Many single working mothers are challenged with the task of balancing work and home demands. Prolonged exposure to stress can threaten individuals' physical and emotional health and well-being. Listening to music is one commonly used positive coping mechanism for stress management and relief. The purpose of this phenomenological study was to explore the lived experiences of single working mothers who regularly listen to New Age music for stress relief. Participants were single working mothers, 30-45 years old, with self-reported stress, who were employed at least part time and who had at least 1 child under 18 years of age in the home. Participants were interviewed on their experiences with home and work-related stress, motherhood, and listening to New Age music for stress relief. This inquiry was guided by feminist theory, and data was analyzed using Moustakas' modification of Van Kaam's method of data analysis. The responses from these interviews identified the stress factors experienced by these single working mothers, which included finances, workplace stress, childcare, transportation, and working mother stereotypes. Participants also described the calming effects of New Age music on self-reported symptoms of physical and emotional stress. These reported effects include the promotion of mental focus and an immediate physical and emotional release from stress. The results of this study may contribute to positive social change by highlighting the benefits of listening to New Age music as an alternate means of stress management and relief; this implication could indirectly save employers considerable expense in stress-related health care and missed work. These findings may serve as a basis for future quantitative research into the use of music for stress relief.

In machining centers, with the increasing trends in high precision machining, chatter has become an important problem which results in poor surface finish and low material removal rate. Chatter can be avoided with stability diagrams which provide the stable regions in the machining process for the depth of cut and spindle speed combinations. In order to obtain stability diagrams, tool point frequency response function (FRF) of the system should be obtained. Throughout this study, contact parameters which are the most critical part of the analytical modeling of spindle-holder-tool assembly in order to obtain tool point FRF, are examined. For the accurate identification of the contact parameters, a recently suggested closed form approach based on measured FRFs is improved and applied to real structures by solving several application problems. In addition to the identification of contact parameters from experimental results, in order to eliminate the dependency on experiments, artificial neural networks are used to predict contact parameters for cases for which no experiments were carried out. By using trained neural network, contact parameters are predicted for the first seen combination of tool gauge length and diameter with a high accuracy. Such an application will have an important contribution to the machining stability studies since elimination of dependency on experiments will make it possible to predict stability diagrams for different combinations of spindle, holder and tool without performing any experiments. Additionally, since accurate identification of contact parameters, thus tool point FRFs and stability diagrams are highly dependent on accuracy of the performed experiments, possible errors due the mass of the accelerometers are also investigated. In order to compensate the mass effect of the accelerometers, a structural modification with matrix inversion method is applied to the accelerometer based results.

Turning is one of the most widely used processes in machining and is characterized by a cutting tool moving along the axis of a rotating workpiece as it removes material. A detrimental phenomenon to productivity in turning operations is unstable cutting or chatter. This can reduce the life of tooling, dimensional accuracy, and the quality of a part's surface finish because of severe levels of vibration. Ideally, cutting conditions are chosen such that material removal is performed in a stable manner. However, it is sometimes unavoidable because of the geometry of the cutting tool or workpiece. This work seeks to develop a dynamic cutting force model that can be used to predict both the point of chatter instability as well as its amplitude growth over time. Previous chatter models fail to capture the physics of the process from a first-principles point of view because they are oversimplified and rely on various "cutting force coefficients" that must be tuned in order to get a desired correlation with experimental results. The proposed approach models the process in a geometrically rigorous fashion, also giving treatment to the strain, strain rate, and temperature effects encountered in machining. It derives the forces encountered during a turning operation from two sources: forces due to chip formation and forces due to plowing and flank interference. This study consists of a detailed derivation of two new cutting force models. One relies on careful approximations in order to obtain a closed-form solution; the other is more explicit and obtains a solution through numerical methods. The models are validated experimentally by comparing their prediction of the point of instability, the magnitude of vibration in the time and frequency domains, as well as the machined surface topography during chatter.

Factors such as environmental requirements and fuel efficiency have pushed aerospace industry to develop reduced-weight engine designs and thereby light-weight and thin-walled components. As component wall thickness gets thinner and the mechanical structures weaker, the structure becomes more sensitive for vibrations during milling operations. Demands on cost efficiency increase and new ways of improving milling operations must follow. Historically, there have been two “schools” explaining vibrations in milling. One states that the entry angle in which the cutting insert hits the work piece is of greater importance than the exit angle. The other states that the way the cutter leaves the work piece is of greater importance than the cutter entry. In an effort to shed some light over this issue, a substantial amount of experiments were conducted. Evaluations were carried out using different tools, different tool-to-workpiece offset positions, and varying workpiece wall overhang. The resultant force, the force components, and system vibrations have been analyzed. The first part of this work shows the differences in force behavior for three tool-to-workpiece geometries while varying the wall overhang of the workpiece. The second part studies the force behavior during the exit phase for five different tool-to-workpiece offset positions while the overhang is held constant. The workpiece alloy throughout this work is Inconel 718. As a result of the project a spread sheet milling stability prediction model is developed and presented. It is based on available research in chatter theory and predicts the stability for a given set of variable input parameters. / <p>QC 20121206</p>

Made available in DSpace on 2016-12-12T20:25:12Z (GMT). No. of bitstreams: 1 Everton Ruggeri.pdf: 24321266 bytes, checksum: d9116328281ce8d4d01d557335e3d70b (MD5) Previous issue date: 2014-09-09 / Coordenação de Aperfeiçoamento de Pessoal de Nível Superior / In recent years, the study of chatter vibrations has been intensifying in the machining of materials, however, the analysis of chatter vibration has been conducted only for machining of ductile materials and few studies analyzing these vibrations in machining of brittle materials are found in the literature. The chatter vibrations in machining process can considerably compromise the workpiece surface finish, tool wear and in some cases provide severe damage to the machine-tool. Thus there is an imminent need to expand the theory of chatter vibrations for the class of brittle materials. To analyze the vibrations of the process and zones where the process is stable, and where it is unstable, the stability lobes diagram was used. This diagram is constructed in most cases for applications at high speed cutting. In this work, the analysis of the stability lobe diagram was made for application at low cutting speed, where the phenomenon of damping arises. The damping is a crucial factor in the process, it increases system stability. The phenomenon of damping was considered in the formulation of chatter vibrations using the indentation model of Wu. Apart from consideration of the damping effect, an analysis of dynamic stiffness on the mechanical system adopted was made by means of a simulation using the peak to peak method of passing of the tool in the workpiece. For experiments validations, the signals of force and acceleration were acquired and an analysis was conducted in time and frequency domain to identify where the vibrations emerged. The workpiece surface finish and RMS value of the signals were checked and compared with the stability conditions of the process. The results demonstrated perfectly the consequences that the chatter vibrations present in machining of grey cast iron and proved that the stability lobe diagram shows good results to detect the vibrations in machining of brittle materials, determining the areas where the material removal should be avoid. / Nos últimos anos, o estudo das vibrações regenerativas tem-se intensificando na usinagem de materiais, entretanto, a análise das vibrações regenerativas vem sendo conduzidas apenas para a usinagem de materiais dúcteis e poucos trabalhos analisando essas vibrações na usinagem de materiais frágeis são encontrados na literatura. As vibrações regenerativas no processo de usinagem podem comprometer consideravelmente o acabamento superficial da peça, o desgaste da ferramenta e em alguns casos proporcionar danos severos à máquina-ferramenta. Por isso, há uma necessidade eminente de expandir a teoria das vibrações regenerativas para a classe de materiais frágeis. Para analisar as vibrações no processo e regiões onde se possui um corte estável e onde há um corte instável, foi utilizado o diagrama de lóbulos de estabilidade. Este diagrama é construído na grande maioria dos casos para aplicações em alta velocidade de corte. Neste trabalho, a análise do diagrama de lóbulos de estabilidade foi feita para ensaios em baixa velocidade de corte, onde o fenômeno de amortecimento surge. O amortecimento é um fator crucial no processo, pois aumenta a estabilidade do sistema. O fenômeno de amortecimento foi considerado na formulação das vibrações regenerativas utilizando o modelo de indentação de Wu. Além da consideração do amortecimento, uma análise da influência da rigidez no sistema mecânico adotado foi realizada por uma simulação utilizando o método pico a pico, da passagem da ferramenta no corpo de prova. Para validação dos experimentos realizados, os sinais de força e de aceleração foram adquiridos e uma análise foi conduzida no domínio do tempo e no domínio da frequência para identificar onde as vibrações surgiram. O acabamento superficial da peça e valor RMS dos sinais também foram verificados e comparados com as condições de estabilidade do processo. Os resultados demonstraram perfeitamente as consequências que as vibrações regenerativas apresentam na usinagem do ferro fundido cinzento e comprovam que o diagrama de lóbulos de estabilidade mostra bons resultados para identificação das vibrações na usinagem de materiais frágeis, determinando as zonas onde se deve evitar a remoção de material.

A mechatronic system of actuators, sensors, and analog circuits is demonstrated to control the self-excited oscillations known as chatter that occur when single-point turning a rigid workpiece with a flexible tool. The nature of this manufacturing process, its complex geometry, harsh operating environment, and poorly understood physics, present considerable challenges to the control system designer. The actuators and sensors must be rugged and of exceptionally high bandwidth and the control must be robust in the presence of unmodeled dynamics. In this regard, the qualitative characterization of the chatter instability itself becomes important. Chatter vibrations are finite and recognized as limit cycles, yet modeling and control efforts have routinely focused only on the linearized problem. The question naturally arises as to whether the nonlinear stability is characterized by a jump phenomenon. If so, what does this imply for the "robustness" of linear control solutions? To answer our question, we present an advanced hardware and control system design for a boring bar application. Initially, we treat the cutting forces merely as an unknown disturbance to the structure which is essentially a cantilevered beam. We then approximate the structure as a linear single-degree-of-freedom damped oscillator in each of the two principal modal coordinates and seek a control strategy that reduces the system response to general disturbances. Modal-based control strategies originally developed for the control of large flexible space structures are employed; they use second-order compensators to enhance selectively the damping of the modes identified for control. To attack the problem of the nonlinear stability, we seek a model that captures some of the behavior observed in experiments. We design this model based on observations and intuition because theoretical expressions for the complex dynamic forces generated during cutting are lacking. We begin by assuming a regenerative chatter mechanism, as is common practice, and presume that it has a nonlinear form, which is approximated using a cubic polynomial. Experiments demonstrate that the cutting forces couple the two principal modal coordinates. To obtain the jump phenomena observed experimentally, we find it necessary to account for structural nonlinearies. Gradually, using experimental observation as a guide, we arrive at a two-degree-of-freedom chatter model for the boring process. We analyze the stability of this model using the modern methods of nonlinear dynamics. We apply the method of multiple scales to determine the local nonlinear normal form of the bifurcation from static to dynamic cutting. We then find the subsequent periodic motions by employing the method of harmonic balance. The stability of these periodic motions is analysed using Floquet theory. Working from a model that captures the essential nonlinear behavior, we develop a new post-bifurcation control strategy based on quench control. We observe that nonlinear state feedback can be used to control the amplitude of post-bifurcation limit cycles. Judicious selection of this nonlinear state feedback makes a supplementary open-loop control strategy possible. By injecting a harmonic force with a frequency incommensurate with the chatter frequency, we find that the self-excited chatter can be exchanged for a forced vibratory response, thereby reducing tool motions. / Ph. D.

Vibration control requires high dynamic stiffness in mechanical structures for a reliable performance under extreme conditions. Dynamic stiffness composes the parameters of stiffness (K) and damping (η) that are usually in a trade-off relationship. This thesis study aims to break the trade-off relationship. After identifying the underlying mechanism of damping in composite materials and joint interfaces, this thesis studies the deposition technique and physical characteristics of nano-structured HDS (high dynamic stiffness) composite thick-layer coatings. The HDS composite were created by enlarging the internal grain boundary surface area through reduced grain size in nano scale (≤ 40 nm). The deposition process utilizes a PECVD (Plasma Enhanced Chemical Vapour Deposition) method combined with the HiPIMS (High Power Impulse Magnetron Sputtering) technology. The HDS composite exhibited significantly higher surface hardness and higher elastic modulus compared to Poly(methyl methacrylate) (PMMA), yet similar damping property. The HDS composites successfully realized vibration control of cutting tools while applied in their clamping interfaces. Compression preload at essential joint interfaces was found to play a major role in stability of cutting processes and a method was provided for characterizing joint interface properties directly on assembled structures. The detailed analysis of a build-up structure showed that the vibrational mode energy is shifted by varying the joint interface’s compression preload. In a build-up structure, the location shift of vibration mode’s strain energy affects the dynamic responses together with the stiffness and damping properties of joint interfaces. The thesis demonstrates that it is possible to achieve high stiffness and high damping simultaneously in materials and structures. Analysis of the vibrational strain energy distribution was found essential for the success of vibration control.

Regenerative chatter is a well-known machining problem that results in unstable cutting process, poor surface quality, reduced material removal rate and damage on the machine tool itself. Stability lobe diagrams supply stable depth of cut &amp / #8211 / spindle speed combinations and they can be used to avoid chatter. The main requirement for generating the stability lobe diagrams is the system dynamics information at the tool tip in the form of point frequency response function (FRF). In this work, an analytical model that uses structural coupling and modification methods for modeling the dynamics of spindle-holder-tool assemblies in order to obtain the tool point FRF is presented. The resulting FRF obtained by the model can be used in the existing analytical and numerical models for constructing the stability lobe diagrams. Timoshenko beam theory is used in the model for improved accuracy and the results are compared with those of Euler-Bernoulli beam theory. The importance of using Timoshenko beam theory in the model is pointed out, and the circumstances, under which the theory being used in the model becomes more important, are explained. The model is verified by comparing the results obtained by the model with those of a reliable finite element software for a case study. The computational superiority in using the model developed against the finite element software is also demonstrated. Then, the model is used for studying the effects of bearing and contact dynamics at the spindle-holder and holder-tool interfaces on the tool point FRF. Based on the results of the effect analysis, a new approach is suggested for the identification of bearing and interface parameters from experimental measurements, which is demonstrated on a spindle-holder-tool assembly. The model is also employed for studying the effects of design and operational parameters on the tool point FRF, from the results of which, suggestions are made regarding the design of spindles and selection of operational parameters. Finally, it is experimentally demonstrated that the stability lobe diagram of an assembly can be predicted pretty accurately by using the model proposed, and furthermore the stability lobe diagram can be modified in a predictable manner for improving chatter stability.

La millora de la productivitat i la qualitat són indubtablement dues de les principals exigències del sector productiu modern i factors clau per la competitivitat i la supervivència. Dins aquest sector,la fabricació per arrancada de material juga encara avui en dia un paper protagonista tot i l'aparició de noves tècniques de conformat per addició.Indústries com l'aeronàutica, l'automobilística,la del motlle o l'energètica, depenen en bona part de les prestacions de les màquines-eina. Aquesta Tesi aborda dos aspectes rellevants quan es tracta de millorar de la productivitat i la qualitat del sector productiu: el problema del fimbrament, més conegut per la denominació anglosaxona chatter,i la monitorització de la rugositat superficial en el mecanitzat a alta velocitat. / Productivity and quality improvement are undoubtedly two of the main demands of themodern manufacturing sector and key factors for competitiveness and survival. Within this sector, material removal processes play, still nowadays, a principal role despite the emergence of additive manufacturing techniques. Industries such as aerospace, automotive, molds and dies or energy largely depend on machine tools performance for improved productivity and quality. This Thesis is focused on two important aspects when it comes to improving productivity and quality of the manufacturing sector: chatter problem, and surface roughness monitoring in high speed milling.

Ce travail de thèse se concentre sur l’étude du comportement dynamique des tubes minces durant leur usinage par tournage et notamment sur la survenue du broutement régénératif. L’étude de l’usinage de ce type de pièce est pertinente car ces pièces font l’objet d’une large diffusion dans divers domaines industriels tels que la construction aéronautique (notamment moteurs), la construction navale, la production de fusées. Ces pièces ayant une faible rigidité, il est fréquent que des vibrations indésirables se produisent en cours d’usinage. Il est donc intéressant d’être à même de les prédire pour les éviter.L’approche proposée vise à permettre un choix rapide et efficace des conditions de coupe, et notamment des profondeurs de passe, pour cette opération d’usinage. Pour cela nous proposons de mettre en place un modèle mécanique analytique du tube (modèle de coque mince utilisant un nombre réduit de degrés de liberté) de manière à réduire les coûts numériques et à faciliter l’analyse du phénomène. L’impact de la taille du modèle sur les résultats est étudié (nombre de formes propres) ainsi que de la prise en compte de l’enlèvement de matière (évolution du comportement dynamique) et du déplacement de l’outil. Afin de valider l’approche une expérience a été mise en place et est également présentée dans ce mémoire. / This work focuses on the study of the dynamic behavior of thin tubes during their machining by turning and gives particular emphasis on the occurrence of regenerative chatter. The study of machining of this type of workpiece is relevant because they are widely used in various industrial fields such as aircraft construction (including engines), shipbuilding, rocket production. As these parts have low rigidity, it is common that undesirable vibrations occur during machining. It is therefore of interest to be able to predict them in order to avoid them.The proposed approach is designed to enable a fast and efficient selection of cutting conditions, including cutting depths for this machining operation. We thus propose to elaborated an analytical model for the dynamics of the tube (thin shell based model using a reduced number of degrees of freedom) to reduce the numerical costs and to facilitate the analysis of the phenomenon. The impact of the size of the model on the results is studied (number of shape functions), as well as the impact of material removal (evolution of the dynamic behavior) and of the motion of the tool. An experiment, presented in this thesis, was also set up in order to validate the approach.