Electromagnetic force generation for dynamic modal testing applications

Milling is one of the most common manufacturing processes for manufacturing sectors. However, high speed machining problems notably tool chatter in function of both spindle speed and depth of cut. Thus, many researchers found that to detect or reduce chatter is by determining its dynamic characteris...

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Main Author:	Norlida, Jamil
Format:	Thesis
Language:	English
Published:	2015
Subjects:	T Technology (General) TJ Mechanical engineering and machinery
Online Access:	http://umpir.ump.edu.my/id/eprint/13153/19/Electromagnetic%20force%20generation%20for%20dynamic%20modal%20testing%20applications.pdf
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spelling	my-ump-ir.131532021-11-17T01:19:09Z Electromagnetic force generation for dynamic modal testing applications 2015 Norlida, Jamil T Technology (General) TJ Mechanical engineering and machinery Milling is one of the most common manufacturing processes for manufacturing sectors. However, high speed machining problems notably tool chatter in function of both spindle speed and depth of cut. Thus, many researchers found that to detect or reduce chatter is by determining its dynamic characteristics such as natural frequency, damping ratio, mode shapes and frequency response functions (FRFs). To predict the stability of the cutting tool system, modal testing using impact hammer is required to gain cutting tool‟s dynamic properties and FRFs. However, this method is suited well for non-rotating tools, but cannot be used to identify the dynamic of a rotating spindle. Thus, a non-contacting Electromagnetic Actuator (EMA) was designed and guided by analytical and numerical method. The geometry was designed using magnetic circuit analysis (MCA) and generalized machined theory (GMT) before FE analysis was conducted using Magnetostatic-Ansys software. Next, impact hammer and EMA were used as a contacting and non-contacting exciter respectively at a conventional milling machine in order to determine the FRFs and dynamic properties of milling tool with amplitude and speed dependencies including comparing with static FRFs. Subsequently, dynamic characteristic and FRFs obtained using non-contacting EMA later used to establish Stability Lobe Diagram (SLD). The magnetostatic analysis result has shown the magnetic flux produced were stable and controllable. Besides, the study has shown a good agreement between impact hammer and EMA with 8.74 percent of percentage error. The error between EMA and impact hammer may have resulted from inconsistencies with impact hammer testing. It should be noted that the EMA applied a distributed load to the tool instead of a point load. Furthermore, the variability in frequency values from FEA is probably due to differences in the boundary conditions of the milling machine. The SLD also showed an improvement which up to 5 percent for depth of cut at lower spindle speed. Thus, EMA produced can determine dynamic properties yet for the purpose of chatter prediction. In conclusion, this research had successfully design and analyzes an EMA that can determine dynamic properties and SLD to increase MRR and production rate, by generating force applies for static and dynamic modal testing. 2015 Thesis http://umpir.ump.edu.my/id/eprint/13153/ http://umpir.ump.edu.my/id/eprint/13153/19/Electromagnetic%20force%20generation%20for%20dynamic%20modal%20testing%20applications.pdf pdf en public masters Universiti Malaysia Pahang Faculty of Mechanical Engineering
institution	Universiti Malaysia Pahang Al-Sultan Abdullah
collection	UMPSA Institutional Repository
language	English
topic	T Technology (General) TJ Mechanical engineering and machinery
spellingShingle	T Technology (General) TJ Mechanical engineering and machinery Norlida, Jamil Electromagnetic force generation for dynamic modal testing applications
description	Milling is one of the most common manufacturing processes for manufacturing sectors. However, high speed machining problems notably tool chatter in function of both spindle speed and depth of cut. Thus, many researchers found that to detect or reduce chatter is by determining its dynamic characteristics such as natural frequency, damping ratio, mode shapes and frequency response functions (FRFs). To predict the stability of the cutting tool system, modal testing using impact hammer is required to gain cutting tool‟s dynamic properties and FRFs. However, this method is suited well for non-rotating tools, but cannot be used to identify the dynamic of a rotating spindle. Thus, a non-contacting Electromagnetic Actuator (EMA) was designed and guided by analytical and numerical method. The geometry was designed using magnetic circuit analysis (MCA) and generalized machined theory (GMT) before FE analysis was conducted using Magnetostatic-Ansys software. Next, impact hammer and EMA were used as a contacting and non-contacting exciter respectively at a conventional milling machine in order to determine the FRFs and dynamic properties of milling tool with amplitude and speed dependencies including comparing with static FRFs. Subsequently, dynamic characteristic and FRFs obtained using non-contacting EMA later used to establish Stability Lobe Diagram (SLD). The magnetostatic analysis result has shown the magnetic flux produced were stable and controllable. Besides, the study has shown a good agreement between impact hammer and EMA with 8.74 percent of percentage error. The error between EMA and impact hammer may have resulted from inconsistencies with impact hammer testing. It should be noted that the EMA applied a distributed load to the tool instead of a point load. Furthermore, the variability in frequency values from FEA is probably due to differences in the boundary conditions of the milling machine. The SLD also showed an improvement which up to 5 percent for depth of cut at lower spindle speed. Thus, EMA produced can determine dynamic properties yet for the purpose of chatter prediction. In conclusion, this research had successfully design and analyzes an EMA that can determine dynamic properties and SLD to increase MRR and production rate, by generating force applies for static and dynamic modal testing.
format	Thesis
qualification_level	Master's degree
author	Norlida, Jamil
author_facet	Norlida, Jamil
author_sort	Norlida, Jamil
title	Electromagnetic force generation for dynamic modal testing applications
title_short	Electromagnetic force generation for dynamic modal testing applications
title_full	Electromagnetic force generation for dynamic modal testing applications
title_fullStr	Electromagnetic force generation for dynamic modal testing applications
title_full_unstemmed	Electromagnetic force generation for dynamic modal testing applications
title_sort	electromagnetic force generation for dynamic modal testing applications
granting_institution	Universiti Malaysia Pahang
granting_department	Faculty of Mechanical Engineering
publishDate	2015
url	http://umpir.ump.edu.my/id/eprint/13153/19/Electromagnetic%20force%20generation%20for%20dynamic%20modal%20testing%20applications.pdf
_version_	1783731979775115264

Electromagnetic force generation for dynamic modal testing applications

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