0
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.

FIGURES IN THIS ARTICLE
<>
Copyright © 2015 by ASME
Your Session has timed out. Please sign back in to continue.

References

Erdel, B., 2003, High-Speed Machining, Society of Manufacturing Engineers, Dearborn, MI.
King, R., 1985, Handbook of High-Speed Machining Technology, Chapman and Hall, New York. [CrossRef]
Knospe, C., 2007, “Active Magnetic Bearings for Machining Applications,” Control Eng. Pract., 15(3), pp. 307–313. [CrossRef]
Zivi, E., Anand, D., Kirk, J., and Anjanappa, M., 1990, “Magnetic Bearing Spindle Control for Accuracy Enhancement in Machining,” ASME Winter Annual Meeting, Dallas, TX, pp. 283–297.
Auchet, S., Chevrier, P., Lacour, M., and Lipinski, P., 2004, “A New Method of Cutting Force Measurement Based on Command Voltage of Active Electro-Magnetic Bearings,” Int. J. Mach. Tools Manuf., 44(14), pp. 1441–1449. [CrossRef]
Chen, M., and Knospe, C., 2007, “Control Approaches to the Suppression of Machining Chatter Using Active Magnetic Bearings,” IEEE Trans. Control Syst. Technol., 15(2), pp. 220–232. [CrossRef]
Pesch, A., and Sawicki, J., 2012, “Application of Robust Control to Chatter Attenuation for a High-Speed Machining Spindle on Active Magnetic Bearings,” Proceedings of the 13th International Symposium on Magnetic Bearings (ISMB13), Washington, DC, pp. 1–11.
Sato, K., and Maeda, G., 2009, “A Practical Control Method for Precision Motion—Improvement of NCTF Control Method for Continuous Motion Control,” Precis. Eng., 33(2), pp. 175–186. [CrossRef]
Rasmussen, J., Tsao, T., Hanson, R., and Kapoor, S., 1994, “Dynamic Variable Depth of Cut Machining Using Piezoelectric Actuators,” Int. J. Mach. Tools Manuf., 34(3), pp. 379–392. [CrossRef]
Woronko, A., Huang, J., and Altintas, Y., 2003, “Piezoelectric Tool Actuator for Precision Machining on Conventional CNC Turning Centers,” Precis. Eng., 27(4), pp. 335–345. [CrossRef]
Tian, Y., Shirinzadeh, B., and Zhang, D., 2009, “A Flexure-Based Mechanism and Control Methodology for Ultra-Precision Turning Operation,” Precis. Eng., 33(2), pp. 160–166. [CrossRef]
Sawicki, J., Maslen, E., and Bischof, K., 2007, “Modeling and Performance Evaluation of Machining Spindle With Active Magnetic Bearings,” J. Mech. Sci. Technol., 21(6), pp. 847–850. [CrossRef]
Wroblewski, A., Sawicki, J., and Pesch, A., 2012, “Rotor Model Updating and Validation for an Active Magnetic Bearing Based High-Speed Machining Spindle,” ASME J. Eng. Gas Turbines Power, 134(12), p. 122509. [CrossRef]
Fittro, R., Knospe, C., and Stephens, L., 2003, “Mu Synthesis Applied to the Compliance Minimization of an Active Magnetic Bearing HSM Spindle's Thrust Axis,” Mach. Sci. Technol., 7(1), pp. 19–51. [CrossRef]
Schweitzer, G., and Maslen, E., 2009, Magnetic Bearings, Springer, Berlin, Heidelberg, Germany.
Altintas, Y., 2000, Manufacturing Automation: Metal Cutting Mechanics, Machine Tool Vibrations, and CNC Design, Cambridge University Press, Cambridge, UK.

Figures

Grahic Jump Location
Fig. 1

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

Grahic Jump Location
Fig. 2

Open-loop AMB rotor system block structure

Grahic Jump Location
Fig. 3

Open-loop AMB rotor system model and experimental identification

Grahic Jump Location
Fig. 4

Structure of the proposed control system for tool tracking

Grahic Jump Location
Fig. 5

Rigid rotor coordinate system

Grahic Jump Location
Fig. 6

Singular value plot of the closed-loop output sensitivity function

Grahic Jump Location
Fig. 7

Step profile for the PID controller at zero speed

Grahic Jump Location
Fig. 8

Tapered profile for the PID controller at zero speed

Grahic Jump Location
Fig. 9

Convex profile for the PID controller at zero speed

Grahic Jump Location
Fig. 10

Step profile for the PID controller at 4500 rpm speed

Grahic Jump Location
Fig. 11

Tapered profile for the PID controller at 4500 rpm speed

Grahic Jump Location
Fig. 12

Convex profile for the PID controller at 4500 rpm speed

Grahic Jump Location
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

Tables

Errata

Discussions

Some tools below are only available to our subscribers or users with an online account.

Related Content

Customize your page view by dragging and repositioning the boxes below.

Related Journal Articles
Related eBook Content
Topic Collections

Sorry! You do not have access to this content. For assistance or to subscribe, please contact us:

  • TELEPHONE: 1-800-843-2763 (Toll-free in the USA)
  • EMAIL: asmedigitalcollection@asme.org
Sign In