Design concept for frequency-variable electromagnetic contactless energy transfer systems powering vibrational actuators in rotary machining

Silge, Martin; Kellerer, Tobias; Sattel, Thomas

doi:10.1109/pedes.2016.7914238

Cited by 3 publications

(7 citation statements)

References 6 publications

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“…The air gap ensures the spatial separation of the coils. However, the magnetic flux in the secondary coil is lower than the induced magnetic flux in the primary coil [17]. Due to leakage flux, only part of the magnetic field of the first coil penetrates the second coil in Eq.…”

Section: Design Of the Cet Systemmentioning

confidence: 97%

“…Depending on the frequency of application, different core structures, such as laminate or solid-core designs, are advisable as the design affects the magnetic properties. Silge and others show the general approach of designing a contactless energy transmission interface [16,17]. This concept is used in the following analytical design study of the CET system.…”

Section: Design Of the Cet Systemmentioning

confidence: 99%

“…2. This is defined as the mutual magnetic influence of two adjacent electric circuits due to the electromagnetic induction by magnetic flux [17].…”

Section: Design Of the Cet Systemmentioning

confidence: 99%

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Design of a contactless powered and piezoelectric-actuated tool for non-resonant low-frequency vibration-assisted machining of brittle-hard materials

Brier

Bleicher

2021

Int J Adv Manuf Technol

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Ultrasonic-assisted grinding (UAG) is the state-of-the-art process for machining of brittle-hard materials. In comparison to conventional processes, the main advantages lie in the reduction of tool wear and process forces. Such a vibration system is based on a resonant actuator and a power supply unit generating the alternating current. Both units are interconnected by a contactless energy transfer (CET) system. This system configuration shows one optimal working point at the resonant frequency with maximum amplitude, which is significantly depending on the tool shape. In this work, a piezo-activated tool system is designed to realize non-resonant low-frequency vibrations. Major emphasis is put on the thermal behavior of the piezo drive, particularly on the in-process heating depending on the working frequency. In addition, focus lays on the theoretical and numerical design of the radial operating transducer CET system for a previously set actuator design. As a result, this system configuration offers a fully variable adjustment of the amplitude from under 1 to over 50 μm at frequency range. Outside this range, higher amplitudes can be achieved for short periods to the detriment of the fatigue strength according to FKM.

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Section: Design Of the Cet Systemmentioning

confidence: 97%

Section: Design Of the Cet Systemmentioning

confidence: 99%

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Design of a contactless powered and piezoelectric-actuated tool for non-resonant low-frequency vibration-assisted machining of brittle-hard materials

Brier

Bleicher

2021

Int J Adv Manuf Technol

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“…The design concept for the broad-band contactless energy transfer (CET) system also used for this contribution is already presented by the authors in [14]. The proposed concept incorporates the effects of leakage flux and eddy currents.…”

Section: Contactless Energy Transfer Systemmentioning

confidence: 99%

“…The leakage flux path corresponding to R m,σ2 is newly introduced into the network and was not part of the design process presented in [14]. Secondly, parametrisation of the air gap reluctance R m,δ has been altered in a way that stray flux around the gap is also considered to influence the value of this parameter and finally the leakage reluctances R m,σ1,2 are now calculated differently to account for the inhomogeneous field distribution (see Appendix A.2 for further details).…”

Section: Model Of Magnetic Circuitmentioning

confidence: 99%

Design of Contactlessly Powered and Piezoelectrically Actuated Tools for Non-Resonant Vibration Assisted Milling

Silge

Sattel

2018

Actuators

Self Cite

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This contribution presents a novel design approach for vibration assisted machining (VAM). A lot of research has already been done regarding the influence of superimposed vibrations during a milling process, but there is almost no information about how to design a VAM tool where the tool is actually rotating. The proposed system consists of a piezoelectric actuator for vibration excitation, an inductive contactless energy transfer system and an electronic circuit for powering the actuated tool. The main benefit of transferring the required power without mechanical contact is that the maximum spindle speed is no longer restricted by friction of slip rings. A detailed model is shown that enables for preliminary estimation of the system's response to different excitation signals. Experimental data are provided to validate the model. Finally, some parts are shown that have been manufactured using the contactlessly actuated milling tool.Actuators 2018, 7, 19 2 of 17 apparent power operation. The vibration frequency and necessary stroke determine the type of the piezoelectric actuator.In VAM, when enhancing the machining process enhancement, e.g., cutting force and tool wear reduction or chip breakage improvement, is the focus, the piezoelectric actuators are driven at a single excitation frequency in resonance operation mode. The used frequencies are mainly in the ultrasonic frequency range. The advantage of high vibration frequencies is a higher possible upfeed velocity and thus decreased machining time at a given rate of vibrations per tool revolution [1] (p. 157).Research in VAT is based on non-resonant piezoelectric actuation to allow for nearly arbitrary periodic vibration forms of the tool tip. Both one-and two dimensional vibrations of either the tool tip or the workpiece are under investigation. Almost all actuators designed for examining VAT are non-rotating devices [8][9][10][11]. In [10], a 1D-actuator design was suggested and investigated that allows for vibration frequencies from DC up to 40 kHz. This enlarged frequency range comes at the cost of larger actuator volume. An off-the-shelf 1D-actuator for examining texturing under turning processes was chosen in [8]. As an add-on tool for conventional machines, Ref.[11] developed a 2D-actuator for elliptic cutting processes with rotating workpieces. Similarly, Ref.[12] developed and investigated an 2D-actuator for elliptic VAT in milling processes. There, the actuator is embedded in a cooling chamber. Contrary to the others, in [9], it is not the tool that is actuated but the workpiece, which limits their sizes. The application is also a milling process.Up to now, only Ref.[13] suggests a milling tool with an integrated rotating piezoelectric actuator. This tool allows for arbitrary cutting profiles. Using a specially shaped cutting plate, they showed the possibility to cut nearly any pattern into the surface of an object. The main disadvantage of this system is that the electrical power is transferred to the actuator using slip rings; therefore, the cutting...

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A semi-active magnetorheological fluid mechanism with variable stiffness and damping

Greiner-Petter

Tan

Sattel

2014

Smart Mater. Struct.

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In this paper a semi-active fluid-mechanism is presented, which offers a variable stiffness and damping by utilizing two magnetorheological fluid valves and two springs. The study incorporates the attributes of variable damping and stiffness into one compact device. A model for the magnetical, rheological, fluidical and mechanical behaviour of the whole system is derived. An experimental setup of the proposed system and an appropriate test bench are built in order to study the variable mechanical impedance behaviour with the corresponding simulations. The results proof that the stiffness of the system can be varied among three different values, while its damping is continuously variable.

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Design concept for frequency-variable electromagnetic contactless energy transfer systems powering vibrational actuators in rotary machining

Cited by 3 publications

References 6 publications

Design of a contactless powered and piezoelectric-actuated tool for non-resonant low-frequency vibration-assisted machining of brittle-hard materials

Design of a contactless powered and piezoelectric-actuated tool for non-resonant low-frequency vibration-assisted machining of brittle-hard materials

Design of Contactlessly Powered and Piezoelectrically Actuated Tools for Non-Resonant Vibration Assisted Milling

A semi-active magnetorheological fluid mechanism with variable stiffness and damping

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