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

Machining chatter is an undesirable phenomenon of material removal processes and hardly to control or avoid. Its occurrence and extent essentially depend onthe kinematic, which alters with the position of the Tool Centre Point, of the machine tool. Research as to chatter was done widely but rarely with respect to changing structural dynamics during manufacturing. This thesis applies intelligent methods to learn the underlying functions of modal parameters – natural frequency, damping ratio, and mode shape – and defines the dynamic properties of a system firstly at this extent. To do so, it embraces three steps: first, the elaboration of the necessary dynamic parameters, second, the acquisition of the data via a simulation,and third, the prediction of the modal parameters with two kinds of Machine Learning techniques: Gradient Boosting Machine and Multilayer Perceptron. In total, it investigates three types of kinematics: cross bed, gantry, and overhead gantry. It becomes apparent that Light Gradient Boosting Machine outperforms Multilayer Perceptron throughout all studies. It achieves a prediction error of at most 1.7 % for natural frequency and damping ratio for all kinematics. However, it cannot really control the prediction of the participation factor yet which might originate in the complexity of the data and the data size. As expected, the error rises with noisy data and less amount of measurement points but at a tenable extent for both natural frequency and damping ratio. / 'Bearbetningsvibrationer är ett oönskat fenomen i materialborttagningsprocesser och är svåra att kontrollera eller undvika. Dess förekomst och omfattning beror i huvudsak på kinematiken, som förändras med positionen för verktygets centrumpunkt på verktygsmaskinen. Det har gjorts mycket forskning om bearbetningsvibrationer, men sällan om förändrad strukturell dynamik under tillverkningen. I denna avhandling tillämpas intelligenta metoder för att lära sig de underliggande funktionerna hos modalparametrar – egenfrekvens, dämpningsgrad och modalform – och definierar systemets dynamiska egenskaper för första gången i denna omfattning. För att göra detta omfattar den tre steg: för det första utarbetandet av de nödvändiga dynamiska parametrarna, för det andra insamling av data via en simulering och för det tredje förutsägelse av modalparametrarna med hjälp av två typer av tekniker för maskininlärning: Gradient Boosting Machine och Multilayer Perceptron. Sammanlagt undersöks tre typer av kinematik: crossbed, gantry och overhead gantry. Det framgår tydligt att Light Gradient Boosting Machine överträffar Multilayer Perceptron i alla studier. Den uppnår ett prediktionsfel på högst 1,7 % för egenfrekvens och dämpningsförhållande för alla kinematiker. Den kan dock ännu inte riktigt kontrollera förutsägelsen av deltagarfaktorn, vilket kan bero på datans komplexitet och datastorlek. Som väntat ökar felet med bullrig data och färre mätpunkter, men i en acceptabel omfattning för både naturfrekvens och dämpningsförhållande.

La thèse concerne un procédé de fabrication par usinage dans son aspect le plus générique. L’objectif est de développer une approche intégrée aux systèmes CFAO permettant de prédire le comportement vibratoire d’un système usinant en fraisage régénératif multiaxe dans une échelle mésoscopique. Cela engage l’estimation des interactions Pièce / Outil instantanées, le calcul des forces de coupe et enfin, la détermination de la stabilité/instabilité du procédé sous certaines conditions de coupe. La géométrie de l’interaction est rendue particulièrement complexe à cause de la forme de l’outil et de la pièce ainsi que de leur position relative. Dans ces travaux, nous proposons une approche générique basée sur un système de CFAO pour l’extraction des éléments géométriques nécessaires au calcul des forces de coupe en chaque point de la trajectoire du fraisage. Et dans le dessein d’une meilleure prédiction, nous nous basons sur la discrétisation de la fraise en des arêtes infinitésimales. Particulièrement, cette approche est implémentée pour un cas d’usage simple. Par la suite, nous développons, sous Simulink/Matlab, un système de calcul permettant la visualisation des forces et de la dynamique de la coupe dans le domaine temporel. Ceci grâce aux modèles de comportement du système usinant identifiés expérimentalement et un modèle spécifique d’efforts de coupe intégrant le facteur retard. Par ailleurs, la stabilité liée à la coupe est déterminée à partir des critères de comportement applicables aux systèmes non linéaires héréditaires. L’interopérabilité de ces deux outils de calcul et de conception est couronnée par la production d’un démonstrateur de comportement vibratoire sur une trajectoire de coupe par fraisage régénératif. Enfin, une première étude expérimentale visant le recalage des modèles de comportement et d’efforts de coupe, ainsi que la validation de l’approche générique et du démonstrateur est produite pour différents processus de fraisage. / This research is a generic aspect enquiry on manufacturing process by machining. Its main objective is supporting CAD/CAM systems through an integrated approach aiming to determine vibratory behavior of multi-axis chatter milling. This involves estimating instantaneous Part / Tool interactions, calculating cutting forces and finally determining process stability or instability under certain cutting conditions. Interaction geometry is made particularly complex because of tool and workpiece’s geometry as well as their relative position. In this work, we propose a generic approach based on CAD/CAM systems to extract geometric elements needed to calculate cutting forces at each point of milling path. In addition, with a view to better prediction, we rely on milling tool discretization into infinitesimal edges while developing and implementing milling simulation system for cutting forces and dynamics calculation tool in Simulink/Matlab software. This, thanks to the behavior models of machining system identified experimentally and a specific model of cutting forces incorporating delay factor. In addition, the milling process behavior is determined by applying some criteria to the hereditary system. The interoperability of these two calculation and design tools is culminated with a visual demonstrator of vibration behaviors in milling tool path. Finally, a first experimental study aiming at behavior and cutting forces models adjustment, as well as the generic approach and the demonstrator validation is realized for different milling processes.

Dans l’industrie de fabrication mécanique et notamment pour l’utilisation des centres d’usinage haute vitesse, la connaissance des propriétés dynamiques du système broche-outil-pièce en opération est d’une grande importance. L’accroissement des performances des machines-outils et des outils de coupe a œuvré au développement de ce procédé compétitif. D’innombrables travaux ont été menés pour accroître les performances et les remarquables avancées dans les matériaux, les revêtements des outils coupants et les lubrifiants ont permis d’accroître considérablement les vitesses de coupe tout en améliorant la qualité de la surface usinée. Cependant, l’utilisation rationnelle de cette technologie est encore fortement pénalisée par les lacunes dans la connaissance de la coupe, que ce soit au niveau microscopique des interactions fines entre l’outil et la matière coupée, aussi bien qu’au niveau macroscopique intégrant le comportement de la cellule élémentaire d’usinage, si bien que le comportement dynamique en coupe garde encore une grande part de questionnement et exige de l’utilisateur un bon niveau de savoir-faire et parfois d’empirisme pour exploiter au mieux les capacités des moyens de production. Le fonctionnement des machines d’usinage engendre des vibrations qui sont souvent la cause des dysfonctionnements et accélère l’usure des composantes mécaniques (roulements) et outils. Ces vibrations sont une image des efforts internes des systèmes, d’où l’intérêt d’analyser les grandeurs mécaniques vibratoires telle que la vitesse ou l’accélération vibratoire. Ces outils sont indispensables pour une maintenance moderne dont l’objectif est de réduire les coûts liés aux pannes / In machining field, chatter phenomenon takes a lot of interest because manufacturing enterprises are turning to the automation system and the development of reliable and robust monitoring system to provide increased productivity, improved part quality and reduced costs. Chatter occurrence has several negatives effects: a) Poor surface quality, b) Unacceptable inaccuracy, c) Excessive noise, d) Machine tool damage, e) Reduced material removal rate, f) Increase costs in terms of production time, g) Waste of material, h) Environmental impact in terms of materials and energy. Moreover, chatter monitoring is not an easy task for various reasons. Firstly, the non linearity of machining processes and the time-varying of systems complicate this task. Secondly, the sensitivity and the dependency of acquired signals from sensors on different factors, such as machining condition, cutting tool geometry and workpiece material. Thirdly, at high rotating speeds, the gyroscopic effects on the spindle dynamics in addition to the centrifugal force on the bearings and thermal effects become more relevant thus affecting the stability of the system. For these reasons, demands for an advanced automatic chatter detection and monitoring system for optimizing and controlling machining processes becomes a topic of enormous interest. Several researches in this field are performed. Advanced monitoring and detection methods are developed mostly relying on time, frequency and time-frequency analysis. In order to detect chatter in milling centers, three new methods are studied and developed using advanced techniques of signal processing and exploiting cyclostationarity property of signals acquired

The aim of this paper is to provide insight into the issue of enterprise social networking (ESN), other collaborative tools , and instruments of social interaction that can facilitate users their individual work tasks as well as contribute to the overall increase in enterprise efficiency. Futhermore, it offer the familiarization with their available functions and features, robustness and simplicity, advantages and disadvantages. It also offers practical guidance for the implementation of enterprise social networks, or other instrument of enterprise social interaction and what to avoid. The entire paper is conceived to three parts that are logically linked. The first part is theoretical, which is discussed fundamental issues what are social networks about. The second part discussed the concept of corporate social networks, the issue of implementation and at the same time this paper shows the major products to the market. The third part is a survey which evaluate the use of social networking in business practice. The paper thus provides a comprehensive

The theoretical part of the thesis deals with materials used in the aircraft industry with a focus on aluminium alloys. Then it describes high speed machining, its characteristics and its comparison with conventional machining. The following chapters describe strategies of machining thin-walled parts and a description of vibration that occurs during machining. The practical part deals with selection appropriate tool geometry, machining of thin-walled parts and evaluation of their deflection during machining.

In this thesis a new frequency domain approach for the analysis of time delay systems is presented. After linearization of a nonlinear delay differential equation (DDE) with constant distributed delay around a constant or periodic reference solution the so-called Hill-Floquet method can be used for the analysis of the resulting linear DDE. In addition, systems with fast or slowly time-varying delays, systems with variable transport delays originating from a transport with variable velocity, and the corresponding spatially extended systems are presented, which can be also analyzed with the presented method. The newly introduced Hill-Floquet method is based on the Hill’s infinite determinant method and enables the transformation of a system with periodic coefficients to an autonomous system with constant coefficients. This makes the usage of a variety of existing methods for autonomous systems available for the analysis of periodic systems, which implies that the typical calculation of the monodromy matrix for the time evolution of the solution over the principle period is no longer required. In this thesis, the Chebyshev collocation method is used for the analysis of the autonomous systems. Specifically, in this case the periodic part of the solution is expanded in a Fourier series and the exponential behavior of the solution is approximated by the discrete values of the Fourier coefficients at the Chebyshev nodes, whereas in classical spectral or pseudo-spectral methods for the analysis of linear periodic DDEs the complete solution is expanded in terms of basis functions. In the last part of this thesis, new results for three applications with time delay effects are presented, which were analyzed with the presented methods. On the one hand, the occurrence of diffusion-driven instabilities in reaction-diffusion systems with delay is investigated. It is shown that wave instabilities are possible already for single-species reaction diffusion systems with distributed or time-varying delay. On the other hand, the stability of metal cutting vibrations at machine tools is analyzed. In particular, parallel orthogonal turning processes with multiple discrete delays and turning processes with a time-varying delay due to a spindle speed variation are studied. Finally, the stability of the synchronized solution in networks with heterogeneous coupling delays is studied. In particular, the eigenmode expansion for synchronized periodic orbits is derived, which includes an extension of the classical master stability function to networks with heterogeneous coupling delays. Numerical results are shown for a network of Hodgkin-Huxley neurons with two delays in the coupling. / In dieser Dissertation wird ein neues Verfahren zur Analyse von Systemen mit Totzeiten im Frequenzraum vorgestellt. Nach Linearisierung einer nichtlinearen retardierten Differentialgleichung (DDE) mit konstanter verteilter Totzeit um eine konstante oder periodische Referenzlösung kann die sogenannte Hill-Floquet Methode für die Analyse der resultierende linearen DDE angewendet werden. Darüber hinaus werden Systeme mit schnell oder langsam variierender Totzeit, Systeme mit einer variablen Totzeit, resultierend aus einem Transport mit variabler Geschwindigkeit, und entsprechende räumlich ausgedehnte Systeme vorgestellt, welche ebenfalls mit der vorgestellten Methode analysiert werden können. Die neu eingeführte Hill-Floquet Methode basiert auf der Hillschen unendlichen Determinante und ermöglicht die Transformation eines Systems mit periodischen Koeffizienten auf ein autonomes System mit konstanten Koeffizienten. Dadurch können zur Analyse periodischer Systeme auch eine Vielzahl existierender Methoden für autonome Systeme genutzt werden und die Berechnung der Monodromie-Matrix für die Lösung des Systems über eine Periode entfällt. In dieser Arbeit wird zur Analyse des autonomen Systems die Tschebyscheff-Kollokationsmethode verwendet. Im Speziellen wird bei diesem Verfahren der periodische Teil der Lösung in einer Fourierreihe entwickelt und das exponentielle Verhalten durch die Werte der Fourierkoeffizienten an den Tschebyscheff Knoten approximiert, wohingegen bei klassischen spektralen Verfahren die komplette Lösung in bestimmten Basisfunktionen entwickelt wird. Im Anwendungsteil der Arbeit werden neue Ergebnisse für drei Beispielsysteme präsentiert, welche mit den vorgestellten Methoden analysiert wurden. Es wird gezeigt, dass Welleninstabilitäten schon bei Einkomponenten-Reaktionsdiffusionsgleichungen mit verteilter oder variabler Totzeit auftreten können. In einem zweiten Beispiel werden Schwingungen an Werkzeugmaschinen betrachtet, wobei speziell simultane Drehbearbeitungsprozesse und Prozesse mit Drehzahlvariationen genauer untersucht werden. Am Ende wird die Synchronisation in Netzwerken mit heterogenen Totzeiten in den Kopplungstermen untersucht, wobei die Zerlegung in Netzwerk-Eigenmoden für synchrone periodische Orbits hergeleitet wird und konkrete numerische Ergebnisse für ein Netzwerk aus Hodgkin-Huxley Neuronen gezeigt werden.

In this thesis a new frequency domain approach for the analysis of time delay systems is presented. After linearization of a nonlinear delay differential equation (DDE) with constant distributed delay around a constant or periodic reference solution the so-called Hill-Floquet method can be used for the analysis of the resulting linear DDE. In addition, systems with fast or slowly time-varying delays, systems with variable transport delays originating from a transport with variable velocity, and the corresponding spatially extended systems are presented, which can be also analyzed with the presented method. The newly introduced Hill-Floquet method is based on the Hill’s infinite determinant method and enables the transformation of a system with periodic coefficients to an autonomous system with constant coefficients. This makes the usage of a variety of existing methods for autonomous systems available for the analysis of periodic systems, which implies that the typical calculation of the monodromy matrix for the time evolution of the solution over the principle period is no longer required. In this thesis, the Chebyshev collocation method is used for the analysis of the autonomous systems. Specifically, in this case the periodic part of the solution is expanded in a Fourier series and the exponential behavior of the solution is approximated by the discrete values of the Fourier coefficients at the Chebyshev nodes, whereas in classical spectral or pseudo-spectral methods for the analysis of linear periodic DDEs the complete solution is expanded in terms of basis functions. In the last part of this thesis, new results for three applications with time delay effects are presented, which were analyzed with the presented methods. On the one hand, the occurrence of diffusion-driven instabilities in reaction-diffusion systems with delay is investigated. It is shown that wave instabilities are possible already for single-species reaction diffusion systems with distributed or time-varying delay. On the other hand, the stability of metal cutting vibrations at machine tools is analyzed. In particular, parallel orthogonal turning processes with multiple discrete delays and turning processes with a time-varying delay due to a spindle speed variation are studied. Finally, the stability of the synchronized solution in networks with heterogeneous coupling delays is studied. In particular, the eigenmode expansion for synchronized periodic orbits is derived, which includes an extension of the classical master stability function to networks with heterogeneous coupling delays. Numerical results are shown for a network of Hodgkin-Huxley neurons with two delays in the coupling.:1. Introduction 2. System definition and equivalent systems 3. Analysis of nonlinear time delay systems 4. Analytical solution of linear time delay systems 5. Frequency domain approach 6. Hill-Floquet method 7. Applications 8. Concluding remarks A Appendix / In dieser Dissertation wird ein neues Verfahren zur Analyse von Systemen mit Totzeiten im Frequenzraum vorgestellt. Nach Linearisierung einer nichtlinearen retardierten Differentialgleichung (DDE) mit konstanter verteilter Totzeit um eine konstante oder periodische Referenzlösung kann die sogenannte Hill-Floquet Methode für die Analyse der resultierende linearen DDE angewendet werden. Darüber hinaus werden Systeme mit schnell oder langsam variierender Totzeit, Systeme mit einer variablen Totzeit, resultierend aus einem Transport mit variabler Geschwindigkeit, und entsprechende räumlich ausgedehnte Systeme vorgestellt, welche ebenfalls mit der vorgestellten Methode analysiert werden können. Die neu eingeführte Hill-Floquet Methode basiert auf der Hillschen unendlichen Determinante und ermöglicht die Transformation eines Systems mit periodischen Koeffizienten auf ein autonomes System mit konstanten Koeffizienten. Dadurch können zur Analyse periodischer Systeme auch eine Vielzahl existierender Methoden für autonome Systeme genutzt werden und die Berechnung der Monodromie-Matrix für die Lösung des Systems über eine Periode entfällt. In dieser Arbeit wird zur Analyse des autonomen Systems die Tschebyscheff-Kollokationsmethode verwendet. Im Speziellen wird bei diesem Verfahren der periodische Teil der Lösung in einer Fourierreihe entwickelt und das exponentielle Verhalten durch die Werte der Fourierkoeffizienten an den Tschebyscheff Knoten approximiert, wohingegen bei klassischen spektralen Verfahren die komplette Lösung in bestimmten Basisfunktionen entwickelt wird. Im Anwendungsteil der Arbeit werden neue Ergebnisse für drei Beispielsysteme präsentiert, welche mit den vorgestellten Methoden analysiert wurden. Es wird gezeigt, dass Welleninstabilitäten schon bei Einkomponenten-Reaktionsdiffusionsgleichungen mit verteilter oder variabler Totzeit auftreten können. In einem zweiten Beispiel werden Schwingungen an Werkzeugmaschinen betrachtet, wobei speziell simultane Drehbearbeitungsprozesse und Prozesse mit Drehzahlvariationen genauer untersucht werden. Am Ende wird die Synchronisation in Netzwerken mit heterogenen Totzeiten in den Kopplungstermen untersucht, wobei die Zerlegung in Netzwerk-Eigenmoden für synchrone periodische Orbits hergeleitet wird und konkrete numerische Ergebnisse für ein Netzwerk aus Hodgkin-Huxley Neuronen gezeigt werden.:1. Introduction 2. System definition and equivalent systems 3. Analysis of nonlinear time delay systems 4. Analytical solution of linear time delay systems 5. Frequency domain approach 6. Hill-Floquet method 7. Applications 8. Concluding remarks A Appendix

近年，IoTに基づく「つながる工場」に関する技術開発が着目され，日本の次世代の製造業を支えるために，新しい研究開発が求められている．特に機械加工の現場では，異常検知や適応制御のために加工現象を精確かつリアルタイムにモニタできる技術が必要とされている．そこで，マシニングセンタなどの工作機械において，回転工具の加工中に多チャンネルで各種の物理量を切削点近傍にてモニタ可能な無線多機能ホルダを開発し，様々な工具，加工方法を対象にその有効性を示した． / Currently, a smart monitoring technology has been attracting particular attention in the factory automation fields regarding the Internet of things (IoT). Particularly in the machining site, the technology of monitoring the processing phenomenon in precision and real-time is required for abnormality detection or adaptive control. Then, we developed a novel tool holder equipped with a wireless communication function to monitor the tool temperature and vibrating accelerations near the cutting point during a tool rotating operation, and we showed effectiveness for various tools and processing method. / 博士(工学) / Doctor of Philosophy in Engineering / 同志社大学 / Doshisha University