We have developed a physics-based transmission-line-circuit model of the Z pulsed-power accelerator. The 33-m-diameter Z machine generates a peak electrical power as high as 85 TW, and delivers as much as 25 MA to a physics load. The circuit model is used to design and analyze experiments conducted on Z. The model consists of 36 networks of transmission-line-circuit elements and resistors that represent each of Zs 36 modules. The model of each module includes a Marx generator, intermediate-energy-storage capacitor, laser-triggered gas switch, pulse-forming line, self-break water switches, and tri-plate transmission lines. The circuit model also includes elements that represent Zs water convolute, vacuum insulator stack, four parallel outer magnetically insulated vacuum transmission lines (MITLs), double-post-hole vacuum convolute, inner vacuum MITL, and physics load. Within the vacuum-transmission-line system the model conducts analytic calculations of current loss. To calculate the loss, the model simulates the following processes: (i) electron emission from MITL cathode surfaces wherever an electric-field threshold has been exceeded; (ii) electron loss in the MITLs before magnetic insulation has been established; (iii) flow of electrons emitted by the outer-MITL cathodes after insulation has been established; (iv) closure of MITL anode-cathode (AK) gaps due to expansion of cathode plasma; (v) energy loss to MITL conductors operated at high lineal current densities; (vi) heating of MITL-anode surfaces due to conduction current and deposition of electron kinetic energy; (vii) negative-space-charge-enhanced ion emission from MITL anode surfaces wherever an anode-surface-temperature threshold has been exceeded; and (viii) closure of MITL AK gaps due to expansion of anode plasma. The circuit model is expected to be most accurate when the fractional current loss is small. We have performed circuit simulations of 52 Z experiments conducted with a variety of accelerator configurations and load-impedance time histories. For these experiments, the apparent fractional current loss varies from 0% to 20%. Results of the circuit simulations agree with data acquired on 52 shots to within 2%.
Thermally induced errors have a major significance on the positional accuracy of a machine tool. Heat generated during the machining process produces thermal gradients that flow through the machine structure causing linear and nonlinear thermal expansions and distortions of associated complex discrete structures, producing deformations that adversely affect structural stability. The heat passes through structural linkages and mechanical joints where interfacial parameters such as the roughness and form of the contacting surfaces affect the thermal resistance and thus the heat transfer coefficients. This paper presents a novel offline technique using finite element analysis (FEA) to simulate the effects of the major internal heat sources such as bearings, motors and belt drives of a small vertical milling machine (VMC) and the effects of ambient temperature pockets that build up during the machine operation. Simplified models of the machine have been created offline using FEA software and evaluated experimental results applied for offline thermal behaviour simulation of the full machine structure. The FEA simulated results are in close agreement with the experimental results ranging from 65% to 90% for a variety of testing regimes and revealed a maximum error range of 70 µm reduced to less than 10 µm.
There is a requirement for improved three-dimensional surface characterisation and reduced tool wear when modern computer numerical control (CNC) machine tools are operating at high cutting velocities, spindle speeds and feed rates. For large depths of cut and large material removal rates, there is a tendency for machines to chatter caused by selfexcited vibration in the machine tools leading to precision errors, poor surface finish quality, tool wear and possible machine damage. This study illustrates a method for improving machine tool performance by understanding and adaptively controlling the machine structural vibration. The first step taken is to measure and interpret machine tool vibration and produce a structural model. As a consequence, appropriate sensors need to be selected and/or designed and then integrated to measure all self-excited vibrations. The vibrations of the machine under investigation need to be clearly understood by analysis of sensor signals and surface finish measurement. The active vibration control system has been implemented on a CNC machine tool and validated under controlled conditions by compensating for machine tool vibrations on time-varying multi-point cutting operations for a vertical milling machine. The design of the adaptive control system using modelling, filtering, active vibration platform and sensor feedback techniques has been demonstrated to be successful.
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