AIMS & OBJECTIVES

To be able to undertake an analysis of a high precision process with the aim of

providing a method for optimal control

To understand the relationship between the components of the different types

system and provide a working solution

TRANSFERABLE SKILLS

Use mathematical simulation software for the solution of control and

instrumentation problems

Obtain mathematical formulation from engineering functional descriptions

MODULE LEARNING OBJECTIVES

This assignment should assist the student in addressing the following learning objectives:
Critically appraise the role of sensors and instrumentation and adaptive / intelligent systems for
process monitoring and control in precision manufacture.
Delineate and explain in clear and concise statements the key features that distinguish high
precision manufacturing from conventional manufacturing.

RECOMMENDED TEXTS
Slocum, A. H. (2004) 'Precision Machine Design' Prentice Hall
Evans, C. (1989) 'Precision Engineering: an Evolutionary View' Cranfield Press
Donfeld, D. and Lee, D. E (2006) 'Precision Manufacturing' Springer
CIRP (1995) 'Keynote Papers :1995 to date'

Introduction
A workpiece turning between centres during a high precision grinding
operation is shown in Figure 1. To a human observer this arrangement may
appear to be rigid, but when an infeed force is applied to the grinding
wheel an oscillatory force may exist. This is due to the cutting shear forces
and the elastic displacement of the materials of machine and workpiece.

Infeed
Force

f(t)
Tailstock
Centre

Workhead
Centre
Mass of Workpiece M = 2.5 kg

Oscillatory
Force

Figure 1 Representation of the High Precision Grinding Operation

The process dynamic stability of the grinding operation can be modelled as

a mass, spring, damper system. The following formula equates inertial,
viscous and spring forces in the system to the infeed force:
M (d2x/dt2) + B (dx/dt) +Ke (x) = f(t)

Equation 1

Where:
M is Mass of the workpiece = 2.5 kg
B is the system damping constant (N/m s-1)
Ke is the effective stiffness constant (N/m)
f(t) is the infeed force that can vary with time (N)
Equation 1 can be written in a standard second order form, by dividing
through by Ke:
1/n2 (d2x/dt2) + 2/n (dx/dt) + x = 1/K f(t)
Where:
n is the natural frequency of the system (rad.s-1)
is the damping ratio

Equation 2

K is the system gain

Answer the following questions
1) Calculate the effective stiffness Ke of the system using the following data
from measurements made during a static stiffness test. Show your working:
Wheelhead Stiffness = 167 N/m
Workhead Stiffness = 60 N/m
Tailstock Stiffness = 40 N/m
Workpiece Deflection is 4 m when subject to a force of 1000 N
Contact Stiffness = 33 N/ m
[5 Marks]
2) Calculate the natural frequency n of the system, using your calculated
stiffness constant Ke and when the damping ratio is 0.5. Show your
working.
[5 Marks]
3) Calculate the system damping constant B. Show your working.
[5 Marks]
4) (i) Use the values from your answers to model the system using (MatLab)
Simulink. Label the components of the system
[10 Marks]
(ii) Show the system response to a step-input (infeed).
Describe your result in terms of desired machine performance.
Describe why the original system response is not acceptable
[25 Marks]
(iii) How would you improve the system response?
Show the output(s) from a simulation of your modified system.
Describe in detail the methods you would use to achieve this system

response.
[30 Marks]
(iv) Simulate machine tool chatter using your model.
In terms of your model, explain the likely causes of this chatter
[20 Marks]