A new constitutive model for cutting simulation of 316L austenitic stainless steel

In this study, a new phenomenological model is proposed to describe the flow stress properties of 316L austenitic stainless steel at high strains strain rates and temperatures encountered in metal cutting. Additionally, a novel approach is presented for calibration of the proposed model which combines the experimental flow stress data with inverse modelling of the orthogonal cutting process. The simulation results including the cutting forces and chip shapes are compared with the experimental results attained using tailored tools with different rake angles. This model showed improved prediction capabilities in comparison with those obtained from the widely used Johnson-Cook material model

Experimental Verification of a Control Algorithm for Nonlinear Systems

NOMENCLATURE ABSTRACT When using electrodynamic vibration exciters to excite structures, the actual force applied to the structure under test is the reaction force between the exciter and the structure. The magnitude and phase of the reaction force is dependent upon the characteristics of the structure and exciter. Therefore the quality of the reaction force i.e. the force applied on the structure depends on the relationship between the exciter and structure under test. Looking at the signal from the force transducer when exciting a structure with a sine wave, the signal will appear harmonically distorted within the regions of the resonance frequencies. This phenomenon is easily observed when performing tests on lightly damped structures. The harmonic distortion is a result of nonlinearities produced by the shaker when undergoing large-amplitude vibrations, at resonances. When dealing with non-linear structures, it's of great importance to be able to keep a constant force level as well as a non-distorted sine wave in order to get reliable results within the regions of the resonance frequencies. This paper presents the method and results from an experimental test creating a nondistorted excitation signal with constant force level

Simulation and Experimental Methods for Characterization of Nonlinear Mechanical Systems

Trial and error and the use of highly time-consuming methods are often necessary for investigation and characterization of nonlinear systems. However, for the rather common case where a nonlinear system has linear relations between many of its degrees of freedom there are opportunities for more efficient approaches. The aim of this thesis is to develop and validate new efficient simulation and experimental methods for characterization of mechanical systems with localized nonlinearities. The purpose is to contribute to the development of analysis tools for such systems that are useful in early phases of the product innovation process for predicting product properties and functionality. Fundamental research is combined with industrial case studies related to metal cutting. Theoretical modeling, computer simulations and experimental testing are utilized in a coordinated approach to iteratively evaluate and improve the methods. The nonlinearities are modeled as external forces acting on the underlying linear system. In this way, much of the linear theories behind forced response simulations can be utilized. The linear parts of the system are described using digital filters and modal superposition, and the response of the system is recursively solved for together with the artificial external forces. The result is an efficient simulation method, which in conjunction with experimental tests, is used to validate the proposed characterization methods. A major part of the thesis addresses a frequency domain characterization method based on broad-band excitation. This method uses the measured responses to create artificial nonlinear inputs to the parameter estimation model. Conventional multiple-input/multiple-output techniques are then used to separate the linear system from the nonlinear parameters. A specific result is a generalization of this frequency domain method, which allows for characterization of continuous systems with an arbitrary number of localized zero-memory nonlinearities in a structured way. The efficiency and robustness of this method is demonstrated by both simulations and experimental tests. A time domain simulation and characterization method intended for use on systems with hysteresis damping is also developed and its efficiency is demonstrated by the case of a dry-friction damper. Furthermore, a method for improved harmonic excitation of nonlinear systems using numerically optimized input signals is developed. Inverse filtering is utilized to remove unwanted dynamic effects in cutting force measurements, which increases the frequency range of the force dynamometer and significantly improves the experimental results compared to traditional methods. The new methods form a basis for efficient analysis and increased understanding of mechanical systems with localized nonlinearities, which in turn provides possibilities for more efficient product development as well as for continued research on analysis methods for nonlinear mechanical structures

Omställning från Campus till Distansundervisning

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Methods for Simulation and Characterization of Nonlinear Mechanical Structures

Trial and error and the use of highly time-consuming methods are often necessary for modeling, simulating and characterizing nonlinear dynamical systems. However, for the rather common special case when a nonlinear system has linear relations between many of its degrees of freedom there are particularly interesting opportunities for more efficient approaches. The aim of this thesis is to develop and validate new efficient methods for the theoretical and experimental study of mechanical systems that include significant zero-memory or hysteretic nonlinearities related to only small parts of the whole system. The basic idea is to take advantage of the fact that most of the system is linear and to use much of the linear theories behind forced response simulations. This is made possible by modeling the nonlinearities as external forces acting on the underlying linear system. The result is very fast simulation routines where the model is based on the residues and poles of the underlying linear system. These residues and poles can be obtained analytically, from finite element models or from experimental measurements, making these forced response routines very versatile. Using this approach, a complete nonlinear model contains both linear and nonlinear parts. Thus, it is also important to have robust and accurate methods for estimating both the linear and nonlinear system parameters from experimental data. The results of this work include robust and user-friendly routines based on sinusoidal and random noise excitation signals for characterization and description of nonlinearities from experimental measurements. These routines are used to create models of the studied systems. When combined with efficient simulation routines, complete tools are created which are both versatile and computationally inexpensive. The developed methods have been tested both by simulations and with experimental test rigs with promising results. This indicates that they are useful in practice and can provide a basis for future research and development of methods capable of handling more complex nonlinear systems

Modelling the dynamics of a large damped boring bar in a lathe.

Boring bars with tuned mass dampers have a passive damper tuned with respect to the frequency of the first bending mode of the tool. When the tool is clamped into the machine tool there is a stiffness loss that lowers the natural frequency of the bar compared to ideal clamping conditions. For large tools the difference can be more than 35%, depending on clamping structure, tool size and overhang. In this paper we investigate a simple two-degree-of-freedom model for the tool-machine interaction consisting of a bending mode coupled with a rotational stiff mode. The model gives good insight into the system behavior and fits well with measurements. © 2019 The Authors. Published by Elsevier B.V. Peer-review under responsibility of the scientific committee of The 17th CIRP Conference on Modelling of Machining Operationsopen access</p

On Nonlinear Parameter Estimation

The industrial demand on good dynamical simulation models is increasing. Since most structures show some form of nonlinear behavior, linear models are not good enough to predict the true dynamical behavior. Therefore nonlinear characterization, localization and parameter estimation becomes important issues when building simulation models. This paper presents identification techniques for nonlinear systems based on both random and harmonic excitation signals. The identification technique based on random excitation builds on the well known reverse-path method developed by Julius S. Bendat. This method treats the nonlinearity as a feedback forcing term acting on an underlying linear system and the parameter estimation is performed in the frequency domain by using conventional MISO/MIMO techniques. Although this method provides a straightforward and systematic way of handling nonlinearities, it has been somewhat limited in use due to the complexity of creating uncorrelated inputs to the model. As is shown in this paper, the parameter estimation will not be improved with conditioned inputs and the nonlinear parameters and the underlying linear system can still be estimated with partially correlated inputs. This paper will also describe a parameter estimation method to be used with harmonic input signals. By using the principle of harmonic balance and multi-harmonic balance it is possible to estimate an analytical frequency response function of the studied nonlinear system. This frequency response function can, in conjunction with measured nonlinear transfer functions, be used to estimate the nonlinearity present in the system. This method is also applicable on nonlinear systems with memory, e.g. systems with hysteresis effects. The above mentioned methods are applied to multi-degree-of-freedom and single-degree-of-freedom systems with different types of nonlinearities. Also, techniques for locating nonlinearities are discussed

Parameter Estimation of Hysteresis Elements Using Harmonic Input

The industrial demand on good dynamical simulation models is increasing. Since most structures show some form of nonlinear behavior, linear models are not good enough to predict the true dynamical behavior. Hysteresis is a highly nonlinear phenomenon which occurs in for example dampers and mechanical joints. This paper presents a method for parameter estimation on nonlinear systems under harmonic excitation. By using the principle of harmonic balance or multi harmonic balance a theoretical frequency response function of the studied system can be estimated. This frequency response function can, in conjunction with measured nonlinear transfer functions, be used to make parameter estimations of the nonlinearity present in the system. A major benefit using this method is the ability to use arbitrary nonlinear functions. This means that the method can be applied to nonlinear systems with memory, for instance systems with hysteresis effects. The method is applied to both simulated systems and an experimental test rig

On Nonlinear Parameter Estimation

The industrial demand on good dynamical simulation models is increasing. Since most structures show some form of nonlinear behavior, linear models are not good enough to predict the true dynamical behavior. Therefore nonlinear characterization, localization and parameter estimation becomes important issues when building simulation models. This paper presents identification techniques for nonlinear systems based on both random and harmonic excitation signals. The identification technique based on random excitation builds on the well known reverse-path method developed by Julius S. Bendat. This method treats the nonlinearity as a feedback forcing term acting on an underlying linear system and the parameter estimation is performed in the frequency domain by using conventional MISO/MIMO techniques. Although this method provides a straightforward and systematic way of handling nonlinearities, it has been somewhat limited in use due to the complexity of creating uncorrelated inputs to the model. As is shown in this paper, the parameter estimation will not be improved with conditioned inputs and the nonlinear parameters and the underlying linear system can still be estimated with partially correlated inputs. This paper will also describe a parameter estimation method to be used with harmonic input signals. By using the principle of harmonic balance and multi-harmonic balance it is possible to estimate an analytical frequency response function of the studied nonlinear system. This frequency response function can, in conjunction with measured nonlinear transfer functions, be used to estimate the nonlinearity present in the system. This method is also applicable on nonlinear systems with memory, e.g. systems with hysteresis effects. The above mentioned methods are applied to multi-degree-of-freedom and single-degree-of-freedom systems with different types of nonlinearities. Also, techniques for locating nonlinearities are discussed

Experimental Verification of a Control Algorithm for Nonlinear Systems

When using electrodynamic vibration exciters to excite structures, the actual force applied to the structure under test is the reaction force between the exciter and the structure. The magnitude and phase of the reaction force is dependent upon the characteristics of the structure and exciter. Therefore the quality of the reaction force i.e. the force applied on the structure depends on the relationship between the exciter and structure under test. Looking at the signal from the force transducer when exciting a structure with a sine wave, the signal will appear harmonically distorted within the regions of the resonance frequencies. This phenomenon is easily observed when performing tests on lightly damped structures. The harmonic distortion is a result of nonlinearities produced by the shaker when undergoing large-amplitude vibrations, at resonances. When dealing with non-linear structures, it's of great importance to be able to keep a constant force level as well as a non-distorted sine wave in order to get reliable results within the regions of the resonance frequencies. This paper presents the method and results from an experimental test creating a nondistorted excitation signal with constant force level