A Study of 2D Roughness Periodical Profiles on a Flat Surface Generated by Milling with a Ball Nose End Mill.

This paper presents a study of 2D roughness profiles on a flat surface generated on a steel workpiece by ball nose end milling with linear equidistant tool paths (pick-intervals). The exploration of the milled surface with a surface roughness tester (on the pick and feed directions) produces 2D roughness profiles that usually have periodic evolutions. These evolutions can be considered as time-dependent signals, which can be described as a sum of sinusoidal components (the wavelength of each component is considered as a period). In order to obtain a good approximate description of these sinusoidal components, two suitable signal processing techniques are used in this work: the first technique provides a direct mathematical (analytical) description and is based on computer-aided curve (signal) fitting (more accurate); the second technique (synthetic, less accurate, providing an indirect and incomplete description) is based on the spectrum generated by fast Fourier transform. This study can be seen as a way to better understand the interaction between the tool and the workpiece or to achieve a mathematical characterisation of the machined surface microgeometry in terms of roughness (e.g., its description as a collection of closely spaced 2D roughness profiles) and to characterise the workpiece material in terms of machinability by cutting.

On the Behaviour of an AC Induction Motor as Sensor for Condition Monitoring of Driven Rotary Machines.

This paper presents some advances in condition monitoring for rotary machines (particularly for a lathe headstock gearbox) running idle with a constant speed, based on the behaviour of a driving three-phase AC asynchronous induction motor used as a sensor of the mechanical power via the absorbed electrical power. The majority of the variable phenomena involved in this condition monitoring are periodical (machines having rotary parts) and should be mechanically supplied through a variable electrical power absorbed by a motor with periodical components (having frequencies equal to the rotational frequency of the machine parts). The paper proposes some signal processing and analysis methods for the variable part of the absorbed electrical power (or its constituents: active and instantaneous power, instantaneous current, power factor, etc.) in order to achieve a description of these periodical constituents, each one often described as a sum of sinusoidal components with a fundamental and some harmonics. In testing these methods, the paper confirms the hypothesis that the evolution of the electrical power (instantaneous and active) has a predominantly deterministic character. Two main signal analysis methods were used, with good, comparable results: the fast Fourier transform of short and long signal sequences (for the frequency domain) and the curve fitting estimation (in the time domain). The determination of the amplitude, frequency and phase at origin of time for each of these components helps to describe the condition (normal or abnormal) of the machine parts. Several achievements confirm the viability of this study: a characterization of a flat driving belt condition and a beating power phenomenon generated by two rotary shafts inside the gearbox. For comparison purposes, the same signal analysis methods were applied to describe the evolution of the vibration signal and the instantaneous angular speed signal at the gearbox output spindle. Many similarities in behaviour among certain mechanical parts (including their electrical power, vibration and instantaneous angular speed) were highlighted.

Surface Quality Optimization in Micromachining with Cutting Tool Having Regular Constructive Geometry.

In this paper we studied the influence of micromachining parameters on processed surface quality. Usually in discussions about micro-cutting or micromachining, the grinding or diamond turning processes are considered. Cutting tools used in the mentioned processes do not have regular constructive geometry and, in this case, it is difficult to use constructive geometric parameters such as clearance angle α or rake angle γ to optimize the quality of the machined surface. In order to determine the influence of the cutting tool's constructive geometry on the hardness of the machined material, we used a fractional factorial design of a centered and rotatable type 26-1. A mathematical model based on five independent cutting parameters was created that allowed optimization of surface quality based on obtained roughness. The results can be applied in micromilling or microturning.

Unimorph mirror for adaptive optics in space telescopes.

This paper presents a unimorph deformable mirror intended to be used as secondary corrector in space telescopes. The deformable mirror consists of a single-crystal silicon wafer (76.2 mm diameter, 500 µm thickness) covered with an optical coating on the front side and an array of 25 independent piezoelectric transducer (PZT) actuators acting in d31 mode on the back side. The mirror is mounted on an isostatic support with three position linear actuators controlling the rigid-body motion. The first part of the paper presents the experimental results obtained with the manufactured prototype. The mirror was tested in terms of root mean square (RMS) wavefront error, open-loop long-term stability, voltage budget for active control, rigid-body actuation, reflectivity, and dynamic response. The prototype is fully compliant with the requirements set by the European Space Agency (ESA). The second part of the paper, purely based on numerical simulations, presents a robust way to face thermal distortion, inherent to unimorph architecture.

Segmented bimorph mirrors for adaptive optics: segment design and experiment.

We discuss the concept of lightweight segmented bimorph mirrors for adaptive optics. The segment consists of a monocrystal silicon substrate actuated by an array of in-plane piezoceramic (PZT) actuators with honeycomb electrodes. We focus on technological aspects of the segment design that are critical for space applications and describe a single segment demonstrator. The morphing capability of the segment is evaluated experimentally. We also discuss the local deformations (dimples) associated with the shape of the electrodes acting on the PZT array.