This paper has developed a genetic algorithm (GA) optimization approach to search for the optimal locations to install bearings on the motorized spindle shaft to maximize its first-mode natural frequency (FMNF). First...This paper has developed a genetic algorithm (GA) optimization approach to search for the optimal locations to install bearings on the motorized spindle shaft to maximize its first-mode natural frequency (FMNF). First, a finite element method (FEM) dynamic model of the spindle-bearing system is formulated, and by solving the eigenvalue problem derived from the equations of motion, the natural frequencies of the spindle system can be acquired. Next, the mathematical model is built, which includes the objective function to maximize FMNF and the constraints to limit the locations of the bearings with respect to the geometrical boundaries of the segments they located and the spacings between adjacent bearings. Then, the Sequential Decoding Process (SDP) GA is designed to accommodate the dependent characteristics of the constraints in the mathematical model. To verify the proposed SDP-GA optimization approach, a four-bearing installation optimazation problem of an illustrative spindle system is investigated. The results show that the SDP-GA provides well convergence for the optimization searching process. By applying design of experiments and analysis of variance, the optimal values of GA parameters are determined under a certain number restriction in executing the eigenvalue calculation subroutine. A linear regression equation is derived also to estimate necessary calculation efforts with respect to the specific quality of the optimization solution. From the results of this illustrative example, we can conclude that the proposed SDP-GA optimization approach is effective and efficient.展开更多
Factors for determining the spindle size are the shaft diameter, positions of bearing and motor, and entire length of the spindle. Then, it is important to find the assembling of the optimal design variables, which sa...Factors for determining the spindle size are the shaft diameter, positions of bearing and motor, and entire length of the spindle. Then, it is important to find the assembling of the optimal design variables, which satisfy the stiffimss and rotational speed required to the spindle. A general full factorial design method was used to verify some factors that affect the natural frequency of a spindle. It is verified that the shorter shaft length and bearing span length represent the higher natural frequency, and there are some effects according to the change in the levels of factors. The detailed spindle dimension is determined by applying an EVD method, which can define the optimal bearing position through considering the limiting condition. Based on the estimated regression model, the optimal spindle size and bearing distance that can improve the primary natural frequency are obtained, and the influence of design factors on the natural frequency is also analyzed.展开更多
In this paper, natural frequencies and vibration modes of spindl D1203 are calculated by us-ing structural analysis program SAP84. It is found that the second natural frequency of D1203spindle is too close to the rang...In this paper, natural frequencies and vibration modes of spindl D1203 are calculated by us-ing structural analysis program SAP84. It is found that the second natural frequency of D1203spindle is too close to the range of working speed. In order to raise the second natural frequencyand to reduce the vibration noise, simple optimal design of several structural parameters are alsodiscussed by means of the orthogonal design method. It is shown that the better design is toshorten the length of the spindle blade appropriately and to increase the elasticity of its uppersupport.展开更多
In order to meet increasing demand for higher productivity and flexibility, recently many kinds of multi-functional machine tools, which are capable of multiple machining functions or different kinds of machining proc...In order to meet increasing demand for higher productivity and flexibility, recently many kinds of multi-functional machine tools, which are capable of multiple machining functions or different kinds of machining processes on one machine, have been developed and widely used in manufacturing industries. In this study, a multi-functional turning lathe, which has two spindles and two turrets so that multiple turning operations and various machining processes could be performed simultaneously, has been developed. Furthermore, the equations of correlation between whole responses and cross responses of the two spindles have been derived to examine to what extent the two spindles affect each other’s vibrations.展开更多
This study presents the development of an ultrasonic transducer with a radius horn for an ultrasonic milling spindle(UMS)system.The ultrasonic transducer was intended to have a working frequency of approximately 30 kH...This study presents the development of an ultrasonic transducer with a radius horn for an ultrasonic milling spindle(UMS)system.The ultrasonic transducer was intended to have a working frequency of approximately 30 kHz.Two different materials were considered in the study:stainless steel(SS 316L)and titanium alloy(Ti-6Al-4V).Titanium alloy gave a higher resonance frequency(33 kHz)than stainless steel(30 kHz)under the same preload compression stress.An electromechanical impedance simulation was carried out to predict the impedance resonance frequency for both materials,and the effect of the overhanging toolbar was investigated.According to the electromechanical impedance simulation,the overhanging toolbar length affected the resonance frequency,and the error was less than 3%.Harmonic analysis confirmed that the damping ratio helps determine the resonance amplitude.Therefore,damping ratios of 0.015-0.020 and 0.005-0.020 were selected for stainless steel and titanium alloy,respectively,with an error of less than 1.5%.Experimental machining was also performed to assess the feasibility of ultrasonic-assisted milling;the result was a lesser cutting force and better surface topography of Al 6061.展开更多
文摘This paper has developed a genetic algorithm (GA) optimization approach to search for the optimal locations to install bearings on the motorized spindle shaft to maximize its first-mode natural frequency (FMNF). First, a finite element method (FEM) dynamic model of the spindle-bearing system is formulated, and by solving the eigenvalue problem derived from the equations of motion, the natural frequencies of the spindle system can be acquired. Next, the mathematical model is built, which includes the objective function to maximize FMNF and the constraints to limit the locations of the bearings with respect to the geometrical boundaries of the segments they located and the spacings between adjacent bearings. Then, the Sequential Decoding Process (SDP) GA is designed to accommodate the dependent characteristics of the constraints in the mathematical model. To verify the proposed SDP-GA optimization approach, a four-bearing installation optimazation problem of an illustrative spindle system is investigated. The results show that the SDP-GA provides well convergence for the optimization searching process. By applying design of experiments and analysis of variance, the optimal values of GA parameters are determined under a certain number restriction in executing the eigenvalue calculation subroutine. A linear regression equation is derived also to estimate necessary calculation efforts with respect to the specific quality of the optimization solution. From the results of this illustrative example, we can conclude that the proposed SDP-GA optimization approach is effective and efficient.
基金Project(RTI04-01-03) supported by the Regional Technology Innovation Program of the Ministry of Knowledge Economy (MKE) of Korea
文摘Factors for determining the spindle size are the shaft diameter, positions of bearing and motor, and entire length of the spindle. Then, it is important to find the assembling of the optimal design variables, which satisfy the stiffimss and rotational speed required to the spindle. A general full factorial design method was used to verify some factors that affect the natural frequency of a spindle. It is verified that the shorter shaft length and bearing span length represent the higher natural frequency, and there are some effects according to the change in the levels of factors. The detailed spindle dimension is determined by applying an EVD method, which can define the optimal bearing position through considering the limiting condition. Based on the estimated regression model, the optimal spindle size and bearing distance that can improve the primary natural frequency are obtained, and the influence of design factors on the natural frequency is also analyzed.
文摘In this paper, natural frequencies and vibration modes of spindl D1203 are calculated by us-ing structural analysis program SAP84. It is found that the second natural frequency of D1203spindle is too close to the range of working speed. In order to raise the second natural frequencyand to reduce the vibration noise, simple optimal design of several structural parameters are alsodiscussed by means of the orthogonal design method. It is shown that the better design is toshorten the length of the spindle blade appropriately and to increase the elasticity of its uppersupport.
文摘In order to meet increasing demand for higher productivity and flexibility, recently many kinds of multi-functional machine tools, which are capable of multiple machining functions or different kinds of machining processes on one machine, have been developed and widely used in manufacturing industries. In this study, a multi-functional turning lathe, which has two spindles and two turrets so that multiple turning operations and various machining processes could be performed simultaneously, has been developed. Furthermore, the equations of correlation between whole responses and cross responses of the two spindles have been derived to examine to what extent the two spindles affect each other’s vibrations.
基金supported by Korea Electrotechnology Research Institute(KERI)Primary Research Program through the National Research Council of Science&Technology(NST)funded by the Ministry of Science and ICT(MSIT)in 2023(No.23A01021)the National Research Foundation of Korea(NRF)grant funded by the Korean Government(MSIT)(No.RS-2023-00278890).
文摘This study presents the development of an ultrasonic transducer with a radius horn for an ultrasonic milling spindle(UMS)system.The ultrasonic transducer was intended to have a working frequency of approximately 30 kHz.Two different materials were considered in the study:stainless steel(SS 316L)and titanium alloy(Ti-6Al-4V).Titanium alloy gave a higher resonance frequency(33 kHz)than stainless steel(30 kHz)under the same preload compression stress.An electromechanical impedance simulation was carried out to predict the impedance resonance frequency for both materials,and the effect of the overhanging toolbar was investigated.According to the electromechanical impedance simulation,the overhanging toolbar length affected the resonance frequency,and the error was less than 3%.Harmonic analysis confirmed that the damping ratio helps determine the resonance amplitude.Therefore,damping ratios of 0.015-0.020 and 0.005-0.020 were selected for stainless steel and titanium alloy,respectively,with an error of less than 1.5%.Experimental machining was also performed to assess the feasibility of ultrasonic-assisted milling;the result was a lesser cutting force and better surface topography of Al 6061.
