Time-Domain Modeling of Varying Dynamic Characteristics in Thin-Wall Machining Using Perturbation and Reduced-Order Substructuring Methods

Author(s):  
Oguzhan Tuysuz ◽  
Yusuf Altintas

The dynamic response of thin-walled parts becomes time and tool position dependent due to material removal along the toolpath. This article proposes a new reduced-order workpiece dynamic parameters update model using substructuring and perturbation methods. The removed volumes between discrete locations along the toolpath are defined as substructures of the initial global workpiece. The dynamically reduced-order initial workpiece structure and the removed substructures are obtained with model order reduction techniques. Equations of motion of the workpiece are updated in time-domain by rigidly coupling fictitious substructures having the negative mass and stiffness of the removed material. Instead of solving the generalized eigenvalue problem repeatedly along the toolpath, the mode shapes of the in-process workpiece are perturbed using the mass and stiffness of the removed substructures. Convergence of the perturbation is improved by integrating a vector sequence convergence accelerating algorithm. The corresponding updated mode frequencies are evaluated using Rayleigh Quotient with the perturbed mode shapes. The proposed reduced-order time-domain dynamics update model is verified in five-axis ball-end milling tests on a thin-walled twisted fan blade, and its predictions are also compared against the authors’ previously developed frequency-domain reduced-order model. It is shown that the newly introduced model is ∼4 times more computationally efficient than the frequency-domain model.

Author(s):  
Sang Woo Kim ◽  
Svein Sævik ◽  
Jie Wu

Abstract This paper addresses the performance evaluation of an empirical time domain Vortex Induced Vibrations (VIV) model which has been developed for several years at NTNU. Unlike the frequency domain which is the existing VIV analysis method, the time domain model introduces new vortex shedding force terms to the well known Morison equation. The extra load terms are based on the relative velocity, a synchronization model and additional empirical coefficients that describe the hydrodynamic forces due to cross-flow (CF) and In-line (IL) vortex shedding. These hydrodynamic coefficients have been tuned to fit experimental data and by considering the results from the one of existing frequency domain VIV programs, VIVANA, which is widely used for industrial design. The feature of the time domain model is that it enables to include the structural non-linearity, such as variable tension, and time-varying flow. The robustness of the new model’s features has been validated by comparing the test results in previous researches. However, the riser used in experiments has a relatively small length/diameter (L/D) ratio. It implies that there is a need for more validation to make it applicable to real riser design. In this study, the time domain VIV model is applied to perform correlation studies against the Hanøytangen experiment data for the case of linear sheared current at a large L/D ratio. The main comparison has been made with respect to the maximum fatigue damage and dominating frequency for each test condition. The results show the time domain model showed reasonable accuracy with respect to the experimental and VIVANA. The discrepancy with regard to experiment results needs to be further studied with a non-linear structural model.


Author(s):  
Jan V. Ulveseter ◽  
Svein Sævik ◽  
Carl M. Larsen

A promising time domain model for calculation of cross-flow vortex induced vibrations (VIV) is under development at the Norwegian University of Science and Technology. Time domain, as oppose to frequency domain, makes it possible to include non-linearities in the structural model. Pipelines that rest on an irregular seabed will experience free spans. In these areas VIV is a concern with respect to the fatigue life. In this paper, a time domain model for calculation of VIV on free spanning pipelines is proposed. The model has non-linear interaction properties consisting of discrete soil dampers and soil springs turning on or off depending on the pipeline response. The non-linear model is compared to two linear models with linear stiffness and damping properties. One linear model is based on the promising time domain VIV model, while the other one is based on RIFLEX and VIVANA, which calculates VIV in frequency domain. Through four case studies the effect of seabed geometry, current velocity and varying soil damping and soil stiffness is investigated for a specific pipeline. The results show that there is good agreement between the results produced by VIVANA and the linear model. The non-linear model predicts smaller stresses at the pipe shoulders, which is positive for the life time estimations. Soil damping does not influence the response significantly.


Author(s):  
Michał Lewandowski ◽  
Janusz Walczak

Purpose – A highly accurate method of current spectrum estimation of a nonlinear load is presented in this paper. Using the method makes it possible to evaluate the current injection frequency domain model of a nonlinear load from previously recorded time domain voltage and current waveforms. The paper aims to discuss these issues. Design/methodology/approach – The method incorporates the idea of coherent resampling (resampling synchronously with the base frequency of the signal) followed by the discrete Fourier transform (DFT) to obtain the frequency spectrum. When DFT is applied to a synchronously resampled signal, the spectrum is free of negative DFT effects (the spectrum leakage, for example). However, to resample the signal correctly it is necessary to know its base frequency with high accuracy. To estimate the base frequency, the first-order Prony's frequency estimator was used. Findings – It has been shown that the presented method may lead to superior results in comparison with window interpolated Fourier transform and time-domain quasi-synchronous sampling algorithms. Research limitations/implications – The method was designed for steady-state analysis in the frequency domain. The voltage and current waveforms across load terminals should be recorded simultaneously to allow correct voltage/current phase shift estimation. Practical implications – The proposed method can be used in case when the frequency domain model of a nonlinear load is desired and the voltage and current waveforms recorded across load terminals are available. The method leads to correct results even when the voltage/current sampling frequency has not been synchronized with the base frequency of the signal. It can be used for off-line frequency model estimation as well as in real-time DSP systems to restore coherent sampling of the analysed signals. Originality/value – The method proposed in the paper allows to estimate a nonlinear load frequency domain model from current and voltage waveforms with higher accuracy than other competitive methods, while at the same time its simplicity and computational efficiency is retained.


Author(s):  
Oguzhan Tuysuz ◽  
Yusuf Altintas

The structural dynamics of thin-walled parts vary as the material is removed during machining. This paper presents a new, computationally efficient reduced order dynamic substructuring method to predict the frequency response function (FRF) of the workpiece as the material is removed along the toolpath. The contribution of the removed mass to the dynamics of the workpiece is canceled by adding a fictitious substructure having the opposite dynamics of the removed material. The equations of motion of the workpiece are updated, and workpiece FRFs are evaluated by solving the hybrid set of assembled equations of motion in frequency domain as the tool removes the material between two consecutive dynamics update steps. The orders of the initial workpiece structure and the removed substructures are reduced using a model order reduction method with a newly introduced automatic master set selection criterion. The reduced order FRF update model is validated with peripheral milling tests and FRF measurements on a plate-shaped workpiece. It is shown that the proposed model provides ∼20 times faster FRF predictions than the full order finite element (FE) model.


2012 ◽  
Vol 29 (5) ◽  
pp. 896 ◽  
Author(s):  
Martin Fiers ◽  
Thomas Van Vaerenbergh ◽  
Ken Caluwaerts ◽  
Dries Vande Ginste ◽  
Benjamin Schrauwen ◽  
...  

Author(s):  
Mats J. Thorsen ◽  
Svein Sævik

The theoretical background of an empirical model for time domain simulation of VIV is reviewed. This model allows the surrounding flow to be time varying, which is in contrast to the traditional frequency domain tools. The hydrodynamic load model consists of Morison’s equation plus an additional term representing the oscillating effect of vortex shedding. The magnitude of the vortex shedding force is given by a dimensionless coefficient, and this force is assumed to act perpendicular to the relative velocity between the cylinder and the fluid. The time variability of the vortex shedding force is described by a synchronization model, which captures how the instantaneous frequency reacts to cylinder motion. The parameters in the time domain load model are calibrated against a commonly used frequency domain VIV analysis tool, VIVANA. To do this, a finite element model of a vertical tensioned riser is established, and the structure is exposed to a linearly sheared flow. Key results such as cross-flow displacements along the riser, frequency content, r.m.s. of bending stresses and mean in-line displacements are compared, and it is shown that the frequency and time domain methods are close to equivalent in this simple case with stationary flow. Finally, the time domain model is utilized to study VIV of a riser subjected to regular waves. The characteristics of wave induced VIV are discussed in light of the simulation results. It is seen that VIV is excited in the zone close to the surface, and the energy is transported downwards as traveling waves. The vibrations typically build up as the horizontal water particle velocity is high, and die out as the velocity decreases. The effect of varying the wave amplitude and period is investigated, and it is found that the dominating frequency, mode and r.m.s. stresses increase together with the wave height. The effect of the wave period is however more complicated. For example, reducing the wave period increases the dominating mode but decreases the displacements. Hence the stress may increase or decrease, depending on which of these effects are strongest.


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