Sergey Voronov - Academia.edu (original) (raw)

Papers by Sergey Voronov

Research paper thumbnail of Simulation of chip-formation by a single grain of pyramid shape

The article focuses on the analysis of thermomechanical modeling of cutting by single abrasive mi... more The article focuses on the analysis of thermomechanical modeling of cutting by single abrasive micro-size grain while the process of grinding. In this research, applying the Johnson-Cook” material model, which relates the intensity of stress with strain rate, temperature and the accumulated plastic strain. Using arbitrary Lagrangian-Eulerian (ALE) approach makes it possible avoid the distortion of finite elements in the simulation of chip-formation under large deformations. The simulation allows predicting cutting force for processing workpiece of titanium alloy Ti6Al4V by single grain grinding.

Research paper thumbnail of Simulating the dynamics of vibration drilling featuring chip control driven by peak-to-peak vibration displacement

Engineering Journal: Science and Innovation, 2019

Chip control is one of the most important problems in deep hole machining. A special self-vibrato... more Chip control is one of the most important problems in deep hole machining. A special self-vibratory drilling head may be used to implement chip control. However, chip control via a self-vibratory head is only possible for specific manufacturing parameters, which limits the use of this method. This paper presents an algorithm for adaptive control of vibration drilling dynamics intended to facilitate chip control and driven by peak-to-peak vibration displacement. We provide a mathematical model of drilling using a self-vibratory head, taking into account the facts that the cutting force is a non-linear function of the chip thickness and that there is additional non-linearity introduced when the drill is exiting the material. In order to validate the efficiency of the algorithm proposed, we performed numerical simulations for a wide range of variable processing parameters. The simulation results obtained confirm that the strategy proposed is efficient for chip control.

Research paper thumbnail of Effect of Abrasive Grain Geometry on Cutting Forces in Grinding

Herald of the Bauman Moscow State Technical University. Series Mechanical Engineering, 2017

Research paper thumbnail of Investigation of vibratory drilling model with adaptive control. Part 1: control of cutting continuity index

Journal of Vibroengineering, 2015

Chip segmentation is one of the major factors of process quality assurance while deep hole drilli... more Chip segmentation is one of the major factors of process quality assurance while deep hole drilling. The reliable chip segmentation can be obtained if a special self-vibratory drilling head is applied. The required self-excited vibrations are maintained due to the regenerative cutting mechanism and the embedded special elastic element which provides sufficient axial flexibility. The algorithm of adaptive control with vibration velocity feedback is proposed for a self-excited vibrations maintenance. The feedback gain is adjusted by cutting continuity index in order to provide the required cutting conditions. The mathematical model of vibratory drilling process dynamics with control is presented in the paper. The results of a multi-variant simulation are also presented and analyzed.

Research paper thumbnail of Ensuring the chatter stability of milling by optimizing the workpiece stock

Vibroengineering PROCEDIA, 2021

The paper considers a new technique for increasing the dynamic stability of the dynamics of milli... more The paper considers a new technique for increasing the dynamic stability of the dynamics of milling flexible parts. The technique is based on the formation of a uniform stock of the workpiece for the finish milling. The paper proposes an optimization algorithm for the automated calculation of the stock distribution based on the sensitivity analysis method. The ratio of the natural frequencies of the flexible workpiece is used as the objective function of the optimization algorithm. The developed technique was tested on a numerical example.

Research paper thumbnail of A stochastic model of plane grinding dynamic for the texture formation analysis

Vibroengineering PROCEDIA, 2021

A mathematical model of plane grinding by the tool which is modeled as a disc with distributed on... more A mathematical model of plane grinding by the tool which is modeled as a disc with distributed on its surface abrasive grains, owning random geometric characteristics in the paper is analyzed. Cutting is modeled separately by each grain under kinematically given tool motion. The system of equations, describing the relations between the surface coordinate cut by permanent grain and the surface coordinate machined by previous grain, is obtained. The solution for a single track is analyzed, determining the configuration of workpiece surface under multiple grains’ passages. An array of varying dimension is used, in order to store the change of all grains’ cutting thickness in grinding process. The interaction forces at each grain being in contact with the machined surface are summarized at each time step. The dynamic model is based on the consideration of insufficient rigidity of the technological system characteristics, which is inherent while grinding of complex parts in aircraft and ...

Research paper thumbnail of Chatter suppression in boring with tool position feedback control

Journal of Vibroengineering, 2017

Regenerative self-excited vibrations (chatter) often occur in boring operation due to low stiffne... more Regenerative self-excited vibrations (chatter) often occur in boring operation due to low stiffness of a slender cantilever holder of a tool. These vibrations lead to significant defects of a machined surface and cutting tool damages. The new chatter suppression method is proposed in the paper. Displacement signal measured in the direction which is orthogonal to machined surface is used for generating a control action in the feed direction. Linear proportional control law is applied. Mathematical model of boring process dynamics with control has been developed for validation of the proposed method efficiency and searching better values of feedback gain.

Research paper thumbnail of Influence of Torsional Motion on the Axial Vibrations of a Drilling Tool

Journal of Computational and Nonlinear Dynamics, 2007

The nonlinear dynamics of a tool commonly employed in deep hole drilling is analyzed. The tool is... more The nonlinear dynamics of a tool commonly employed in deep hole drilling is analyzed. The tool is modeled as a two-degree of freedom system that vibrates in the axial and torsional directions as a result of the cutting process. The mechanical model of cutting forces is a nonlinear function of cutting tool displacement including state variables with time delay. The equations of new surface formation are constructed as a specific set. These equations naturally include the regeneration effect of oscillations while cutting, and it is possible to analyze continuous and intermittent cutting as stationary and nonstationary processes, respectively. The influence of the axial and torsional dynamics of the tool on chip formation is considered. The Poincaré maps of state variables for various sets of operating conditions are presented. The obtained results allow the prediction of conditions for stable continuous cutting and unstable regions. The time domain simulation allows determination of t...

Research paper thumbnail of Non-conservative oscillations of a tool for deep hole honing

Communications in Nonlinear Science and Numerical Simulation, 2006

The dynamics of a rotating tool, commonly employed in deep hole honing, is considered. A mathemat... more The dynamics of a rotating tool, commonly employed in deep hole honing, is considered. A mathematical model of the process including a dynamic representation of tool, workpiece surface and honing stones interaction is suggested and analyzed. It is shown that interaction forces are non-conservative. The honing tool is modeled as a rotating continuous slender beam with a mandrel attached at an intermediate crosssection. The transverse oscillations of tool shaft cause variation in expansion pressure and change the interaction forces on the surface of the workpiece. The interaction forces are nonlinear and non-conservative in the general case including delayed functions. The expansion pressure of stones turns out to be a critical parameter in a honing process. Since the removal of stock increases linearly with pressure, the productivity can be improved by increasing expansion pressure, but in certain conditions may cause dynamic instability of the tool shaft. On the other hand, the lower expansion pressure and feed rates increase accuracy. Another source of shaft instability is due to the asymmetry of the tool that leads to discrepancy of the system stiffness in the transverse directions. As a result, under certain conditions unstable parametric vibrations may occur. Needless to say, the dynamic behavior of the tool can considerably influence the machined surface formation. In this study a model of honing surface formation is introduced and integrated into the model of process simulation. The system response is studied for different parameters in a non-dimensional form.

Research paper thumbnail of Modeling of chatter vibrations in gun drilling process

Vibroengineering PROCEDIA, 2021

The dynamics of the gun drilling process is analyzed in this paper. The tool shank is modeled as ... more The dynamics of the gun drilling process is analyzed in this paper. The tool shank is modeled as long straight beam vibrating in transverse direction under action of cutting forces. Axial force component is expressed as proportional to cutting thickness, which is determined as nonlinear function of beam transverse deflection with time delay. Nonlinear equations of motion of the drilling shank are derived. The stability diagram of the system dynamics was determined. The bifurcation analysis of nonlinear differential delay equations by means of multiple scale method was performed. The obtained results were verified by numerical integration of nonlinear equations. The influence of cutting conditions on system stability and chatter amplitude was observed.

Research paper thumbnail of A Literature Review on Mathematical Models of Drilling Process Dynamics

Science and Education of the Bauman MSTU, 2014

Research paper thumbnail of Numerical Simulation of a Grinding Process for the Spatial Work-pieces: a Model of the Work-piece and Grinding Wheel

Science and Education of the Bauman MSTU, 2014

Research paper thumbnail of Methodic of Rational Cutting Conditions Determination for 3-D Shaped Detail Milling Based on the Process Numerical Simulation

Volume 6: 10th International Conference on Multibody Systems, Nonlinear Dynamics, and Control, 2014

The paper is devoted for the analysis of the dynamics effect on the 5-axis milling process of fle... more The paper is devoted for the analysis of the dynamics effect on the 5-axis milling process of flexible details. The integrated model of milling dynamics composed by block principle in the paper is presented. The model consist of: 1) dynamical model of tool; 2) dynamical model of machined detail based on Finite Element Method (FEM); 3) phenomenological model of cutting forces and 4) algorithm of geometry modeling for instant machined chip thickness calculation. Regeneration mechanism of cutting and calculation of the machined surface are into this algorithm embedded. The elaborated model is adapted for 5-axis processing of the profiled details with 3-D complex geometry. Alteration of workpiece dynamic characteristics while the allowance removal is considered by the special algorithm of FEM grid changing based on the results of cutting geometry modeling. The results of modeling give us opportunity determine cutting forces, estimate the machined surface quality, calculate the magnitude...

Research paper thumbnail of Existing Methods for Ensuring Low Frequency Tool Vibrations to Chip Breakage in Deep Drilling

Science and Education of the Bauman MSTU, 2014

Одной из важных задач современного машиностроения является обеспечение дробления стружки при обра... more Одной из важных задач современного машиностроения является обеспечение дробления стружки при обработке резанием и, в частности, при сверлении. В работе произведён обзор конструкций, направленных на сообщение сверлу осевых колебательных перемещений, амплитуды которых обеспечивают выход инструмента из материала в зоне резания и, как следствие, дробление стружки. Важной разновидностью таких конструкций являются вибропатроны, работающие по автоколебательному принципу. Параметры этих вибропатронов выбираются таким образом, чтобы колебательная система сама забирала энергию рабочего процесса на поддержание перемещений сверла в осевом направлении. Приведены математические модели, предназначенные для описания динамического поведения сверла при резании, а также для предсказания автоколебательных режимов.

Research paper thumbnail of Estimation of damping model correctness using experimental modal analysis

This paper is dedicated to the damping identification problem. Short outlook of damping identific... more This paper is dedicated to the damping identification problem. Short outlook of damping identification methods is given in the first part of the paper. All these methods can successfully identify internal damping of free-moving structures but it becomes problematically to correctly estimate damping forces when the structure is fixed and there are some joints. The recent methods of structural damping identification don’t give a full understanding of dissipation problem too. An explanation of damping-frequency relation features based on the existence of another damping nature, external damping for example, is proposed in this paper. These assumptions are demonstrated by the modal parameters identification of a turbine blade.

Research paper thumbnail of Simulation of chip-formation by a single grain of pyramid shape

The article focuses on the analysis of thermomechanical modeling of cutting by single abrasive mi... more The article focuses on the analysis of thermomechanical modeling of cutting by single abrasive micro-size grain while the process of grinding. In this research, applying the Johnson-Cook” material model, which relates the intensity of stress with strain rate, temperature and the accumulated plastic strain. Using arbitrary Lagrangian-Eulerian (ALE) approach makes it possible avoid the distortion of finite elements in the simulation of chip-formation under large deformations. The simulation allows predicting cutting force for processing workpiece of titanium alloy Ti6Al4V by single grain grinding.

Research paper thumbnail of Simulating the dynamics of vibration drilling featuring chip control driven by peak-to-peak vibration displacement

Engineering Journal: Science and Innovation, 2019

Chip control is one of the most important problems in deep hole machining. A special self-vibrato... more Chip control is one of the most important problems in deep hole machining. A special self-vibratory drilling head may be used to implement chip control. However, chip control via a self-vibratory head is only possible for specific manufacturing parameters, which limits the use of this method. This paper presents an algorithm for adaptive control of vibration drilling dynamics intended to facilitate chip control and driven by peak-to-peak vibration displacement. We provide a mathematical model of drilling using a self-vibratory head, taking into account the facts that the cutting force is a non-linear function of the chip thickness and that there is additional non-linearity introduced when the drill is exiting the material. In order to validate the efficiency of the algorithm proposed, we performed numerical simulations for a wide range of variable processing parameters. The simulation results obtained confirm that the strategy proposed is efficient for chip control.

Research paper thumbnail of Effect of Abrasive Grain Geometry on Cutting Forces in Grinding

Herald of the Bauman Moscow State Technical University. Series Mechanical Engineering, 2017

Research paper thumbnail of Investigation of vibratory drilling model with adaptive control. Part 1: control of cutting continuity index

Journal of Vibroengineering, 2015

Chip segmentation is one of the major factors of process quality assurance while deep hole drilli... more Chip segmentation is one of the major factors of process quality assurance while deep hole drilling. The reliable chip segmentation can be obtained if a special self-vibratory drilling head is applied. The required self-excited vibrations are maintained due to the regenerative cutting mechanism and the embedded special elastic element which provides sufficient axial flexibility. The algorithm of adaptive control with vibration velocity feedback is proposed for a self-excited vibrations maintenance. The feedback gain is adjusted by cutting continuity index in order to provide the required cutting conditions. The mathematical model of vibratory drilling process dynamics with control is presented in the paper. The results of a multi-variant simulation are also presented and analyzed.

Research paper thumbnail of Ensuring the chatter stability of milling by optimizing the workpiece stock

Vibroengineering PROCEDIA, 2021

The paper considers a new technique for increasing the dynamic stability of the dynamics of milli... more The paper considers a new technique for increasing the dynamic stability of the dynamics of milling flexible parts. The technique is based on the formation of a uniform stock of the workpiece for the finish milling. The paper proposes an optimization algorithm for the automated calculation of the stock distribution based on the sensitivity analysis method. The ratio of the natural frequencies of the flexible workpiece is used as the objective function of the optimization algorithm. The developed technique was tested on a numerical example.

Research paper thumbnail of A stochastic model of plane grinding dynamic for the texture formation analysis

Vibroengineering PROCEDIA, 2021

A mathematical model of plane grinding by the tool which is modeled as a disc with distributed on... more A mathematical model of plane grinding by the tool which is modeled as a disc with distributed on its surface abrasive grains, owning random geometric characteristics in the paper is analyzed. Cutting is modeled separately by each grain under kinematically given tool motion. The system of equations, describing the relations between the surface coordinate cut by permanent grain and the surface coordinate machined by previous grain, is obtained. The solution for a single track is analyzed, determining the configuration of workpiece surface under multiple grains’ passages. An array of varying dimension is used, in order to store the change of all grains’ cutting thickness in grinding process. The interaction forces at each grain being in contact with the machined surface are summarized at each time step. The dynamic model is based on the consideration of insufficient rigidity of the technological system characteristics, which is inherent while grinding of complex parts in aircraft and ...

Research paper thumbnail of Chatter suppression in boring with tool position feedback control

Journal of Vibroengineering, 2017

Regenerative self-excited vibrations (chatter) often occur in boring operation due to low stiffne... more Regenerative self-excited vibrations (chatter) often occur in boring operation due to low stiffness of a slender cantilever holder of a tool. These vibrations lead to significant defects of a machined surface and cutting tool damages. The new chatter suppression method is proposed in the paper. Displacement signal measured in the direction which is orthogonal to machined surface is used for generating a control action in the feed direction. Linear proportional control law is applied. Mathematical model of boring process dynamics with control has been developed for validation of the proposed method efficiency and searching better values of feedback gain.

Research paper thumbnail of Influence of Torsional Motion on the Axial Vibrations of a Drilling Tool

Journal of Computational and Nonlinear Dynamics, 2007

The nonlinear dynamics of a tool commonly employed in deep hole drilling is analyzed. The tool is... more The nonlinear dynamics of a tool commonly employed in deep hole drilling is analyzed. The tool is modeled as a two-degree of freedom system that vibrates in the axial and torsional directions as a result of the cutting process. The mechanical model of cutting forces is a nonlinear function of cutting tool displacement including state variables with time delay. The equations of new surface formation are constructed as a specific set. These equations naturally include the regeneration effect of oscillations while cutting, and it is possible to analyze continuous and intermittent cutting as stationary and nonstationary processes, respectively. The influence of the axial and torsional dynamics of the tool on chip formation is considered. The Poincaré maps of state variables for various sets of operating conditions are presented. The obtained results allow the prediction of conditions for stable continuous cutting and unstable regions. The time domain simulation allows determination of t...

Research paper thumbnail of Non-conservative oscillations of a tool for deep hole honing

Communications in Nonlinear Science and Numerical Simulation, 2006

The dynamics of a rotating tool, commonly employed in deep hole honing, is considered. A mathemat... more The dynamics of a rotating tool, commonly employed in deep hole honing, is considered. A mathematical model of the process including a dynamic representation of tool, workpiece surface and honing stones interaction is suggested and analyzed. It is shown that interaction forces are non-conservative. The honing tool is modeled as a rotating continuous slender beam with a mandrel attached at an intermediate crosssection. The transverse oscillations of tool shaft cause variation in expansion pressure and change the interaction forces on the surface of the workpiece. The interaction forces are nonlinear and non-conservative in the general case including delayed functions. The expansion pressure of stones turns out to be a critical parameter in a honing process. Since the removal of stock increases linearly with pressure, the productivity can be improved by increasing expansion pressure, but in certain conditions may cause dynamic instability of the tool shaft. On the other hand, the lower expansion pressure and feed rates increase accuracy. Another source of shaft instability is due to the asymmetry of the tool that leads to discrepancy of the system stiffness in the transverse directions. As a result, under certain conditions unstable parametric vibrations may occur. Needless to say, the dynamic behavior of the tool can considerably influence the machined surface formation. In this study a model of honing surface formation is introduced and integrated into the model of process simulation. The system response is studied for different parameters in a non-dimensional form.

Research paper thumbnail of Modeling of chatter vibrations in gun drilling process

Vibroengineering PROCEDIA, 2021

The dynamics of the gun drilling process is analyzed in this paper. The tool shank is modeled as ... more The dynamics of the gun drilling process is analyzed in this paper. The tool shank is modeled as long straight beam vibrating in transverse direction under action of cutting forces. Axial force component is expressed as proportional to cutting thickness, which is determined as nonlinear function of beam transverse deflection with time delay. Nonlinear equations of motion of the drilling shank are derived. The stability diagram of the system dynamics was determined. The bifurcation analysis of nonlinear differential delay equations by means of multiple scale method was performed. The obtained results were verified by numerical integration of nonlinear equations. The influence of cutting conditions on system stability and chatter amplitude was observed.

Research paper thumbnail of A Literature Review on Mathematical Models of Drilling Process Dynamics

Science and Education of the Bauman MSTU, 2014

Research paper thumbnail of Numerical Simulation of a Grinding Process for the Spatial Work-pieces: a Model of the Work-piece and Grinding Wheel

Science and Education of the Bauman MSTU, 2014

Research paper thumbnail of Methodic of Rational Cutting Conditions Determination for 3-D Shaped Detail Milling Based on the Process Numerical Simulation

Volume 6: 10th International Conference on Multibody Systems, Nonlinear Dynamics, and Control, 2014

The paper is devoted for the analysis of the dynamics effect on the 5-axis milling process of fle... more The paper is devoted for the analysis of the dynamics effect on the 5-axis milling process of flexible details. The integrated model of milling dynamics composed by block principle in the paper is presented. The model consist of: 1) dynamical model of tool; 2) dynamical model of machined detail based on Finite Element Method (FEM); 3) phenomenological model of cutting forces and 4) algorithm of geometry modeling for instant machined chip thickness calculation. Regeneration mechanism of cutting and calculation of the machined surface are into this algorithm embedded. The elaborated model is adapted for 5-axis processing of the profiled details with 3-D complex geometry. Alteration of workpiece dynamic characteristics while the allowance removal is considered by the special algorithm of FEM grid changing based on the results of cutting geometry modeling. The results of modeling give us opportunity determine cutting forces, estimate the machined surface quality, calculate the magnitude...

Research paper thumbnail of Existing Methods for Ensuring Low Frequency Tool Vibrations to Chip Breakage in Deep Drilling

Science and Education of the Bauman MSTU, 2014

Одной из важных задач современного машиностроения является обеспечение дробления стружки при обра... more Одной из важных задач современного машиностроения является обеспечение дробления стружки при обработке резанием и, в частности, при сверлении. В работе произведён обзор конструкций, направленных на сообщение сверлу осевых колебательных перемещений, амплитуды которых обеспечивают выход инструмента из материала в зоне резания и, как следствие, дробление стружки. Важной разновидностью таких конструкций являются вибропатроны, работающие по автоколебательному принципу. Параметры этих вибропатронов выбираются таким образом, чтобы колебательная система сама забирала энергию рабочего процесса на поддержание перемещений сверла в осевом направлении. Приведены математические модели, предназначенные для описания динамического поведения сверла при резании, а также для предсказания автоколебательных режимов.

Research paper thumbnail of Estimation of damping model correctness using experimental modal analysis

This paper is dedicated to the damping identification problem. Short outlook of damping identific... more This paper is dedicated to the damping identification problem. Short outlook of damping identification methods is given in the first part of the paper. All these methods can successfully identify internal damping of free-moving structures but it becomes problematically to correctly estimate damping forces when the structure is fixed and there are some joints. The recent methods of structural damping identification don’t give a full understanding of dissipation problem too. An explanation of damping-frequency relation features based on the existence of another damping nature, external damping for example, is proposed in this paper. These assumptions are demonstrated by the modal parameters identification of a turbine blade.