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Research Papers

High-Precision Cutting Tool Tracking With a Magnetic Bearing Spindle

[+] Author and Article Information
Alexander Smirnov

LUT Energy,
Lappeenranta University of Technology,
P.O. Box 20,
Lappeenranta 53851, Finland
e-mail: alexander.smirnov@lut.fi

Alexander H. Pesch

Mem. ASME
Center for Rotating Machinery
Dynamics and Control,
Cleveland State University,
Cleveland, OH 44115-2214
e-mail: a.pesch@csuohio.edu

Olli Pyrhönen

LUT Energy,
Lappeenranta University of Technology,
P.O. Box 20,
Lappeenranta 53851, Finland
e-mail: olli.pyrhonen@lut.fi

Jerzy T. Sawicki

Fellow ASME
Center for Rotating Machinery
Dynamics and Control,
Cleveland State University,
Cleveland, OH 44115-2214
e-mail: j.sawicki@csuohio.edu

1Corresponding author.

Contributed by the Dynamic Systems Division of ASME for publication in the JOURNAL OF DYNAMIC SYSTEMS, MEASUREMENT, AND CONTROL. Manuscript received November 12, 2013; final manuscript received November 11, 2014; published online January 27, 2015. Assoc. Editor: Yang Shi.

J. Dyn. Sys., Meas., Control 137(5), 051017 (May 01, 2015) (8 pages) Paper No: DS-13-1443; doi: 10.1115/1.4029194 History: Received November 12, 2013; Revised November 11, 2014; Online January 27, 2015

A method is presented for tool tracking in active magnetic bearing (AMB) spindle applications. The method uses control of the AMB air gap to achieve the desired tool position. The reference tracking problem is transformed from the tool coordinates into the AMB control axes by bearing deflection optimization. Therefore, tool tracking can be achieved by an off-the-shelf AMB controller. The method is demonstrated on a high-speed AMB boring spindle with a proportional integral derivative (PID) control. The hypothetical part geometries are traced in the range of 30 μm. Static external loading is applied to the tool to confirm disturbance rejection. Finally, a numerical simulation is performed to verify the ability to control the tool during high-speed machining.

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Figures

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Fig. 5

Rigid rotor coordinate system

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Fig. 4

Structure of the proposed control system for tool tracking

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Fig. 6

Singular value plot of the closed-loop output sensitivity function

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Fig. 7

Step profile for the PID controller at zero speed

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Fig. 8

Tapered profile for the PID controller at zero speed

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Fig. 9

Convex profile for the PID controller at zero speed

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Fig. 10

Step profile for the PID controller at 4500 rpm speed

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Fig. 3

Open-loop AMB rotor system model and experimental identification

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Fig. 2

Open-loop AMB rotor system block structure

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Fig. 13

Numerical simulation results for tool tip tracking at: (a) 4500 rpm with no machining, (b) 4500 rpm with machining, and (c) 50,000 rpm with machining

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Fig. 1

AMB Spindle photograph (top) and FE diagram of the rotor showing workpiece location (bottom)

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Fig. 11

Tapered profile for the PID controller at 4500 rpm speed

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Fig. 12

Convex profile for the PID controller at 4500 rpm speed

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