machining. FE modelling of the milling process has the purpose of being accountable for a thorough validation of the parametric identification approach, and of providing a good physical insight into the phenomena investigated. The system considered here has a lower number of degree-of-freedoms which permits a thorough analysis. However, when taking into account the system’s nonlinear and time-varying nature, it is clear that the results are far from being trivial. Therefore, the analysis of the milling process, taking into account nonlinearities restricting the growth of response amplitudes in the case of chatter-type instability, provides some intrinsic information of the basic features on the system that might be of both fundamental interest and practical use.

Place, publisher, year, edition, pages
Brno: , 2011
Series
International conference Newtech on Advance manufacturing engineering
Keyword
FEM, milling, simulation, model order selection
National Category
Engineering and Technology
Research subject
SRA - Production
Identifiers
urn:nbn:se:kth:diva-41268 (URN)978-80-214-4267-2 (ISBN)
Conference
International Conference Newtech. 14-15 September 2011. Brno.
Projects
FFI Robust maskinbearbetning
Funder
XPRES - Initiative for excellence in production research
Note
QC 20110929Available from: 2011-09-25 Created: 2011-09-25 Last updated: 2012-06-19Bibliographically approved

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