Orientadores: Katia Lucchesi Cavalca, Rainer Nordmann / Tese (doutorado) - Universidade Estadual de Campinas, Faculdade de Engenharia Mecanica / Made available in DSpace on 2018-08-12T14:22:54Z (GMT). No. of bitstreams: 1 Furtado_RogerioMendonca_D.pdf: 2160863 bytes, checksum: 4c54a9ce5fcded113554dc24287e591a (MD5) Previous issue date: 2008 / Resumo: Um atuador magnético como fonte de excitação em sistemas rotativos é desenvolvido para emprego na análise modal e em outros estudos, envolvendo a excitação sem contato. Embora os sistemas magnéticos para aplicação de forças em máquinas rotativas sejam empregados com alto desempenho (como por exemplo os mancais magnéticos), o desenvolvimento de um sistema simples, para aplicações laboratoriais, se apresenta como uma contribuição experimental útil, para ser empregado numa bancada de testes utilizada no desenvolvimento de projetos de máquinas rotativas. O conceito apresentado é simples, mas permite a excitação externa sem contatos ou mesmo o controle das amplitudes de vibração, quando associado a um sistema de controle. Contudo, a calibração e o estudo do desempenho dinâmico do sistema não são análises simples. Neste sentido, o trabalho apresenta uma experiência prática e discussões sobre o desenvolvimento do atuador magnético utilizado para testes em máquinas rotativas. A influência da corrente elétrica, entreferro, superfície do pólo do atuador e também da freqüência de excitação, são apresentadas. A força magnética é estimada, baseando-se na medida da densidade de fluxo magnético, medida por sensores hall. / Abstract: A magnetic actuator as excitation source in rotating systems is developed, in order to accomplish modal analysis and other studies involving contacless excitation. Although the use of magnetic systems to apply forces onto rotating machinery has been carried out with high performance level (for example, magnetic bearings), the development of a conveniently easy and simples device for laboratory application presents interesting contribution to experimental methods used in test rigs based on similarity design to rotating machinery. The initial concept of the magnetic actuator proposed here is simple, but enables either the external excitation without contact or the vibration control when associated with a controller system. However, the performance characteristics tunning to attend the dynamic demand of the system is not so trivial. Following this focus, the work brings practical experience and discussion about the development and performance analysis of a magnetic actuator used for rotating machinery tests. The influence of the electrical current in the actuator coils, the air-gap between actuator and rotative system, thetype of surface of the actuator poles (flat or curved) as well as excitation frequency was verified. Force estimation was based on the magnetic flux density, measured by hall sensors. / Doutorado / Mecanica dos Sólidos e Projeto Mecanico / Doutor em Engenharia Mecânica

New environmental regulations as well as the increasing industrial competitiveness have set new more demanding rules on the manufacturing industry. In order to abide by those rules not only from the legal point of view but also to be able survive, manufacturing has to be more sustainable from many aspects, especially the economical one. One way to achieve the previous target is an unfortunately often oversighted aspect of the industry sector, the maintenance strategy. Condition based maintenance, CBM, can be used successfully in the industry and accurate estimation of spindle life time can lead to large savings in downtime and cost. CBM requires accurate sensors and equipment in order to get the right indicators whether equipment performance is deteriorating or not. One performance factor when planning a machining process is chatter vibration and one way to avoid this deteriorating phenomenon is to choose cutting parameters that allow stable machining. Various types of sensors are available for vibration and other CBM related measurements. Depending on the situation, the most applicable sensor is selected. The core of this thesis is to investigate the usefulness of measurements with the contactless excitations and response unit in terms of condition based maintenance. In the first part of the thesis, some of the theoretical aspects of maintenance are extensively elaborated upon and later on, the experimental part is presented along with the results’ discussion. The hardware required by the experiments has been provided by KTH and the experiments took place in two of an automotive industry’s production sites. There have been two visits at site A and one at site B, apart from the initial meetings. The measurements have been analyzed with the use of MATLAB. / Nya miljöregler samt ökande industriell konkurrens har satt nya mer krävande regler för tillverkningsindustrin. För att följa dessa regler, inte bara ur rättslig synpunkt utan också för att kunna överleva, behöver tillverkningen ske mer hållbar ur många aspekter, särskilt den ekonomiska. Ett sätt att uppnå målen är via, en tyvärr ofta underskattad metod, underhållsstrategin. Tillståndsbaserat underhåll, CBM, kan användas med framgång inom branschen och korrekt uppskattning av spindellivstid kan leda till stora besparingar genom minskade driftstopp och kostnader. CBM kräver noggranna sensorer och utrustning för att få rätt indikatorer för att avgöra om utrustningens prestanda försämras eller ej. En prestationsavgörande faktor vid planering av bearbetningsprocesser är vibrationer. Ett sätt att undvika dessa försämrade fenomen är att välja skärparametrar som tillåter stabil bearbetning. Olika typer av sensorer finns tillgängliga för vibrations- och andra CBM-relaterade mätningar. Beroende på situation, väljs den mest lämpliga sensorn. Kärnan i denna rapport är att undersöka nyttan av mätningar med en beröringsfri excitations- och mätenhet för tillståndsbaserat underhåll. I de första avsnitten av rapporten redogörs några av de teoretiska aspekterna av underhåll och i de senare är den experimentella delen presenterad, tillsammans med diskussion kring resultat. Hårdvaran som krävs för experimenten har tillhandahållits av KTH och experimenten ägde rum på två produktionsanläggningar hos en fordonstillverkare. Det har varit två besök på plats A och ett besök på plats B, bortsett från inledande möten. Mätningarna har analyserats med hjälp av MATLAB.

Dynamic characteristics of machining systems are analysed for improved understanding of both structural and process properties. The thesis stresses the use of testing methods under operational like conditions as these are more representative of closed loop systems, such as machining systems, as compared to conventional testing methods. The test instrument proposed is a contactless excitation and response system, developed for testing of machine tool spindles under load and with rotating spindle. The instrument uses electromagnetic excitation and displacement sensors for analysis of rotating milling tools subject to load. A graphical tool for displaying and analysing rotor displacement was developed in conjunction with this. A modelling procedure for both off-line and on-line estimation of dynamic properties of mechanical structure and process information is presented. The proposed auto-regressive moving average models enable calculation of operational dynamic parameters and they can be estimated in a recursive manner, thus enabling real-time monitoring. The discrimination between stable and unstable processes, both in turning and milling, was performed by analysing the damping obtained from the operational dynamic parameters. / <p>QC 20170330</p>

Comprehensive knowledge and information about the static and dynamic behaviour of machine tools, cutting processes and their interaction is essential for machining system design, simulation, control and robust operation in safe conditions. The very complex system of a machine tool, fixture and cutting tools during the machining of a part is almost impossible to model analytically with sufficient accuracy. In combination with increasing demands for precision and efficiency in machining call for new control strategies for machining systems. These strategies need to be based on the identification of the static and dynamic stability under both the operational and off-operational conditions. To achieve this it is necessary to monitor and analyze the real system at the factory floor in full production. Design information and operational data can then be linked together to make a realistic digital model of a given machining system. Information from such a model can then be used as input in machining simulation software to find the root causes of instability. The work presented in this thesis deals with the static and dynamic capability of machining systems. The main focus is on the operational stability of the machining system and structural behaviour of only the machine tool, as well. When the accuracy of a machining system is measured by traditional techniques, effects from neither the static stiffness nor the cutting process are taken into account. This limits the applicability of these techniques for realistic evaluation of a machining system’s accuracy. The research presented in this thesis takes a different approach by introducing the concept of operational dynamic parameters. The concept of operational dynamic parameters entails an interaction between the structural elements of the machining systems and the process parameters. According to this concept, the absolute criterion of damping is used to evaluate the dynamic behaviour of a machining system. In contrast to the traditional theory, this methodology allows to determine the machining system's dynamic stability, in real time under operating conditions. This framework also includes an evaluation of the static deformations of a machine tool.  In this context, a novel concept of elastically linked system is introduced to account for the representation of the cutting force trough an elastic link that closes the force loop. In addition to the elastic link which behaves as a static element, a dynamic non-contact link has been introduced. The purpose is to study the non-linear effects introduced by variations of contact conditions in joints due to rotational speed. / QC 20111123

Manufacturing industry works on Overall Equipment Effectiveness (OEE) to increase the yield and speed of machining. A good knowledge of the machine properties is important to increase the speed while still maintaining stable cutting with low tool usage.To make models of the machine is therefore important and in machining a common way to extract the dynamic properties is frequency response measurement. One way is to use an impact hammer to excite the machine tool and measure the response. The problem is that a hammer can only be used on a non running machine. At Manufacturing and Metrology Systems division at KTH (MMS) a test method for contactless excitation has been developed that uses electromagnets to excite the machine tool. By using contactless testing it can be used on rotating machine tools without real cutting in materials. In this thesis a new test system for the contact less testing method has been designed and constructed to test if it is possible to do test on a bigger variety of rotating cutting machine tools. The results for the prototype is presented and evaluated. / Dagens tillverkningsindustri arbetar för att utrsutningens totala effiktivitet ska höjas genomatt öka hastigheten och minska material- och verktygsanvändningen vid bearbetningen utan att minska kvalitén på slutprodukten. För att öka hastigheten krävs en god kännedom om maskinens egenskaper för att maskinen ska arbeta under stabila förhållanden där också verktygets slitage minskas. Att ta fram modeller över maskinen är därför viktigt och inom skärande bearbetning är frekvensresponsmätning ett sätt att få ut de dynamiska egenskaperna av det skärandeverktyget. En vanlig testmetod är att med en hammare exitera verktyget och mäta responsen. Problemet är dock att hammaren bara kan mäta vid stillastående maskin. Vid MMS har en testmetod för kontaktlös exitering tagits fram där elektromagneter användsför exiteringen. På så sätt kan testet utföras på roterande verktyg utan att man behöver förbruka material. I detta arbete har ett nytt testsystem för denna testmetod designats och konstruerats för att testa om det är möjligt med testning på flera storlekar på maskiner för skärandebearbetning. Resultaten för prototypen presenteras och utvärderas.