Enhancement of Turning Process Using Vibration Signature Analysis

2005 ◽  
Author(s):  
Marlon C. Batey ◽  
Hamid R. Hamidzadeh
Keyword(s):  
Manufacturing Process ◽  
Vibration Analysis ◽  
Manufacturing System ◽  
Cutting Tool ◽  
Operating Conditions ◽  
Turning Process ◽  
Analysis Problem ◽  
Frequency Domains ◽  
Vibration Signature ◽  
Vibration Signatures

Analytical and experimental vibration analyses are conducted for a lathe system to detect the possibility of faults and develop an accurate cutting process. The data acquisition system utilized for this purpose processes the analog input from the manufacturing system and displays the response in both the real time and frequency domains. The vibration signatures for different arrangements are recorded to determine the dynamic characteristics of the system which includes work pieces, tool, and lathe components. These vibration signatures were analyzed to determine cause of inaccuracy in the manufacturing process and the faulty components. In this study, two major problem causing sources were identified using vibration analysis for the system under different operating conditions. In addition to the identified problems, the phenomena of cutting tool chatter with various intensities was examined and recorded during testing. In this study the best possible operating conditions for a specific turning process were determined using vibration analysis. Problem causing components for several case studies (different speeds, feed rates, and tool lengths) were identified and guidelines for improving a typical manufacturing process were recommended.

Transient and Steady State Vibration Analysis of a Wavy Thrust Bearing

2005 ◽  
Vol 128 (1) ◽  
pp. 139-145 ◽  
Author(s):  
H. Zhao ◽  
F. K. Choy ◽  
M. J. Braun
Keyword(s):  
Steady State ◽  
Vibration Analysis ◽  
Thrust Bearing ◽  
Numerical Procedure ◽  
Operating Conditions ◽  
System Stability ◽  
Thrust Bearings ◽  
External Perturbations ◽  
Vibration Signature ◽  
Transient And Steady State

This paper describes a numerical procedure for analyzing the dynamics of transient and steady state vibrations in a wavy thrust bearing. The major effects of the wavy geometry and the operating parameters on the dynamic characteristics of the bearing had been discussed in a previous paper; the present paper thus concentrates on examining the relationships between the development of the transient and steady state vibrations when operating conditions are parametrically varied. Special attention is given to the development of steady state vibrations from initial transients with comparisons and consequences to the overall system stability. Numerical based vibration signature analysis procedures are then used to identify and quantify the transient vibrations. The conclusions provide general indicators for designing wavy thrust bearings that are less susceptible to transients induced by external perturbations.

A Geometric Model for Tolerance Analysis with Manufacturing Signature and Operating Conditions

2019 ◽  
Vol 9 (3) ◽  
pp. 1-13
Author(s):  
Wilma Polini ◽  
Andrea Corrado
Keyword(s):  
Concurrent Engineering ◽  
Manufacturing Process ◽  
Geometric Model ◽  
Tolerance Analysis ◽  
Operating Conditions ◽  
Geometric Reasoning ◽  
Assembly Sequence ◽  
Turning Process ◽  
Engineering Approach

In this work, a geometric model for tolerance analysis has been carried out. Geometric reasoning has been implemented in the model to simulate the manufacturing process and, then, the assembly sequence. The proposed geometric model has been applied to a case study consisting of two circular profiles due to the turning process, and a hollow rectangular box. The two circular profiles have been assembled inside the box by considering the gravity, and the friction among the parts and the actual points of contact with and without using the manufacturing signature. Matlab® software has been used to implement the geometric model for tolerance analysis. The results have been compared with those obtained by using a literature model with and without considering the manufacturing signature. This work aims to be a first step towards the integration of the design and the manufacturing in a concurrent engineering approach.

Transient and Steady State Vibration Analysis of a Wavy Thrust Bearing

2004 ◽  
Author(s):  
Hongmei Zhao ◽  
F. K. Choy ◽  
M. J. Braun
Keyword(s):  
Steady State ◽  
Vibration Analysis ◽  
Thrust Bearing ◽  
Numerical Procedure ◽  
Operating Conditions ◽  
System Stability ◽  
Thrust Bearings ◽  
External Perturbations ◽  
Vibration Signature ◽  
Transient And Steady State

This paper describes a numerical procedure for analyzing the dynamics of transient and steady state vibrations in a wavy thrust bearing. The major effects of the wavy geometry and the operating parameters on the dynamic characteristics of the bearing had been discussed in previous work. The present study thus concentrates on examining the relationships between the development of the transient and steady state vibrations when operating conditions including rotational speed and load magnitude are parametrically varied. Special attention is given to the development of steady state vibrations from initial transients with comparisons and consequences to the overall system stability. Numerical based vibration signature analysis procedures are then used to identify and quantify the transient vibrations. The conclusions provide general indicators for designing wavy thrust bearings that are less susceptible to transients induced by external perturbations.

Comparative Analysis between Conventional and Dry Turning

2017 ◽  
Vol 261 ◽  
pp. 267-274
Author(s):  
Pantelis N. Botsaris ◽  
Chaido Kyritsi ◽  
Dimitris Iliadis
Keyword(s):  
Experimental Data ◽  
Surface Roughness ◽  
Cutting Tool ◽  
Spindle Motor ◽  
Air Cooling ◽  
Machining Parameters ◽  
Turning Process ◽  
Dry Cutting ◽  
Cold Air ◽  
Cooling And Lubrication

In this paper, there is an attempt to monitor and evaluate machining parameters when turning 34CrNiMo6 material under different cooling and lubrication conditions. The machining parameters concerned are temperature of the cutting tool and the workpiece, level of vibrations of the cutting tool, surface roughness of the workpiece, noise levels of the turning process and current drawn by the main spindle motor. Four different experimental machining scenarios were completed, specifically: conventional wet turning process, dry cutting and two additional modes employing cooling by cold air. Experimental data were acquired and recorded by an optimally designed network of sensors. Experimental data were statistically analyzed in order to reach conclusions. According to the research that has been done, although, overall, minimum cutting tool and workpiece temperatures were observed under wet machining, cold air cooling is capable of achieving comparable cooling results to wet machining. The lowest values of surface roughness were achieved by wet machining, whereas the lowest level of cutting tool vibrations were observed under cold air cooling.

A Hybrid Analytical, Solid Modeler and Feature-Based Methodology for Extracting Tool-Workpiece Engagements in Turning

2007 ◽  
Vol 7 (3) ◽  
pp. 192-202 ◽  
Author(s):  
Jing Zhou ◽  
Derek Yip-Hoi ◽  
Xuemei Huang
Keyword(s):  
Analytical Solution ◽  
Critical Points ◽  
Cutting Forces ◽  
Cutting Tool ◽  
Critical Component ◽  
Turning Process ◽  
Boolean Operations ◽  
Feature Based ◽  
Solid Modeler ◽  
Turning System

In order to optimize turning processes, cutting forces need to be accurately predicted. This in turn requires accurate extraction of the geometry of tool-workpiece engagements (TWE) at critical points during machining. TWE extraction is challenging because the in-process workpiece geometry is continually changing as each tool pass is executed. This paper describes research on a hybrid analytical, solid modeler, and feature-based methodology for extracting TWEs generated during general turning. Although a pure solid modeler-based solution can be applied, it will be shown that because of the ability to capture different cutting tool inserts with similar geometry and to model the process in 2D, an analytical solution can be used instead of the solid modeler in many instances. This solution identifies features in the removal volumes, where the engagement conditions are not changing or changing predictably. This leads to significant reductions in the number of Boolean operations that are executed during the extraction of TWEs and associated parameters required for modeling a turning process. TWE extraction is a critical component of a virtual turning system currently under development.

Design for Product Variety: Key to Product Line Structuring

1995 ◽  
Author(s):  
Kosuke Ishii ◽  
Cheryl Juengel ◽  
C. Fritz Eubanks
Keyword(s):  
Supply Chain ◽  
Life Cycle ◽  
Manufacturing Process ◽  
Life Cycle Cost ◽  
Manufacturing System ◽  
Product Variety ◽  
Product Line ◽  
Customer Preference ◽  
The Cost ◽  
Structure Graph

Abstract This study develops a method to capture the broadest customer preference in a product line while minimizing the life-cycle cost of providing variety. The paper begins with an overview of product variety and its importance in overhead costs: supply chain, equipment and tooling, service, and recycling. After defining the product structure graph as a representation of variety, the paper introduces an approximate measure for the customer importance and life-cycle cost of product variety The cost measure utilizes the concept of late point identification which urges standardization early in the manufacturing process and differentiation at the end of the process. The variety importance-cost map allows engineers to identify cost drivers in the design of the product or the manufacturing system and seek improvements. The refrigerator door example illustrates the concept. On-going work seeks to validate and enhance the method with several companies from different industries.

Vibration Analysis of Gears with Fatigue Crack in Tooth Root

2006 ◽  
Vol 324-325 ◽  
pp. 835-838
Author(s):  
Aleš Belšak ◽  
Jože Flašker
Keyword(s):  
Fatigue Crack ◽  
Laboratory Test ◽  
Signal Analysis ◽  
Vibration Analysis ◽  
Operating Conditions ◽  
Test Plant ◽  
Tooth Root ◽  
Unit Operation ◽  
Time Frequency ◽  
Non Stationary Signal

A crack in the tooth root, which often leads to failure in gear unit operation, is the most undesirable damage caused to gear units. This article deals with fault analyses of gear units with real damages. Numerical simulations of real operating conditions have been used in relation to the formation of those damages. A laboratory test plant has been used and a possible damage can be identified by monitoring vibrations. The influences of defects of a single-stage gear unit upon the vibrations they produce are presented. Signal analysis has been performed also in concern to a non-stationary signal, using the Time Frequency Analysis tools. Typical spectrograms, which are the result of reactions to damages, are a very reliable indication of the presence of damages.

scholarly journals Improving the Performance of Steel Machining Processes through Cutting by Vibration Control

Materials ◽  
2021 ◽  
Vol 14 (19) ◽  
pp. 5712
Author(s):  
Mihaela Oleksik ◽  
Dan Dobrotă ◽  
Mădălin Tomescu ◽  
Valentin Petrescu
Keyword(s):  
Fourier Transformation ◽  
Vibration Analysis ◽  
Cutting Tool ◽  
Cutting Process ◽  
Manufacturing Processes ◽  
Machining Processes ◽  
Short Time ◽  
Short Time Fourier Transformation ◽  
Dynamic Phenomena

Machining processes through cutting are accompanied by dynamic phenomena that influence the quality of the processed surfaces. Thus, this research aimed to design, make, and use a tool with optimal functional geometry, which allowed a reduction of the dynamic phenomena that occur in the cutting process. In order to carry out the research, the process of cutting by front turning with transversal advance was taken into account. Additionally, semi-finished products with a diameter of Ø = 150 mm made of C45 steel were chosen for processing (1.0503). The manufacturing processes were performed with the help of two tools: a cutting tool, the classic construction version, and another that was the improved construction version. In the first stage of the research, an analysis was made of the vibrations that appear in the cutting process when using the two types of tools. Vibration analysis considered the following: use of the Fast Fourier Transform (FFT) method, application of the Short-Time Fourier-Transformation (STFT) method, and observation of the acceleration of vibrations recorded during processing. After the vibration analysis, the roughness of the surfaces was measured and the parameter Ra was taken into account, but a series of diagrams were also drawn regarding the curved profiles, filtered profiles, and Abbott–Firestone curve. The research showed that use of the tool that is the improved constructive variant allows accentuated reduction of vibrations correlated with an improvement of the quality of the processed surfaces.

Low Cost Vibration Measurement and Optimization during Turning Process

2018 ◽  
Vol 1148 ◽  
pp. 103-108 ◽  
Author(s):  
N.V.S. Shankar ◽  
A. Gopi Chand ◽  
K. Hanumantha Rao ◽  
K. Prem Sai
Keyword(s):  
Surface Roughness ◽  
Cutting Tool ◽  
Low Cost ◽  
Machining Process ◽  
Vibration Measurement ◽  
Depth Of Cut ◽  
Turning Process ◽  
Taguchi Analysis ◽  
Series Of Experiments

During machining any material, vibrations play a major role in deciding the life of the cutting tool as well as machine tool. The magnitude acceleration of vibrations is directly proportional to the cutting forces. In other words, if we are able to measure the acceleration experienced by the tool during machining, we can get a sense of force. There are many commercially available, pre-calibrated accelerometer sensors available off the shelf. In the current work, an attempt has been made to measure vibrations using ADXL335 accelerometer. This accelerometer is interfaced to computer using Arduino. The measured values are then used to optimize the machining process. Experiments are performed on Brass. During machining, it is better to have lower acceleration values. Thus, the first objective of the work is to minimize the vibrations. Surface roughness is another major factor which criterion “lower is the better” applies. In order to optimize the values, a series of experiments are conducted with three factors, namely, tool type (2 levels), Depth of cut (3 levels) and Feed are considered (3 levels). Mixed level optimization is performed using Taguchi analysis with L18 orthogonal array. Detailed discussion of the parameters shall be given in the article.

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