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An Analysis of Machining System Capability and Its Link with Machined Component Quality
KTH, School of Industrial Engineering and Management (ITM), Production Engineering, Machine and Process Technology.ORCID iD: 0000-0003-0155-127X
2013 (English)Licentiate thesis, comprehensive summary (Other academic)
Abstract [en]

Machining components out of tolerances is of no use in competitiveproduction. The machining system sets the limitations of dimensionalaccuracy and surface quality of a machined component. The capabilityof the machining system describes these limits in terms of specifiedvalues. This thesis deals with machining system capability analysismainly focused on machine tool static and dynamic stiffness.The influence of stiffness and flexibility on machining systemcapability is analytically and experimentally investigated. Theexperimental work presented in the thesis complies with the theoriesand shows the relation between machine tool capability and theoutcome on the machine component.The concept of capability analysis by elastic linked system andthe currently available tools for such an evaluation is presented anddiscussed. The basis of elastic linked system analysis is the use ofmeasurements under loaded condition. The machine tool is loadedwith a known force creating a test condition closer to real machining,compared to current methods of unloaded machine tools. Twomeasurement tools for elastic linked system capability analysis areexplained in the thesis: Loaded Double Ball Bar and ContactlessExcitation and Response System.The thesis consists of an analytical base and an experimental casestudy on spiral bevel gear face milling. The experiments are discussedand compiled with the given theories.

Place, publisher, year, edition, pages
Stockholm: KTH Royal Institute of Technology, 2013. , xiii, 54 p.
Series
Trita-IIP, ISSN 1650-1888 ; 13:03
Keyword [en]
Machining System Capability, Elastic Linked System, Spiral Bevel Gear Face Milling
National Category
Production Engineering, Human Work Science and Ergonomics
Research subject
SRA - Production
Identifiers
URN: urn:nbn:se:kth:diva-122144ISBN: 978-91-7501-757-0 (print)OAI: oai:DiVA.org:kth-122144DiVA: diva2:620981
Presentation
2013-05-17, Sal M311, Brinellvägen 68, KTH, Stockholm, 10:00 (English)
Opponent
Supervisors
Funder
XPRES - Initiative for excellence in production research
Note

QC 20130513

Available from: 2013-05-13 Created: 2013-05-13 Last updated: 2013-05-13Bibliographically approved
List of papers
1. Improvement of Gear Cutter Dynamics by Use of Acoustic Imaging and High Damping Interface
Open this publication in new window or tab >>Improvement of Gear Cutter Dynamics by Use of Acoustic Imaging and High Damping Interface
2012 (English)In: 3rd CIRP Conference on Process Machine Interactions / [ed] Shamoto, E, 2012, 17-21 p.Conference paper, Published paper (Refereed)
Abstract [en]

This paper presents a study where acoustic imaging technology was employed for problem identification and high damping interfaces (HDI) were implemented in the machine tool structure to improve performance of process machine interaction, in bevel gear cutting, in terms of resistance to instability. Chatter marks at the gear root and tool fracturing represent a serious and widespread problem in the studied process. The acoustic image approach showed good agreement with modal analysis and also allowed to identify the chatter frequency. Once identified the problem, the paper also presents a novel approach for improving resistance to cutting instability by implementing HDI in the structure. The HDI consists of a viscoelastic composite material and is used to damp out the stick blade motion relative to the clamp block by transformation of vibratory energy, into heat. The primary contributions of this paper are the introduction of acoustic imaging for identification of chatter in gear cutting and employment of HDI for performance improvement for rotating tools.

Series
Procedia CIRP, ISSN 2212-8271 ; 4
Keyword
Gear cutter, Testing, High Damping Interface, Acoustic Imaging
National Category
Production Engineering, Human Work Science and Ergonomics
Identifiers
urn:nbn:se:kth:diva-119570 (URN)10.1016/j.procir.2012.10.004 (DOI)000315024500003 ()2-s2.0-84883854848 (Scopus ID)
Conference
3rd CIRP Conference on Process Machine Interactions (PMI), OCT 29-30, 2012, Nagoya, Japan
Funder
XPRES - Initiative for excellence in production research
Note

QC 20130318

Available from: 2013-03-18 Created: 2013-03-18 Last updated: 2017-03-28Bibliographically approved
2. Evaluation and Representation of Machine tool Deformations
Open this publication in new window or tab >>Evaluation and Representation of Machine tool Deformations
2011 (English)In: Journal of Machine Engineering, ISSN 1895-7595, Vol. 11, no 4, 118-129 p.Article in journal (Refereed) Published
Abstract [en]

This paper presents a novel test concept for the evaluation of the accuracy of NC machine tools. The evaluation of machine tools deformations is performed by help of a device similar to the 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 are used to plot diagrams displaying characteristic aspects of achine tool performance and a number of key figures such as static stiffness may be etermined. The data can also be used for trend analysis; to predict any accuracy deviations, 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 that are caused by deflection.

Place, publisher, year, edition, pages
Wroclaw: Editorial Institution of the Wroclaw Board of Scientific Technical Societies Federation NOT, 2011
Keyword
machine tool, testing, deformation, static stiffness, circular test, loaded double ball bar
National Category
Production Engineering, Human Work Science and Ergonomics
Research subject
SRA - Production
Identifiers
urn:nbn:se:kth:diva-105190 (URN)
Funder
XPRES - Initiative for excellence in production research
Note

QC 20130123

Available from: 2012-11-18 Created: 2012-11-18 Last updated: 2017-03-30Bibliographically approved

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Österlind, Tomas

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