Modelling and real-time control of a high performance rotary wood planing machine

Rotary planing is one of the most valuable machining operations in the timber processing industry. It has been established that cutting tool inaccuracy and forced vibration during the machining process are the primary causes of surface quality degradation. The main aim of this thesis is to design a control architecture that is suitable for adaptive operation of a wood planing machining in order to improve the quality of its surface finish. In order to achieve the stated goal, thorough understanding of the effects of machine deficiencies on surface finish quality is required. Therefore, a generic simulation model for synthesising the surface profiles produced by wood planing process is first developed. The model is used to simulate the combined effects of machining parameters, vibration and cutting tool inaccuracy on the resultant surface profiles. It has been postulated that online monitoring of surface finish quality can be used to provide feedback information for a secondary control loop for the machining process, which will lead to the production of consistently high quality surface finishes. There is an existing vision-based wood surface profile measurement technique, but the application of the technique has been limited to static wood samples. This thesis extends the application of the technique to moving wood samples. It is shown experimentally that the method is suitable for in-process surface profile measurements. The current industrial wood planing machines do not have the capability of measuring and adjusting process parameters in real-time. Therefore, knowledge of the causes of surface finish degradation would enable the operators to optimise the mechanical structure of the machines offline. For this reason, two novel approaches for characterising defects on planed timber surfaces have been created in this thesis using synthetic data. The output of this work is a software tool that can assist machine operators in inferring the causes of defects based on the waviness components of the workpiece surface finish. The main achievement in this research is the design of a new active wood planing technique that combines real-time cutter path optimisation (cutting tool inaccuracy compensation) with vibration disturbance rejection. The technique is based on real-time vertical displacements of the machine spindle. Simulation and experimental results obtained from a smart wood planing machine show significant improvements in the dynamic performance of the machine and the produced surface finish quality. Potential areas for future research include application of the defects characterisation techniques to real data and full integration of the dynamic surface profile measurements with the smart wood planing machine

Active vibration control of a flexible robot link using piezoelectric actuators

Nuisance vibrations are a concern throughout the engineering realm, and many re-searchers are dedicated to finding a solution to attenuate them. This research primarily focusses upon the suppression of vibrations in a robot system, with the control system being designed so that it is both affordable and lightweight. Such constraints aim to provide a solution that may be utilised in a variety of applications. The utilisation of piezoelectric elements as both actuators and sensors provides several advantages in that they are lightweight, easily integrated into an existing system and have a good force to weight ratio when used as actuators. To read and control these elements a single board computer was employed, in acknowledgement of the constraining parameters of the design. The amalgamation of vibration control and robotics has lent to the re-search being conducted with separate objectives set, isolating certain elements of the overall system design for validation. Ultimately, these separate investigations progress to the integration of the robot and control systems prior to further research concerning nonlinear vibrations, dynamic control and the discrete-time domain modelling of the system.This research first investigates the viability of the chosen components as a vibration attenuation solution. In addition, analytical models of the system have been created, for two types of sensors to determine the most effective; an inertial measurement unit and a collocated pair of piezoelectric sensors. These models are based on Euler-Bernoulli beam theory and aim to validate the control theory through a comparison of the experimental data. These experiments isolate the vibration problem from a robot system through the investigation of the control of a long slender beam envisioned as a robot manipulator link, but excited using a shaker platform in a sinusoidal manner. An observation of the theory related to the voltage produced by the piezoelectric elements, suggests that even with the application of only proportional control by the system, the controlled output would have components indicative of both proportional and derivative control. This observation and the underlying theory are further analysed within this research.The next objectives are to compare the performance of the control system developed in this research which utilises a Raspberry Pi 3B+ [1] with one that employs a dSPACE MicroLabBox [2], and to determine the suitability of the former for use with robot sys-tems. With the former ensuring that the constraints placed on the design, those which influenced the selection of the components, does not conclude to the dSPACE Micro-LabBox system being overtly preferable. The latter investigates both the impact of the system’s inclusion on the functionality of the system and the system’s perform-ance with respect to the intended application. The KUKA LBR iiwa 7 R800 [3] robot manipulator is utilised to satisfy this objective, wherein the link is mounted on the end effector of the manipulator acting as an eighth link. The final investigation in this research pertains to the attenuation of nonlinear vibrations experienced by a robot manipulator link. Additional components were added to the link to induce a geometric nonlinearity in the system. An analytical model of the amended system was created to validate the theory through comparison with experimental results. The control system was employed for multiple cases to ascertain the level of its performance with regards to the suppression of nonlinear vibrations

Investigation into vibration assisted micro milling: theory, modelling and applications

PhD ThesisPrecision micro components are increasingly in demand for various engineering industries, such as biomedical engineering, MEMS, electro-optics, aerospace and communications. The proposed requirements of these components are not only in high accuracy, but also in good surface performance, such as drag reduction, wear resistance and noise reduction, which has become one of the main bottlenecks in the development of these industries. However, processing these difficult-to-machine materials efficiently and economically is always a challenging task, which stimulates the development and subsequent application of vibration assisted machining (VAM) over the past few decades. Vibration assisted machining employs additional external energy sources to generate high frequency vibration in the conventional machining process, changing the machining (cutting) mechanism, thus reducing cutting force and cutting heat and improving machining quality. The current awareness on VAM technology is incomplete and effective implementation of the VAM process depends on a wide range of technical issues, including vibration device design and setup, process parameters optimization and performance evaluation. In this research, a 2D non-resonant vibration assisted system is developed and evaluated. Cutting mechanism and relevant applications, such as functional surface generation and microfluidic chips manufacturing is studies through both experimental and finite element analysis (FEA) method. A new two-dimensional piezoelectric actuator driven vibration stage is proposed and prototyped. A double parallel four-bar linkage structure with double layer flexible hinges is designed to guide the motion and reduce the displacement coupling effect between the two directions. The compliance modelling and dynamic analysis are carried out based on the matrix method and lagrangian principle, and the results are verified by finite element analysis. A closed loop control system is developed and proposed based on LabVIEW program consisting of data acquisition (DAQ) devices and capacitive sensors. Machining experiments have been carried out to evaluate the performance of the vibration stage and the results show a good agreement with the tool tip trajectory simulation results, which demonstrates the feasibility and effectiveness of the vibration stage for vibration assisted micro milling. The textured surface generation mechanism is investigated through both modelling and experimental methods. A surface generation model based on homogenous matrices transformation is proposed by considering micro cutter geometry and kinematics of vibration assisted milling. On this basis, series of simulations are performed to provide insights into the effects of various vibration parameters (frequency, amplitude and phase difference) on the generation mechanism of typical textured surfaces in 1D and 2D vibration-assisted micro milling. Furthermore, the wettability tests are performed on the machined surfaces with various surface texture topographies. A new contact model, which considers both liquid infiltration effects and air trapped in the microstructure, is proposed for predicting the wettability of the fish scales surface texture. The following surface textures are used for T-shaped and Y-shaped microchannels manufacturing to achieve liquid one-way flow and micro mixer applications, respectively. The liquid flow experiments have been carried out and the results indicate that liquid flow can be controlled effectively in the proposed microchannels at proper inlet flow rates. Burr formation and tool wear suppression mechanisms are studied by using both finite element simulation and experiment methods. A finite element model of vibration assisted micro milling using ABAQUS is developed based on the Johnson-Cook material and damage models. The tool-workpiece separation conditions are studied by considering the tool tip trajectories. The machining experiments are carried out on Ti-6Al-4V with coated micro milling tool (fine-grain tungsten carbides substrate with ZrO2-BaCrO4 (ZB) coating) under different vibration frequencies (high, medium and low) and cutting states (tool-workpiece separation or nonseparation). The results show that tool wear can be reduced effectively in vibration assisted micro milling due to different wear suppression mechanisms. The relationship between tool wear and cutting performance is studied, and the results indicate that besides tool wear reduction, better surface finish, lower burrs and smaller chips can also be obtained as vibration assistance is added

The investigation and design of a piezoelectric active vibration control system for vertical machining centres

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Polymer Materials in Sensors, Actuators and Energy Conversion

Polymer-based materials applications in sensors, actuators, and energy conversion play a key role in recently developing areas of smart materials and electronic devices. These areas cover the synthesis, structures, and properties of polymers and composites, including energy-harvesting devices and energy-storage devices for electromechanical (electrical to mechanical energy conversion) and magneto-mechanical (magnetic to mechanical energy conversion), light-emitting devices, and electrically driving sensors. Therefore, the modulation of polymer-based materials and devices for controlling the detection, actuation, and energy with functionalized relative device can be achieved with the present reprint, comprising 12 chapters.This reprint is principally concerned with the topic of materials of materials, especially polymers. The contents not only involve essential information but also possess many novel academic applications in the fields. This Special Issue's title is "Polymer Materials in Sensors, Actuators and Energy Conversion" and covers the research field of polymers .Finally, I am very proud of my dear wife Winnie, son Vincent, and daughter Ruby. I thank them for supporting me in finishing the reprint. The reprint, involving 2 reviews and 10 regular papers, has been accomplished, and I am deeply thankful to all the authors for their assistance in producing a reprint with considerable number of chapters. I also hope that readers can achieve some useful understanding of polymer materials in sensors, actuators, and energy conversion, and that that they will be employed by scientists and researchers

ON THE STABILITY OF VARIABLE HELIX MILLING TOOLS

One of the main aims of the manufacturing industry has been to maximise the material removal rate of machining processes. However, this goal can be restricted by the appearance of regenerative chatter vibrations. In milling, one approach for regenerative chatter suppression is the implementation of variable-helix cutters. However, these tools can lead to isolated unstable regions in the stability diagram. Currently, variable-helix unstable islands have not been extensively researched in the literature. Therefore, the current thesis focuses on studying and experimentally validating these islands. For the validation, an experimental setup that scaled not only the structural dynamics but also the cutting force coefficients was proposed. Therefore, it was possible to attain larger axial depths of cut while assuming linear dynamics. The variable-helix process stability was modelled using the semi-discretization method and the multi-frequency approach. It was found that the variable helix tools can further stabilise a larger width of cut due to the distributed time delays that are a product of the tool geometry. Subsequently, a numerical study about the impact of structural damping on the variable-helix stability diagram revealed a strong relationship between the damping level and instability islands. The findings were validated by performing trials on the experimental setup, modified with constrained layer damping to recreate the simulated conditions. Additionally, a convergence analysis using the semi-discretization method (SDM) and the multi-frequency approach (MFA) revealed that these islands are sensitive to model convergence aspects. The analysis shows that the MFA provided converged solutions with a steep convergence rate, while the SDM struggled to converge. In this work, it is demonstrated that variable-helix instability islands only emerge at relatively high levels of structural damping and that they are particularly susceptible to model convergence effects. Meanwhile, the model predictions are compared to and validated against detailed experimental data that uses a specially designed configuration to minimise experimental error. To the authors' knowledge, this provides the first experimentally validated study of unstable islands in variable helix milling, while also demonstrating the importance of accurate damping estimates and convergence studies within the stability predictions