Chatter milling modeling of active magnetic bearing spindle in high-speed domain

A new dynamical modeling of Active Magnetic Bearing Spindle (AMBS) to identify machining stability of High Speed Milling (HSM) is presented. This original modeling includes all the minimum required parameters for stability analysis of AMBS machining. The stability diagram generated with this new model is compared to classical stability lobes theory. Thus, behavior’s specificities are highlighted, especially the major importance of forced vibrations for AMBS. Then a sensitivity study shows impacts of several parameters of the controller. For example, gain adjustment shows improvements on stability. Side milling ramp test is used to quickly evaluate the stability. Finally, the simulation results are then validated by HSM cutting tests on a 5 axis machining center with AMBS

Nonlinear dynamics of attractive magnetic bearings

The nonlinear dynamics of a ferromagnetic shaft suspended by the force of attraction of 1, 2, or 4 independent electromagnets is presented. Each model includes a state variable feedback controller which has been designed using the pole placement method. The constitutive relationships for the magnets are derived analytically from magnetic circuit theory, and the effects of induced eddy currents due to the rotation of the journal are included using Maxwell's field relations. A rotor suspended by four electro-magnets with closed loop feedback is shown to have nine equilibrium points within the bearing clearance space. As the rotor spin speed increases, the system is shown to pass through a Hopf bifurcation (a flutter instability). Using center manifold theory, this bifurcation can be shown to be of the subcritical type, indicating an unstable limit cycle below the critical speed. The bearing is very sensitive to initial conditions, and the equilibrium position is easily upset by transient excitation. The results are confirmed by numerical simulation

Influence of Back-Up Bearings and Support Structure Dynamics on the Behavior of Rotors With Active Supports

This report presents a synopsis of the research work. Specific accomplishments are itemized below: (1) Experimental facilities have been developed. This includes a magnetic bearing test rig and an auxiliary bearing test rig. In addition, components have been designed, constructed, and tested for use with a rotordynamics test rig located at NASA Lewis Research Center. (2) A study of the rotordynamics of an auxiliary bearing supported T-501 engine model was performed. (3) An experimental/simulation study of auxiliary bearing rotordynamics has been performed. (4) A rotordynamical model for a magnetic bearing supported rotor system, including auxiliary bearing effects has been developed and simulation studies performed.(5) A finite element model for a foil bearing has been developed and studies of a rotor supported by foil bearings have been performed. (6) Two students affiliated with this project have graduated with M.S. degrees

Vibration analysis and intelligent control of flexible rotor systems using smart materials

Flexible rotor-bearing system stability is a very important subject impacting the design, control, maintenance and operating safety. As the rotor bearing-system dynamic nonlinearities are significantly more prominent at higher rotating speeds, the demand for better performance through higher speeds has rendered the use of linear approaches for analysis both inadequate and ineffective. To address this need, it becomes important that nonlinear rotor-dynamic responses indicative of the causes of nonlinearity, along with the bifurcated dynamic states of instabilities, be fully studied. The objectives of this research are to study rotor-dynamic instabilities induced by mass unbalance and to use smart materials to stabilise the performance of the flexible rotor-system. A comprehensive mathematical model incorporating translational and rotational inertia, bending stiffness and gyroscopic moment is developed. The dynamic end conditions of the rotor comprising of the active bearing-induced axial force is modelled, the equations of motion are derived using Lagrange equations and the Rayleigh-Ritz method is used to study the basic phenomena on simple systems. In this thesis the axial force terms included in the equations of motion provide a means for axially directed harmonic force to be introduced into the system. The Method of Multiple Scales is applied to study the nonlinear equations obtained and their stabilities. The Dynamics 2 software is used to numerically explore the inception and progression of bifurcations suggestive of the changing rotor-dynamic state and impending instability. In the context of active control of flexible rotors, smart materials particularly SMAs and piezoelectric stack actuators are introduced. The application of shape memory alloy (SMA) elements integrated within glass epoxy composite plates and shells has resulted in the design of a novel smart bearing based on the principle of antagonistic action in this thesis. Previous work has shown that a single SMA/composite active bearing can be very effective in both altering the natural frequency of the fundamental whirl mode as well as the modal amplitude. The drawback with that design has been the disparity in the time constant between the relatively fast heating phase and the much slower cooling phase which is reliant on forced air, or some other form of cooling. This thesis presents a modified design which removes the aforementioned existing shortcomings. This form of design means that the cooling phase of one half, still using forced air, is significantly assisted by switching the other half into its heating phase, and vice versa, thereby equalising the time constants, and giving a faster push-pull load on the centrally located bearing; a loading which is termed ‘antagonistic’ in this present dissertation. The piezoelectric stack actuator provides an account of an investigation into possible dynamic interactions between two nonlinear systems, each possessing nonlinear characteristics in the frequency domain. Parametric excitations are deliberately introduced into a second flexible rotor system by means of a piezoelectric exciter to moderate the response of the pre-existing mass-unbalance vibration inherent to the rotor. The intended application area for this SMA/composite and piezoelectric technologies are in industrial rotor systems, in particular very high-speed plant, such as small light pumps, motor generators, and engines for aerospace and automotive application

Computationalcost Reduction of Robust Controllers Foractive Magnetic Bearing Systems

This work developed strategies for reducing the computational complexity of implementing robust controllers for active magnetic bearing (AMB) systems and investigated the use of a novel add-on controller for gyroscopic effect compensation to improve achievable performance with robust controllers. AMB systems are multi-input multi-output (MIMO) systems with many interacting mechanisms that needs to fulfill conflicting performance criteria. That is why robust control techniques are a perfect application for AMB systems as they provide systematic methods to address both robustness and performance objectives. However, robust control techniques generally result in high order controllers that require high-end control hardware for implementation. Such controllers are not desirable by industrial AMB vendors since their hardware is based on embedded systems with limited bandwidths. That is why the computational cost is a major obstacle towards industry adaptation of robust controllers. Two novel strategies are developed to reduce the computational complexity of singlerate robust controllers while preserving robust performance. The first strategy identifies a dual-rate configuration of the controller for implementation. The selection of the dualrate configuration uses the worst-case plant analysis and a novel approach that identifies the largest tolerable perturbations to the controller. The second strategy aims to redesign iv the controller by identifying and removing negligible channels in the context of robust performance via the largest tolerable perturbations to the controller. The developed methods are demonstrated both in simulation and experiment using three different AMB systems, where significant computational savings are achieved without degrading the performance. To improve the achievable performance with robust controllers, a novel add-on controller is developed to compensate the gyroscopic effects in flexible rotor-AMB systems via modal feedback control. The compensation allows for relaxing the robustness requirements in the control problem formulation, potentially enabling better performance. The effectiveness of the developed add-on controller is demonstrated experimentally on two AMB systems with different rotor configurations. The effects of the presence of the add-on controller on the performance controller design is investigated for one of the AMB systems. Slight performance improvements are observed at the cost of increased power consumption and increased computational complexity

Dynamics of multi-disk shafting supported on journal bearing

For permanent magnet disc motor-impeller shafting, the dynamic model was established to calculate principle modes and nonlinear dynamic responses. The influences of eccentric magnitude, dynamic viscosity, bearing clearance on nonlinear dynamics were discussed. The results show the shafting have conical mode, translational mode, the first and second bending mode. Two critical speeds were corresponding to conical and translational modes. The shafting has period N and quasi-periodicity characteristics by effect of nonlinear oil film force. When other basic parameters were unchanged, the increasing eccentric magnitude made compressor vibration be larger firstly and then smaller. The larger oil viscosity and smaller bearing clearance increase the stability of motion. The conclusions of the paper provide a theoretical reference for dynamic design and fault diagnosis of the shafting

Dynamic behavior of a magnetic bearing supported jet engine rotor with auxiliary bearings

This paper presents a study of the dynamic behavior of a rotor system supported by auxiliary bearings. The steady-state behavior of a simulation model based upon a production jet engine is explored over a wide range of operating conditions for varying rotor imbalance, support stiffness, and damping. Interesting dynamical phenomena, such as chaos, subharmonic responses, and double-valued responses, are presented and discussed

12th International Conference on Vibrations in Rotating Machinery

Since 1976, the Vibrations in Rotating Machinery conferences have successfully brought industry and academia together to advance state-of-the-art research in dynamics of rotating machinery. 12th International Conference on Vibrations in Rotating Machinery contains contributions presented at the 12th edition of the conference, from industrial and academic experts from different countries. The book discusses the challenges in rotor-dynamics, rub, whirl, instability and more. The topics addressed include: - Active, smart vibration control - Rotor balancing, dynamics, and smart rotors - Bearings and seals - Noise vibration and harshness - Active and passive damping - Applications: wind turbines, steam turbines, gas turbines, compressors - Joints and couplings - Challenging performance boundaries of rotating machines - High power density machines - Electrical machines for aerospace - Management of extreme events - Active machines - Electric supercharging - Blades and bladed assemblies (forced response, flutter, mistuning) - Fault detection and condition monitoring - Rub, whirl and instability - Torsional vibration Providing the latest research and useful guidance, 12th International Conference on Vibrations in Rotating Machinery aims at those from industry or academia that are involved in transport, power, process, medical engineering, manufacturing or construction