Characterization of metal cutting dynamics. Final report
A Hardinge CNC lathe has been fitted with sensors and a data acquisition system for the measurement, processing and storage of accelerations and forces associated with orthogonal cutting. This system has been completely validated. Orthogonal cutting experiments were designed in order to study the effects of critical cutting parameters on machining dynamics. Three major experimental sets were conducted. In the first set the depth of cut was increased in a stepwise fashion, while the workpiece surface speed, the spindle speed, and the tool feedrate were maintained invariant. In the second and third sets, the spindle speed and feedrate were varied, respectively, while maintaining all the other parameters invariant. In total over two hundred orthogonal cutting experiments were performed. In each experiment, the two non-zero components of the tool acceleration and the two non-zero components of the cutting force were measured. Despite high noise levels, mutual information calculations with smoothing kernels and false nearest neighbor algorithms proved to be sufficiently robust to provide upper bounds on attractor dimension for all fifty data sets studied. These results prove that the infinite dimensional cutting process has an associated attractor of dimension {le} 4. This result is important as a guide to model construction. An analysis of the power spectral sideband structure proved that sideband spacing is identical to the turning frequency. This result was further substantiated through envelope detection techniques. A linear delay model was shown to emulate the experimental power spectrum and possess predictive capacity.
- Research Organization:
- Maryland Univ., College Park, MD (United States). Dept. of Mechanical Engineering
- Sponsoring Organization:
- USDOE Office of Energy Research, Washington, DC (United States)
- DOE Contract Number:
- FG02-93ER14336
- OSTI ID:
- 588027
- Report Number(s):
- DOE/ER/14336-4; ON: DE98004716; TRN: AHC29809%%104
- Resource Relation:
- Other Information: PBD: 1 Nov 1997
- Country of Publication:
- United States
- Language:
- English
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