GREEN MACHINING ORIENTED TO DIMINISH DENSITY GRADIENT FOR MINIMIZATION of DISTORTION IN ADVANCED CERAMICS

After sintering advanced ceramics, there are invariably distortions, caused in large part by the heterogeneous distribution of density gradients along the compacted piece. To correct distortions, machining is generally used to manufacture pieces within dimensional and geometric tolerances. Hence, narrow material removal limit conditions are applied, which minimize the generation of damage. Another alternative is machining the compacted piece before sintering, called the green ceramic stage, which allows machining without damage to mechanical strength. Since the greatest concentration of density gradients is located in the outer-most layers of the compacted piece, this study investigated the removal of different allowance values by means of green machining. The output variables are distortion after sintering, tool wear, cutting force, and the surface roughness of the green ceramics and the sintered ones. The following results have been noted: less distortion is verified in the sintered piece after 1mm allowance removal; and the higher the tool wear the worse the surface roughness of both green and sintered pieces.

A sustainable alternative for cooling the machining processes using a refrigerant fluid in recirculation inside the toolholder

This article presents a cooling system for cutting tool in turning based in a toolholder with cooling fluid flowing inside its body being that this fluid must necessarily be able to phase change due to heat generated from machining processes. In this way, the fluid evaporates just under the cutting tool allowing a heat transfer more efficient than if were used a fluid without phase change once the latent heat of evaporation is beneficial for removal heat. Following, the cooling fluid evaporated passes through a condenser located out of the toolholder where it is condensated and returns to the toolholder again and a new cycle is started. In this study, the R-123, a hydrochlorofluorocarbon (HCFC) fluid, was selected for the turning of a Cr-Ni-Nb-Mn-N austenitic steel of hard machinability. The machining tests were carried out under three different machining conditions: dry machining, external cutting fluid (conventional method), and with the toolholder proposed. As result, the developed system allows a surface roughness up to 10% better than dry machining and a tool life close to the conventional method, but 32% superior to dry machining; moreover, there are environmental and economics advantages once the cooling fluid is maintained in a loop circuit.

Notes on vibration control of a micro/macromanipulator mounted on a flexible structure

The objective of this study is to describe the design and the implementation of an experimental set-up used to study the dynamics, the experimental identification, and the active vibration control of a flexible structure mounted manipulator system. The system consists of a three-degree-of-freedom cylindrical manipulator system with a flexible link on its tip. A two-degree-of-freedom polar rigid manipulator is mounted on the flexible macromanipulator. The dynamic modelling and experimental modal analysis identification in the frequency domain are being applied to design active digital control strategies for the micro-manipulator system to damp the mechanical vibrations of the flexible structure on the tip of the macro-manipulator system.

Beam Search Algorithms for Minimizing Tool Switches on a Flexible Manufacturing System

In the minimization of tool switches problem we seek a sequence to process a set of jobs so that the number of tool switches required is minimized. In this work different variations of a heuristic based on partial ordered job sequences are implemented and evaluated. All variations adopt a depth first strategy of the enumeration tree. The computational test results indicate that good results can be obtained by a variation which keeps the best three branches at each node of the enumeration tree, and randomly choose, among all active nodes, the next node to branch when backtracking.

A planar flexible robotic manipulator

Presents the dynamic modelling of a flexible robotic manipulator with two flexible links and two revolute joints, which rotates in the horizontal plane. The dynamic equations are derived using the Newton-Euler formulation and the finite element method, based on elementary beam theory, which is used to discretize the displacements such that the small motion is represented in terms of nodal displacements. Computer simulation results are presented to illustrate this study. The dynamic model becomes necessary for use in future design and control applications.

System identification and active vibration control of a flexible structure

Fundação de Amparo à Pesquisa do Estado de São Paulo (FAPESP)

Damage Detection in Flexible Plate Using Lamb Waves

This paper presents an experimental technique for structural health monitoring (SHM) based on Lamb waves approach in an aluminum plate using piezoelectric material as actuators and sensors. Lamb waves are a form of elastic perturbation that remains guided between two parallel free surfaces, such as the upper and lower surfaces of a plate, beam or shelf. Lamb waves are formed when the actuator excites the surface of the structure with a pulse after receiving a signal. Two PZTs were placed in the plate surface and one of them was used to send a predefined wave through the structure. Thus, the other PZT (adjacent) becomes the sensor. Using this methodology, this paper presents one case of damage detection considering the aluminum plate in the free-free-free-free boundary condition. The damage was simulated by adding additional mass on the plate. It is proposed two damage detection indexes obtained from the experimental signal, involving the Fast Fourier Transform (FFT) and the power spectral density (PSD) that were computed using the output signal. The results show the viability of the presented methodology to damage detection in smart structures

Optimal and robust modal control of a flexible structure using an active dynamic vibration absorber

This paper is concerned with feedback vibration control of a lightly damped flexible structure that has a large number of well-separated modes. A single active electrical dynamic absorber is used to reduce a particular single vibration mode selectively or multiple modes simultaneously. The absorber is realized electrically by feeding back the structural acceleration at one position to a collocated piezoceramic patch actuator via a controller consisting of one or several second order lowpass filters. A simple analytical method is presented to design a modal control filter that is optimal in that it maximally flattens the mobility frequency response of the target mode, as well as robust in that it works within a prescribed maximum control spillover of 2 dB at all frequencies. Experiments are conducted with a free-free beam to demonstrate its ability to control any single mode optimally and robustly. It is also shown that an active absorber with multiple such filters can effectively control multiple modes simultaneously.

Robust broadband vibration control of a flexible structure using an electrical dynamic absorber

This paper presents a simple but practical feedback control method to suppress the vibration of a flexible structure in the frequency range between 10 Hz and 1 kHz. A dynamic vibration absorber is designed for this, which has a natural frequency of 100 Hz and a normalized bandwidth (twice the damping ratio) of 9.9. The absorber is realized electrically by feeding back the structural acceleration at one position on the host structure to a collocated piezoceramic patch actuator via an analog controller consisting of a second-order lowpass filter. This absorber is equivalent to a single degree-of-freedom mechanical oscillator consisting of a serially connected mass-spring-damper system. A first-order lowpass filter is additionally used to improve stability at very high frequencies. Experiments were conducted on a free-free beam embedded with a piezoceramic patch actuator and an accelerometer at its center. It is demonstrated that the single absorber can simultaneously suppress multiple vibration modes within the control bandwidth. It is further shown that the control system is robust to slight changes in the plant. The method described can be applied to many other practical structures, after retuning the absorber parameters for the structure under control.

Electromyographic activity of trunk muscles during exercises with flexible and non-flexible poles

Objective: Hand-held flexible poles which are brought into oscillation to cause alternating forces on trunk, are advocated as training devices that are supposed to solicit increased levels of stabilizing trunk muscle activity. The aim of this study was to verify this claim by comparing electromyographic (EMG) activity of trunk muscles during exercises performed with a flexible pole and a rigid pole.Methods: Twelve healthy females performed three different exercises with flexible and rigid poles. EMG activity of iliocostalis lumborum (IL), multifidus (MU), rectus abdominis (RA), external oblique (EO) and internal oblique (IO), and was continuously measured. The EMG signals were analyzed in time domain by calculation of the Root Mean Square (RMS) amplitudes over 250 ms windows. The mean RMS-values over time were normalized by the maximum RMS obtained for each muscle.Results: The IO showed a 72% greater EMG activity during the exercises performed with the flexible pole than with the rigid pole (p = 0.035). In exercises performed in standing, the IO was significantly more active than when sitting (p = 0.006).Conclusion: As intended, the cyclic forces induced by the oscillating pole did increase trunk muscle activation. However, the effect was limited and significant for the IO muscle only.

Short comments on self-synchronization of two non-ideal sources supported by a flexible portal frame structure

A practical problem of synchronization of a non-ideal (i.e. when the excitation is influenced by the response of the system) and non-linear vibrating system was posed and investigated by means of numerical simulations. Two rotating unbalanced motors compose the mathematical model considered here with limited power supply mounted on the horizontal beam of a simple portal frame. As a starting point, the problem is reduced to a four-degrees-of-freedom model and its equations of motion, derived elsewhere via a Lagrangian approach, are presented. The numerical results show the expected phenomena associated with the passage through resonance with limited power. Further, for a two-to-one relationship between the frequencies associated with the first symmetric mode and the sway mode, by using the variation of torque constants, the control of the self-synchronization and synchronization (in the system) are observed at certain levels of excitations.

The rigid-flexible nonlinear robotic manipulator: Modeling and control

Fundação de Amparo à Pesquisa do Estado de São Paulo (FAPESP)

Automation and cybernetics: Control of a flexible one-link manipulator

States that control is of the essence in cybernetics. Summarizes the dynamic equations for a flexible one-link manipulator moving in the horizontal plane. Employs the finite element method, based on elementary beam theory, during the process of formulation. Develops and instruments a one-link flexible manipulator in order to control its vibration modes. Uses a simple second-order vibration model which permits vibrations on the rod to be estimated using the hub angle. The validation of the dynamic model and the structural analysis of the flexible manipulator is reached using proper infrared cameras and active light sources for determining actual positions of objects in space. Shows that the performance of the control is satisfactory, even under perturbation action.