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Consider the elastic torsion formula, which applies to a circular shaft with a consistent cross-section. This formula assumes that the shaft's ends are loaded with rigid plates firmly attached. However, in many cases, torques are applied to the shaft through mechanisms like flange couplings or gears, which are connected by keys inserted into keyways. This application method modifies the stress distribution near the point of torque application, causing it to deviate from the distributions...
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Residual Stresses in Circular Shafts01:10

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In materials that exhibit elastic and plastic behavior, known as elastoplastic materials, residual stresses can accumulate when these materials experience plastic deformation. This deformation arises from either high levels of shearing stress or significant strains. Residual stresses are internal stresses that persist within a material after removing the external force causing deformation. This phenomenon is demonstrated when observing the behavior of a shaft under torque; notably, the...
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Designing a transmission shaft requires a thorough understanding of the stresses induced by bending moments and torques, especially in systems where power is transferred through gears. These forces create force-couple systems at the centers of the shaft's cross-sections, leading to both transverse and torsional loading. Although shearing stresses from transverse loads are typically smaller than those from torques and are often overlooked, the significant normal stresses from these loads...
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Feedback control systems are categorized in various ways based on their design, analysis, and signal types.
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Mechanical systems are analogous to to electrical networks where springs and masses play similar roles to inductors and capacitors, respectively. A viscous damper in mechanical systems functions similarly to a resistor in electrical networks, dissipating energy. The forces acting on a mass in such systems include an applied force in the direction of motion, counteracted by forces from the spring, a viscous damper, and the mass's acceleration. This interplay of forces is mathematically...
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Control systems are foundational elements in automation and engineering. They are broadly categorized into open-loop and closed-loop systems. These classifications hinge on the presence or absence of feedback mechanisms, significantly influencing the system's performance, complexity, and application.
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Related Experiment Video

Updated: Oct 13, 2025

Design and Application of a Fault Detection Method Based on Adaptive Filters and Rotational Speed Estimation for an Electro-Hydrostatic Actuator
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Integrated Design of Spindle Speed Modulation and Cutting Vibration Suppression Controls Using Disturbance Observer

Syh-Shiuh Yeh1, Chai-Wei Chen2

  • 1Department of Mechanical Engineering, National Taipei University of Technology, Taipei 10608, Taiwan.

Materials (Basel, Switzerland)
|November 13, 2021
PubMed
Summary

This study introduces an integrated control for thread milling, balancing efficiency and quality. It uses spindle speed modulation and vibration suppression to enhance manufacturing processes without extra sensors.

Keywords:
cutting vibration suppressiondisturbance observerspindle speed modulationthread milling

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Area of Science:

  • Manufacturing Engineering
  • Control Systems

Background:

  • Thread milling faces a trade-off between manufacturing efficiency and product quality.
  • Existing sensor-based methods for vibration control can be costly and complex.

Purpose of the Study:

  • To develop an integrated control system for thread milling that enhances both efficiency and quality.
  • To address limitations of sensor-based methods by proposing a sensorless approach.

Main Methods:

  • Developed an integrated design combining spindle speed modulation (SSM) and cutting vibration suppression (CVS) controls.
  • Utilized a disturbance observer to estimate cutting torque for feedback control.
  • Implemented CVS to detect and suppress cutting vibrations by adjusting the SSM control's torque command.

Main Results:

  • The integrated SSM and CVS controls effectively managed cutting torque and suppressed vibrations.
  • The proposed method demonstrated cost-effectiveness and avoided sensor installation issues.
  • Experimental validation on a CNC milling machine confirmed the system's feasibility and performance.

Conclusions:

  • The integrated disturbance observer-based SSM and CVS control is a viable solution for improving thread milling.
  • This approach successfully balances high manufacturing efficiency with superior thread quality.
  • The sensorless design offers practical advantages for implementation in industrial settings.