Machining complex thin-wall components (such as compressor disks and casings in aircraft engines) has been a challenging task because workpiece deformations and vibrations not only compromise the surface integrity but also induce residual stresses in the final products. Based on the annular plate model in Chap. 3, this chapter presents a physics-based method that accounts for the damping effects and external loads for reconstructing the dynamic displacement and strain fields of a thin-wall workpiece in real-time with non-contact displacement measurements during machining. In order to establish criteria for designing non-contact sensors to monitor workpiece vibration, this chapter also presents plate dynamic analysis along with experimentally identified damping ratios for an annular workpiece under constraints emulating those of a duplex turning machine. Given that plate dynamic behaviors can be characterized by superposition of mode shapes, the time-varying displacement and strain fields are reconstructed with modal coefficients that are updated in real time using in situ measurements.
- 2.M. Yu, J. Guo, K.M. Lee, Strain field sensing and reconstruction for a thin-wall plate, in Proceedings of the IEEE International Conference on Advanced Intelligent Mechatronics (AIM), Banff, Alberta, Canada, pp. 788–793 (2016)Google Scholar
- 3.J. Guo, R. Liu, K.-M. Lee, Dynamic modeling and analysis for thin-wall plate machining, in Proceedings of the ASME Dynamic Systems and Control Conference, Columbus, Ohio, USA, vol. 3 (2015)Google Scholar