Abstract: The paper describes the availability analysis of milling system of a rice milling plant using probabilistic approach. The subsystems under study are special purpose machines. The availability analysis of the system is carried out to determine the effect of failure and repair rates of each subsystem on overall performance (i.e. steady state availability) of system concerned. Further, on the basis of effect of repair rates on the system availability, maintenance repair priorities have been suggested. The problem is formulated using Markov Birth-Death process taking exponential distribution for probable failures and repair rates. The first order differential equations associated with transition diagram are developed by using mnemonic rule. These equations are solved using normalizing conditions and recursive method to drive out the steady state availability expression of the system. The findings of the paper are presented and discussed with the plant personnel to adopt a suitable maintenance policy to increase the productivity of the rice milling plant.
Abstract: Chatter vibration has been a troublesome problem
for a machine tool toward the high precision and high speed machining.
Essentially, the machining performance is determined by the dynamic
characteristics of the machine tool structure and dynamics of cutting
process, which can further be identified in terms of the stability lobe
diagram. Therefore, realization on the machine tool dynamic behavior
can help to enhance the cutting stability. To assess the dynamic
characteristics and machining stability of a vertical milling system
under the influence of a linear guide, this study developed a finite
element model integrated the modeling of linear components with the
implementation of contact stiffness at the rolling interface. Both the
finite element simulations and experimental measurements reveal that
the linear guide with different preload greatly affects the vibration
behavior and milling stability of the vertical column spindle head
system, which also clearly indicate that the predictions of the
machining stability agree well with the cutting tests. It is believed that
the proposed model can be successfully applied to evaluate the
dynamics performance of machine tool systems of various
configurations.
Abstract: The machining performance is determined by the
frequency characteristics of the machine-tool structure and the
dynamics of the cutting process. Therefore, the prediction of dynamic
vibration behavior of spindle tool system is of great importance for the
design of a machine tool capable of high-precision and high-speed
machining. The aim of this study is to develop a finite element model
to predict the dynamic characteristics of milling machine tool and
hence evaluate the influence of the preload of the spindle bearings. To
this purpose, a three dimensional spindle bearing model of a high
speed engraving spindle tool was created. In this model, the rolling
interfaces with contact stiffness defined by Harris model were used to
simulate the spindle bearing components. Then a full finite element
model of a vertical milling machine was established by coupling the
spindle tool unit with the machine frame structure. Using this model,
the vibration mode that had a dominant influence on the dynamic
stiffness was determined. The results of the finite element simulations
reveal that spindle bearing with different preloads greatly affect the
dynamic behavior of the spindle tool unit and hence the dynamic
responses of the vertical column milling system. These results were
validated by performing vibration on the individual spindle tool unit
and the milling machine prototype, respectively. We conclude that
preload of the spindle bearings is an important component affecting
the dynamic characteristics and machining performance of the entire
vertical column structure of the milling machine.
Abstract: Chatter vibration has been a troublesome problem for a
machine tool toward the high precision and high speed machining.
Essentially, the machining performance is determined by the dynamic
characteristics of the machine tool structure and dynamics of cutting
process. Therefore the dynamic vibration behavior of spindle tool
system greatly determines the performance of machine tool. The
purpose of this study is to investigate the influences of the machine
frame structure on the dynamic frequency of spindle tool unit through
finite element modeling approach. To this end, a realistic finite
element model of the vertical milling system was created by
incorporated the spindle-bearing model into the spindle head stock of
the machine frame. Using this model, the dynamic characteristics of
the milling machines with different structural designs of spindle head
stock and identical spindle tool unit were demonstrated. The results of
the finite element modeling reveal that the spindle tool unit behaves
more compliant when the excited frequency approaches the natural
mode of the spindle tool; while the spindle tool show a higher dynamic
stiffness at lower frequency that may be initiated by the structural
mode of milling head. Under this condition, it is concluded that the
structural configuration of spindle head stock associated with the
vertical column of milling machine plays an important role in
determining the machining dynamics of the spindle unit.