Jaroslaw Rolek

The article presents an analytical and experimental method for determining the dynamic coefficients of cutting tools, with particular emphasis on turning tools. The method involves aligning the acceleration profile obtained from empirical investigations with a mathematical model describing the oscillations of the cutting tool tip. The stiffness (k) and damping (c) coefficients determined using this approach enable the design of tools with desired dynamic characteristics, tailored to specific machining processes, such as machining with long overhangs. From the perspective of mechanical dynamics, selecting appropriate stiffness and damping values allows for the design of tools with optimal dynamic properties. High stiffness reduces the occurrence of deformations under external forces, while adequate damping facilitates the rapid attenuation of vibrations, thereby minimising their adverse effects on the machining process. The developed method could serve as a practical tool for identifying the dynamic parameters applicable to a wide variety of cutting tools. The analysis includes three types of turning tools: one with a steel shank, another with a carbide-core steel shank, and a third with a carbon fibre-core steel shank. The results of the tests indicate that the E-A20Q SDUCL 11 tool is best suited for operations requiring high stability and minimal vibration, owing to its favourable damping and stiffness properties.

Three-phase diode bridge rectifiers are widely employed in various industrial applications because of their inherent simplicity, robustness, low electromagnetic interference and good overall performance. However, their use causes harmonic distortion in the electric power network line currents due to their nonlinear nature, which, in turn, affects the electric power quality. The fundamental approach to limit the line currents’ total harmonic distortion (THD) introduced by the diode bridge rectification systems is based on increasing the number of steps in their waveform per power supply cycle and drawing them closer to the pure-sine waveforms. This can be achieved by employing the conventional twelve-pulse rectification system composed of two parallel connected six-pulse diode bridge rectifiers, in which the DC circuit is expanded on the auxiliary circuit responsible for adequately shaping the line currents’ waveforms per power supply cycle. When the auxiliary circuit is connected to the interphase reactor (IPR) additional (secondary) winding, the ability of the rectification system to reduce the line current THD depends mainly on the auxiliary circuit current waveform and its parameters. This paper provides a space vector analysis of the twelve-pulse diode bridge rectifier operation. It leads to devising a formula for the auxiliary circuit current related to the phase angle of the rectification system line currents’ space vector and the load current, which has been missing in the literature so far. The formula explicitly defines the auxiliary circuit current waveform that guarantees the optimal line currents’ THD for the twelve-pulse diode bridge rectifier which is expanded with the auxiliary circuit connected to the IPR secondary winding. The theoretical studies are validated through experimental investigations.

This article looked at how insert mounting errors affect the cutting tool performance in the face milling of 1.0503 steel. This study was conducted for 490-050Q22-08M inserts mounted in a Sandvik Coromant 490-050Q22-08M CoroMill cutter attached to an AVIA VMC 800 vertical milling center. A 3D geometrical model of the cutter was developed to determine the engagement of the particular inserts in the material removal process at different feeds per tooth. The test results showed that, at feeds ranging from 0.02 mm/tooth to 0.06 mm/tooth, only three out of five inserts took part in the face milling process, while at feeds higher than 0.12 mm/tooth, all the inserts mounted in the cutter body were engaged. The relative displacements in the tool-workpiece system were measured along the axis of rotation of the tool using a Renishaw XL-80 laser interferometer. The vibration signals recorded during cutting confirmed that there was a clear relationship between the number of inserts engaged in the process and the root mean square, the arithmetic mean, and the DC component. Multiple 2D scans of the face milled surface to measure parameters Ra and Rt helped determine the feed range where the cutting process was stable. The conducted studies allowed for the identification of optimal operating ranges for a tool with parameterized errors in the mounting of inserts within the tool body. The influence of these mounting errors, in correlation with the feed per tooth, on the surface roughness of 1.0503 steel was presented and compared with five other materials.

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Drilling with standard twist drill bits is the most common method to create cylindrical holes. With the constant development of additive manufacturing technologies and easier access to additive manufacturing equipment, it is now possible to design and fabricate solid tools suitable for various machining applications. Specially designed 3D printed drill bits seem more convenient for standard and nonstandard drilling operations than conventionally made tools. The study described in this article aimed to analyze the performance of a solid twist drill bit made from steel 1.2709 using direct metal laser melting (DMLM), which was compared with that of a drill bit manufactured conventionally. The experiments involved assessing the dimensional and geometric accuracy of the holes made by the two types of drill bits and comparing the forces and torques occurring during the drilling of holes in cast polyamide 6 (PA6).

Speed feedback is indispensable not only for closed-loop controlled induction motors (IM) but also for the state monitoring systems of open-loop controlled IMs. Replacing speed sensors with speed estimations has many advantages including, e.g., hardware complexity reduction, sensor cabling elimination, and reduction of IM drive costs. From the various methods for IM speed estimation proposed in the literature, the model reference adaptive system (MRAS)-based speed estimator stands out because of its straightforward synthesis technique and lower computational complexity. On the other hand, this estimator is inherently sensitive to mismatching of IM equivalent circuit parameters. During transients, when the slip frequency cannot be temporarily controlled over the assumed operating point, rotor impedance varies with the slip frequency changes. This phenomenon is even more significant for open-loop controlled high-slip IMs (NEMA design D IMs), which operate under the cycling load like in, e.g., oil well pumps. The rate and the range of rotor impedance variability are related to the rate and the range of the slip frequency changes. Therefore, a speed estimator capable of modelling the slip frequency dependent variability of the rotor impedance may be required, particularly for the state monitoring systems of open-loop controlled IMs. This paper presents an MRAS-based speed estimator developed on the IM space vector model with the rotor impedance variability modelled by the parallel connected branches of the series rotor equivalent resistance and leakage inductance. The experimental test results confirm the precise speed estimation of the tested IMs achieved by the devised MRAS-based speed estimator in the considered slip frequency range and indicate its potential industrial application.

The various measurement procedures for determination of electromagnetic parameters for the induction motor (IM) equivalent circuits including the rotor deep-bar effect were proposed in the literature. One of them is the procedure based on the load curve test (LCT). Since the execution of the LCT can pose some difficulties, especially in industrial conditions, as an alternative, the finite element method (FEM) can be employed to simulate the IM operation under the LCT. In this work we developed the optimisation technique for the finite element (FE) model. This technique is performed with the use of the stator current space-vector components which determine the IM input active and reactive power consumption during no-load operation. Relying on the LCT simulation carried out with the optimised FE model the inductance frequency characteristic can be determined and then used as the reference characteristic in the electromagnetic parameter estimation for the IM equivalent circuit including the rotor deep-bar effect. The presented research results demonstrate proper conformity between the inductance frequency characteristics obtained from the LCT performed experimentally and determined by means of the optimised FE model. Satisfactory conformity is also achieved in the case of the torque-versus-slip frequency curves acquired from the measurement and calculated by the IM space-vector model with estimated electromagnetic parameters. All of this validates the effectiveness of the proposed technique for the FE-model optimisation and the usefulness of the presented approach using the FEM in the electromagnetic parameter estimation for the IM equivalent circuit including the rotor deep-bar effect.

Accurate information on Induction Motor (IM) speed is essential for robust operation of vector controlled IM drives. Simultaneous estimation of speed provides redundancy in motor drives and enables their operation in case of a speed sensor failure. Furthermore, speed estimation can replace its direct measurement for low-cost IM drives or drives operated in difficult environmental conditions. During torque transients when slip frequency is not controlled within the set range of values, the rotor electromagnetic time constant varies due to the rotor deep-bar effect. The model-based schemes for IM speed estimation are inherently more or less sensitive to variability of IM electromagnetic parameters. This paper presents the study on robustness improvement of the Model Reference Adaptive System (MRAS) based speed estimator to variability of IM electromagnetic parameters resulting from the rotor deep-bar effect. The proposed modification of the MRAS-based speed estimator builds on the use of the rotor flux voltage-current model as the adjustable model. The verification of the analyzed configurations of the MRAS-based speed estimator was performed in the slip frequency range corresponding to the IM load adjustment range up to 1.30 of the stator rated current. This was done for a rigorous and reliable assessment of estimators’ robustness to rotor electromagnetic parameter variability resulting from the rotor deep-bar effect. The theoretical reasoning is supported by the results of experimental tests which confirm the improved operation accuracy and reliability of the proposed speed estimator configuration under the considered working conditions in comparison to the classical MRAS-based speed estimator.

During torque transients, rotor electromagnetic parameters of an induction motor (IM) vary due to the rotor deep-bar effect. The accurate representation of rotor electromagnetic parameter variability by an adopted IM mathematical model is crucial for a precise estimation of the rotor flux space vector. An imprecise estimation of the rotor flux phase angle leads to incorrect decoupling of electromagnetic torque control and rotor flux amplitude regulation which in turn, causes deterioration in field-oriented control of IM drives. Variability of rotor electromagnetic parameters resulting from the rotor deep-bar effect can be modeled by the IM mathematical model with rotor multi-loop representation. This paper presents a study leading to define the unique rotor flux space vector on the basis of the IM mathematical model with rotor two-terminal network representation. The novel rotor flux estimation scheme was validated with the laboratory test bench employing the IM of type Sg 132S-4 with two variants of rotor construction: a squirrel-cage rotor and a solid rotor manufactured from magnetic material S235JR. The accuracy verification of the rotor flux estimation was performed in a slip frequency range corresponding to the IM load adjustment range up to 1.30 of the stator rated current. This study proved the correct operation of the developed rotor flux estimation scheme and its robustness against electromagnetic parameter variability resulting from the rotor deep-bar effect in the considered slip frequency range.