Dynamics modeling and analysis of feed drive system for a frame saw machine considering time-varying load
At a Glance
Section titled âAt a Glanceâ| Metadata | Details |
|---|---|
| Publication Date | 2021-01-01 |
| Journal | Mechanics & Industry |
| Authors | Depeng Sun, Jinsheng Zhang |
| Institutions | Shandong University |
| Citations | 5 |
| Analysis | Full AI Review Included |
Technical Documentation & Analysis: MPCVD Diamond for High-Stability Feed Drive Systems
Section titled âTechnical Documentation & Analysis: MPCVD Diamond for High-Stability Feed Drive SystemsâExecutive Summary
Section titled âExecutive SummaryâThis documentation analyzes the research on dynamic modeling of a novel Feed Drive System (FDS) for heavy-duty frame saw machines used in dimension stone processing (e.g., granite). The primary objective of the FDS redesign is to stabilize the cutting process, thereby reducing the excessive wear of diamond particlesâa critical factor for tool cost and processing quality.
- Core Challenge: Traditional FDS designs suffer from velocity fluctuation, leading to increased cutting force, decreased dynamic chip holding space, and severe diamond tool wear.
- Proposed Solution: A novel servo feed mechanism utilizing a rotary-nut lead screw, demonstrating higher stiffness and stability.
- Key Dynamic Improvement: The new FDS achieved a significantly faster response feed and reduced velocity fluctuation (down to < 0.005 mm/s in stable state) compared to traditional systems (~0.025 mm/s).
- Material Impact: The improved FDS stability reduces the maximum undeformed chip thickness, bringing the cutting process closer to the ideal state and directly extending the lifespan of the diamond cutting segments.
- Dynamic Sensitivity: The systemâs natural frequencies (first-order: 20.05 Hz to 14.96 Hz; second-order: 216.5 Hz to 215.2 Hz) are highly sensitive to time-varying load (stone mass and position), necessitating high-quality, robust diamond materials to withstand resonance risks.
- 6CCVD Value Proposition: 6CCVD supplies the necessary high-performance Polycrystalline Diamond (PCD) and Single Crystal Diamond (SCD) plates, custom-engineered to withstand the high-frequency dynamic loads and thermal stresses inherent in heavy-duty stone cutting.
Technical Specifications
Section titled âTechnical SpecificationsâThe following hard data points were extracted from the modeling parameters and simulation results of the novel FDS:
| Parameter | Value | Unit | Context |
|---|---|---|---|
| Stone Lifting Platform Mass (mt) | 750 | kg | Base mass for modeling |
| Axial Stiffness of Screw (Ksa) | 8.4 x 107 | N/m | High stiffness component |
| Axial Stiffness of Supporting Bearing (Kna) | 2.3 x 108 | N/m | High stiffness component |
| Meshing Stiffness of Gears (K12) | 6.2 x 108 | N/m | High stiffness component |
| Helical Pitch (p) | 10 | mm | Trapezoidal screw specification |
| New FDS Velocity Fluctuation (Stable) | < 0.005 | mm/s | Demonstrates high stability |
| Traditional FDS Velocity Fluctuation (Stable) | ~0.025 | mm/s | Baseline instability |
| First-Order Natural Frequency Range (Load Dependent) | 14.96 to 20.05 | Hz | Varies with stone mass (3000 kg to 6000 kg) |
| Second-Order Natural Frequency Range (Load Dependent) | 215.2 to 216.5 | Hz | Varies with stone mass (3000 kg to 6000 kg) |
| Saw Blade Experimental Natural Frequencies | 22 and 44 | Hz | Modal test results (Risk of resonance with FDS) |
| Maximum Acceleration Amplitude (Light Load) | 4.293 | dB | At starting position (42.81 Hz) |
Key Methodologies
Section titled âKey MethodologiesâThe dynamic characteristics of the Feed Drive System (FDS) were analyzed using a combination of theoretical modeling and experimental verification:
- Dynamic Modeling: The FDS was modeled using the Lumped Parameter Method (LPM) to account for the stiffness and inertia of components (motor, coupling, gears, screw, nut, platform).
- Energy Formulation: The kinetic and potential energies of the system were derived using the Lagrange energy method, leading to the dynamic equation in matrix form (Mq + Kq = Q).
- State-Space Conversion: The dynamic equation was converted into state-space form (X = AX + BU) for numerical simulation and frequency response analysis.
- Simulation: Velocity fluctuation characteristics were simulated using Simulink-Simscape to compare the performance of the novel FDS against the traditional FDS.
- Time-Varying Load Analysis: Frequency response characteristics were calculated by simulating the effects of varying stone mass (3000 kg to 6000 kg) and varying screw length (position) to model the time-dependent nature of the cutting load.
- Experimental Verification: Modal tests were performed on the tensioned saw blade using a hammer, acceleration sensor, and LMS Test.lab system to experimentally determine the saw bladeâs first two natural frequencies (22 Hz and 44 Hz).
6CCVD Solutions & Capabilities
Section titled â6CCVD Solutions & CapabilitiesâThe stability of the frame saw FDS directly dictates the wear rate and performance of the diamond cutting tools. 6CCVD provides the high-quality MPCVD diamond materials necessary to maximize tool life and maintain precision under the severe, time-varying dynamic loads identified in this research.
Applicable Materials for Heavy-Duty Stone Cutting
Section titled âApplicable Materials for Heavy-Duty Stone Cuttingâ| 6CCVD Material | Application Relevance | Technical Specification |
|---|---|---|
| Polycrystalline Diamond (PCD) | Ideal for the diamond saw teeth/segments used in heavy-duty granite cutting, where high impact resistance and superior wear rate are paramount. | Custom Plates/Wafers up to 125mm diameter. Thicknesses from 0.1 ”m to 500 ”m. |
| Optical Grade Single Crystal Diamond (SCD) | Suitable for high-precision inserts or specialized segments requiring the highest thermal stability and lowest defect density. | Thicknesses from 0.1 ”m to 500 ”m. Polishing capability to Ra < 1 nm. |
Customization Potential for Saw Blade Integration
Section titled âCustomization Potential for Saw Blade IntegrationâThe research highlights the need for precise, stable cutting tools. 6CCVDâs advanced manufacturing capabilities ensure the diamond material meets the exact specifications required for integration into complex feed systems:
- Custom Dimensions: We provide PCD and SCD plates in custom sizes up to 125mm, allowing engineers to design optimized diamond segments for large-span saw blades.
- Precision Polishing: Our capability to achieve ultra-low roughness (Ra < 5 nm for inch-size PCD) minimizes friction and thermal stress during cutting, which is crucial for reducing the dynamic load fluctuations that cause diamond wear.
- Advanced Metalization: For robust segment bonding onto the saw frame, 6CCVD offers internal metalization services, including Au, Pt, Pd, Ti, W, and Cu layers, ensuring reliable mechanical and thermal contact under high-frequency vibration (22 Hz and 44 Hz).
Engineering Support & Material Consultation
Section titled âEngineering Support & Material ConsultationâThe study emphasizes that the FDS dynamics are complex, with natural frequencies shifting nonlinearly based on load and position. Selecting the correct diamond material requires expertise that bridges material science and mechanical dynamics.
- Dynamic Load Expertise: 6CCVDâs in-house PhD team specializes in the mechanical and thermal properties of diamond under extreme conditions. We can assist engineers in selecting the optimal diamond grade (SCD vs. PCD) based on the specific acceleration amplitudes and natural frequency ranges identified in similar Feed Drive System (FDS) projects.
- Global Supply Chain: We offer global shipping (DDU default, DDP available) to ensure timely delivery of critical diamond components, supporting international manufacturing and research efforts.
For custom specifications or material consultation, visit 6ccvd.com or contact our engineering team directly.
View Original Abstract
Frame saw machine is one of machine tools that is used to process dimension stone. The velocity fluctuation of traditional feed drive system (FDS) lead to excessive wear of diamond particles. The dynamic performance of the FDS has time-varying characteristics during the processing of stone with a large material removal rate. In this paper, a novel FDS was proposed. Firstly, the dynamic modeling of FDS was set up on account of lumped parameter method (LPM). Then the speed of the new FDS was compared with that of the traditional FDS. Finally, the frequency response characteristics of the system were solved by Lagrange and state space method. Results showed that the new FDS has a faster response feed and less velocity fluctuation. The natural frequency and the amplitude of acceleration increase with decreasing load. With the time-varying load, the range of the second-order natural frequency increased by 50 Hz, which was larger than that of the first-order. The modal test verified that the first two natural frequencies of the saw blade are within the range of the natural frequencies of FDS. The proposed FDS can guide for design, reduce the wear of diamond, and improve processing quality.