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Suppressing tool chatter with novel multi-layered nanostructures of carbon based composite coatings
KTH, School of Industrial Engineering and Management (ITM), Production Engineering, Machine and Process Technology. (MMS)ORCID iD: 0000-0002-4677-7005
KTH, School of Industrial Engineering and Management (ITM), Production Engineering, Machine and Process Technology.
Show others and affiliations
2015 (English)In: Journal of Materials Processing Technology, ISSN 0924-0136, E-ISSN 1873-4774, Vol. 223, 292-298 p.Article in journal (Refereed) 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.

Place, publisher, year, edition, pages
2015. Vol. 223, 292-298 p.
Keyword [en]
Milling, Tool regenerative chatter, Metal matrix composites, Nano-structures, Internal friction damping, Plasma enhanced chemical vapour deposition (PECVD)
National Category
Production Engineering, Human Work Science and Ergonomics Nano Technology Composite Science and Engineering
Identifiers
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: diva2:840139
Funder
EU, European Research Council, 260048, 608800
Note

QC 20150707

Available from: 2015-07-07 Created: 2015-07-03 Last updated: 2017-12-04Bibliographically approved
In thesis
1. High dynamic stiffness nano-structured composites for vibration control: A Study of applications in joint interfaces and machining systems
Open this publication in new window or tab >>High dynamic stiffness nano-structured composites for vibration control: A Study of applications in joint interfaces and machining systems
2015 (English)Doctoral thesis, comprehensive summary (Other academic)
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.

Place, publisher, year, edition, pages
Stockholm: KTH Royal Institute of Technology, 2015. ix, 71 p.
Series
TRITA-IIP, ISSN 1650-1888
Keyword
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
National Category
Nano Technology Production Engineering, Human Work Science and Ergonomics Composite Science and Engineering Fusion, Plasma and Space Physics Chemical Sciences Manufacturing, Surface and Joining Technology Applied Mechanics
Research subject
Production Engineering
Identifiers
urn:nbn:se:kth:diva-176869 (URN)978-91-7595-740-1 (ISBN)
Public defence
2015-12-01, M311, Brinellvägen 68, KTH, Stockholm, 10:00 (English)
Opponent
Supervisors
Funder
EU, FP7, Seventh Framework Programme, 608800EU, FP7, Seventh Framework Programme, 260048VINNOVA, E!4329VINNOVA, HydroMod
Available from: 2015-11-11 Created: 2015-11-10 Last updated: 2015-11-11Bibliographically approved
2. Estimation of Machining System Dynamic Properties - Measurement and Modelling
Open this publication in new window or tab >>Estimation of Machining System Dynamic Properties - Measurement and Modelling
2017 (English)Doctoral thesis, comprehensive summary (Other academic)
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.

Place, publisher, year, edition, pages
Stockholm: Kungliga Tekniska högskolan, 2017. 57 p.
Series
TRITA-IIP, ISSN 1650-1888 ; 17-02
Keyword
Machining system, Operational dynamic parameters, Displacement map, Contactless excitation and response system
National Category
Production Engineering, Human Work Science and Ergonomics
Research subject
SRA - Production; Production Engineering
Identifiers
urn:nbn:se:kth:diva-204579 (URN)978-91-7729-323-1 (ISBN)
Public defence
2017-04-28, F3, Lindstedtsvägen 26, Stockholm, 10:00 (English)
Opponent
Supervisors
Funder
VINNOVA
Note

QC 20170330

Available from: 2017-03-30 Created: 2017-03-28 Last updated: 2017-03-30Bibliographically approved

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