Machining
Dynamics
Grad. Students — none
Undergrads — ME 4610 is required
Stability
analysis techniques, stability margins, stability charts and forced vibration
analysis for single and multi-dimensional machine-tool dynamics. Advanced process mechanics modeling as
related to process damping and process nonlienarity. Modeling approximations to account for periodic time variation
and process nonlinearities toward realizing industrially applicable results. Special consideration is given to
high-speed, variable-speed, ultrahigh-speed, and parallel-process machining.
·
Graduate
students working in manufacturing processes, especially those working in
machining processes.
·
Graduate
students in the area of dynamics or vibrations interested in applications of
dynamic analysis to real problems.
·
Graduate
students interested in working in the machine-tool, cutting tool, or their
end-user (automotive, aerospace, etc. manufacturing) industries.
·
Advanced
undergraduate students interested in machining processes beyond static
performance (covered in ME 4610)
1.
To teach the basic
dynamics of machining processes including effects of multiple teeth,
nonlinearities and time variation.
2.
To teach stability
analysis for machining based on the delay-differential equation that represents
its salient dynamics.
3.
To teach the effects
of real/practical tool geometry and structural dynamics, including
multi-dimensionality and mode orientation.
4.
To teach the concept
of cutting process damping, model forms to account for it, and the conditions
under which it becomes noticeable.
5.
To introduce the
techniques of variable-speed, ultrahigh-speed and parallel-process machining,
motivations for applying them, and their effects on stability.
1.
Be able to
differentiate between dynamics that are linear and nonlinear, and those that
are time invariant and time varying.
2.
Understand sources of
mechanical energy and energy transfer within a machining system.
3.
Be able to analyze
for machining process dynamic response and stability.
4.
Understand
assumptions required for analyses and the resulting limitations.
5.
Be able to diagnose
and correct stability and excessive vibration problems through qualitative
adjustments in conditions.
6.
Be familiar with and
understand the mechanisms unique to variable-speed, high-speed, ultrahigh-speed
and parallel-process machining.
7.
Be able to develop a
dynamic simulation or analytical solution of a machining process or a mechanism
within (project).
|
1 Introduction to Advanced Machining Analysis 1.1 Mechanics versus Dynamics 1.2 Review of the Ideal Chip Formation Model 1.3 Nonlinearities in Machining 1.4 Review of Steady-State Dynamics Analysis 1.5 Machining Dynamics Problems 2 A Structured Dynamic Model for Orthogonal Cutting 2.1 A Single-Tooth, 1-D, LTI Model 2.2 Process Orientations 2.3 Feedback Mechanisms and Phase Shifts 2.4 Stability and Energy Considerations |
3 Linear Time-Invariant Stability Analysis of Machining 3.1 Traditional Frequency-Domain Approach 3.2 Eigenvalue Problem Approach 3.3 Energy-Based Approach 3.4 Evaluation of the Single-Tooth, 1-D, LTI
Assumption 4 Real Tooling, Processes and Structures 4.1 Accounting for Size-Effect Nonlinearity 4.2 Effects of Corner Radius – Turning 4.3 Accounting for Periodic Time Variation 4.4 Effects of Multiple Teeth and Multi-D
Dynamics 4.5 Real Multi-Tooth, Time-Varying
Processes – Boring and Milling |
5 The Cutting Process Damping Mechanism 5.1 Linear Penetration Rate Model 5.2 Linear Effective Clearance Angle Model 5.3 Penetration Volume Model 5.4 Practical Issues – Modeling vs.
Matching 6 Vibration Analysis Solutions 6.1 Chatter Vibration Level – Linear
Process 6.2 Chatter Vibration Level – Nonlinear
Process 6.3 Forced Vibration Level 7 Special Stability Topics 7.1 Ultrahigh-speed
Machining 7.2 Parallel-Process Machining (PPM) |