arXiv subjects

Alain Gérard

Publications and source records attributed to Alain Gérard.

At least 19 recordsLinked to original sources

arXiv2012

The milling process monitoring using 3D envelope method

This paper proposes a method to vibration analysis in order to on-line monitoring of milling process quality. Adapting envelope analysis to characterize the milling tool materials is an important contribution to the qualitative and quantitative characterization of milling capacity and a step by modeling the three-dimensional cutting process. An experimental protocol was designed and developed for the acquisition, processing and analyzing three-dimensional signal. The vibration envelope analysis is proposed to detect the cutting capacity of the tool with the optimization application of cutting parameters. The research is focused on Hilbert transform optimization to evaluate the dynamic behavior of the machine/ tool/workpiece.

cs.OH↗

arXiv2012

Dynamic behavior analysis for a six axis industrial machining robot

The six axis robots are widely used in automotive industry for their good repeatability (as defined in the ISO92983) (painting, welding, mastic deposition, handling etc.). In the aerospace industry, robot starts to be used for complex applications such as drilling, riveting, fiber placement, NDT, etc. Given the positioning performance of serial robots, precision applications require usually external measurement device with complexes calibration procedure in order to reach the precision needed. New applications in the machining field of composite material (aerospace, naval, or wind turbine for example) intend to use off line programming of serial robot without the use of calibration or external measurement device. For those applications, the position, orientation and path trajectory precision of the tool center point of the robot are needed to generate the machining operation. This article presents the different conditions that currently limit the development of robots in robotic machining applications. We analyze the dynamical behavior of a robot KUKA KR240-2 (located at the University of Bordeaux 1) equipped with a HSM Spindle (42000 rpm, 18kW). This analysis is done in three stages. The first step is determining the self-excited frequencies of the robot structure for three different configurations of work. The second phase aims to analyze the dynamical vibration of the structure as the spindle is activated without cutting. The third stage consists of vibration analysis during a milling operation.

cs.RO↗

arXiv2012

Experimental Characterization of Robot Arm Rigidity in Order to Be Used in Machining Operation

Attempts to install a rotating tool at the end of a robot arm poly-articulated date back twenty years, but these robots were not designed for that. Indeed, two essential features are necessary for machining: high rigidity and precision in a given workspace. The experimental results presented are the dynamic identification of a poly-articulated robot equipped with an integrated spindle. This study aims to highlight the influence of the geometric configuration of the robot arm on the overall stiffness of the system. The spindle is taken into account as an additional weight on board but also as a dynamical excitation for the robot KUKA KR_240_2. Study of the robotic machining vibrations shows the suitable directions of movement in milling process

cs.RO↗

arXiv2012

New Approach of Envelope Dynamic Analysis for Milling Process

This paper proposes a method to vibration analysis in order to on-line monitoring of milling process quality. Adapting envelope analysis to characterize the milling tool materials is an important contribution to the qualitative and quantitative characterization of milling capacity and a step by modeling the three-dimensional cutting process. An experimental protocol was designed and developed for the acquisition, processing and analyzing three-dimensional signal. The vibration envelope analysis is proposed to detect the cutting capacity of the tool with the optimization application of cutting parameters. The research is focused on FFT Fourier transform optimization of vibration analysis and vibration envelope to evaluate the dynamic behavior of the machine/ tool/workpiece

cs.OH↗

arXiv2012

Link between chips and cutting moments evolution

The better understanding of the material cutting process has been shown with the benefit of the forces and moments measurement since some years ago. In paper, simultaneous six mechanical components and chip orientation measurements were realized during turning tests. During these tests, the influence of the depth of cut or feed rate has been observed and a link between the chip orientation and the moment vector orientation or the central axis characteristics has been shown.

physics.gen-ph↗

arXiv2012

Analyse du comportement dynamique d'une broche de machine-outils

Vibrations appearance, either unstability system, is the result of the dynamic interaction of the cutting process with the elastic system of machine tools in various working conditions. Our objective is to develop an experimental three-dimensional dynamic model in milling. Our purpose is to applied this model to optimize the cutting parameters and to monitor cutting process, milling tool and machine-tool. To reach the detailed knowledge of the dynamic phenomena we divide our study into two parts : the machine and the cutting process. The dynamic analysis of the machine is compulsory before modelling the vibratory phenomena during the cutting. A dynamic analysis method is developed to characterize completely the various machine tools components.

physics.gen-ph↗

arXiv2010

Self-excited vibrations in turning: cutting moment analysis

This work aims at analysing the moment effects at the tool tip point and at the central axis, in the framework of a turning process. A testing device in turning, including a six-component dynamometer, is used to measure the complete torsor of the cutting actions in the case of self-excited vibrations. Many results are obtained regarding the mechanical actions torsor. A confrontation of the moment components at the tool tip and at the central axis is carried out. It clearly appears that analysing moments at the central axis avoids the disturbances induced by the transport of the moment of the mechanical actions resultant at the tool tip point. For instance, the order relation between the components of the forces is single. Furthermore, the order relation between the moments components expressed at the tool tip point is also single and the same one. But at the central axis, two different order relations regarding moments are conceivable. A modification in the rolling moment localization in the (y, z) tool plan is associated to these two order relations. Thus, the moments components at the central axis are particularly sensitive at the disturbances of machining, here the self-excited vibrations.

physics.gen-ph↗

arXiv2009

A force torsor analysis for a turning process in the presence of self-excited vibrations

A testing device in turning including, in particular, a six-component dynamometer, is used to measure the complete torque of the cutting actions, in a case of self-excited vibrations. For the tests, the used tool was a noncoated carbide tool (TNMA 160412) without chip breaker. The cutting material is a chrome molybdenum alloy type (ASI 4140). The cylindrical test tubes have a diameter of 120 mm and a length of 30 mm. For the first time, we present an analysis of forces and moments for different depths of cut and different feed rates.

physics.class-ph↗

arXiv2009

Using Tracking Analysis and Predictive Maintenance in Order to Obtain Dynamics of Machine Tool Spindle

Predictive maintenance is directed towards recognizing the earliest significant changes in machinery condition. Contrasted with protective condition monitoring in which fast response is the primary requirement, predictive monitoring is not limited by time and may use a greather range of complex characteristics. Vibration analysis has long been used for the detection and identification of machine tool condition. Main focus is to identify a procedure to obtain eigenvalue frequencies for machine tool spindle using tracking analysis.

physics.class-ph↗

arXiv2009

Three-Dimensional Dynamic Cutting Model

The determination of a dynamic law of cut is complex and often very difficult to develop. Several formulations were developed, in very complex ways being given that 3 AD crosses from there, the number of variables is much higher than out of orthogonal cut. The existence of the plan of displacements and the correlations with the elastic characteristics of the machining system thus make it possible to simplify the dynamic model 3D. A dynamic model on the basis of experimental approach is proposed. Simulation is in concord with the experimental results.

physics.class-ph↗

arXiv2009

Regeneratives Vibrations Analyzes On The Part And Chip

The actions of cut applied to the elastic system generate relative tool/part displacements, which induce a temperature increasing in the components of the machine tools, its environment, the system-tools-part and generate vibrations. The experimental procedures used, at the dynamic level, made it possible to determine the elements necessary to analyze the influence of the tool geometry, its displacement and evolution of the contacts tool/part and tool/chip on surface carried out

physics.class-ph↗

arXiv2009

Optimization and Dynamic Characterization System Part in Turning

The appearance of the self-sustained vibrations corresponds to the dynamic instability of the machine tool. An experimental device and a model were designed to characterize the cutting system, the block part. This analysis shows the need for knowing more details of it the behavior of the coin at the time of the cut, and for envisaging for the continuation the appearance of vibrations.

physics.class-ph↗

arXiv2009

Analyzes Geometry of Part and Chips at the Time of Regeneratives Vibrations

The actions of cut applied to the elastic system cause relative displacements tool/part, which induce a rise in the temperature in the components of the machine tools, its environment, the system-tools-part and generate vibrations. The experimental procedures installation, at the dynamic level, made it possible to determine the elements necessary to a rigorous analysis of the influence of the geometry of the tool, its displacement and evolution of the contacts tool/part and tool/chip on surface carried out

physics.class-ph↗

arXiv2009

Metrology Influence on the Cutting Modelisation

High speed machining has been improved thanks to considerable advancement on the tools (optimum geometry, harder materials), on machined materials (increased workability and machining capacity for harder workpieces) and finally on the machines (higher accuracy and power at the high speeds, performances of the numerical control system). However at such loading velocities, the cutting process generates high strain and high-speed strain which cause complex, various and irreversible phenomena in plasticity. These phenomena are comprehended through the complete measurement of the mechanical actions using a six-component dynamometer and flux and temperatures measurements at the tip of the cutting tool. Balanced energy assessments are the starting points of our reflection on the machining modelling. The modelling of these phenomena and the material behaviour under this type of loading requires a suitable theoretical approach. The main points of the strain gradient theory are developed. A theoretical behaviour law adapted to the cutting phenomena is then expressed.

physics.class-ph↗

arXiv2009

The Regenerative Vibrations Influence on the Mechanical Actions in Turning

In manufacturing during the cutting process the appearance of vibrations can not be avoided. These vibrations constitute a major obstacle to obtain a greater productivity and a better quality of the workpiece. It is thus necessary to develop models which make it possible to study, the totality of the 3D dynamic phenomena. Thanks to an experimental approach the complete torque of the mechanical actions is measured in the presence of the vibrations during a turning operation. This study makes it possible to analyze the variations of the central axis which is a significant parameter of the vibratory phenomena.

physics.class-ph↗

arXiv2009

Self-Excited Vibrations in Turning: Efforts Torsor and Average Friction Coefficient Analysis

An experimental device in turning including, in particular, a six-component dynamometer is exploited to measure the complete torque of cutting forces in a case of self-excited vibrations. For the tests, the tool used is type TNMA 16 04 12 carbide not covered (nuance carbide-SUMITIMO ELECTRIC), without chip breeze. The machined material is an alloy of chrome molybdenum type 42 CrMo24. The test-tubes are cylindrical with a diameter of 120 mm and a length of 30 mm. The effort of analysis relates to the moments. In particular, to the tool tip point, when feed rate increases the friction coefficient of swivelling is increasing while that of bearing is decreasing. Innovative remarks on the evolution of the average friction coefficient for various depths of cut and feed rate are presented

physics.class-ph↗

arXiv2009

Self-excited vibrations in turning : Forces torsor analysis

The present work deals with determining the necessary parameters considering a three dimensional model to simulate in a realistic way the turning process on machine tool. This paper is dedicated to the study of the self-excited vibrations incidence on various major mechanics characteristics of the system workpiece / tool / material. The efforts (forces and moments) measurement using a six components dynamometer confirms the tool tip moments existence. The fundamental frequency of 190 Hz proves to be common to the tool tip point displacements, the action application point or at the torque exerted to the tool tip point. The confrontation of the results concerning displacements and efforts shows that the applications points of these elements evolve according to similar ellipses located in quasi identical planes. The large and the small axes of these ellipses are increasing with the feed rate motion values accordingly to the mechanical power injected into the system. Conversely, the respective axes ratios of these ellipses are decreasing functions of the feed rate while the ratio of these ratios remains constant when the feed rate value is increasing. In addition, some chip characteristics are given, like the thickness variations, the width or the hardening phenomenon.

physics.class-ph↗

arXiv2009

Displacements analysis of self-excited vibrations in turning

The actual research deals with determining by a new protocol the necessary parameters considering a three-dimensional model to simulate in a realistic way the turning process on machine tool. This paper is dedicated to the experimental displacements analysis of the block tool / block workpiece with self-excited vibrations. In connexion with turning process, the self-excited vibrations domain is obtained starting from spectra of two accelerometers. The existence of a displacements plane attached to the tool edge point is revealed. This plane proves to be inclined compared to the machines tool axes. We establish that the tool tip point describes an ellipse. This ellipse is very small and can be considered as a small straight line segment for the stable cutting process (without vibrations). In unstable mode (with vibrations) the ellipse of displacements is really more visible. A difference in phase occurs between the tool tip displacements on the radial direction and on the cutting one. The feed motion direction and the cutting one are almost in phase. The values of the long and small ellipse axes (and their ratio) shows that these sizes are increasing with the feed rate value. The axis that goes through the stiffness center and the tool tip represents the maximum stiffness direction. The maximum (resp. minimum) stiffness axis of the tool is perpendicular to the large (resp. small) ellipse displacements axis. FFT analysis of the accelerometers signals allows to reach several important parameters and establish coherent correlations between tool tip displacements and the static - elastic characteristics of the machine tool components tested.

physics.class-ph↗