Brian P. Mann

Reversible hysteresis for broadband magnetopiezoelastic energy harvesting

We model and experimentally validate a nonlinear energy harvester capable of bidirectional hysteresis. In particular, both hardening and softening response within the quadratic potential field of a power generating piezoelectric beam (with a permanent magnet end mass) is invoked by tuning nonlinear magnetic interactions. Not only is this technique shown to increase the bandwidth of the device but experimental results additionally verify the capability to outperform linear resonance. Engaging this nonlinear phenomenon is ideally suited to efficiently harvest energy from ambient excitations with slowly varying frequencies.

Stability of Interrupted Cutting by Temporal Finite Element Analysis

Chatter in milling and other interrupted cutting operations occurs at different combinations of speed and depth of cut from chatter in continuous cutting. Prediction of stability in interrupted cutting is complicated by two facts: (1) the equation of motion when cutting is not the same as the equation when the tool is free; (2) no exact analytical solution is known when the tool is in the cut. These problems are overcome by matching the free response with an approximate solution that is valid white the tool is cutting. An approximate solution, not restricted to small times in the cut, is obtained by the application of finite elements in time. The complete, combined solution is cast in the form of a discrete map that relates position and velocity at the beginning and end of each element to the corresponding values one period earlier. The eigenvalues of the linearized map are used to determine stability. This method can be used to predict stability for arbitrary times in the cut; the current method is applicable only to a single degree of freedom. Predictions of stability for a 1-degree of freedom case are confirmed by experiment.

Stability of up-milling and down-milling, part 1: alternative analytical methods

Abstract The dynamic stability of the milling process is investigated through a single degree of freedom mechanical model. Two alternative analytical methods are introduced, both based on finite dimensional discrete map representations of the governing time periodic delay-differential equation. Stability charts and chatter frequencies are determined for partial immersion up- and down-milling, and for full immersion milling operations. A special duality property of stability regions for up- and down-milling is shown and explained.

Multiple chatter frequencies in milling processes

Analytical and experimental identifications of the chatter frequencies in milling processes are presented. In the case of milling, there are several frequency sets arising from the vibration signals, as opposed to the single well-defined chatter frequency of the unstable turning process. Frequency diagrams are constructed analytically and attached to the stability charts of mechanical models of high-speed milling. The corresponding quasiperiodic solutions of the governing time-periodic delay-differential equations are also identified with some milling experiments in the case of highly intermittent cutting.

Stability of up-milling and down-milling, part 2: experimental verification

The stability of interrupted cutting in a single degree of freedom milling process was studied experimentally. An instrumented flexure was used to provide a flexible workpiece with a natural frequency comparable to the tooth pass frequency, mimicking high speed milling dynamics. The displacement of the system was sampled continuously and periodically once per cutter revolution. These data samples were used to asses the stability of the system. Results confirm the theoretical predictions obtained in Part 1.

Nonlinear piezoelectricity in electroelastic energy harvesters: Modeling and experimental identification

We propose and experimentally validate a first-principles based model for the nonlinear piezoelectric response of an electroelastic energy harvester. The analysis herein highlights the importance of modeling inherent piezoelectric nonlinearities that are not limited to higher order elastic effects but also include nonlinear coupling to a power harvesting circuit. Furthermore, a nonlinear damping mechanism is shown to accurately restrict the amplitude and bandwidth of the frequency response. The linear piezoelectric modeling framework widely accepted for theoretical investigations is demonstrated to be a weak presumption for near-resonant excitation amplitudes as low as 0.5 g in a prefabricated bimorph whose oscillation amplitudes remain geometrically linear for the full range of experimental tests performed (never exceeding 0.25% of the cantilever overhang length). Nonlinear coefficients are identified via a nonlinear least-squares optimization algorithm that utilizes an approximate analytic solution obta...

Simultaneous Stability and Surface Location Error Predictions in Milling

Optimizing the milling process requires a priori knowledge of many process variables. However the ability to include both milling stability and accuracy information is limited because current methods do not provide simultaneous milling stability and accuracy predictions. The method described within this paper, called Temporal Finite Element Analysis (TFEA), provides an approach for simultaneous prediction of milling stability and surface location error. This paper details the application of this approach to a multiple mode system in two orthogonal directions. The TFEA method forms an approximate analytical solution by dividing the time in the cut into a finite number of elements. The approximate solution is then matched with the exact solution for free vibration to obtain a discrete linear map. The formulated dynamic map is then used to determine stability, steady-state surface location error, and to reconstruct the time series for a stable cutting process. Solution convergence is evaluated by simply increasing the number of elements and through comparisons with numerical integration. Analytical predictions are compared to several different milling experiments. An interesting period two behavior, which was originally believed to be a flip bifurcation, was observed during experiment. However, evidence is presented to show this behavior can be attributed to runout in the cutter teeth.

Effects of Radial Immersion and Cutting Direction on Chatter Instability in End-Milling

Low radial immersion end-milling involves intermittent cutting. If the tool is flexible, its motion in both the x- and y-directions affects the chip load and cutting forces, leading to chatter instability under certain conditions. Interrupted cutting complicates stability analysis by imposing sharp periodic variations in the dynamic model. Stability predictions for the 2-DOF model differ significantly from prior 1-DOF models of interrupted cutting. In this paper stability boundaries of the 2-DOF milling process are determined by three techniques and compared: (1) a frequency-domain technique developed by Altintas and Budak (1995); (2) a method based on time finite element analysis; and (3) the statistical variance of periodic 1/tooth samples in a time-marching simulation. Each method has advantages in different situations. The frequency-domain technique is fastest, and is accurate except at very low radial immersions. The temporal FEA method is significantly more efficient than time-marching simulation, and provides accurate stability predictions at small radial immersions. The variance estimate is a robust and versatile measure of stability for experimental tests as well as simulation. Experimental up-milling and down-milling tests, in a simple model with varying cutting directions, agree well with theory.Copyright

Nonlinear nonconservative behavior and modeling of piezoelectric energy harvesters including proof mass effects

Nonlinear piezoelectric effects in flexural energy harvesters have recently been demonstrated for drive amplitudes well within the scope of anticipated vibration environments for power generation. In addition to strong softening effects, steady-state oscillations are highly damped as well. Nonlinear fluid damping was previously employed to successfully model drive dependent decreases in frequency response due to the high-velocity oscillations, but this article instead harmonizes with a body of literature concerning weakly excited piezoelectric actuators by modeling nonlinear damping with nonconservative piezoelectric constitutive relations. Thus, material damping is presumed dominant over losses due to fluid-structure interactions. Cantilevers consisted of lead zirconate titanate (PZT)-5A and PZT-5H are studied, and the addition of successively larger proof masses is shown to precipitate nonlinear resonances at much lower base excitation thresholds while increasing the influence of higher-order nonlinearities. Parameter identification results using a multiple scales perturbation solution suggest that empirical trends are primarily due to higher-order elastic and dissipation nonlinearities and that modeling linear electromechanical coupling is sufficient. This article concludes with the guidelines for which utilization of a nonlinear model is preferred.

Nonlinear Dynamics of High-Speed Milling—Analyses, Numerics, and Experiments

High-speed milling is often modeled as a kind of highly interrupted machining, when the ratio of time spent cutting to not cutting can be considered as a small parameter. In these cases, the classical regenerative vibration model, playing an essential role in machine tool vibrations, breaks down to a simplified discrete mathematical model. The linear analysis of this discrete model leads to the recognition of the doubling of the so-called instability lobes in the stability charts of the machining parameters. This kind of lobe-doubling is related to the appearance of period doubling vibrations originated in a flip bifurcation. This is a new phenomenon occurring primarily in low-immersion high-speed milling along with the Neimark-Sacker bifurcations related to the classical self-excited vibrations or Hopf bifurcations. The present work investigates the nonlinear vibrations in the case of period doubling and compares this to the well-known subcritical nature of the Hopf bifurcations in turning processes. The identification of the global attractor in the case of unstable cutting leads to contradiction between experiments and theory. This contradiction draws the attention to the limitations of the small parameter approach related to the highly interrupted cutting condition.