Research on Modeling and Simulation of cutting cha

Research on Modeling and Simulation of cutting chatter control based on ERF

Abstract: in view of the difficulties of ER damper in suppressing cutting chatter, an ER damper with mixed flow and shear mode is designed. This paper introduces the working principle and performance characteristics of ER fluid and ER damper; Based on Bingham's plastic theory, the mechanical model of ER damper with mixed flow and shear mode is established. The experimental and simulation results show that the ER damper can realize the real-time control of vibration and effectively suppress the occurrence of cutting chatter

key words: Modeling and Simulation of ER damper cutting chatter real-time control

abstract: facing the difficulty that ER fluid damper contains the cutting chatter, we designed a damper based on flow and shear mixed model to control the cutting chatter This paper introduces the principle and ER fluid damper; based on Bingham plastic theory, founds the mechanical model of ER fluid damper of flow and shear mixed model. The result of experiment and simulation shows this ER fluid damper can well control the vibration and the cutting chatter.

key words: ER damper, cutting chatter, real time control, found model and simulation

1 Introduction

in the field of vibration control, there are four commonly used intelligent materials: electrorheological (magnetorheological) fluids, shape memory alloys, piezoelectric materials and electro (magnetic) stretch and shrink materials. The force produced by piezoelectric materials and electro (magnetostrictive) materials is often not large enough, while shape memory materials have the problem of lagging response and need power heating, and the response speed is slow. In contrast, electrorheological (magnetorheological) fluids are widely used

electrorheological (magnetorheological) fluid refers to the fluid whose viscosity and other rheological properties will change with the change of electric field (magnetic field) intensity under the action of electric field (magnetic field). 10. Cooling mode selection test box. If there is a refrigeration system body, a technician cuts carbon fiber or glass fiber fabric composites into a series of irregular shapes and wraps them on the concrete beams and columns. Once the electric field or (magnetic field) is removed, The material returns to its original state, and the response time is only milliseconds. This excellent electromechanical coupling performance makes electrorheological (magnetorheological) fluid an ideal controllable damping medium. The controllable damping medium has the outstanding advantages of stepless and reversible adjustment of damping, fast response speed and low energy consumption. Therefore, electrorheological (magnetorheological) fluids in vibration control

2 electrorheological fluids

electrorheological fluids, also known as electrorheological fluids, or ER fluids for short, is a relatively special fluid. Under the action of an applied electric field, its rheological properties change from a fluid with low viscosity that is easy to flow to a plastic solid with high viscosity that is difficult to flow. When the applied electric field is removed, it can return to liquid in an instant. This performance change of ER fluid can be completed in only milliseconds, which is the most utilized advantage of ER fluid

2.1 basic concept

electrorheology [4,5] (electricity) is a discipline that studies the viscosity, modulus and yield capacity of a certain dispersion system under the action of electric field, which are related to the rheological performance parameters of objects. It is an important branch of rheology. The influence of electric field on the structure and rheological properties of dispersion system is called electrorheological effect. The dispersion system with electrorheological effect is called electrorheological fluid, or er body for short. According to the current research situation of Er body, the specific Er body refers to the suspension formed by adding fine solid particles into the insulating continuous phase liquid medium. Under the action of a certain electric field, the liquid will obviously show solid like characteristics different from the original liquid. When the electric field is removed, the liquid will return to its original performance. This change is continuous, rapid, reversible and controllable

the characteristics of electrorheological fluid have great research value in both scientific research and technical application. However, at present, the main factor restricting the development and application of ER technology is that the performance of ER materials still cannot meet the requirements of large-scale industrial applications. Manufacturing high-performance ER materials is the key to breaking this bottleneck [6,7]

2.2 performance characteristics

2.2.1 rheological properties

ER fluid. Therefore, there is no throttling loss and overflow loss. The rheological properties directly affect the possibility of practical application of ER fluid. At present, people have carried out in-depth research on the change of rheological properties of ERF after yield in the steady shear field, but there is little research on the rheological behavior in the unsteady shear field before yield. There are two main indicators for the rheological properties of ERF: one is the non field viscosity, and the other is the dynamic and static yield stress

2.2.2 current density

current density is an important index to evaluate the performance of electrorheological fluid. If the current density is too high, it will cause the rheological fluid of Shanghai Jung Exhibition Co., Ltd. to overheat, and the temperature has a great impact on the performance of electrorheological fluid. If the temperature is too high, it will cause the electrorheological fluid to be unstable, make its efficiency low, and in serious cases, breakdown may occur. Therefore, the requirements for high-voltage power supply are very high, and the most ideal current density should be in

2.2.3 response time

the response time of electrorheological fluid is generally milliseconds, which is an important feature that electrorheological fluid is superior to other intelligent materials. The response time of erf/a electrorheological fluid of American Lord company is only about 8ms [8]

2.2.4 stability

the stability of electrorheological fluid mainly refers to the fact that electrorheological fluid does not have stratification under long-term storage, which is a key characteristic related to whether it can be applied to industrial processes. At present, the stability of ER fluid configured by various research units is not very ideal. The stability time of the electrorheological fluid developed by the Institute of physics of the Chinese Academy of Sciences is about several months. The stability time of the electrorheological fluid used in this research experiment is only a few hours

3 ER damper

3.1 working principle

ER damper can be divided into three types according to the flow pattern of its working fluid: shear mode, flow mode and extrusion mode. Figure 1, figure 2 and figure 3 are the working principle diagrams of three modes of dampers respectively

Figure 1 working principle diagram of shear mode damper Figure 2 working principle diagram of flow mode damper

Figure 3 working principle diagram of squeeze mode damper

now focus on the structure and performance characteristics of flow mode ER damper