Investigation on Machining Stability during Turning and Grin
发布时间：2021-11-24 16:23
本文以车削和磨削过程的稳定性为主要研究内容,基于对国内外车削与磨削稳定性研究现状的分析,旨在通过刀具与工件系统的动力学建模、仿真和实验的研究,深入揭示导致切削系统失稳的内在机理和主要原因,为进一步提升工件的加工质量和制造装备的稳定性提供理论参考。本文主要研究内容和结果包括:（1）提出了一种新的基于车削刀具偏转引起的再生振动模型,该模型将切削力作为影响刀具变形的主要因素,研究发现,由于刀具与工件之间相互的非线性作用,刀具偏转导致系统的复杂动力学行为,从而导致颤振。系统呈现周期、准周期和混沌运动;同时进给量和切削深度的增加会降低加工稳定性;（2）采用三维有限元法分析计算了车刀在切削载荷作用下的挠度变化,及其对车削系统稳定性的影响。实验结果表明,当切削参数较小时,切削系统处于稳定工作状态;而当车削速度和车削深度分别大于0.1mm/n和1.5mm时,系统失稳且颤振频率逐渐增大,并在周期、准周期和混沌状态之间的跃迁;（3）建立了以工件为刚性、砂轮非线性二自由度质量弹簧-阻尼振子的磨削加工的动力学模型。对磨削力的法向分量和切向分量对平面磨削过程的影响研究,发现切削深度和切削速度的变化会引起了加工过...
【文章来源】：兰州理工大学甘肃省
【文章页数】：184 页
【学位级别】：博士
【文章目录】：
Abstract
摘要
List of Symbols
Chapter 1 Introduction
1.1 Motivation
1.2 The scope of the research
1.3 Research aim
1.4 Research objective
1.5 The layout of the dissertation
Chapter 2 Literature Review
2.1 Overview
2.2 Dynamics of the turning operation
2.2.1 Cutting tools in turning operation
2.2.3 Effects of the tool geometry on the dynamic stability of theturning operation
2.2.4 Monitoring of the tool condition in the turning operation
2.2.5 Vibrations in turning operation
2.2.6 Chatter in turning operation
2.3 Dynamics of the grinding operation
2.3.1 Types of grinding operations
2.3.2 Grinding wheel marking system
2.3.3 Grinding forces
2.3.4 Vibrations in grinding operations
2.3.5 Dynamic stability in grinding operations
2.4 Dynamic modeling in the machining processes
2.5 Methods for chatter detection in machining processes
2.5.1 Method of chip analysis
2.5.2 Method of artificial intelligence
2.5.3 Method of signal acquisition and processing
2.6 Analytical methods for chatter detection in machining processes
2.6.1 Method of Nyquist plots
2.6.2 Method of Stability Lobe Diagram(SLD)
2.6.3 Method of finite element analysis and finite element model(FEA/FEM)
Chapter 3 Experimental Equipment
3.1 Introduction
3.2 Basic equipment of the experimental setup
3.2.1 Lathe machine
3.2.2 High-speed steel cutting tool
3.2.3 Flat surface grinding machine
3.2.4 Cylindrical grinding machine
3.2.5 Grinding wheel
3.2.6 Force measurement dynamometer
3.2.7 Charge amplifier
3.2.8 Oscilloscope
3.2.9 Data acquisition system(DAQ)
3.3 Chapter summary
Chapter 4 Methods of Chatter Analysis in Machining Operations
4.1 Introduction
4.2 Methods of numerical integration in chatter analysis
4.3 Time-domain analysis
4.4 Frequency response analysis
4.5 Finite Element Method(FEM)/Finite Element Analysis(FEA)
4.6 Experimental methods in chatter analysis
4.7 Chapter Summary
Chapter 5 Stability Analysis of the Turning Operation
5.1 Introduction
5.2 Development of mathematical formulation of a cantilever beam
5.3 Estimation of the tool deflection by a simple cantilever beam model
5.4 Dynamic cutting forces components with regenerative chatter inturning operation
5.5 Dynamic cutting force model by the flexible cutting tool
5.6 Dynamic model of the turning operation for cutting tool deflection
5.7 Governing equation of the dynamic model vibration
5.8 3-D Finite element model analysis
5.9 Experimentation
5.10 Experiment setup
5.11 Results of model simulation for stability analysis of the turningoperation
5.11.1 Cutting parameters
5.11.2 Analysis of dynamic model vibration results
5.12 3D-finite element model analysis results
5.13 Experimental results
5.14 Chapter Summary
Chapter 6 Stability Analysis of the Flat Surface Grinding Operation
6.1 Introduction
6.2 Modeling of vibration excitation forces in flat surface grindingoperation
6.3 Vibration modeling of the flat surface grinding operation
6.4 Experimental procedure
6.5 Experimental setup
6.6 Results analysis and discussion
6.6.1 Vibration condition analysis of the flat surface grindingoperation
6.6.2 Experimental verification
6.7 Chapter summary
Chapter 7 Stability Analysis of the Traverse Cylindrical GrindingOperation
7.1 Introduction
7.2 Problem description
7.3 Traverse cylindrical grinding process nonlinear dynamic modeling
7.3.1 Workpiece nonlinear dynamics analysis
7.3.2 Grinding wheel nonlinear dynamics analysis
7.4 Experimental setup
7.5 Results analysis and discussion
7.5.1 Model simulation results
7.5.2 Experimental results
7.6 Chapter summary
Conclusions and Future Works
References
Publications Originated from this Dissertation
Acknowledgements
Appendix- Derivation of the equation to calculate the magnitude of thedeflection for a cantilever beam
本文编号：3516343
【文章来源】：兰州理工大学甘肃省
【文章页数】：184 页
【学位级别】：博士
【文章目录】：
Abstract
摘要
List of Symbols
Chapter 1 Introduction
1.1 Motivation
1.2 The scope of the research
1.3 Research aim
1.4 Research objective
1.5 The layout of the dissertation
Chapter 2 Literature Review
2.1 Overview
2.2 Dynamics of the turning operation
2.2.1 Cutting tools in turning operation
2.2.3 Effects of the tool geometry on the dynamic stability of theturning operation
2.2.4 Monitoring of the tool condition in the turning operation
2.2.5 Vibrations in turning operation
2.2.6 Chatter in turning operation
2.3 Dynamics of the grinding operation
2.3.1 Types of grinding operations
2.3.2 Grinding wheel marking system
2.3.3 Grinding forces
2.3.4 Vibrations in grinding operations
2.3.5 Dynamic stability in grinding operations
2.4 Dynamic modeling in the machining processes
2.5 Methods for chatter detection in machining processes
2.5.1 Method of chip analysis
2.5.2 Method of artificial intelligence
2.5.3 Method of signal acquisition and processing
2.6 Analytical methods for chatter detection in machining processes
2.6.1 Method of Nyquist plots
2.6.2 Method of Stability Lobe Diagram(SLD)
2.6.3 Method of finite element analysis and finite element model(FEA/FEM)
Chapter 3 Experimental Equipment
3.1 Introduction
3.2 Basic equipment of the experimental setup
3.2.1 Lathe machine
3.2.2 High-speed steel cutting tool
3.2.3 Flat surface grinding machine
3.2.4 Cylindrical grinding machine
3.2.5 Grinding wheel
3.2.6 Force measurement dynamometer
3.2.7 Charge amplifier
3.2.8 Oscilloscope
3.2.9 Data acquisition system(DAQ)
3.3 Chapter summary
Chapter 4 Methods of Chatter Analysis in Machining Operations
4.1 Introduction
4.2 Methods of numerical integration in chatter analysis
4.3 Time-domain analysis
4.4 Frequency response analysis
4.5 Finite Element Method(FEM)/Finite Element Analysis(FEA)
4.6 Experimental methods in chatter analysis
4.7 Chapter Summary
Chapter 5 Stability Analysis of the Turning Operation
5.1 Introduction
5.2 Development of mathematical formulation of a cantilever beam
5.3 Estimation of the tool deflection by a simple cantilever beam model
5.4 Dynamic cutting forces components with regenerative chatter inturning operation
5.5 Dynamic cutting force model by the flexible cutting tool
5.6 Dynamic model of the turning operation for cutting tool deflection
5.7 Governing equation of the dynamic model vibration
5.8 3-D Finite element model analysis
5.9 Experimentation
5.10 Experiment setup
5.11 Results of model simulation for stability analysis of the turningoperation
5.11.1 Cutting parameters
5.11.2 Analysis of dynamic model vibration results
5.12 3D-finite element model analysis results
5.13 Experimental results
5.14 Chapter Summary
Chapter 6 Stability Analysis of the Flat Surface Grinding Operation
6.1 Introduction
6.2 Modeling of vibration excitation forces in flat surface grindingoperation
6.3 Vibration modeling of the flat surface grinding operation
6.4 Experimental procedure
6.5 Experimental setup
6.6 Results analysis and discussion
6.6.1 Vibration condition analysis of the flat surface grindingoperation
6.6.2 Experimental verification
6.7 Chapter summary
Chapter 7 Stability Analysis of the Traverse Cylindrical GrindingOperation
7.1 Introduction
7.2 Problem description
7.3 Traverse cylindrical grinding process nonlinear dynamic modeling
7.3.1 Workpiece nonlinear dynamics analysis
7.3.2 Grinding wheel nonlinear dynamics analysis
7.4 Experimental setup
7.5 Results analysis and discussion
7.5.1 Model simulation results
7.5.2 Experimental results
7.6 Chapter summary
Conclusions and Future Works
References
Publications Originated from this Dissertation
Acknowledgements
Appendix- Derivation of the equation to calculate the magnitude of thedeflection for a cantilever beam
本文编号：3516343
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