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.

Research on the iterative method for model updating based on the frequency response function

Model reduction technique is usually employed in model updating process. In this paper, a new model updat- ing method named as cross-model cross-frequency response function （CMCF） method is proposed and a new iterative method associating the model updating method with the mo- del reduction technique is investigated. The new model up- dating method utilizes the frequency response function to avoid the modal analysis process and it does not need to pair or scale the measured and the analytical frequency re- sponse function, which could greatly increase the number of the equations and the updating parameters. Based on the traditional iterative method, a correction term related to the errors resulting from the replacement of the reduction ma- trix of the experimental model with that of the finite element model is added in the new iterative method. Comparisons be- tween the traditional iterative method and the proposed itera- tive method are shown by model updating examples of solar panels, and both of these two iterative methods combine the CMCF method and the succession-level approximate reduc- tion technique. Results show the effectiveness of the CMCF method and the proposed iterative method .

Uncertainty analysis of strain modal parameters by Bayesian method using frequency response function

Structural strain modes are able to detect changes in local structural performance, but errors are inevitably intermixed in the measured data. In this paper, strain modal parameters are considered as random variables, and their uncertainty is analyzed by a Bayesian method based on the structural frequency response function （FRF）. The estimates of strain modal parameters with maximal posterior probability are determined. Several independent measurements of the FRF of a four-story reinforced concrete flame structural model were performed in the laboratory. The ability to identify the stiffness change in a concrete column using the strain mode was verified. It is shown that the uncertainty of the natural frequency is very small. Compared with the displacement mode shape, the variations of strain mode shapes at each point are quite different. The damping ratios are more affected by the types of test systems. Except for the case where a high order strain mode does not identify local damage, the first order strain mode can provide an exact indication of the damage location.

Pilot study on the Non-Invasive Detectability of Femoral Neck Fractures with Frequency Response Functions

A suspicion of a femoral neck fracture is a frequently recurring situation, especially in nursing homes. For the clarification of such a suspicion normally imaging techniques are used. Such equipment is expensive and therefore is located in hospitals. In addition to the costs, a transport causes stress for the patient. This pilot study is devoted to the question whether the detection of a femoral neck fracture with vibration measurements is possible in principal. In such a case, the clarification could be done on-site by an ordinary person using much cheaper equipment. This would reduce the stress for the patient and save money. For this purpose vibration measurements on a dead body with intact, with partially fractured and with complete cut femoral neck have been performed. Two different methods for the vibration initiation have been investigated, the so called impact testing and the shaker testing. The frequency response function has been determined for all combinations on both sides of the body. It turned out that there is a clear difference in the frequency response functions of the fractured bone with respect to the intact bone when shaker testing is used. This indicates that the method could have the potential to be a cost-saving alternative to imaging techniques. However, in a next step a statistically reliable clinical survey on living persons needs to be done.

THE HOMOGENEOUS POLYNOMIAL SOLUTIONS FOR THE GRUSHIN OPERATOR

In this paper, the author computes the dimension of space of homogeneous Grushin-harmonic functions, and give an orthogonal basis of them. Moreover, the author describes the nodal curves of these homogenous Grushin-harmonic basis. As an application of the orthogonal basis, the author proves a Liouville-type theorem for the Grushin operator, that is the Grushin-harmonic functions are homogeneous polynomials provided that the frequency of such a function is equal to some constant.

Adaptive inverse control of random vibration based on the filtered-X LMS algorithm

Random vibration control is aimed at reproducing the power spectral density （PSD） at specified control points. The classical frequency-spectrum equalization algorithm needs to compute the average of the multiple frequency response functions （FRFs）, which lengthens the control loop time in the equalization process. Likewise, the feedback control algorithm has a very slow convergence rate due to the small value of the feedback gain parameter to ensure stability of the system. To overcome these limitations, an adaptive inverse control of random vibrations based on the filtered-X least mean-square （LMS） algorithm is proposed. Furthermore, according to the description and iteration characteristics of random vibration tests in the frequency domain, the frequency domain LMS algorithm is adopted to refine the inverse characteristics of the FRF instead of the traditional time domain LMS algorithm. This inverse characteristic, which is called the impedance function of the system under control, is used to update the drive PSD directly. The test results indicated that in addition to successfully avoiding the instability problem that occurs during the iteration process, the adaptive control strategy minimizes the amount of time needed to obtain a short control loop and achieve equalization.

Optimization of the Tuned Mass Damper for Chatter Suppression in Turning

The tuned mass damper（TMD） has been successfully applied to the vibration control in machining, while the most widely adopted tuning is equal peaks, which splits the magnitude of the frequency response function（FRF） into equal peaks. However, chatter is a special self-excited problem and a chatter-flee machining is determined by FRF at the cutting zone. A TMD tuning aiming at achieving the maximum chatter stability is studied, and it is formulated as an optimization problem of maximizing the minimum negative real part of FRF. By employing the steepest descend method, the optimum frequency and damping ratio of TMD are obtained, and they are compared against the equal peaks tuning. The advantage of the proposed tuning is demonstrated numerically by comparing the minimum point of the negative real part, and is further verified by damping a flexible mode from the fixture of a turning machine. A TMD is designed and placed on the fixture along the vibration of the target mode after performing modal analysis and mode shape visualization. Both of the above two ttmings are applied to modify the tool point FRF by tuning TMD respectively. Chatter stability chart of the turning shows that the proposed tuning can increase the critical depth of cut 37% more than the equal peaks. Cutting tests with an increasing depth of cut are conducted on the turning machine in order to distinguish the stability limit. The tool vibrations during the machining are compared to validate the simulation results. The proposed damping design and optimization routine are able to further increase the chatter suppression effect.

Response Characteristics of Load on Vessels in Waves

Considering the requirement of direct design and fatigue test for ships and floating structures by use of FEM technique, a computational procedure of spectral analysis for wave load on the hull surface is developed in this paper. The response of hydrodynamic pressure on the body surface to a designated sea state for ships and floating structures is calculated by use of the revised strip method with the hull bound perturbation flow concept. The spectral function of wave load for the defined point on the body surface can be determined from the Wiener-Khinhine theorem and the characteristic load value can be also obtained from spectral moment analysis. A container ship is taken as a computational example acid the sample of wave load with a certain probability and corresponding encountered frequency is provided.

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.

Centrifuge modelling of ground-borne vibrations induced by railway traffic in underground tunnels

Increased attention has been given to ground-borne vibrations induced by railway vehicles and to the effects of these vibrations as they propagate through the ground into nearby buildings.Various studies,mainly based on numerical methods as well as physical modelling,have been carried out to investigate this problem.To study the dynamic response of tunnels and the surrounding soil due to train-induced vibration loads,a centrifuge test was conducted with a small-scale model in 1 g and 50 g stress field environments.An aluminum tube was embedded in sand to model the underground tunnel.A small parallel pre-stressed actuator(PPA)was employed to apply vibration loads on the tunnel invert.The model responses were measured using accelerometers.Both time and frequency domain analyzes were performed.The test results demonstrated that electronic noise had a clear impact on the test results and should be eliminated.It also found that the dynamic response of both the tunnel and soil were affected by the stress field.Therefore,it is important to account for the stress field effects when assessing the ground-borne vibration from tunnels.

Power spectral density analysis for nonlinear systems based on Volterra series

A consequence of nonlinearities is a multi-harmonic response via a monoharmonic excitation.A similar phenomenon also exists in random vibration.The power spectral density(PSD)analysis of random vibration for nonlinear systems is studied in this paper.The analytical formulation of output PSD subject to the zero-mean Gaussian random load is deduced by using the Volterra series expansion and the conception of generalized frequency response function(GFRF).For a class of nonlinear systems,the growing exponential method is used to determine the first 3 rd-order GFRFs.The proposed approach is used to achieve the nonlinear system’s output PSD under a narrow-band stationary random input.The relationship between the peak of PSD and the parameters of the nonlinear system is discussed.By using the proposed method,the nonlinear characteristics of multi-band output via single-band input can be well predicted.The results reveal that changing nonlinear system parameters gives a one-of-a-kind change of the system’s output PSD.This paper provides a method for the research of random vibration prediction and control in real-world nonlinear systems.

Damage detection of 3D structures using nearest neighbor search method

An innovative damage identification method using the nearest neighbor search method to assess 3D structures is presented.The frequency response function was employed as the input parameters to detect the severity and place of damage in 3D spaces since it includes the most dynamic characteristics of the structures.Two-dimensional principal component analysis was utilized to reduce the size of the frequency response function data.The nearest neighbor search method was employed to detect the severity and location of damage in different damage scenarios.The accuracy of the approach was verified using measured data from an experimental test;moreover,two asymmetric 3D numerical examples were considered as the numerical study.The superiority of the method was demonstrated through comparison with the results of damage identification by using artificial neural network.Different levels of white Gaussian noise were used for polluting the frequency response function data to investigate the robustness of the methods against noise-polluted data.The results indicate that both methods can efficiently detect the damage properties including its severity and location with high accuracy in the absence of noise,but the nearest neighbor search method is more robust against noisy data than the artificial neural network.

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.

ODS & Modal Testing Using a Transmissibility Chain

In this paper, we show how Operating Deflection Shapes (ODS’s) andmode shapes can be obtained experimentally from measurements thatare made using only two sensors and two short wires to connect them to amulti-channel acquisition system. This new test procedure is depicted inFigure 1. Not only is the equipment required to do a test much more costeffective, but this method can be used to test any sized test article, especiallylarge ones.

On the low frequency characteristics of head-related transfer function

A method to correct the measured head-related transfer functions （HRTFs） at low frequency was proposed. By analyzing the HRTFs from the spherical head model at low frequency, it is proved that below the frequency of 400 Hz, magnitude of HRTF is nearly constant and the phase is a linear function of frequency both for the far and near field. Therefore, if the HRTFs above 400 Hz are accurately measured by experiment, it is able to correct the HRTFs at low frequency by the theoretical model. The results of calculation and subjective experiment show that the feasibility of the proposed method.

Relative Varying Dynamics Based Whole Cutting Process Optimization for Thin‑walled Parts

Thin-walled parts are typically difficult-to-cut components due to the complex dynamics in cutting process.The dynamics is variant for part during machining,but invariant for machine tool.The variation of the relative dynamics results in the difference of cutting stage division and cutting parameter selection.This paper develops a novel method for whole cutting process optimization based on the relative varying dynamic characteristic of machining system.A new strategy to distinguish cutting stages depending on the dominated dynamics during machining process is proposed,and a thickness-dependent model to predict the dynamics of part is developed.Optimal cutting parameters change with stages,which can be divided by the critical thickness of part.Based on the dynamics comparison between machine tool and thickness-varying part,the critical thicknesses are predicted by an iterative algorithm.The proposed method is validated by the machining of three benchmarks.Good agreements have been obtained between prediction and experimental results in terms of stages identification,meanwhile,the optimized parameters perform well during the whole cutting process.

Time-delay identification for vibration systems with multiple feedback

An approach for time-delay identification is proposed in multiple-degree-of-freedom (MDOF) linear systems with multiple feedback. The applicability of the approach is discussed in detail. Based on the characteristics of frequency domain in feedback controlled system with multiple time-delays, this paper proposes a time-delay identification approach, which is based on the pseudo impedance function of reference point. Treating feedback time-delays as the 'frequencies' of the oscillation curve, the time-delays can be obtained from the 'frequencies' of the curve. Numerical simulation is conducted to validate the proposed approach. The application scope of the approach is discussed with regard to different forms of feedback.

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.

Measurements in Situ and Spectral Analysis of Wind Flow Effects on Overhead Transmission Lines

In the paper an important issue of vibrations of the transmission line in real conditions was analyzed.Such research was carried out by the authors of this paper taking into account the cross-section of the cable being in use on the transmission line.Analysis was performed for the modern ACSR high voltage transmission line with span of 213.0 m.The purpose of the investigation was to analyze the vibrations of the power transmission line in the natural environment and compare with the results obtained in the numerical simulations.Analysis was performed for natural and wind excited vibrations.The numerical model was made using the Spectral Element Method.In the spectral model,for various parameters of stiffness,damping and tension force,the system response was checked and compared with the results of the accelerations obtained in the situ measurements.A frequency response functions(FRF)were calculated.The credibility of the model was assessed through a validation process carried out by comparing graphical plots of FRF functions and numerical values expressing differences in acceleration amplitude(MSG),phase angle differences(PSG)and differences in acceleration and phase angle total(CSG)values.Particular attention was paid to the hysteretic damping analysis.Sensitivity of the wave number was performed for changing of the tension force and section area of the cable.The next aspect constituting the purpose of this paper was to present the wide possibilities of modelling and simulation of slender conductors using the Spectral Element Method.The obtained results show very good accuracy in the range of both experimental measurements as well as simulation analysis.The paper emphasizes the ease with which the sensitivity of the conductor and its response to changes in density of spectral mesh division,cable cross-section,tensile strength or material damping can be studied.

Investigation of Rotor Radial Rotating Error upon AMB System

This paper first suggests the use of the Fourier frequency transmission method of two dimensions function （ 2D FFT） to analyze radial rotating errors that occurred in a rotor. Based on this method a magnetic rotor is measured. The authors point out that the main cause to affect radial rotating accuracy of the rotating shaft at a high speed is the dynamic imbalance of the shaft itself. Finally the feedforward control scheme is suggested to improve the accuracy of the shaft in an active magnetic bearing （ AMB ） system.