This paper investigates the design and analysis of a novel energy harvesting device that uses magnetic levitation to produce an oscillator with a tunable resonance. The governing equations for the mechanical and electrical domains are derived to show the designed system reduces to the form of a Duffing oscillator under both static and dynamic loads. Thus, nonlinear analyses are required to investigate the energy harvesting potential of this prototypical nonlinear system. Theoretical investigations are followed by a series of experimental tests that validate the response predictions.The motivating hypothesis for the current work was that nonlinear phenomenon could be exploited to improve the effectiveness of energy harvesting devices.

Regenerative chatter is a self-excited vibration that can occur during milling and other machining processes. It leads to a poor surface finish, premature tool wear, and potential damage to the machine or tool. Variable pitch and variable helix milling tools have been previously proposed to avoid the onset of regenerative chatter. Although variable pitch tools have been considered in some detail in previous research, this has generally focussed on behaviour at high radial immersions. In contrast there has been very little work focussed on predicting the stability of variable helix tools. In the present study, three solution processes are proposed for predicting the stability of variable pitch or helix milling tools.The first is a semi-discretisation formulation that performs spatial and temporal discretisation of the tool. Unlike previously published methods this can predict the stability of variable pitch or variable helix tools, at low or high radial immersions.The second is a time-averaged semi-discretisation formulation that assumes time-averaged cutting force coefficients. Unlike previous work, this can predict stability of variable helix tools at high radial immersion.The third is a temporal-finite element formulation that can predict the stability of variable pitch tools with a constant uniform helix angle, at low radial immersion.

Vibration absorbers have been widely used to suppress undesirable vibrations in machining operations, with a particular emphasis on avoiding chatter. However, it is well known that for vibration absorbers to function effectively their stiffness and damping must be accurately tuned based upon the natural frequency of the vibrating structure. For general vibration problems, suitable tuning strategies were developed by Den Hartog and Brock over 50 years ago. However, the special nature of the chatter stability problem means that this classical tuning methodology is no longer optimal. Consequently vibration absorbers for chatter mitigation have generally been tuned using ad-hoc methods, or numerical or graphical approaches. The present article introduces a new analytical solution to this problem, and demonstrates its performance using time domain milling simulations. A 40-50% improvement in the critical limiting depth of cut is observed, compared to the classically tuned vibration absorber.

Magnetorheological (MR) and electrorheological (ER) dampers are known to exhibit nonlinear behaviour which can make it difficult to predict their performance, particularly when they are integrated into engineering structures. As a result it can be impossible to properly assess the feasibility of using such semi-active devices to solve practical engineering problems. In this paper, a new model format is proposed which represents an extension of earlier work by the authors. The proposed model is more general and yet maintains the physical significance of key parameters. A novel model updating (or system identification) technique is developed so that the model can account for the behaviour of various configurations of device without the need for prior knowledge of the fluid properties. The technique relies upon the iterative adjustment of the model’s stiffness parameter so that the quasi-steady behaviour of the device can be estimated. Correlation between a bi-viscous model and the estimated quasi-steady behaviour is used as the criterion for choosing the most suitable value of stiffness. The modelling technique is completed by establishing empirical shape relationships between the pre-yield parameters, post-yield parameters, yield force and the applied excitation conditions. The modelling and identification procedures are applied to an MR damping device and the results are validated by comparing predicted and experimental responses under both non-sinusoidal and broadband excitation conditions.