Literature Review of Electromagnetic Actuator Force Generation for Dynamic Modal Testing Applications
DOI:
https://doi.org/10.15282/jmes.3.2012.7.0029Keywords:
Chatter, frequency response function, modal testingAbstract
Milling is one of the most common manufacturing processes for automotive components, but its productivity is limited by the onset of regenerative chatter. This is a form of unstable self-excited vibration that occurs when the volume of material removed is too large for a particular spindle speed. This form of chatter is undesirable because it results in premature tool wear, poor surface finish on the machined component and the possibility of serious damage to the machine itself. The chatter stability of a milling process can be determined using well-established theory, provided that the frequency response of the flexible structure can be determined. In practice this usually involves the excitation of a stationery (non-rotating) milling tool with a modal hammer, and measurement of the response of the tool with a co-located accelerometer. However, this measurement is not necessarily accurate due to amplitude dependency factor consideration. There is anecdotal evidence that structural nonlinearity can have a significant effect on the chatter stability of some milling machines. This project develops non-contact electromagnetic actuators to measure the frequency response of
milling tools to machine automotive parts. In addition it will describe the practical application of this approach, and discuss its amplitude dependency for current excitation during frequency response function measurement using magnetic force generation.
References
Abele, E., Kreis, M., & Schiffler, A. (2007). Online diagnosis and identification of high accuracy HSC machining centers. 6th International Conference on High Speed Machining, pp. 1-8.
Al-Khazali, H. A. H., & Askari, M. R. (2011). Experimental technique to investigate vibration monitoring in revolving structures using oscilloscopic/modal testing. International Journal of Engineering Science and Technology, 3, 7799-7814.
Altintas, Y. 2000. Manufacturing automation: metal cutting mechanics, machine tool vibrations and CNC design. UK, Cambridge University Press.
Altintaş, Y., & Budak, E. (1995). Analytical prediction of stability lobes in milling. CIRP Annals - Manufacturing Technology, 44, 357-362.
Anderson, I. A. (1990). Avoiding stinger rod resonance effects on small structures. Proceedings of the 8th International Modal Analysis Conference, pp. 673-678.
Appun, P., & Ritter, G. (1975). Calculation and optimization of the magnets for an electromagnetic levitation system. IEEE Transactions on Magnetics, 11 (1), 39-44.
Arnold, R. N. (1946). The mechanism of tool vibration in the cutting steel. Proceedings of the Institution of Mechanical Engineers, 154 (4), 261-284.
Ashory, M. R. (1999). High quality modal testing methods. PhD Thesis, Imperial College of Science, Technology and Medicine, University of London.
Billhart, R. D., Hunt, D. L., & Pierre, M. S. (1993). Advantages of excitation using plastic stinger rods. Proceedings of the 11th International Modal Analysis Conference, pp. 1217-1220.
Bujang, I. Z., Kamaruddin, K. A., & Nordin, M. T. M. (2008). Identification of structural defects using modal technology. International Conference on Construction and Building Technology, pp. 193-200.
Caulfield, F. D. (2002). Electromechanical actuator development for integrated chatter prediction on high speed machining centers. Master Thesis, North Carolina State University, USA.
Chen, M. Y., Lin, T. B., Huang, S. G., & Fu, L. C. (2003). Design, analysis and control of an electro-magnetic actuator. Proceedings of the American Control Conference (ACC), Denver, Colorado, pp. 3095-3100.
Cloutier, D., Avitabile, D. P., Bono, R., & Peres, M. (2009). Shaker/stinger effects on measured frequency response function. Proceedings of the IMAC-XXVII, Florida, USA, pp. 1-7.
Comstock, T. R. (1999). Improving exciter performance in modal testing. Proceedings of the 17th International Modal Analysis Conference, Florida, USA, pp. 1770-1775.
Cope, D., Wright, A., Corcoran, C. J., Pasch, K., & Fischer, D. (2008). Fully flexible electromagnetic valve actuator: design, modeling, and measurements. SAE Paper No. 2008-01-1350.
Davies, M. A., Dutterer, B., Pratt, J. R., Schaut, A. J., & Bryan, J. B. (1998). On the dynamics of high-speed milling with long, slender endmills. CIRP Annals - Manufacturing Technology, 47, 55-60.
Esterling, D., Caufield, F. D., Kiefer, A., Buckner, G., & Jaju, P. (2003). Non-contact device for measuring frequency response functions of CNC machine tools. ASME International Mechanical Engineering Congress, pp. 77-83.
Ewins, D. J. (1984). Modal testing: theory and practice. Hertfordshire, Research Studies Press.
Ewins, D. J. (2000). Modal testing: theory, practice and application. UK, Baldock.
Faassen, R. P. H. (2007). Chatter prediction and control for high-speed milling. PhD Thesis, Eindhoven University of Technology, Netherlands.
Faassen, R. P. H., Van De Wouw, N., Oosterling, J. A. J., & Nijmeijer, H. (2003). Prediction of regenerative chatter by modelling and analysis of high-speed milling. International Journal of Machine Tools and Manufacture, 43, 1437-1446.
Gradišek, J., Kalveram, M., Insperger, T., Weinert, K., Stépán, G., Govekar, E., & Grabec, I. (2005). On stability prediction for milling. International Journal of Machine Tools and Manufacture, 45, 769-781.
Insperger, T., & Stepan, G. (2002). Semi-discretization method for delayed systems. International Journal for Numerical Methods in Engineering, 55, 503-518.
Ismail, F., & Ziaei, R. (2002). Chatter suppression in five-axis machining of flexible parts. International Journal of Machine Tools and Manufacture, 42, 115-122.
Kiefer, A. J. (2004). Integrating electromechanical actuator hardware with receptance coupling substructure analysis for chatter prediction on high speed machining centers. Master Thesis, North Carolina State University, USA.
Koenigsberger, F., & Tlusty, J. (1967). Machine tool structures. Vol. I: Stability against chatter. London, Pergamon Press.
Lan, J. V. L., Marty, A., & Debognie, J. F. (2006). A stability diagram computation method for milling adapted to automotive industry. CIRP Second International Conference on High Performance Cutting, Vancouver, British Columbia, Canada.
Mann, B. P., Young, K. A., Schmitz, T. L., & Dilley, D. N. (2005). Simultaneous stability and surface location error predictions in milling. Journal of Manufacturing Science and Engineering, 127, 446-453.
Markovic, M., Jufer, M., & Perriard, Y. (2008). Analytical Force determination in an electromagnetic actuator. IEEE Transactions on Magnetics, 44, 2181-2185.
Mehdigholi, H. (1991). Force vibration of rotating discs and interaction with non-rotating structures. PhD Thesis, Imperial College of Science, Technology and Medicine, University of London, UK.
Melgoza, E., & Rodger, D. (2002). Comparison of table models of electromagnetic actuator. IEEE Transactions on Magnetics, 38, 953-957.
Merrit, H. 1965. Theory of self-excited machine tool chatter. Journal of Engineering for Industry, 87, 447-454.
Movaheddy, M., & Mosaddegh, P. (2006). Prediction of chatter in high speed milling including gyroscopic effects. International Journal of Machine Tools and Manufacture, 46, 996-1001.
Quintana, G., Ciurana, J., & Teixidor, D. (2008). A new experimental methodology for identification of stability lobes diagram in milling operations. International Journal of Machine Tools and Manufacture, 48, 1637-1645.
Rantatalo, M., Aidanpaa, J. O., Goransson, B., & Norman, P. (2007). Milling machine spindle analysis using FEM and non-contact spindle excitation and response measurement. International Journal of Machine Tools and Manufacture, 47, 1034-1045.
Sarkar, M., Biswas, P., Sarkar, P., Bhaduri, R., & Banerjee, S. (2011). A review note on different components of simple electromagnetic levitation systems. IETE Technical Review, 28 (3), 256-264.
Schmitz, T. L., Ziegert, J. C., & Stanislaus, C. (2004). A method for predicting chatter stability for systems with speed-dependent spindle dynamics. Aerospace Engineering, 32, 17-24.
Sheng-Ming, Y. (2011). Electromagnetic actuator implementation and control for resonance vibration reduction in miniature magnetically levitated rotating machines. IEEE Transactions on Industrial Electronics, 58, 611-617.
Sims, N. D., Bayly, P. V., & Young, K. A. (2005). Piezoelectric sensors and actuators for milling tool stability lobes. Journal of Sound and Vibration, 281, 743-762.
Smith, S., & Tlusty, J. (1991). An overview of modelling and simulation of the milling process. Journal of Engineering for Industry, 113, 169-175.
Sylvester, P. (1968). Modern electromagnetic fields. London, Prentice Hall.
Tatar, K., Rantatalo, M., & Gren, P. (2007). Laser vibrometry measurements of an optically smooth rotating spindle. Mechanical Systems and Signal Processing, 21, 1739-1745.
Tlusty, J., & Moriwaki, T. (1976). Experimental and computational identification of dynamic structural models. Annals of the CIRP, 25, 497-503.
Tlusty, J., & Polocek, M. (1963) The stability of the machine-tool against self-excited vibration in machining. Proceedings of the International Research in Production Engineering Conference, Pittsburgh, pp. 465-474.
Tobias, S. A. (1965). Machine tool vibration. New York: John Wiley.
Tobias, S. A., & Fishwick, W. (1958). Theory of regenerative machine tool chatter. London, The Engineer.
Wu, D., Zhou, S., & Xie, X. (2010). Design and control of an electromagnetic fast tool servo with high bandwidth. IET Electric Power Applications, 5(2), 217-223.
Yamamura, S., & Yamaguchi, H. (1990). Electromagnetic levitation system by means of salient-pole type magnets coupled with laminated slotless rails. IEEE Transactions on Vehicular Technology, 39, 83-87.
Yusoff, A., Turner, S., Taylor, C., & Sims, N. (2010). The role of tool geometry in process damped milling. International Journal of Advanced Manufacturing Technology, 50, 883-895.
Yusoff, A. R., & Sims, N. D. (2008). Non contacting electromagnetic actuators for chatter stability analysis of milling tools. 9th International Conference on Vibrations in Rotating Machinery, pp. 305-316.
Yusoff, A. R., & Sims, N. D. (2011). Determination of optimal variable helix and variable pitch tool geometry for chatter suppression in milling process. Journal of Advanced Manufacturing Technology, 5, 45-60.
Yusoff, A. R., Suffian, M. R. Z. M., & Taib, M. Y. (2011). Literature review of optimization technique for chatter suppression in machining. Journal of Mechanical Engineering and Science, 1, 47-61.
Downloads
Published
How to Cite
Issue
Section
License
Copyright (c) 2012 The Author(s)
This work is licensed under a Creative Commons Attribution 4.0 International License.
