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Journal articles on the topic 'Spindle operation accuracy'
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1
Казакова, Ольга, Ol'ga Kazakova, Лана Гаспарова, and Lana Gasparova. "EXPERIMENTAL DEFINITION OF BASING ACCURACY AND TOOL FASTENING." Bulletin of Bryansk state technical university 2019, no. 9 (October 7, 2019): 15–24. http://dx.doi.org/10.30987/article_5d9317b24f2524.52540627.
Full textAbstract:
There are presented results of experimental investigations allowing the definition of factors (parameters) influencing the accuracy of basing and fastening a tool in a machine spindle.
The plant design developed allows modeling the work of elements and mechanisms of a spindle unit of a jig-boring machine (JBM) at the moment of tool changing.
The series of experiments carried out allowed drawing the following conclusions:
- the accuracy of a tool installation in a machine spindle depends upon its angular position in a spindle taper;
- angular errors of a tool cone element decrease a rigidity of a “spindle-tool” subsystem by 10…15%;
- elastic movements in the area of a contact increase by 2-2.5 times at the presence of ovality in the cross-section of a holder (at ovality 18mkm);
- the accuracy of tool location in a spindle increases with the increase of an axial tightening force (recommended tightening force – 3 ≤ Ptight. ≤ 5kN);
- the holder operation results in the rigidity decrease of a tool system by 10…15% (operation term – 5 years).
2
Holub, Michal, Jan Vetiska, Josef Knobloch, and Petr Minar. "Analysis of Machine Tool Spindles under Load." Applied Mechanics and Materials 821 (January 2016): 608–13. http://dx.doi.org/10.4028/www.scientific.net/amm.821.608.
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This paper deals with a new experimental approach to the analysis of radial, axial, and tilt error movements of machine tool spindles under load. The main focus is on the identification of error spindle movements under different machine operation conditions between 500 - 5000 rev / min and loads in the range of 50 - 500 N. Errors of the spindle movements are measured on the cylindrical workpiece using capacitance sensors for different loads. The analysis of measurements of radial, axial, and tilt error movements of machine tool spindle indicates a dependency of loads and measured errors. The integration of error measurements into novel multi-body dynamic models of machine tool spindles is very important for prediction of machine behaviour during a cutting process and for prediction of workpiece geometric accuracy.
3
Pan, Xin, Xiaotian He, Kunzhu Wei, Haiqi Wu, Jinji Gao, and Zhinong Jiang. "Performance Analysis and Experimental Research of Electromagnetic-Ring Active Balancing Actuator for Hollow Rotors of Machine Tool Spindles." Applied Sciences 9, no. 4 (February 18, 2019): 692. http://dx.doi.org/10.3390/app9040692.
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Active balancing actuators are essential components of intelligent machine tool spindles to automatically reduce the unbalance vibration and promote machining accuracy and efficiency. In this study, a novel electromagnetic-ring actuator is introduced, which can be integrated into the hollow rotor of the spindle and compensate the initial mass imbalance through step rotation of two counterweight discs driven by the magnetic field. The working principle of the actuator is described in detail and its performance is analyzed, including balancing ability, balancing accuracy and self-lock capacity. To control the normal operation of the actuator, a phase detection and control program was developed. Finally, to verify the effectiveness of the novel actuator, function experiments and active balancing experiments were carried out. The experimental results show that the novel actuator could reduce the unbalance vibration of the machine tool spindle by 87.5% at 3600 rpm.
4
Gagnol, Vincent, Belhassen C. Bouzgarrou, Pascal Ray, and Christian Barra. "Stability-Based Spindle Design Optimization." Journal of Manufacturing Science and Engineering 129, no. 2 (November 8, 2006): 407–15. http://dx.doi.org/10.1115/1.2673400.
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Prediction of stable cutting regions is a critical requirement for high-speed milling operations. These predictions are generally made using frequency-response measurements of the tool-holder-spindle set obtained from a nonrotating spindle. However, significant changes in system dynamics occur during high-speed rotation. In this paper, a dynamic high-speed spindle-bearing system model is elaborated on the basis of rotor dynamics prediction and readjusted on the basis of experimental modal identification. The dependency of dynamic behavior on speed range is then investigated and determined with accuracy. Dedicated experiments are carried out in order to confirm model results. They show that dynamic effects due to high rotational speed and elastic deformations, such as gyroscopic coupling and spin softening, have a significant influence on spindle behavior. By integrating the modeled speed-dependent spindle transfer function in the chatter vibration stability approach of Altintas and Budak (1995, CIRPS Ann, 44(1), pp. 357–362), a new dynamic stability lobe diagram is predicted. Significant changes are observed in the stability limits constructed using the proposed approach and allow accurate prediction of cutting conditions to be established. Finally, optimization studies are performed on spindle design parameters in order to obtain a chatter vibration-free cutting operation at the desired speed and depth of cut for a given cutter.
5
Lu, Feng, Shi Chao Chen, Song Hua Li, Ke Zhang, and Yu Hou Wu. "The Inner Hole Grinding Surface Roughness Analysis of Zirconia Ceramics Electric Spindle." Key Engineering Materials 487 (July 2011): 99–103. http://dx.doi.org/10.4028/www.scientific.net/kem.487.99.
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The high-speed ceramic electric spindle is applied in high-speed NC machine tools. Each surface processing accuracy requirement of high-speed ceramic electric spindle is high. The inner hole surface roughness is the key factor which affects its high-speed stability and moving accuracy. This paper focuses on the research of the relationship between inner hole and grinding wheel granularity and grinding wheel linear velocity and transverse feeding and grinding camber ratio through the experiment of diamond wheel grinding the inner hole of ceramic spindle. The optimal grinding parameter combination of ceramic spindle inner hole grinding is obtained. The surface roughness of ceramic spindle inner hole reaches 0.21μm, through the analysis of orthogonal test. The results can completely satisfy the ceramic spindle high-speed operation requirements and enhance the ability of corrosion resistance and fatigue damage resistance. It then improves the whole work performance, reliability and life of ceramic spindle.
6
Krstić, Vladislav, Dragan Milčić, and Miodrag Milčić. "A THERMAL ANALYSIS OF THE THREADED SPINDLE BEARING ASSEMBLY IN NUMERICALLY CONTROLLED MACHINE TOOLS." Facta Universitatis, Series: Mechanical Engineering 16, no. 2 (August 1, 2018): 261. http://dx.doi.org/10.22190/fume170512022k.
Full textAbstract:
A threaded gear in machine tools is a mechanical actuator that converts rotary motion into linear one of the machine axis using a recirculating ball-nut. It provides positioning accuracy, uniform motion, silent operation, reduced wear and an increased service life. The bearing assembly of the threaded spindles should provide load transfer (cutting forces and friction forces) while maintaining high guiding accuracy. Due to a high number of the threaded spindle revolutions and the presence of tension in the bearing and a high axial force originating from the cutting and friction forces, the increased heat load due to friction in the bearings is normally expected. For this reason, this paper presents a thermal analysis of the bearing assembly of the threaded spindle which is realized via an axial ball bearing with angular contact of the ZKLN type, produced by the German manufacturer Schaeffler (INA); in other words, a numerical thermal analysis has been performed.
7
Orlowski, Kazimierz A., Przemyslaw Dudek, Daniel Chuchala, Wojciech Blacharski, and Tomasz Przybylinski. "The Design Development of the Sliding Table Saw Towards Improving Its Dynamic Properties." Applied Sciences 10, no. 20 (October 21, 2020): 7386. http://dx.doi.org/10.3390/app10207386.
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Cutting wood with circular saws is a popular machining operation in the woodworking and furniture industries. In the latter sliding table saws (panel saws) are commonly used for cutting of medium density fiberboards (MDF), high density fiberboards (HDF), laminate veneer lumber (LVL), plywood and chipboards of different structures. The most demanded requirements for machine tools are accuracy and precision, which mainly depend on the static deformation and dynamic behavior of the machine tool under variable cutting forces. The aim of this study is to present a new holistic approach in the process of changing the sliding table saw design solutions in order to obtain a better machine tool that can compete in the contemporary machine tool market. This study presents design variants of saw spindles, the changes that increase the critical speeds of spindles, the measurement results of the dynamic properties of the main drive system, as well as the development of the machine body structure. It was proved that the use of only rational imitation in the spindle design on the basis of the other sliding table saws produced does not lead to the expected effect in the form of correct spindle operation.
8
Yang, Zheng, Fei Chen, Wei Luo, Binbin Xu, and Song Wang. "Reliability Test Rig of the Motorized Spindle and Improvements on Its Ability for High-Speed and Long-Term Tests." Shock and Vibration 2021 (January 22, 2021): 1–14. http://dx.doi.org/10.1155/2021/6637335.
Full textAbstract:
To realize the accurate performance test under high-speed operation and the long-term stable reliability test of the motorized spindle, a reliability test rig (RTR) which can simulate the cutting force in the actual machining process is presented. Firstly, a reasonable prototype integrating dynamic force loading devices and torque loading devices is designed and established based on the load analysis of the spindle, and a complete and explicit control strategy of the reliability loading test is designed. Secondly, the effects of misalignment of the diaphragm coupling caused by assembling are analyzed, and experiments are conducted to test the axis orbit of the motorized spindle. The experimental results illustrate that the axis orbit can identify the occurrence of misalignment, which ensures timely adjustment of misalignment and the accurate performance test under high-speed operation. Lastly, a damper is added in the mechanical structure of the electrohydraulic servo loading system (EHSLS), and the comparison of Bode maps before and after optimization is analyzed by the Nyquist criterion. After the optimization, the gain and phase margin of the Bode diagram are 12.9 dB and 57.2°, respectively, which are both within the stable range and validate the improvements on the ability of long-term reliability tests of the motorized spindle. The presented RTR is able to simulate the actual cutting force and provides an efficient loading approach to guarantee the accuracy and stability of motorized spindle tests.
9
Su, Dan. "Monitoring and Control System Design for Tool Wear Condition of CNC Machine Based on Artificial Neural Networks." Applied Mechanics and Materials 556-562 (May 2014): 3251–54. http://dx.doi.org/10.4028/www.scientific.net/amm.556-562.3251.
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Spindle wear of CNC machine affects the working efficiency of the machine. To solve this problem, the reasons for the generation of CNC machine tool equipment wear is analyzed, the system's hardware modules and software modules are designed and implemented in accordance with the system requirements. Parameters such as input and output power, spindle speed of CNC machine tool equipment are acquired by the sensor circuit. After a comprehensive analysis of the data, system software combined with neural network model displays the test results on the LCD screen, real-time output of CNC machine tool equipment operating status and the spindle wear. Thus the operation of CNC machine is ensured and equipment failure is avoided. Through the system test, indicating that the proposed system can real-time output the monitor results of spindle wear of CNC machine tool equipment, and has high measurement accuracy for the main parameters such as power and efficiency of the equipment.
10
Marui, E., S. Kato, M. Hashimoto, and T. Yamada. "The Mechanism of Chatter Vibration in a Spindle-Workpiece System: Part 1—Properties of Self-Excited Chatter Vibration in Spindle-Workpiece System." Journal of Engineering for Industry 110, no. 3 (August 1, 1988): 236–41. http://dx.doi.org/10.1115/1.3187875.
Full textAbstract:
The elimination of chatter vibration is important to improve cutting accuracy and to improve productivity of the cutting operation. In this study, the characteristics of the primary and regenerative chatter vibration occurring in the spindle-workpiece system are investigated experimentally using six spindle-workpiece systems having different vibratory properties. The vibratory locus of the spindle-workpiece system is found. The phase lag between the cutting force and chatter displacement and the phase lag between the successive chatter marks are obtained quantitatively. These phase lags are closely related to the energy supply. The chatter vibration hardly grows up in the spindle-workpiece system having large dynamic rigidity.
11
Yousefi, S., and M. Zohoor. "Experimental Studying of the Variations of Surface Roughness and Dimensional Accuracy in Dry Hard Turning Operation." Open Mechanical Engineering Journal 12, no. 1 (October 26, 2018): 175–91. http://dx.doi.org/10.2174/1874155x01812010175.
Full textAbstract:
Objective: Hard turning in dry condition using cubic boron nitride tools, as an alternative of traditional grinding operation, is an advanced machining operation in which hardened steel with the hardness greater than 46 HRc is machined without the use of any coolant. Method: In the hard turning process, due to its hard nature, usually the cutting depth is selected lower than or equal to the nose radius, and the cutting zone is mainly limited within the tool nose area. Thus, unlike the traditional turning, the effect of the nose radius on the surface finish and dimensional accuracy becomes more complicated. Therefore, in this paper, firstly, the effect of processing parameters such as nose radius on the surface roughness and dimensional accuracy is investigated. Then, the relationship between the surface finish and dimensional accuracy variations with vibration, cutting forces, and tool wear is studied experimentally. The results revealed that feed rate is the most important factor influencing the surface roughness, whereas spindle speed and cutting depth are insignificant factors. On the other hand, cutting depth and spindle speed have the greatest effect on the dimensional accuracy, while nose radius has no significant effect. The vibration and wear analysis revealed that compared with the vibration, the tool wear has no considerable effect on the dimensional accuracy. It was also observed that the spindle speed has a contradictory effect on the surface roughness and dimensional accuracy. The best dimensional accuracy is obtained at 500 rpm, while the best surface quality is achieved at 2000 rpm. Result: The obtained results also showed that increasing the feed rate from a particular value not only leads to no significant changes in the surface roughness value but in some cases can also decrease the surface roughness. Conclusion: According to the analysis results, the lowest cutting depth, the moderate feed rate, and the speed lower than 1100 rpm provide the best dimensional accuracy. Compared with carbides and ceramics, cubic boron nitride tools produce a better surface roughness at both higher cutting depth and speed. 0.202 µm is the best surface roughness that was obtained at rε = 1.2 mm, N = 2000 rpm, f = 0.08 mm/rev, d = 0.5 mm which is comparable with the surface quality obtained by the conventional grinding operation.
12
Li, Fang Yuan. "The Research of ASR Strategy for the Spindle Inverter Control in CNC Machine Tool." Advanced Materials Research 915-916 (April 2014): 426–29. http://dx.doi.org/10.4028/www.scientific.net/amr.915-916.426.
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It is known for rendering more torque in operation at low speed and suitably attaining high performance dynamic control for the inverter. This paper describes the research of ASR strategy for the spindle inverter control in CNC machine tool. The principles of the vector control and formulas for the coordinate transformation are illustrated. The accuracy of the torque depends on the accuracy of the motor parameters used in the control. So the powerful parameter tuning function should be enabled for all kinds of spindle to run effectively. The response of ASR will be perfect if the switching frequencies is used which is usually constant and set by the user.
13
Wu, Zhou Ping, Bei Zhi Li, and Jian Guo Yang. "Order Vibration Analysis of High-Speed Spindle System." Advanced Materials Research 712-715 (June 2013): 1653–58. http://dx.doi.org/10.4028/www.scientific.net/amr.712-715.1653.
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Before the working speed of high-speed spindle system reaches the critical speed, violent vibration which directly affects the quality of the work piece has been already discovered. To precisely study the speed at which violent vibration happens and the modes of vibration, this paper provided an order vibration approach through studying the model analysis and order of spindle system. The nature frequencies of model analysis were verified and the order of spindle system was confirmed by speed ascend experiment. The result shows that the violent vibration is caused by the manufacturing error of outer ring race of bearing and the mode of vibration mainly located on the grinding wheel which greatly affects the accuracy of spindle system. It is useful for optimizing the structure and operation procedure of high-speed spindle system.
14
Xu, F., Ke Zhang, and Zheng Xing Cui. "Research on Spindle Induction Motor Stator Flux Observer Algorithm." Key Engineering Materials 455 (December 2010): 507–10. http://dx.doi.org/10.4028/www.scientific.net/kem.455.507.
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In order to enhance observation accuracy of the spindle induction stator flux and decrease observation error which is influenced by temperature, frequency and magnetic path in operation process, a full order observer was used to observe stator flux. The change of stator flux observer which adopted u-i model and low pass filter estimation model observation error was analyzed when the parameters of motor changed through the mathematical model in the stationary coordinates. A method to determine the gain matrix of full order observer was presented. The results showed that the error changed with the changes of motor speed and torque. On the premise of assuring stability of the observer, according to different speed ranges, choosing the proper observer pole assignment, the method can be used to enhance the observation accuracy of stator flux at high speed, and it is also validated in the Matlab/Simulink condition. It is shown that it can improve observer accuracy of the induction motor stator flux effectively.
15
Dong, Weihang, Xiaolei Guo, Yong Hu, Jinxin Wang, and Guangjun Tian. "Discrete wavelet transformation and genetic algorithm – back propagation neural network applied in monitoring woodworking tool wear conditions in the milling operation spindle power signals." BioResources 16, no. 2 (February 5, 2021): 2369–84. http://dx.doi.org/10.15376/biores.16.2.2369-2384.
Full textAbstract:
Tool wear conditions monitoring is an important mechanical processing system that can improve the processing quality of wood plastic composite furniture and reduce industrial energy consumption. An appropriate signal, feature extraction method, and model establishment method can effectively improve the accuracy of tool wear monitoring. In this work, an effective method based on discrete wavelet transformation (DWT) and genetic algorithm (GA) – back propagation (BP) neural network was proposed to monitor the tool wear conditions. The spindle power signals under different spindle speeds, depths of milling, and tool wear conditions were collected by power sensors connected to the machine tool control box. Based on the feature extraction method, the approximate coefficients of spindle power signal were extracted by DWT. Then, the extracted approximate coefficients, spindle speeds, depths of milling, and tool wear conditions were taken as samples to train the monitoring model. Threshold and weight of BP neural network were optimized by GA, and the accuracy of monitoring model established by the GA – BP neural network can reach 100%. Thus, the proposed monitoring method can accurately monitor tool wear conditions with different milling parameters, which can achieve the purpose of improving the processing quality of wood plastic composite furniture and reducing energy consumption.
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Fedorynenko, Dmytro, and Serhii Sapon. "HYDROSTATIC SPINDLE FOR ULTRA-PRECISION TWO-SIDED MACHINING." TECHNICAL SCIENCES AND TECHNOLOGIES, no. 1 (15) (2019): 97–105. http://dx.doi.org/10.25140/2411-5363-2019-1(15)-97-105.
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Urgency of the research. Modern development of mechanical engineering creates constantly increasing demands concerning maintenance of quality indicators of detail processing. So, indicator of roughness, admissions of linear sizes and angular are decreased constantly. Application of precision machine tools is an effective way of decision of the tasks in view. Target setting. Today ultra-precision processing of materials is widely used for manufacture of electronic components of techniques, telecommunication, medical, automobile, optical equipment. Therefore, the designing of ultra-precision machine tools is an urgent task for ensuring the high efficiency of the processes of machining. Actual scientific researches and issues analysis. Basic component of precision machine tool which defines quality of machining is a spindle. Quality indicators of a spindle are mostly provided with a correct choice of type and design of its bearings. It is showed that hydrostatic bearings together with increase of machining reliability and productivity allow providing of exclusively high indicators of detail machining quality compared with other types of spindle bearings. Besides, they are the most perspective type of spindle bearings for realization of high-speed machining and ultra-precision machining. However hydrostatic bearings are characterized by relatively big power losses on friction and, as a consequence, vigorous heating at increased rotational frequencies. Therefore lubrication of hydrostatic bearings with low viscous liquids, in particular water, presents separate interest. Uninvestigated parts of general matters defining are designing of new design of a spindle with combined hydrostatic bearing based on special water lubrication for increased precision and efficiency of two-sided ultra-precision machining. The research objective of this article is designing of new design of a spindle unit with direct drive, clamping fixture and combined hydrostatic bearing, which based on special water lubrication, for increased precision and efficiency of two-sided ultra-precision machining. The statement of basic materials. New design of a spindle with combined hydrostatic bearing based on special water lubrication and clamping fixture is proposed for increased precision and efficiency of two-sided ultra-precision machining. The design of this precision spindle with direct drive by hollow-shaft torque motor provides two-sided machining of disk-shaped workpieces. The regularities of the formation of stiffness, flow rate and power losses in the combined spindle bearing, depending on viscosity of the working fluid, clearances in the journal and thrust bearings, pump pressure, and size of the bearing lands are defined. As a result of mathematical and CFD modeling rational parameters of combined spindle bearing were identified that provide minimum power losses at operation at simultaneous insuring of the high accuracy of a spindle. For increase of accuracy of clamping advanced design of the clamping fixture with a screw clamping of workpieces on the basis of use of PVC paste as pressure-transmitting environment is offered. The article introduce the use of water lubrication as an effective way of solving issues of increase concerning spindle unit efficiency, the reduction of operating costs due to simultaneous cooling of bearings and spindle drive, and also the increase of environmental friendliness of the design as a whole. Conclusions. The new design of a spindle unit for two-sided ultra-precision machining with direct drive and clamping device was presented in this article. The main advantage of this solution is the compact structure of the spindle. The direct drive of the spindle with hollow-shaft torque motor can effectively be used for two-sided ultra-precision end turning of the workpieces. The regularities of the flatness deviation formation of the end surface of the workpiece during clamping are established. It is shown that clamping forces acting on the workpiece do not have a significant impact on accuracy of the surfaces machined. The rational geometrical and operational parameters of the clamping for maintenance of high operational reliability are received.
17
Lei, Chun Li, Zhi Yuan Rui, Jun Liu, and Jing Fang Fang. "Comparison of Forecasting Methods for Thermal Error on High-Speed Motorized Spindle." Advanced Materials Research 291-294 (July 2011): 2991–94. http://dx.doi.org/10.4028/www.scientific.net/amr.291-294.2991.
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In order to reduce the thermal error of the motorized spindle and improve the manufacturing accuracy of NC machine tool, the thermal error forecasting models based on multivariate autoregressive (MVAR) method and genetic radial basis function (GARBF) neural network method are proposed, respectively. According to different representations of generation mechanism of motorized spindle thermal deformation, operation efficiency and curve fit precision of these two models are compared. The studied results show that under the same temperature rise variable conditions, MVAR model and GARBF neural network model have almost the same convergence and operation time and relative errors of two models are less than 3%. The results also show that the MVAR model has higher forecast precision in the prediction former stages; in contrast, the GARBF neural network model has higher forecast precision in the latter stages.
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Shete, Hanmant V., and Madhav S. Sohani. "Effect of Process Parameters on Hole Diameter Accuracy in High Pressure Through Coolant Peck Drilling Using Taguchi Technique." International Journal of Materials Forming and Machining Processes 5, no. 1 (January 2018): 12–31. http://dx.doi.org/10.4018/ijmfmp.2018010102.
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Machining with pressurized coolant is nowadays widely accepted technique in the manufacturing industry, especially in high performance machining conditions. The data on the effects of variation of high coolant pressure in drilling operation is limited. This paper presents the effect of high coolant pressures along with spindle speed, feed rate and peck depth on hole diameter accuracy. Experiments were performed on EN9 steel with TiAIN coated through coolant drill on CNC vertical machining center. Taguchi technique was employed for design of experiments and analysis of results. Results showed that the higher values of optimal coolant pressure and spindle speed were demanded for drilling at bottom of hole as compared to that for drilling at top of hole. The optimal values of feed rate and peck depth were same for both the cases of drilling at top and bottom of hole. Use of high coolant pressure in drilling permits higher peck depth for better hole diameter control which results in reduced cycle time and hence production cost.
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Zheng, De-xing, Weifang Chen, and Miaomiao Li. "An improved model on forecasting temperature rise of high-speed angular contact ball bearings considering structural constraints." Industrial Lubrication and Tribology 70, no. 1 (January 8, 2018): 15–22. http://dx.doi.org/10.1108/ilt-06-2016-0133.
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Purpose Thermal performances are key factors impacting the operation of angular contact ball bearings. Heat generation and transfer about angular contact ball bearings, however, have not been addressed thoroughly. So far, most researchers only considered the convection effect between bearing housings and air, whereas the cooling/lubrication operation parameters and configuration effect were not taken into account when analyzing the thermal behaviors of bearings. This paper aims to analyze the structural constraints of high-speed spindle, structural features of bearing, heat conduction and convection to study the heat generation and transfer of high-speed angular contact ball bearings. Design/methodology/approach Based on the generalized Ohm’s law, the thermal grid model of angular contact ball bearing of high-speed spindle was first established. Next Gauss–Seidel method was used to solve the equations group by Matlab, and the nodes temperature was calculated. Finally, the bearing temperature rise was tested, and the comparative analysis was made with the simulation results. Findings The results indicate that the simulation results of bearing temperature rise for the proposed model are in better agreement with the test values. So, the thermal grid model established is verified. Originality/value This paper shows an improved model on forecasting temperature rise of high-speed angular contact ball bearings. In modeling, the cooling/lubrication operation parameters and structural constraints are integrated. As a result, the bearing temperature variation can be forecasted more accurately, which may be beneficial to improve bearing operating accuracy and bearing service life.
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Budi Harja, Herman, Tri Prakosa, Yatna Yuwana Martawirya, Indra Nurhadi, and Andrian Sagisky Januartha. "Development of Real Time Machine Tools Component Utilization Data Acquisition for developing Dynamic Model of Maintenance Scheduling." E3S Web of Conferences 130 (2019): 01015. http://dx.doi.org/10.1051/e3sconf/201913001015.
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Maintenance scheduling accuracy of CNC machine tools components should be calculated based on actual data utilization of each component. Actual usage of each component can be approached by component grouping based on machine operation phase utilization, which is divided into Power-On, cutting and noncutting phase. This paper describes a study on development of machine monitoring data utilization for obtaining real time information of spindle and machine axis positions as well as current consumption of spindle servo motor. Data collection was conducted by a termination method on wiring feedback control of spindle encoder signal and axes encoder signals. On the other hand, current consumption of spindle servo motor was measured by a CT current transducer. Afterward, a WEMOS microcontroller was used to process and to transfer data wirelessly to a Raspberry which acted as a broker. The data will used to update the data status of CNC Machine Tools utilization database, where it was communicated by using a MQTT protocol. A monitoring system has been developed and resulted the real time information of machine phase utilization. It will be further utilized as primary data input for building a dynamic maintenance model.
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Il’inykh, Viktor. "Evaluation of quality parameters of conical profile compounds in nodes of multi-purpose machines." E3S Web of Conferences 140 (2019): 02003. http://dx.doi.org/10.1051/e3sconf/201914002003.
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The article presents a study of the mandrel spindle assembly for accuracy, contact stiffness and strength. The study was made on the basis of conical profile connections with an equiaxed contour. Experiments were carried out for multi-purpose machines of various layouts on the basis of the previously developed program-mathematical complex of evaluating the parameters of the shaft-sleeve coupling. The analysis of the simulation modeling results of the accuracy of the shaft (mandrel) installation in the hole of the sleeve (spindle) is carried out taking into account the error in shape, taper, the magnitude of the assembly force and the external conditional load in the spatial setting. With respect to the three coordinate axes, the possible displacements and rotations of the tool mandrels with a modified shank design are determined when they are based and secured in the spindle. In each design case, the accuracy of the relative position of the parts of the conical profile connections was compared during reusable assembly for the horizontal and vertical machine, respectively, and during the operation of the spindle-mandrel assembly under the condition of an external load. As a result of research, it was found that the layout of the machine does not significantly affect the quality parameters of the profile connection in conditions of reusable assembly. A significant effect of the error in the shape of the mating parts of the connection has been determined, which leads to an increase in maximum contact pressures till 22MPa, a displacement of the mandrel along the Z axis up to 25 µm, and a significant influence on the ultimate external load, which leads to elastic displacements of the mandrel along the Y axis to 2 µm for tapering 1:10.
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Goldobina, V. "ACCURACY OF HOLE PROCESSING WITH A COMBINED TOOL." Bulletin of Belgorod State Technological University named after. V. G. Shukhov 6, no. 6 (June 17, 2021): 80–86. http://dx.doi.org/10.34031/2071-7318-2021-6-6-80-86.
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Cement, powder metallurgy and various large-sized equipment are used in the industry of building materials for grinding raw materials. During operation, such equipment is exposed to external influences, especially at the joints, which reduce the reliability of the units. This leads to the early replacement of wearing parts. Large components of grinding mills are connected by flanges. The flanges are fastened with bolts, some of which must be precision, since they take the load of the equipment and ensure the tightness of the connection. The holes for precision bolts, respectively, must be accurate and of high quality. A study of the processing of holes with a reamer is given. The cutting elements of the tool, in the form of multifaceted plates, are mechanically attached to the body, which makes it possible to quickly replace the plate in case of wear or breakage. Such an assembled combined cutting tool allows to perform countersinking and reaming in one operation and thereby reduce the processing time of one hole and, in general, all precision holes in the flanges of the mill being repaired. The dependence of the precision hole accuracy on the shape and spatial deviation from the cutting modes of processing when using a combined tool is derived. The dependence is established for processing using a portable device with a rising spindle, as the most used equipment for repairs. The presented dependence makes it possible to predict the accuracy of machining holes with a combined tool, taking into account the rigidity of the technological system and calculate the required reamer accuracy.
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Hu, Yuh-Chung, Ping-Jung Chen, and Pei-Zen Chang. "Thermal-Feature System Identification for a Machine Tool Spindle." Sensors 19, no. 5 (March 9, 2019): 1209. http://dx.doi.org/10.3390/s19051209.
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The internal temperature is an important index for the prevention and maintenance of a spindle. However, the temperature inside the spindle is undetectable directly because there is no space to embed a temperature sensor, and drilling holes will reduce its mechanical stiffness. Therefore, it is worthwhile understanding the thermal-feature of a spindle. This article presents a methodology to identify the thermal-feature model of an externally driven spindle. The methodology contains self-made hardware of the temperature sensing and wireless transmission module (TSWTM) and software for the system identification (SID); the TSWTM acquires the temperature training data, while the SID identifies the parameters of the thermal-feature model of the spindle. Then the resulting thermal-feature model is written into the firmware of the TSWTM to give it the capability of accurately calculating the internal temperature of the spindle from its surface temperature during the operation, or predicting its temperature at various speeds. The thermal-feature of the externally driven spindle is modeled by a linearly time-invariant state-space model whose parameters are identified by the SID, which integrates the command “n4sid” provided by the System ID Toolbox of MATLAB and the k-fold cross-validation that is common in machine learning. The present SID can effectively strike a balance between the bias and variance of the model, such that both under-fitting and over-fitting can be avoided. The resulting thermal-feature model can not only predict the temperature of the spindle rotating at various speeds but can also calculate the internal temperature of the spindle from its surface temperature. Its validation accuracy is higher than 98.5%. This article illustrates the feasibility of accurately calculating the internal temperature (undetectable directly) of the spindle from its surface temperature (detectable directly).
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Yang, Xue Bing, Wan Li Xiong, Zhi Quan Hou, and Ju Long Yuan. "Optimization of Thermal Performance of Hybrid Journal Bearings for High Speed Machine Tool Spindle with Small Diameter." Advanced Materials Research 139-141 (October 2010): 731–38. http://dx.doi.org/10.4028/www.scientific.net/amr.139-141.731.
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Multi-array hole-entry hybrid journal bearings have been widely applied to support the high speed precision machine tool spindle with small diameter used in high efficient inner grinding, due to their prominent properties of high rotation accuracy, high dynamic stiffness, high vibration damping and long life. But the imperfection of the hybrid bearing is the significant temperature rising in the oil film on the condition of high speed operation, which brings about the sharp decreasing of load capacity and the larger thermal deformation of the bushing that cause the bearing failure immediately. In this paper, CFD analysis of the temperature fields of the multi-array hole-entry hybrid journal bearing with various bearing construction parameters and operation parameters are presented. According to the simulation results, the temperature rising in the oil film can be controlled efficiently by optimizing the matching of the bearing construction parameters and operation parameters and excellent characteristics of load capacity and static stiffness have been obtained simultaneously.
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Zhou, Chun Jiang. "Research on the Radial Accuracy and Stiffness of HSK Tool System in High Speed Machining." Key Engineering Materials 480-481 (June 2011): 1335–40. http://dx.doi.org/10.4028/www.scientific.net/kem.480-481.1335.
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The radial positioning accuracy and stiffness are two important indexes to measure the performance of tool system. Once HSK tool system is in operation, the gap between the spindle and shank will enlarge, thus will make the radial positioning accuracy and stiffness lower. The influence factor leading to this problem is analyzed in this paper through elastic mechanics and finite element analysis. It can get from the analysis that the double-position structure and certain amount of interface are key factors to keep HSK high radial positioning accuracy and stiffness. In addition, the influence of clamping force and rotate speed to radial stiffness is presented that higher speed and larger clamping force make the radial stiffness better. Finally, the paper has verified the analysis of radial stiffness through the experimental measurement with different fit of HSK.
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Kim, Dong Woo, Young Jae Shin, Kyoung Taik Park, Eung Sug Lee, Jong Hyun Lee, and Myeong Woo Cho. "Prediction of Surface Roughness in High Speed Milling Process Using the Artificial Neural Networks." Key Engineering Materials 364-366 (December 2007): 713–18. http://dx.doi.org/10.4028/www.scientific.net/kem.364-366.713.
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The objective of this research was to apply the artificial neural network algorithm to predict the surface roughness in high speed milling operation. Tool length, feed rate, spindle speed, cutting path interval and run-out were used as five input neurons; and artificial neural networks model based on back-propagation algorithm was developed to predict the output neuron-surface roughness. A series of experiments was performed, and the results were estimated. The experimental results showed that the applied artificial neural network surface roughness prediction gave good accuracy in predicting the surface roughness under a variety of combinations of cutting conditions.
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Марчук І. В., Марчук В.І., Джугурян Т.Г., Гринюк С.В., and Карпюк В.О. "ON THE INFLUENCE OF OPERATING CHARACTERISTICS OF GRINDED WHEELS ON THE QUALITY INDICATORS OF GRINDED PARTS." Перспективні технології та прилади, no. 17 (December 24, 2020): 86–92. http://dx.doi.org/10.36910/6775-2313-5352-2020-17-13.
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The quality of the surfaces of roller bearing parts is formed in the process of interaction of the cutting tool with the surfaces to be treated. In addition to technological factors, a significant place in providing a quality surface layer is occupied by the correct choice of grinding wheels.
The abrasive tool has different properties depending on its characteristics. When choosing an abrasive tool, it is necessary to take into account its characteristics and their suitability for a particular type of work. Stable operation of abrasive wheels depends on the correct choice of their size, characteristics and modes of operation.
The selection of grinding wheels depends on the type and properties of machined materials, power of grinding machines, spindle speed, grinding mode, requirements for accuracy and surface cleanliness and other factors that apply to the workpieces.
Depending on the accuracy requirements for machining parts made of different materials, the characteristics of abrasive wheels are selected, the main of which are hardness, grain size, bond, structure, shape, size and allowable speed.
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Jin, Hongyu, Avitus Titus, Yulong Liu, Yang Wang, and and Zhenyu Han. "Fault Diagnosis of Rotary Parts of a Heavy-Duty Horizontal Lathe Based on Wavelet Packet Transform and Support Vector Machine." Sensors 19, no. 19 (September 20, 2019): 4069. http://dx.doi.org/10.3390/s19194069.
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The spindle box is responsible for power transmission, supporting the rotating parts and ensuring the rotary accuracy of the workpiece in the heavy-duty machine tool. Its assembly quality is crucial to ensure the reliable power supply and stable operation of the machine tool in the process of large load and cutting force. Therefore, accurate diagnosis of assembly faults is of great significance for improving assembly efficiency and ensuring outgoing quality. In this paper, the common fault types and characteristics of the spindle box of heavy horizontal lathe are analyzed first, and original vibration signals of various fault types are collected. The wavelet packet is used to decompose the signal into different frequency bands and reconstruct the nodes in the frequency band where the characteristic frequency points are located. Then, the power spectrum analysis is carried out on the reconstructed signal, so that the fault features in the signal can be clearly expressed. The structure of the feature vector used for fault diagnosis is analyzed and the feature vector is extracted from the collected signals. Finally, the intelligent pattern recognition method based on support vector machine is used to classify the fault types. The results show that the method proposed in this paper can quickly and accurately judge the fault types.
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Aravamudhan, Pavithra, Renjie Chen, Babhrubahan Roy, Janice Sim, and Ajit P. Joglekar. "Dual mechanisms regulate the recruitment of spindle assembly checkpoint proteins to the budding yeast kinetochore." Molecular Biology of the Cell 27, no. 22 (November 7, 2016): 3405–17. http://dx.doi.org/10.1091/mbc.e16-01-0007.
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Recruitment of spindle assembly checkpoint (SAC) proteins by an unattached kinetochore leads to SAC activation. This recruitment is licensed by the Mps1 kinase, which phosphorylates the kinetochore protein Spc105 at one or more of its six MELT repeats. Spc105 then recruits the Bub3-Bub1 and Mad1-Mad2 complexes, which produce the inhibitory signal that arrests cell division. The strength of this signal depends, in part, on the number of Bub3-Bub1 and Mad1-Mad2 molecules that Spc105 recruits. Therefore regulation of this recruitment will influence SAC signaling. To understand this regulation, we established the physiological binding curves that describe the binding of Bub3-Bub1 and Mad1-Mad2 to the budding yeast kinetochore. We find that the binding of both follows the mass action law. Mps1 likely phosphorylates all six MELT repeats of Spc105. However, two mechanisms prevent Spc105 from recruiting six Bub3-Bub1 molecules: low Bub1 abundance and hindrance in the binding of more than one Bub3-Bub1 molecule to the same Spc105. Surprisingly, the kinetochore recruits two Mad1-Mad2 heterotetramers for every Bub3-Bub1 molecule. Finally, at least three MELT repeats per Spc105 are needed for accurate chromosome segregation. These data reveal that kinetochore-intrinsic and -extrinsic mechanisms influence the physiological operation of SAC signaling, potentially to maximize chromosome segregation accuracy.
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Archary, Hamresin, Walter Schmitz, and Louis Jestin. "Mass flow and particle size monitoring of pulverised fuel vertical spindle mills." Chemical and Process Engineering 37, no. 2 (June 1, 2016): 175–97. http://dx.doi.org/10.1515/cpe-2016-0016.
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Abstract The first step towards condition based maintenance of the milling plant is the implementation of online condition monitoring of the mill. The following paper presents and analyses methods of monitoring the key performance factors of a vertical spindle mill that is suited for implementation on older power stations, i.e. the quantity (mass flow rate) and quality (particle fineness) of the pulverised fuel produced by the mill. It is shown herein that the mill throughput can be monitored on-line using a simple mill energy balance that successfully predicts the coal throughput within 2.33% as compared to a calibrated coal feeder. A sensitivity analysis reveals that the coal moisture is a critical measurement for this method to be adopted as an on-line mass flow monitoring tool. A laser based particle size analyser tool was tested for use in the power plant environment as an online monitoring solution to measure pulverised fuel fineness. It was revealed that several factors around the set-up and operation of the instrument have an influence on the perceived results. Although the instrument showed good precision and repeatability of results, these factors must be taken into account in order to improve the accuracy of the reported results before the instrument can be commissioned as an on-line monitoring solution.
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Okokpujie, Imhade Princess, Omolayo M. Ikumapayi, Ugochukwu C. Okonkwo, Enesi Y. Salawu, Sunday A. Afolalu, Joseph O. Dirisu, Obinna N. Nwoke, and Oluseyi O. Ajayi. "Experimental and Mathematical Modeling for Prediction of Tool Wear on the Machining of Aluminium 6061 Alloy by High Speed Steel Tools." Open Engineering 7, no. 1 (December 29, 2017): 461–69. http://dx.doi.org/10.1515/eng-2017-0053.
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AbstractIn recent machining operation, tool life is one of the most demanding tasks in production process, especially in the automotive industry. The aim of this paper is to study tool wear on HSS in end milling of aluminium 6061 alloy. The experiments were carried out to investigate tool wear with the machined parameters and to developed mathematical model using response surface methodology. The various machining parameters selected for the experiment are spindle speed (N), feed rate (f), axial depth of cut (a) and radial depth of cut (r). The experiment was designed using central composite design (CCD) in which 31 samples were run on SIEG 3/10/0010 CNC end milling machine. After each experiment the cutting tool was measured using scanning electron microscope (SEM). The obtained optimum machining parameter combination are spindle speed of 2500 rpm, feed rate of 200 mm/min, axial depth of cut of 20 mm, and radial depth of cut 1.0mm was found out to achieved the minimum tool wear as 0.213 mm. The mathematical model developed predicted the tool wear with 99.7% which is within the acceptable accuracy range for tool wear prediction.
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Kozeruk, A. S., Y. L. Malpica, A. A. Sukhotzkiy, M. I. Filonova, and V. O. Kuznechik. "Investigation of Machine Tool Developed Settings Influence on Productivity and Quality of Simultaneous Double-Sided Lens Processing." Science & Technique 17, no. 5 (October 12, 2018): 390–400. http://dx.doi.org/10.21122/2227-1031-2018-17-5-390-400.
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The paper presents methodology for determining rational modes of abrasive processing for high-precision lenses while using a method of free lapping at finishing operations. Analytical expressions have been obtained to determine coordinates of reference points on a spherical surface which are necessary for mathematical modeling of its processing at pivotal machines. The paper contains results of a theoretical qualitative evaluation of high-precision operating lens surfaces formation in case of various combinations of setting parameters for technological equipment. In this case the most rational and unfavorable modes of processing have been identified. In particular, the last case presupposes shaping by changing rotational frequencies of an input link in an executive mechanism of the machine tool w2and the lens wл. An indicative feature is that a poor quality of processing has been obtained over the entire range of variation interval w2 at maximum value wл, and especially in the case when these frequencies are equal. It has been determined that the highest accuracy of processing is achieved with maximum amplitude of an oscillating tool motion, its diameter and frequency of part rotation and minimum rotational speed of the input link in the executive machine-tool mechanism. As such values of these setting parameters lead to an increased removal of an allowance in the marginal zone of a work-piece, then while processing a convex lens surface, its radius of curvature in each previous operation should be larger than a radius of curvature which is to be obtained in the process of subsequent operations. The inverse regularity of curvature radius values must be observed for a concave surface. The most advantageous values of the machine-tool setting parameters with various combinations have been proposed with the purpose to eliminate errors in the form of common as “knoll” and “hole” with due account of processing productivity and accuracy. The paper describes an influence of machine tool spindle wavering value on the processing accuracy of lenses having a wide range of diameters.
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Nguyen, Loc Huu, and Thuy Van Tran. "Advances in the dynamic characteristics of high -speed machine structure." Science and Technology Development Journal 20, K5 (August 31, 2017): 73–80. http://dx.doi.org/10.32508/stdj.v20ik5.1162.
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The quality of machining is dependent on the machine’s dynamic behavior throughout the operating process. Because of the loads or vibration during operation, the rigidity of the machine structure can be reduced. Therefore, the study of advances in the dynamic characteristics has great significance for the development of machine tools, especially for high-speed machines. This paper presents the design and analysis of a rigid gantry structure with a spindle speed in the range of (6.000 ÷ 24.000)rpm, corresponding to the natural frequency of the machine structure more than (100 ÷ 400)Hz. Use CAE (computer-aided engineering) analysis software to analyze the natural frequency of machine structure. The research results show that the machine structure will have good stiffness, high vibration resistance and avoid resonance to achieve the best machining surface. In addition, it is the basis for selection of cutting mode suitable for the machining process in order to improve the reliability and efficiency of work of the machine structure and the accuracy of the processed products.
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Polishetty, Ashwin, Basil Raju, and Guy Littlefair. "Secondary Machining Characteristics of Additive Manufactured Titanium Alloy Ti-6Al-4V." Key Engineering Materials 779 (September 2018): 149–52. http://dx.doi.org/10.4028/www.scientific.net/kem.779.149.
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Titanium alloy, Ti-6Al-4V is a popular alloy used in wide range of design applications mostly in aerospace and biomedical industry due to its advantageous material properties. This research is based on threading operation in a cylindrical workpiece of Ti-6Al-4V additive manufactured by Selective Laser Melting (SLM) technique. Secondary machining is described as the operations that are performed on the workpiece after a primary machining in order to achieve a required finish and form. Common secondary operations after drilling includes threading, reaming and knurling. Threading is a significant machining process in almost all applications of Titanium alloys. The development of an efficient threading process for Titanium alloys and enhancing existing methods may lead to a wider application of additive manufactured Titanium alloys. The aim of this research is to find out favorable threading conditions for Titanium alloy Ti-6Al-4V to obtain better machinability. Threads are tapped into the workpiece using variable machining parameters such as spindle speed and depth of cut. Statistical data are collected and analyzed by qualitative and quantitative evaluation of the threads. The outputs under consideration to evaluate efficiency of the secondary machining include surface texture (roughness (Ra)), dimensional accuracy (thread geometry) and power required (cutting force).
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Amin, A. K. M. Nurul, Syidatul Akma, Maizatul Akma, and M. D. Arif. "Optimization of Surface Roughness in End Milling of Medium Carbon Steel under the Influence of Magnets Attached to the Machine Spindle." Advanced Materials Research 576 (October 2012): 115–18. http://dx.doi.org/10.4028/www.scientific.net/amr.576.115.
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One of the major technological parameters in metal cutting is surface roughness. It is an unavoidable, and often, unwanted by-product of all machining operations, especially end milling. Surface roughness is directly related to product quality and performance, operation cost, machining accuracy, and chatter. Today’s stringent customer requirements demand machined parts with minimum (mirror finished) products. Hence, the prediction, modeling, and optimization of surface roughness is a quintessential concern in machining research and industrial endeavor. This research was undertaken in order to determine whether end milling of medium carbon steel performed using chosen ranges of cutting parameter and under magnetic field generated by permanent magnets could effectively improve surface roughness. A small central composite design with five levels and an alpha value of 1.4142, in Response Surface Methodology, was used in developing the relationship between cutting speed, feed, and depth of cut, with surface roughness. Design-Expert 6.0 software was utilized to develop the quadratic empirical mathematical model for surface roughness. The experiments were performed under two different conditions. The first condition was cutting under normal conditions, while the other one was cutting under the application of magnetic fields from two permanent magnets. Medium carbon steel was used as the work material. The resultant average surface roughness was found to be reduced by a maximum of 59% due to magnet application.
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Калиниченко, Николай Юрьевич. "ТЕХНИКО-ЭКОНОМИЧЕСКОЕ ОБОСНОВАНИЕ ЭФФЕКТИВНОСТИ ПРИМЕНЕНИЯ ПЛАНЕТАРНЫХ ШЛИФОВАЛЬНЫХ ГОЛОВОК." Aerospace technic and technology, no. 4 (August 31, 2019): 95–100. http://dx.doi.org/10.32620/aktt.2019.4.15.
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The development of aviation technology is based on the introduction of new progressive technologies, the use of new materials, the improvement of technological equipment and tools. Improving aircraft engines often leads to greater use of wear-resistant, heat-resistant, heat-resistant materials based on nickel and titanium, which are characterized by low machinability. Blade processing of such alloys faces many difficulties: increased equipment wear, increased machine setup time for the operation, high cutting forces, increased wear of the cutting tool, increased processing time, etc. All this harms productivity, an increase in production time and a decrease in economic efficiency. The use of the operation of creep feed grinding instead of blade milling operations, pulling, planning and abrasive operations (pre-grinding, final grinding) reduces the time to manufacture parts while maintaining its quality and accuracy. The study of the technical and economic aspect of the proposed technology of creep feed grinding instead of preliminary and final grinding operations is of interest. The paper compares two methods of abrasive machining: traditional grinding and creep feed grinding on the SPD-30B surface grinder from Jotes (Poland) with a planetary grinding head (PGH) installed on its spindle. The study was conducted when grinding the castle part of turbine blades. The removable allowance was 3.8 mm. The processing according to the traditional grinding scheme took place in 10 passes, while the processing time was about three and a half minutes. The processing under the scheme of creep feed grinding with the use of PGH for 4 passes took about a minute of machine time. It should be noted a significant increase in productivity at the first transition when removing an allowance of 3.5 mm in the mode of deep grinding compared to traditional grinding 2.1 times. On the second and third transitions, the performance of both methods is virtually the same.
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Bidgoli, Hassan Sharifi, and Ramezan Ali Mahdavinejad. "Vibration Effects on Tailstock of a Turning Machine." Advanced Materials Research 118-120 (June 2010): 876–80. http://dx.doi.org/10.4028/www.scientific.net/amr.118-120.876.
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Machine tools as a main device in manufacturing and production lines are widely used nearly in all branches of industries. Precision continuation of these systems with times and against inspected shocks is necessary and very important. Turning as a main kind and high usage machine tool is used in many industrial parts production, especially those with rounded sections. Spindle, tailstock and bed in machine tools play engraving role in dimensional accuracy. In this paper the vibration effects on the tailstock of a turning machine during its operation, is analyzed. For this purpose, a LZ330 VS machine from Weiler Co. in Germany is modeled with Solid Works software. This model with IGES format is transferred to ANSYS 5.4 analytical software. In this area, the model is analyzed via modal and transient dynamic analysis. The results show that, the more tailstock’s sleeve length, the less critical frequency amount.
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Yuan, Jun, Libing Liu, Zeqing Yang, and Yanrui Zhang. "Tool Wear Condition Monitoring by Combining Variational Mode Decomposition and Ensemble Learning." Sensors 20, no. 21 (October 27, 2020): 6113. http://dx.doi.org/10.3390/s20216113.
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Most online tool condition monitoring (TCM) methods easily cause machining interference. To solve this problem, we propose a method based on the analysis of the spindle motor current signal of a machine tool. Firstly, cutting experiments under multi-conditions were carried out at a Fanuc vertical machining center, using the Fanuc Servo Guide software to obtain the spindle motor current data of the built-in current sensor of the machine tool, which can not only apply to the actual processing conditions but, also, save costs. Secondly, we propose the variational mode decomposition (VMD) algorithm for feature extraction, which can describe the tool conditions under different cutting conditions due to its excellent performance in processing the nonstationary current signal. In contrast with the popular wavelet packet decomposition (WPD) method, the VMD method was verified as a more effective signal-processing technique according to the experimental results. Thirdly, the most indicative features that relate to the tool condition were fed into the ensemble learning (EL) classifier to establish a nonlinear mapping relationship between the features and the tool wear level. Compared with existing TCM methods based on current sensor signals, the operation process and experimental results show that using the proposed method for the monitoring signal acquisition is suitable for the actual processing conditions, and the established tool wear prediction model has better performance in both accuracy and robustness due to its good generalization capability.
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Shinde, Sachin Manohar, and Ramesh R. Lekurwale. "Experimental and numerical investigation of difference in diameter enlargement and circularity of micro-holes drilled by flexural spindle head." Journal of Micromanufacturing 3, no. 2 (November 2020): 121–41. http://dx.doi.org/10.1177/2516598420964049.
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The flexural bearing or the flexural cartridge allows very nano-meter axial displacement movement, which is frictionless and noiseless. The repeatability of the mechanism obtained is achieved by bending of the load element. The bearing can operate under stringent conditions such as vacuum, elevated temperatures (0–40 °C), and moist conditions. Hence, due to these indigenous properties, these bearings are observed in applications such as linear bearing of linear compressor, flexural bearing electromagnetic linear actuator, and parasitic error-free mechanism. The endorsed capability of obtaining high-level positional accuracy along with repeatability leads to design and development of low-cost flexural cartridge for micro-drilling spindle head. This flexural cartridge provides a linear guideway while feeding inside the test specimen (in micro-drilling operation). The designed head dampens and nullifies the force, acting on the shaft carrying the micro-tool. The designed spindle head carrying the three-leg spiral flexural stack is assembled on the designed machine tool. The run out measured on the spindle shaft is 50 µm. Four test specimens, namely aluminum, brass, acrylic and mild steel, are drilled by three drills of diameter 1 mm, 0.8 mm, and 0.5 mm each. The main objective of the article is to understand the differential analysis of diameter enlargement and circularity between the experimental method and the numerical method. The answers predicted by the experimental method may have second possible value as it depends upon judgment of inscribing the circle/points in the computer-aided design (CAD) environment. This ambiguity is excluded by the MATLAB code, which gives one specific answer. The maximum difference in diameter enlargement for aluminum, brass, acrylic, and mild steel specimens are 3.8 µm, 11 µm, 24.6 µm, and 16.1 µm, respectively, whereas the maximum difference in circularity for the same specimens is 11.8 µm, 1.3 µm, 8.2 µm, and 16.8 µm, respectively. This difference is termed as the |error|.
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Prydalnyi, Borys. "MECHATRONIC DEVICE FOR TWO-STAGE CLAMPING OF CYLINDRICAL OBJECTS IN MACHINE TOOL SPINDLES." Journal of Mechanical Engineering and Transport 13, no. 1 (2021): 118–23. http://dx.doi.org/10.31649/2413-4503-2021-13-1-118-123.
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The design of an electromechanical device for fixing cylindrical objects in the spindle units of technological equipment is presented. The new two-stage concept of the clamping process with a separated first stage is developed. The design of the presented mechanism provides advanced capabilities for control and regulation of its operating characteristics. The control system with the possibility of carrying out the first stage of clamping in automatic mode and without connecting to the upper-level control system in a technological machine is proposed. The involvement of electrical devices for the conversion and transmission of energy instead of their mechanical analogues is used as one of the promising ways to increase the performance efficiency of machine units. It helps to simplify and expand control capabilities, as well as reduce energy losses during intermediate transformations. The absence of mechanical energy converters in the proposed structure helps to reduce energy losses on intermediate transformations. The simplicity of the design expands the possibilities of integration of the proposed clamping mechanism into the structure of both new and existing technological machines in order to modernize it. This allows to achieve technical results, such as an expansion of the metalworking machines functionality, increase the level of automation of the clamping process and the accuracy of clamping objects in spindle units. The task is achieved by equipping the jaw of the clamping chuck with a special mechanism for identifying the presence of the object for clamping. For this goal, the clamping jaw is equipped with a probe that is capable of simultaneous force interaction with the object and the plunger. The plunger is rigidly attached to the magnetic element whose magnetic field has the possibility to interact with the magnetic field sensor. The sensor transmits its electrical signals to the control system of the device. The research results are aimed at meeting the requirements for effective control of clamping mechanisms with the possibility of automatic operation according to a preset algorithm for maintenance of optimal characteristics of a clamping process and a wide range of optional settings.
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Aguilar, Juan José, Raquel Acero, Francisco Javier Brosed, and Jorge Santolaria. "Development of a High Precision Telescopic Instrument Based on Simultaneous Laser Multilateration for Machine Tool Volumetric Verification." Sensors 20, no. 13 (July 7, 2020): 3798. http://dx.doi.org/10.3390/s20133798.
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This paper presents the design of a high precision telescopic system consisting in three lines, with measuring principle based on simultaneous laser multilateration. The system offers the high precision of the interferometer systems and allows the autonomous tracking of a sphere joined to the spindle nose of the machine tool by simultaneous contact of all the lines. The main advantage of the system is that it allows data capture to be carried out in a single cycle thanks to simultaneous operation with at least three telescopic arms using a novel multipoint kinematic coupling. This results in a significant reduction of the time taken for data capture and improves measurement accuracy due to avoiding the effect of temperature variations between cycles and machine tool repeatability. The work explains the working principle of the system, its main components, and the design parameters considered for the development of the system. The system is simple to operate, compact, agile, and suitable for the verification of small- or medium-sized machine tools with linear and/or rotary axes.
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KHARCHENKO, A. O., and A. S. CHASOVITINA. "STRUCTURE OF A THREAD PROCESSING MODULE WITH PARALLEL KINEMATICS MECHANISMS." Fundamental and Applied Problems of Engineering and Technology 4, no. 2 (2020): 95–102. http://dx.doi.org/10.33979/2073-7408-2020-342-4-2-95-102.
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In the article the principles of construction of modern thread-cutting equipment based on mechanisms of parallel structures are considered. The optimal structure was identified and combined with a variant of the combination of MPS with the ability to simultaneously change the length of the rods and the coordinates of reference hinge, ensuring the implementation of a significant number of technological methods in the same workplace for one installation details. The principle of operation of the resulting hybrid thread-cutting machine with a combined MPS of a modular construction in which the executive body can perform a complex spatial movement is described. Based on morphological analysis and structural-layout synthesis, followed by optimization according to the criterion of reliability and economic efficiency, the hybrid layout of a six-spindle thread-cutting machine with MPS. The design of a precast plastically deforming tap of increased resistance is presented due to the possibility of multiple regrindings by shortening the worn-out section of the working part; providing high accuracy and quality of the obtained threads.
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Smith, D. A., S. Smith, and J. Tlusty. "High Performance Milling Torque Sensor." Journal of Manufacturing Science and Engineering 120, no. 3 (August 1, 1998): 504–14. http://dx.doi.org/10.1115/1.2830153.
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Machine tool supervision and control algorithms require reliable and effective sensor signals to operate properly. In effort to satisfy this need, a high stiffness, wide bandwidth torque sensor for use in milling has been developed which directly measures the torque applied to a milling cutter during operation. The sensor is designed to fit between the tool and holder on conventional tooling with very little effect on the cutting process. The sensor is strain gage based and provides a virtually distortionless torque measurement over a bandwidth from DC to 2000 Hz when using a 100 mm diameter face mill on a commercial machining center. High torsional stiffness was achieved to provide a wide measurement bandwidth while allowing enough material strain, in the sensing element, to provide sufficient resolution of the milling torque. The radial stiffness of the sensor was also designed to be large enough not to compromise the stability and accuracy of the machine tool. The sensor is designed to house the critical electronic components which amplify the small voltage strain gage signal and convert the measurement into digital samples. These samples are continuously transmitted from the rotating spindle, in all positions, to a stationary receiver. Because the sensor is part of a structural system which also includes the spindle, tool holder and tool, the frequency response has distortions associated with the vibrational modes of the system. In order to obtain a wide undistorted bandwidth, a compensation filter having the reciprocal response of the sensor has been designed and implemented on a digital signal processor (DSP). The combined system of the sensor cascaded with the DSP provides a flat magnitude and linear phase frequency response.
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Dahbi, Samya, Latifa Ezzine, and Haj El Moussami. "ARIMA-Based Time Series Model of Cutting Temperature in Facing Process." Journal of Advanced Manufacturing Systems 18, no. 03 (September 2019): 395–411. http://dx.doi.org/10.1142/s0219686719500215.
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During machining processes, cutting temperature directly affects cutting performances, such as surface quality, dimensional precision, tool life, etc. Thus, evaluation of cutting temperature rise in the tool–chip interface by reliable techniques can lead to improved cutting performances. In this paper, we present the modeling of cutting temperature during facing process by using time series approach. The experimental data were collected by conducting facing experiments on a Computer Numerical Control lathe and by measuring the cutting temperature by an infrared camera. The collected data were used to test several Autoregressive Integrated Moving Average (ARIMA) models by using Box–Jenkins time series procedure. Then, the adequate model was selected according to four performance criteria: Akaike criterion, Schwarz Bayesian criterion, maximum likelihood, and standard error. The selected model corresponded to the ARIMA (1, 1, 1) and it was tested by conducting a new facing operation under the same cutting conditions (spindle speed, feed rate, depth of cut, and nose radius). It was clearly seen that there is a good agreement between experimental and simulated temperatures, which reveals that this approach simulates the evolution of cutting temperature in facing process with high accuracy (average percentage error [Formula: see text] 0.57%).
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Sulaiman, Syidatul Akma, A. K. M. Nurul Amin, and M. D. Arif. "Application of Permanent Magnets for Chatter Control in End Milling of Titanium Alloy Ti-6Al-4V." Advanced Materials Research 576 (October 2012): 15–18. http://dx.doi.org/10.4028/www.scientific.net/amr.576.15.
Full textAbstract:
Machining of metals is generally accompanied by a violent relative vibration between work and tool, known as chatter. Chatter is undesirable due to its adverse effects on product quality, operation cost, machining accuracy, tool life, and productivity. This paper presents an innovative approach to chatter control during end milling of titanium alloy Ti-6Al-4V using ferrite permanent magnets to reduce the unwanted vibrations. A special fixture was fabricated and mounted on a Vertical Machining Center‘s spindle for holding the permanent magnet bars, used in suppressing the vibration amplitudes. DASY Lab 5.6 was used for signal analysis and processing to compare the intensity of chatter under normal and magnet application conditions. Fast Fourier Transform (FFT) was subsequently used to transform the vibration data to a function of frequency domain. The experiments focused on monitoring the vibration amplitudes and analysis of chip formation process during metal cutting. It was observed that the magnetic fields contributed to reduction of chatter amplitudes. It was apparent that a reduction of chatter amplitude would result in improved surface finish of the work-piece and lead to uniform chip formation.
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Cepero-Mejias, Fernando, Nicolas Duboust, Vaibhav A. Phadnis, Kevin Kerrigan, and Jose L. Curiel-Sosa. "A Novel Finite Element Method Approach in the Modelling of Edge Trimming of CFRP Laminates." Applied Sciences 11, no. 11 (May 21, 2021): 4743. http://dx.doi.org/10.3390/app11114743.
Full textAbstract:
Nowadays, the development of robust finite element models is vital to research cost-effectively the optimal cutting parameters of a composite machining process. However, various factors, such as the high computational cost or the complicated nature of the interaction between the workpiece and the cutting tool significantly hinder the modelling of these types of processes. For these reasons, the numerical study of common machining operations, especially in composite machining, is still minimal. This paper presents a novel approach comprising a mixed multidirectional composite damage mode with composite edge trimming operation. An ingenious finite element framework which infer the cutting edge tool wear assessing the incremental change of the machining forces is developed. This information is essential to replace tool inserts before the tool wear could cause severe damage in the machined parts. Two unidirectional carbon fibre specimens with fibre orientations of 45° and 90° manufactured by pre-preg layup and cured in an autoclave were tested. Excellent machining force predictions were obtained with errors below 10% from the experimental trials. A consistent 2D FE composite damage model previously performed in composite machining was implemented to mimic the material failure during the machining process. The simulation of the spring back effect was shown to notably increase the accuracy of the numerical predictions in comparison to similar investigations. Global cutting forces simulated were analysed together with the cutting tool tooth forces to extract interesting conclusions regarding the forces received by the spindle axis and the cutting tool tooth, respectively. In general terms, vertical and normal forces steadily increase with tool wear, while tangential to the cutting tool, tooth and horizontal machining forces do not undergo a notable variation.
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Li, Hongqi, and Yung C. Shin. "Integrated Dynamic Thermo-Mechanical Modeling of High Speed Spindles, Part 1: Model Development." Journal of Manufacturing Science and Engineering 126, no. 1 (February 1, 2004): 148–58. http://dx.doi.org/10.1115/1.1644545.
Full textAbstract:
This paper presents a comprehensive integrated thermo-dynamic model for various high speed spindles. The entire model consists of fully coupled three sub-models: bearing, spindle dynamic and thermal models. Using a finite element approach, a new thermal model has been generated, which can describe complex structures of high-speed motorized spindles, and can predict more accurate temperature distributions. The spindle dynamic model is constructed using finite elements based on Timoshenko beam theory and has been improved by considering shear deformation, material and bearing damping, and the spindle/tool-holder interface. Using the new thermo-dynamic model, more general and detailed bearing configurations can be modeled through a systematic coupling procedure. The thermal expansions of the shaft, housing and bearings are calculated based on predicted temperature distributions and are used to update the bearing preloads depending on the operating conditions, which are again used to update the thermal model. Therefore, the model is fully integrated and can provide solutions in terms of all the design parameters and operating conditions.
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Jianmei, Wang, Kang Jianfeng, and Tang Liang. "Theoretical and experimental studies for wind turbine’s shrink disk." Proceedings of the Institution of Mechanical Engineers, Part C: Journal of Mechanical Engineering Science 229, no. 2 (May 7, 2014): 325–34. http://dx.doi.org/10.1177/0954406214533529.
Full textAbstract:
With the wide application of multi-layer interference fit in many engineering fields, as for key component in the wind turbine generator, wind turbine’s shrink disk uses interference fit to transmit rated torque and axial force. In order to ensure the work reliability of shrink disk during the actual operation, the paper presents a more precise method on the design calculation of contact pressure on the mating surfaces with interference fit. In accordance with the order from the inside to the outside, the contact pressure of spindle-to-sleeve surface can be calculated based on the rated load required to transmit. Combining with Thick-wall Cylinder Theory and Lame Equation, taking into account the impact of fit clearance, the checking method of the bushing was used to calculate the contact pressure on mating surface of bushing-to-inner ring; and the stress analysis of the inner ring was used to calculate the contact pressure on mating surface of inner ring-to-outer ring. At the same time, the effects of frictional coefficient, fit clearance, and other design parameters on theoretical results were also analyzed. The pressure distribution of each mating surface was obtained by Abaqus software simulation, which showed that the results from improved method was closer to simulation results and had higher accuracy than traditional method by comparing the results with three different methods. Finally, the test was designed to verify whether the shrink disk could bear the load or not on the test platform of shrink disk, and the results indicated that it could meet the requirements of given loadcase.
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Tachiya, Hiroshi, Hiroki Hirata, Takayuki Ueno, Yoshiyuki Kaneko, Katsuhiro Nakagaki, and Yoshiaki Ishino. "Evaluation of and Compensation for Thermal Deformation in a Compact CNC Lathe." International Journal of Automation Technology 6, no. 2 (March 5, 2012): 137–46. http://dx.doi.org/10.20965/ijat.2012.p0137.
Full textAbstract:
Because heat sources for compact Computer Numerically Controlled (CNC) lathes are likely to be closely arranged, they may cause large and complicated thermal deformation. Previously, we developed a CNC lathe with its heat sources arranged so as to reduce thermal deformation. This lathe achieved highprecision work under stable temperatures in continuous operation. However, in some cases, it could cause rapid thermal deformation. Previously, we proposed a simple method to compensate for the thermal deformation in CNC lathes by measuring temperatures at only a few points. By developing amodified compensation method capable of estimating minute and complicated thermal deformation and applying this method to the current lathe, processing accuracy will become more precise. Thus, we evaluated the thermal deformation of a compact CNC lathe. As a result, we found that the thermal deformation of the lathe was caused not only by movable parts, such as the spindle motor, but also by non-movable parts, such as the hydraulic unit. We therefore approximated the thermal deformation caused by the non-movable parts and estimated the change in the deformation caused only by the movable parts. This enabled us to express the thermal deformation by a simple linear equation, the form of which was same as that used for previous lathes. From these results, we were able to compensate for the thermal deformation using approximate equations for both movable and non-movable parts and we applied this method to the current lathe. We confirmed that the work error can be reduced under stable conditions using this method.
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Fedorynenko, Dmytro, Serhii Sapon, and Sergiy Boyko. "Accuracy of Spindle Units with Hydrostatic Bearings." Acta Mechanica et Automatica 10, no. 2 (June 1, 2016): 117–24. http://dx.doi.org/10.1515/ama-2016-0019.
Full textAbstract:
AbstractThe work is devoted to the research of precision regularities in a spindle unit by the trajectory of the spindle installed on hydrostatic bearings. The mathematical model of trajectories spindle with lumped parameters that allows to define the position of the spindle with regard the simultaneous influence of design parameters, geometrical deviations ofform, temperature deformation bearing surfaces, the random nature of operational parameters and technical loads of hydrostatic bearings has been developed. Based on the results of numerical modeling the influence of shape errors of bearing surface of hydrostatic bearing on the statistical characteristics of the radius vector trajectories of the spindle by varying the values rotational speed of the spindle and oil pressure in front hydrostatic bearing has been developed. The obtained statistical regularities of precision spindle unit have been confirmed experimentally. It has been shown that an effective way to increase the precision of spindle units is to regulate the size of the gap in hydrostatic spindle bearings. The new design of an adjustable hydrostatic bearing, which can improve the accuracy of regulation size gap has been proposed.