Dynamic analysis of runout correction in milling

Tool runout and its effects is an important area of research within modelling, simulation, and control of milling forces. Tool runout causes tool cutting edges to experience uneven forces during milling. This fact also affects tool life and deteriorates workpiece surface quality. In this article a procedure, in order to diminish the effects of tool runout, is presented. The procedure is based on chip thickness modification by means of the fast correction of the tool feed rate. Dynamic feed rate modification is provided by superposing our own design of a fast feed system driven by a piezoelectric actuator to the conventional feed drive of the CNC machine tool. Previously, a model of the dynamic behaviour of the system was developed to analyze the influence of fast feed rate modification on cutting forces. The model incorporates the piezoelectric actuator response as well as the structural dynamics of the tool and the designed Fast Feed Drive System (FFDS). Simulated and experimental results presented in this paper show the effectiveness and benefits of this new tool runout correction procedure

Active vibration control (AVC) of a satellite boom structure using optimally positioned stacked piezoelectric actuators

In this paper, results for active vibration control predicted from experimental measurements on a lightweight structure are compared with purely computational predictions. The structure studied is a 4.5m long satellite boom consisting of 10 identical bays with equilateral triangular cross sections. First, the results from a Fortran code that is based on a receptance analysis are validated against the experimental forced response of the boom structure. Exhaustive searches are then carried out to find the optimum positions for one and two actuators. Finally, a genetic algorithm is employed to find high-quality positions for three actuators on the structure that will achieve the greatest reductions in vibration transmission. Having found these actuator positions, experiments are then carried out to verify the quality of the theoretical predictions. It was found that the attenuation achievable in practice for one, two and three actuators were, respectively, 15.1, 26.1 and 33.5 dB

Thermal gradient-induced forces on geodetic reference masses for LISA

The low frequency sensitivity of space-borne gravitational wave observatories will depend critically on the geodetic purity of the trajectories of orbiting test masses. Fluctuations in the temperature difference across the enclosure surrounding the free-falling test mass can produce noisy forces through several processes, including the radiometric effect, radiation pressure, and outgassing. We present here a detailed experimental investigation of thermal gradient-induced forces for the LISA gravitational wave mission and the LISA Pathfinder, employing high resolution torsion pendulum measurements of the torque on a LISA-like test mass suspended inside a prototype of the LISA gravitational reference sensor that will surround the test mass in orbit. The measurement campaign, accompanied by numerical simulations of the radiometric and radiation pressure effects, allows a more accurate and representative characterization of thermal-gradient forces in the specific geometry and environment relevant to LISA free-fall. The pressure dependence of the measured torques allows clear identification of the radiometric effect, in quantitative agreement with the model developed. In the limit of zero gas pressure, the measurements are most likely dominated by outgassing, but at a low level that does not threaten the LISA sensitivity goals.Comment: 21 pages, 16 figures, submitted to Physical Review

Active vibration control (AVC) of a satellite boom structure using optimally positioned stacked piezoelectric actuators

In this paper, results for active vibration control predicted from experimental measurements on a lightweight structure are compared with purely computational predictions. The structure studied is a 4.5m long satellite boom consisting of 10 identical bays with equilateral triangular cross sections. First, the results from a Fortran code that is based on a receptance analysis are validated against the experimental forced response of the boom structure. Exhaustive searches are then carried out to find the optimum positions for one and two actuators. Finally, a genetic algorithm is employed to find high-quality positions for three actuators on the structure that will achieve the greatest reductions in vibration transmission. Having found these actuator positions, experiments are then carried out to verify the quality of the theoretical predictions. It was found that the attenuation achievable in practice for one, two and three actuators were, respectively, 15.1, 26.1 and 33.5 dB

Potential effects of optical solar sail degredation on trajectory design

The optical properties of the thin metalized polymer films that are projected for solar sails are assumed to be affected by the erosive effects of the space environment. Their degradation behavior in the real space environment, however, is to a considerable degree indefinite, because initial ground test results are controversial and relevant inspace tests have not been made so far. The standard optical solar sail models that are currently used for trajectory design do not take optical degradation into account, hence its potential effects on trajectory design have not been investigated so far. Nevertheless, optical degradation is important for high-fidelity solar sail mission design, because it decreases both the magnitude of the solar radiation pressure force acting on the sail and also the sail control authority. Therefore, we propose a simple parametric optical solar sail degradation model that describes the variation of the sail film's optical coefficients with time, depending on the sail film's environmental history, i.e., the radiation dose. The primary intention of our model is not to describe the exact behavior of specific film-coating combinations in the real space environment, but to provide a more general parametric framework for describing the general optical degradation behavior of solar sails. Using our model, the effects of different optical degradation behaviors on trajectory design are investigated for various exemplary missions

Hydraulic Actuator System for Rotor Control

In the last ten years, several different types of actuators were developed and fabricated for active control of rotors. A special hydraulic actuator system capable of generating high forces to rotating shafts via conventional bearings is addressed. The actively controlled hydraulic force actuator features an electrohydraulic servo valve which can produce amplitudes and forces at high frequencies necessary for influencing rotor vibrations. The mathematical description will be given in detail. The experimental results verify the theoretical model. Simulations already indicate the usefulness of this compact device for application to a real rotor system

A simulated investigation on the machining instability and dynamic surface generation

In this paper, the authors propose the generic concept of machining instability based on the analysis of all kinds of machining instable behaviors and their features. The investigation covers all aspects of the machining process, including the machine tool structural response, cutting process variables, tooling geometry and workpiece material property in a full dynamic scenario. The paper presents a novel approach for coping with the sophisticated machining instability and enabling better understanding of its effect on the surface generation through a combination of the numerical method with the characteristic equations and using block diagrams/functions to represent implicit equations and nonlinear factors. It therefore avoids the lengthy algebraic manipulations in deriving the outcome and the solution scheme is thus simple, robust and intuitive. Several machining case studies and their simulation results demonstrate the proposed approach is feasible for shop floor CNC machining optimisation in particular. The results also indicate the proposed approach is useful to monitor the machining instability and surface topography and to be potentially applied in adaptive control of the instability in real time

Accurate Tracking of Aggressive Quadrotor Trajectories using Incremental Nonlinear Dynamic Inversion and Differential Flatness

Autonomous unmanned aerial vehicles (UAVs) that can execute aggressive (i.e., high-speed and high-acceleration) maneuvers have attracted significant attention in the past few years. This paper focuses on accurate tracking of aggressive quadcopter trajectories. We propose a novel control law for tracking of position and yaw angle and their derivatives of up to fourth order, specifically, velocity, acceleration, jerk, and snap along with yaw rate and yaw acceleration. Jerk and snap are tracked using feedforward inputs for angular rate and angular acceleration based on the differential flatness of the quadcopter dynamics. Snap tracking requires direct control of body torque, which we achieve using closed-loop motor speed control based on measurements from optical encoders attached to the motors. The controller utilizes incremental nonlinear dynamic inversion (INDI) for robust tracking of linear and angular accelerations despite external disturbances, such as aerodynamic drag forces. Hence, prior modeling of aerodynamic effects is not required. We rigorously analyze the proposed control law through response analysis, and we demonstrate it in experiments. The controller enables a quadcopter UAV to track complex 3D trajectories, reaching speeds up to 12.9 m/s and accelerations up to 2.1g, while keeping the root-mean-square tracking error down to 6.6 cm, in a flight volume that is roughly 18 m by 7 m and 3 m tall. We also demonstrate the robustness of the controller by attaching a drag plate to the UAV in flight tests and by pulling on the UAV with a rope during hover.Comment: To be published in IEEE Transactions on Control Systems Technology. Revision: new set of experiments at increased speed (up to 12.9 m/s), updated controller design using quaternion representation, new video available at https://youtu.be/K15lNBAKDC

Verification of the bursting and spalling formulas in the FIB model code by finite element analyses of anchorage zones of pretensioned girders

In order to predict the stress and possible crack distribution in the anchorage zones of pretensioned girders several models have been developed as can be found in the fib Model Code, the ASHTOO code or Eurocode 2. In this paper, the bursting and spalling formulas from the fib Model Code are evaluated by finite element calculations since some issues could be raised when applying the proposed formulas for industrial applications, especially for beams of limited dimensions. The effect of the upper strands, the assumed stress distribution at the opposite side of the equivalent symmetric prism, the stress transfer diagram along the strands and the effects of the strand position relative to the simplified resultant forces remain unclear. Accordingly two-dimensional finite element models were developed to gain insight into the bursting and spalling formulations from the fib Model Code. The numerical models render stresses and the stress flow results, which allow a more clear coupling to well-known strut-and-tie models. The results indicate that for various strand configurations, especially for small beams, the fib formulations may be too conservative

Shape manipulation using physically based wire deformations

This paper develops an efficient, physically based shape manipulation technique. It defines a 3D model with profile curves, and uses spine curves generated from the profile curves to control the motion and global shape of 3D models. Profile and spine curves are changed into profile and spine wires by specifying proper material and geometric properties together with external forces. The underlying physics is introduced to deform profile and spine wires through the closed form solution to ordinary differential equations for axial and bending deformations. With the proposed approach, global shape changes are achieved through manipulating spine wires, and local surface details are created by deforming profile wires. A number of examples are presented to demonstrate the applications of our proposed approach in shape manipulation