Tool Condition Monitoring Based on Nonlinear Output Frequency Response Functions and Multivariate Control Chart

Tool condition monitoring(TCM)is a key technology for intelligent manufacturing.The objective is to monitor the tool operation status and detect tool breakage so that the tool can be changed in time to avoid significant damage to workpieces and reduce manufacturing costs.Recently,an innovative TCM approach based on sensor data modelling and model frequency analysis has been proposed.Different from traditional signal feature-based monitoring,the data from sensors are utilized to build a dynamic process model.Then,the nonlinear output frequency response functions,a concept which extends the linear system frequency response function to the nonlinear case,over the frequency range of the tooth passing frequency of the machining process are extracted to reveal tool health conditions.In order to extend the novel sensor data modelling and model frequency analysis to unsupervised condition monitoring of cutting tools,in the present study,a multivariate control chart is proposed for TCM based on the frequency domain properties of machining processes derived from the innovative sensor data modelling and model frequency analysis.The feature dimension is reduced by principal component analysis first.Then the moving average strategy is exploited to generate monitoring variables and overcome the effects of noises.The milling experiments of titanium alloys are conducted to verify the effectiveness of the proposed approach in detecting excessive flank wear of solid carbide end mills.The results demonstrate the advantages of the new approach over conventional TCM techniques and its potential in industrial applications.

Parametric characteristic of the random vibration response of nonlinear systems

Volterra series is a powerful mathematical tool for nonlinear system analysis,and there is a wide range of nonlinear engineering systems and structures that can be represented by a Volterra series model.In the present study,the random vibration of nonlinear systems is investigated using Volterra series.Analytical expressions were derived for the calculation of the output power spectral density（PSD） and input-output cross-PSD for nonlinear systems subjected to Gaussian excitation.Based on these expressions,it was revealed that both the output PSD and the input-output crossPSD can be expressed as polynomial functions of the nonlinear characteristic parameters or the input intensity.Numerical studies were carried out to verify the theoretical analysis result and to demonstrate the effectiveness of the derived relationship.The results reached in this study are of significance to the analysis and design of the nonlinear engineering systems and structures which can be represented by a Volterra series model.

Nonlinear Dynamic Analysis of the Whole Vehicle on Bumpy Road

Through the research into the characteristics of 7-DoF high dimensional nonlinear dynamics of a vehicle on bumpy road, the periodic movement and chaotic behavior of the vehicle were found.The methods of nonlinear frequency response analysis, global bifurcation, frequency chart and Poincaré maps were used simultaneously to derive strange super chaotic attractor.According to Lyapunov exponents calculated by Gram-Schmidt method, the unstable region was compartmentalized and the super chaotic characteristic of ...

Identification of Composite-Metal Bolted Structures with Nonlinear Contact Effect

The middle layer model has been used in recent years to better describe the connection behavior in composite structures.The influencing parameters including low pre-screw and high preload have the main effects on nonlinear behavior of the connection as well as the amplitude of the excitation force applied to the structure.Therefore,in this study,the effects of connection behavior on the general structure in two sections of increasing damping and reducing the stiffness of the structures that lead to non-linear phenomena have been investigated.Due to the fact that in composite structure we are faced to the limitation of increasing screw preload which tend to structural damage,so the investigation on the hybrid connection(metal-composite)behavior is conducted.In this research,using the two-dimensional middle layer theory,the stiffness properties of the connection are modeled by normal stiffness and the connection damping is modeled using the structural damping in the shear direction.Nonlinear frequency response diagrams have been extracted twice for two different excitation forces and then proposed by a high-order multitasking approximation according to the response range of the nonlinear finite element model for stiffness and damping of the connection.The effect of increasing the amplitude of the excitation force and decreasing the preload of the screw on the nonlinear behavior of the component has been extracted.The results show that the limited presented novel component model has been accurately verified on the model obtained from the vibration experimental test and the reduction of nonlinear model updating based on that is represented.The comparison results show good agreementwith a maximumof 1.33%error.

Dynamics Analysis of Active Variable Stiffness Vibration Isolator for Whole-Spacecraft Systems Based on Nonlinear Output Frequency Response Functions

In order to improve the harsh dynamic environment experienced by heavy rockets during different external excitations,this study presents a novel active variable stiffness vibration isolator(AVS-VI)used as the vibration isolation device to reduce excessive vibration of the whole-spacecraft isolation system.The AVS-VI is composed of horizontal stiffness spring,positive stiffness spring,parallelogram linkage mechanism,piezoelectric actuator,acceleration sensor,viscoelastic damping,and PID active controller.Based on the AVS-VI,the generalized vibration transmissibility determined by the nonlinear output frequency response functions and the energy absorption rate is applied to analyze the isolation performance of the whole-spacecraft system with AVS-VI.The AVS-VI can conduct adaptive vibration suppression with variable stiffness to the whole-spacecraft system,and the analysis results indicate that the AVS-VI is efTective in reducing the extravagant vibration of the whole-spacecraft system,where the vibration isolation is decreased up to above 65%under different acceleration excitations.Finally,different parameters of AVS-VI are considered to optimize the whole-spacecraft system based on the generalized vibration transmissibility and the energy absorption rate.