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.

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.