Non-linear analysis and quench control of chatter in plunge grinding

Yan, Yao; Xu, Jian; Wiercigroch, Marian

doi:10.1016/j.ijnonlinmec.2014.06.012

Cited by 25 publications

(7 citation statements)

References 40 publications

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“…The objective of this research work is monitoring the occurrence onset of the chatter phenomenon in the grinding process by using aluminum oxide grinding wheel and SAE 1045 steel by means of vibration signals and digital signal processing techniques. The present paper differs from previous ones, such as the research conducted by Ahrens et al [3,7], Yan et al [4,8] and Gradišek et al [6], because here it was applied the Ratio of Power (ROP) statistical parameter to detect such phenomenon, characterizing a novel approach for the chatter monitoring.…”

Section: Introductionmentioning

confidence: 74%

“…Some factors, such as high rates of material removal, imbalance and eccentricity of the grinding wheel, can contributes for the chatter occurrence. Usually, in the grinding process, the chatter phenomenon occurs by means of vibrations with higher magnitude, close to the harmonic vibrations of the workpiece and of the grinding wheel, which compromise the quality of the workpiece surface [3][4][5][6].…”

Section: Introductionmentioning

confidence: 99%

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Chatter Vibration Monitoring in the Surface Grinding Process through Digital Signal Processing of Acceleration Signal

Alexandre

Lopes

Ferreira

et al. 2017

The 4th International Electronic Conference on Sensors and Applications

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The grinding process is a manufacturing process that is performed at the end of the machining chain. In such step, the workpiece has a high added-value and therefore critical problems are not allowed, as they may lead to scrap and significant financial loss. Regenerative chatter is the most common form of self-excited vibration. It can occur often because most metal cutting operations involve overlapping cuts which can be a source of vibration amplification. The occurrence of the chatter phenomenon in the grinding process is considered a critical problem because it causes several negative effects, such as poor surface quality, unacceptable inaccuracy, and disproportionate tool wear, to name a few. The objective of this research work is to monitor the onset of the chatter phenomenon in grinding of SAE 1045 steel with an aluminum oxide grinding wheel by digital signal processing techniques of the acceleration signals. Experimental tests were performed in a surface grinding machine and using a data acquisition system with sampling frequency of 2 MHz. The data was analyzed with respect to the frequency content and the Ratio of Power (ROP) statistical parameter obtained for normal and chatter conditions. Visual inspections through digital images of the workpieces surfaces were conducted and then chatter frequency was determined. Results showed that the magnitudes related to the frequencies close to 30 Hz change as chatter phenomenon occurs. The ROP shows features related to the chatter vibrations. The methodology presented herein therefore allows for the automation and optimization of the grinding process.

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Section: Introductionmentioning

confidence: 74%

Section: Introductionmentioning

confidence: 99%

Chatter Vibration Monitoring in the Surface Grinding Process through Digital Signal Processing of Acceleration Signal

Alexandre

Lopes

Ferreira

et al. 2017

The 4th International Electronic Conference on Sensors and Applications

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“…When analyzing dynamic behavior, the main problem to arise concerns the difficulty to position the accelerometers near to the grinding zone, which limits the possibility of achieving a highly accurate analysis, particularly when there is a need to analyze low amplitude vibratory phenomena. Several works can be found in the literature, particularly in relation to the avoidance of vibratory effects such as chatter [53][54][55][56] and the appearance of surface marks [56,57]. Accelerometers are still usually positioned relatively far away from the contact point between wheel and workpiece.…”

Section: Several Attempts Have Been Made To Analyze the Wear Of New Tmentioning

confidence: 99%

Expectations and limitations of Cyber-Physical Systems (CPS) for Advanced Manufacturing: A View from the Grinding Industry

et al. 2020

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Grinding is a critical technology in the manufacturing of high added-value precision parts, accounting for approximately 20–25% of all machining costs in the industrialized world. It is a commonly used process in the finishing of parts in numerous key industrial sectors such as transport (including the aeronautical, automotive and railway industries), and energy or biomedical industries. As in the case of many other manufacturing technologies, grinding relies heavily on the experience and knowledge of the operatives. For this reason, considerable efforts have been devoted to generating a systematic and sustainable approach that reduces and eventually eliminates costly trial-and-error strategies. The main contribution of this work is that, for the first time, a complete digital twin (DT) for the grinding industry is presented. The required flow of information between numerical simulations, advanced mechanical testing and industrial practice has been defined, thus producing a virtual mirror of the real process. The structure of the DT comprises four layers, which integrate: (1) scientific knowledge of the process (advanced process modeling and numerical simulation); (2) characterization of materials through specialized mechanical testing; (3) advanced sensing techniques, to provide feedback for process models; and (4) knowledge integration in a configurable open-source industrial tool. To this end, intensive collaboration between all the involved agents (from university to industry) is essential. One of the most remarkable results is the development of new and more realistic models for predicting wheel wear, which currently can only be known in industry through costly trial-and-error strategies. Also, current work is focused on the development of an intelligent grinding wheel, which will provide on-line information about process variables such as temperature and forces. This is a critical issue in the advance towards a zero-defect grinding process.

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“…Multistability introduces a twofold effect in engineering systems. On the one hand, this phenomenon has to be avoided in order to prevent costly failures by stabilizing the desired state against a noisy environment when designing a commercial device with specific characteristics [3,4]. On the other hand, coexistence of several stable solutions offers great flexibility in the performance of engineering systems, because the system behavior can be changed without altering its major control parameters.…”

Section: Introductionmentioning

confidence: 99%

Controlling multistability in a vibro-impact capsule system

Liu

Chávez

2017

Nonlinear Dyn

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This work concerns the control of multistability in a vibro-impact capsule system driven by a harmonic excitation. The capsule is able to move forward and backward in a rectilinear direction, and the main objective of this work is to control such motion in the presence of multiple coexisting periodic solutions. A position feedback controller is employed in this study, and our numerical investigation demonstrates that the proposed control method gives rise to a dynamical scenario with two coexisting solutions, corresponding to forward and backward progression. Therefore, the motion direction of the system can be controlled by suitably perturbing its initial conditions, without altering the system parameters. To study the robustness of this control method, we apply numerical continuation methods in order to identify a region in the parameter space in which the proposed controller can be applied. For this purpose, we employ the MATLAB-based numerical platform COCO, which

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Non-linear analysis and quench control of chatter in plunge grinding

Cited by 25 publications

References 40 publications

Chatter Vibration Monitoring in the Surface Grinding Process through Digital Signal Processing of Acceleration Signal

Chatter Vibration Monitoring in the Surface Grinding Process through Digital Signal Processing of Acceleration Signal

Expectations and limitations of Cyber-Physical Systems (CPS) for Advanced Manufacturing: A View from the Grinding Industry

Controlling multistability in a vibro-impact capsule system

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