The aim of the thesis is to propose active damping as a potential control strategy for chatter instability in machine tools.<p>The regenerative process theory explains chatter as a closed loop interaction between the structural dynamics and the cutting process. This is considered to be the most dominant reason behind machine tool chatter although other instability causing mechanisms exist.<p>The stability lobe diagram provides a quantitative idea of the limits of stable machining in terms of two physical parameters: the width of contact between tool and the workpiece, called the width of cut and the speed of rotation of the spindle. It is found that the minimum value of the stability limit is proportional to the structural damping ratio for turning operations. This important finding provides the motivation of influencing the structural dynamics by active damping to enhance stability limits of a machining operation.<p>A direct implementation of active damping in an industrial environment may be difficult. So an intermediate step of testing the strategy in a laboratory setup, without conducting real cutting is proposed. Two mechatronic "Hardware in the Loop" simulators for chatter in turning and milling are presented, which simulate regenerative chatter experimentally without conducting real cutting tests. A simple cantilever beam, representing the MDOF dynamics of<p>the machine tool structure constitutes the basic hardware part and the cutting process is simulated in real time on a DSP board. The values of the cutting parameters such as spindle speed and the axial width of cut can be changed on the DSP board and the closed loop interaction between the structure and the cutting process can be led to instability.<p><p>The demonstrators are then used as test beds to investigate the efficiency of active damping, as a potential chatter stabilization strategy. Active damping is easy to implement, robust and does not require a very detailed model of the structure for proper functioning, provided a collocated sensor and actuator configuration is followed. The idea of active damping is currently being implemented in the industry in various metal cutting machines as part of the European Union funded SMARTOOL project (www.smartool.org), intended to propose smart chatter control technologies in machining operations. / Doctorat en sciences appliquées / info:eu-repo/semantics/nonPublished

This master thesis deals with passive compensation of a thermal deformation for a binder of portal machining center. The problem is solved by computational modeling with finite element method using ANSYS Workbench software. Afterwards mathematical optimization (also using ANSYS Workbench software) is used for finding binder parameters in order to reduce thermal deformation and its weight. The output is two new versions of binder which are compared to the original configuration.

The Master’s thesis deals with the precision of machine tools, especially with the three-axis vertical milling machine. It is structurally divided into a theoretical and practical part. While the theoretical part focuses on problems of geometric errors and measuring devices, the practical one is devoted to the machine tool being tested. In this case, the data processing and the proposed statistical analysis are essential, and at the end of the thesis another possible way of developing the data processing is outlined.

The thesis summarizes the legislative requirements for the operation of machines in the Czech Republic and the European Union. This thesis deals in detail with the analysis of technical standards related to machining tools, followed by the risk analysis of a specific machining tool operated in laboratories of the Faculty of Mechanical Engineering of the Brno University of Technology. The result of the thesis is the processing of identified risks and compliance with legislative requirements for the operation of the machining tool.

This diploma thesis deals with the construction of an NC rotary table with a linear axis. The first part is devoted to the analysis of the current state of science and technology in the problem, the use of various drives, mechanisms for torque transmission, linear feed lines, measuring and an overview of tables from various manufacturers. Furthermore, the work is devoted to the creation of 4 variants of construction, then the selection of the best variant and technical calculations. At the end, the work deals with a detailed description of the machine.

The diploma thesis deals with the design of a rotary table for machining large non-rotary workpieces up to a maximum weight of 65 000 kg. The aim of the work is to analyze and evaluate the current state of knowledge in the field of rotary tables, to create a table design according to the assignment and its 3D model with part of the drawing documentation. The theoretical part of the work searches for solutions used in the construction of rotary tables in the category of table according to the assignment. The information obtained is further used in the design of rotary table solution variants. By evaluating the weight of the required properties and their degree of fulfillment, a variant of the design solution of the table is selected, which is then designed. The individual design steps are described and explained in the text part of the work accompanied by pictures and calculations. The result of the process is a structural design of the mechanical part of the rotary table with a 3D model and partially processed drawing documentation. The contribution of the work is the summarization of relevant information for the design of rotary tables, the processed procedure of solving the design of the table and the modeled design of the rotary table. These outputs can be further treated as documentation for the production of the designed table, the development of the rotary table design to deeper details or technical development in this area.

This diploma thesis deals with the design and optimization of a headstock for machine tool. Thesis was focused to comparison of several types of slide-ways and linear guides of headstock, considering their static and dynamic rigidity. An overview in the field of machine tools, their static and dynamic properties, use materials and design of headstocks, considering types of guideways, types of guideways drives and types of drives of spindle was made. Among the other main goals is included design of several types of guideway of headstock for horizontal machine tool, elaboration of computational models and evaluation of results.

This diploma work is dealing with the progressive production technology proposal of the valve body type S43 components. This is the high-pressure valve for the classical power supply. Here in the work is described the structural design of the valves, the material of the valve body and its machinability. Following an analysis of the existing production technology is the new production technology proposal for this part. All is designed with regards to the business possibilities of the Armaturka Vranová Lhota company. In conclusion of the work is presented the technical economic evaluation of both the existing and the proposed manufacturing technology.

The main objective of the work was to perform a computational analysis of the hybrid (steel-composite) carrier and compare the results with the original metal carrier. Static analysis, modal analysis and frequency response were solved. Computation was performed for three different relative positions of the carrier. Static stiffness, natural frequencies and dynamic compliance have been calculated. The results were verified by an experiment performed on a scaled-down model of the carrier. Modern software products, namely MSC Patran, MD Nastran, Matlab and ProENGINEER, were used for the calculation.

Dans l’industrie manufacturière, la consommation d’énergie électrique est considérée comme l'un des problèmes majeurs qui est malheureusement liée systématiquement à l'émission de gaz contenant du dioxyde de carbone et amenant à l’effet de serre. Des études sur l’estimation de l’énergie électrique consommée par les machines outils sont développées par des chercheurs au cours des dernières décennie pour proposer des modèles d’estimation de cette énergie. Ces modèles sont soit empiriques soit théoriques et se limitent à tenir compte du comportement dynamique du système de coupe lors des opérations d’usinage. La contribution fondamentale de cette thèse de doctorat est la caractérisation du comportement non linéaire des efforts de coupe et du système de guidage lors de l’estimation de l’énergie consommée par une machine outil. La modélisation repose sur la détermination de l’effort de coupe et de l’effort des roulements qui sont variables en fonction du temps et qui sont déduites de l’écriture de l’équation de mouvement du système (broche ou machine-outil)discrétisé en éléments finis en utilisant la méthode de Newark couplée avec l’algorithme de Newton Raphson. Ces efforts de coupe et de roulements sont utilisés pour calculer la puissance puis l’énergie consommée par la table d’avance, la broche et par conséquent la machine outil. Afin de valider notre approche, la puissance et l’énergie obtenues à partir du modèle développé sont comparées avec la puissance et l’énergie obtenues avec un dispositif expérimental. Une étude paramétrique est réalisée pour mettre l’accent sur l’impact de la variation des paramètres de coupe sur la valeur de la puissance et de l’énergie consommées. On introduit par la suite des défauts d’usure et de montage au niveau des roulements et nous présentons leurs impacts sur le comportement énergétique de la machine. Une attention particulière a également été consacrée à développer un modèle d’optimisation des mouvement d’une machine outil globale minimisant à la fois l’énergie consommée, le temps de production, le coût et la rugosité de surface en respectant les consignes technologiques. / In manufacturing, the electrical energy consumption is considered as one of the major problems which are systematically related to the gas emission containing carbon dioxide and leading to the greenhouse effect. Studies based on the estimation of the machine tools energy consumption become the interest of researchers in recent decades.As a result, different models for energy estimating are developed in order to minimize the quantity of consumed energy. These models are either empirical or theoretical and are limited to taking into account the dynamic behavior of the cutting system during machining operations. The fundamental contribution of this doctoral thesis is the characterization of the nonlinear behavior of cutting and rolling forces during estimating the consumed energy by a machine tool. The developed approach is based on the determination of the variable cutting forces and bearings forces which are function of time. These forces are deduced by solving the equation of motion based on finite element method using Newark's method coupled with Newton Raphson's algorithm. These forces are used to calculate the power then the consumed energy by the axis feed, the spindle and therefore the machine tool. In order to validate our approach, the power and energy obtained from the model developed are compared with the power and energy obtained with an experimental device. A parametric study is carried out to focus on the impact of the variation of the cutting parameters on the value of the consumed power and energy. An interest is given for different types of defect (innerring spalling, outer ring spalling, eccentricity and unbalance) in order to study their impact on the spindle consumed power during approach and cutting phases under different rotating conditions. Particular attention has also been devoted to develop a global model for optimizing machine too lmovements that minimizes the consumed energy, the production time, the cost and the surface roughness with respect of the technological constraints.