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Research Papers

Eddy Current-Based Vibration Suppression for Finish Machining of Assembly Interfaces of Large Aircraft Vertical Tail

[+] Author and Article Information
Wei Fan

School of Mechanical Engineering and Automation,
Beihang University,
Beijing 100191, China
e-mail: fanweiok@buaa.edu.cn

Lianyu Zheng

School of Mechanical Engineering and Automation,
Beihang University,
Beijing 100191, China
e-mail: lyzheng@buaa.edu.cn

Wei Ji

AB Sandvik Coromant,
Stockholm 12679, Sweden;
Department of Production Engineering,
KTH Royal Institute of Technology,
Stockholm 10044, Sweden
e-mail: weiji@kth.se

Xiong Zhao

School of Mechanical Engineering and Automation,
Beihang University,
Beijing 100191, China
e-mail: zhaoxiong@buaa.edu.cn

Lihui Wang

Department of Production Engineering,
KTH Royal Institute of Technology,
Stockholm 10044, Sweden
e-mail: lihuiw@kth.se

Yiqing Yang

School of Mechanical Engineering and Automation,
Beihang University,
Beijing 100191, China
e-mail: yyiqing@buaa.edu.cn

1Corresponding author.

2The author was at KTH Royal Institute of Technology when the research was done. However, the author had been working at AB Sandvik Coromant when the manuscript was submitted.

Manuscript received March 7, 2019; final manuscript received May 5, 2019; published online May 28, 2019. Assoc. Editor: Tony Schmitz.

J. Manuf. Sci. Eng 141(7), 071012 (May 28, 2019) (16 pages) Paper No: MANU-19-1130; doi: 10.1115/1.4043733 History: Received March 07, 2019; Accepted May 05, 2019

Assembly interface of aircraft vertical tail is a large thin-wall structure and made from titanium alloys, which causes easily machining vibration, deformation and undercutting in finish machining due to its low stiffness, low thermal conductivity, and high chemical activity. To address these problems, a novel eddy current damper for assembly interfaces machining (ECD-AIM) is proposed to suppress multimodal vibration in the machining of the assembly interfaces. Within the context, the mathematical model of damping performance of the damper is established based on the principle of electromagnetic induction, based on which a novel design of the damper is proposed, and optimized by considering the relationship between damping performance and the key components of the damper. Then, the dynamics model of the suppression system of the assembly interface machining is established, where the relationship between vibration velocity and damping performance of the damper is obtained by using numerical analysis and finite element simulation. Finally, the damping performance of the damper is validated in terms of the three configurations (no applied ECD-AIM, a single ECD-AIM, and dual ECD-AIMs) via a set of dynamic tests (impact tests and harmonic tests) and cutting tests. The test results demonstrate that the configuration of dual ECD-AIMs can guarantee stability and reliability of assembly interface machining. The proposed damper can provide a feasible solution for vibration suppression in a limited workspace.

Copyright © 2019 by ASME
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Figures

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Fig. 1

Finish machining system and traditional finishing schematic diagram of assembly interface: (1–3) NC positioner 1, 2, 3; (4) assistant NC support; (5) positioning plate; (6) clamping plate; and (7) auxiliary electric clamping unit

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Fig. 2

ECD-AIM and its working principle: (1) assembly interface; (2) end milling cutter; (3) executive end; (4) shield cover; (5) heat dissipating hole; (6) air gap; (7) permanent magnet; (8) magnetic shoe; (9) front baffle; (10) rear baffle; (11) moving rod; (12) conductive plate 1; (13) spiral spring; (14) auxiliary support unit; (15) conductive tube; (16) conductive plate 2; and (17) fixture base

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Fig. 3

Magnetic flux density B of the point Q in the main magnetic field

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Fig. 4

Working principle of ECD-AIM

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Fig. 5

Influence of thickness of magnetic pole on damping performance: (a) influence of l1 on fe; (b) influence of l1 on ce; (c) influence of l on fe; and (d) influence of l on ce

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Fig. 6

Influence of thickness of conductor on damping performance: (a) influence of δ1 on fe; (b) influence of δ1 on ce; (c) influence of δ2 on ce; and (d) influence of R1 on ce

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Fig. 7

Influence of number of magnetic pole on damping performance: (a) fe as function of the number nm of the magnetic pole and (b) ce as function of the number nm

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Fig. 8

Dual damper setup for assembly interface machining: (a) vibration suppression system of the assembly interface and (b) dynamics model of the vibration suppression system

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Fig. 9

Influence of vy on damping performance: (a) influence of vy on fe and (b) influence of vy on ce

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Fig. 10

Experimental setup

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Fig. 11

Schematic diagram of the impact test

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Fig. 12

Measured FRF of assembly interface

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Fig. 13

Dynamic vibration characteristics of the assembly interface under different damper configurations

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Fig. 14

Schematic diagram of the harmonic test for assembly interface

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Fig. 15

Influence of amplitude A and frequency f on effective values of vibration signals: (a) A = 0.2 mm; (b) A = 0.5 mm; and (c) A = 1.5 mm

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Fig. 16

Time domain dynamic response signals of the assembly interface under excitation signal of A = 0.2 mm and f = 50 Hz

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Fig. 17

Vibration signals in the time and frequency domains under the three configurations: (a) no applied ECD-AIM; (b) a single ECD-AIM; and (c) dual ECD-AIMs

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Fig. 18

Wall thickness measurement of selected points on machined interface of the assembly interface

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Fig. 19

Vibration signals in the time and frequency domains with cutting depth: (a) ap = 1.0 mm; (b) ap = 2.0 mm; and (c) ap = 2.5 mm

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Fig. 20

Wall thickness measurement of selected points on machined interface at cutting depth ap = 1.0, 2.0, and 2.5 mm

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Fig. 21

Vibrations of the assembly interface in time and frequency domains with spindle speed: (a) n = 350 rpm; (b) n = 500 rpm; and (c) n = 550 rpm

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Fig. 22

Wall thickness measurement of selected points on machining interfere at spindle speed n = 350 rpm, 500 rpm, and 550 rpm

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