Search Results (4)

This study aimed to investigate the dynamic characteristics of shafts joined by friction welding and to update their finite element models. The first five bending mode resonance frequencies, damping ratios, and mode shapes of SAE 304 steel beams, friction-welded at three different rotational speeds (1200, 1500, and 1800 rpm), were determined using the Experimental Modal Analysis method. This approach allowed for an examination of how the dynamic properties of friction-welded beams change at varying rotational speeds. A slight decrease in resonance frequency values was observed with the transition from lower to higher rotational speeds. The largest difference of 3.28% was observed in the first mode, and the smallest difference of 0.19% was observed in the second mode. Different trends in damping ratios were observed for different modes. In the first, second, and fourth modes, damping ratios tended to increase with increasing rotational speeds, while they tended to decrease in the third and fifth modes. The largest difference was calculated as 52.83% in the third vibration mode. However, no significant change in mode shapes was observed for different rotational speeds. Based on the examined Modal Assurance Criterion (MAC) results, cross-comparisons of the mode shapes obtained for all three different speeds yielded a minimum similarity of 93.8%, reaching up to 99.9%. For model updating, a Frequency Response Assurance Criterion (FRAC)-based method utilizing frequency response functions (FRFs) was employed. Initially, a numerical model of the welded shaft was created using MATLAB-R2015a, based on the Euler–Bernoulli beam theory. Since rotational coordinates were not used in the EMA analyses, static model reduction was performed on the numerical model to reduce the effect of rotational coordinates to translational coordinates. For model updating, experimentally obtained FRFs from EMA and FRFs from the numerical model were used. The equivalent modulus of elasticity and equivalent density of the friction weld region were used as updating parameters. Successful results were achieved by developing an algorithm that ensured the convergence of the numerical model’s FRFs and natural frequencies. Full article

This study addresses the challenge of accurately modeling the dynamic behavior of industrial robots for precision manufacturing applications. Using a comprehensive experimental approach with modal impulse hammer testing and triaxial acceleration measurements, 360 frequency response functions were recorded along orthogonal measurement paths for a KUKA KR10 robot. Two dynamic models with different parameter dimensions (12-parameter and 24-parameter) were developed in Matlab/Simscape, and their parameters were identified using genetic algorithm optimization. The KUKA KR10 features Harmonic Drives at each joint, whose high transmission ratio and zero backlash characteristics significantly influence rotational dynamics and allow for meaningful static structural measurements. Objective functions based on the Frequency Response Assurance Criterion (FRAC) and Root Mean Square Error (RMSE) metrics were employed, utilizing a frequency-dependent weighting function. The performance of the models was evaluated across different robot configurations and frequency ranges. The 24-parameter model demonstrated significantly superior performance, achieving 70% overall average Global FRAC in the limited frequency range (≤200 Hz) compared to 41% for the 12-parameter model when optimized using a representative subset of 9 measurement points. Both models showed substantially better performance in the limited frequency range than in the full spectrum. This research provides a validated methodology for dynamic characterization of industrial robots and demonstrates that higher-dimensional models, incorporating transverse joint compliance, can accurately represent robot dynamics up to approximately 200 Hz. Future work will investigate nonlinear effects such as torsional stiffness hysteresis, particularly relevant for Harmonic Drive systems. Full article

The Finite Element Method (FEM) has emerged as a powerful tool for predicting the behavior of industrial products, including those with complex geometries or uncommon materials. Finite Element Analysis (FEA) is widely used to study structural vibration-related aspects such as stress, displacement, and velocity. Modal analysis, a standard technique for characterizing the vibrational behavior of structures, is essential for identifying resonance frequencies, optimizing component design, and assessing structural integrity. Finite Elements (FE) modal analysis enables engineers to evaluate numerically the modal parameters, whereas model order reduction (MOR) schemes are exploited to achieve a balance between computational efficiency and accuracy, enabling a more efficient solution for computing transient dynamic analysis. Assessing the accuracy and reliability of FE solutions is a crucial aspect of the design cycle, and model-updating procedures are commonly employed to maximize the correlation between measured and predicted dynamic behavior. This study investigated the accuracy and computational efficiency of linear, quadratic, and cubic hexahedral FE formulations for modal analysis and transient dynamic solutions. More specifically, the documented results demonstrate the profitable use of the eigenenergy norm obtained in eigen solutions as a valid predictor of the accuracy reported using either the time response assurance criterion (TRAC) or the frequency response assurance criterion (FRAC), measured in transient dynamic cases. Moreover, our results also highlight the superior computational efficiency of higher-order formulations for both the eigen and transient dynamic solutions. Full article

In cementless Total Hip Arthroplasty (THA), achieving high primary implant fixation is crucial for the long-term survivorship of the femoral stem. While orthopedic surgeons traditionally assess fixation based on their subjective judgement, novel vibration-analysis fixation-monitoring techniques show promising potential in providing the surgeon with objective and quantifiable fixation measurements. This study presents a dynamic response measurement protocol for implant endpoint insertion and evaluates this protocol in the presence of artificial soft tissue. After the artificial femur was prepared in accordance with the THA protocol, the implant was inserted and progressively hammered into the cavity. The Pearson Correlation Coefficient (PCC) and Frequency Response Assurance Criterion (FRAC) corresponding to each insertion hammer hit were derived from the Frequency Response Functions (FRF) corresponding to each insertion step. The protocol was repeated with the artificial femur submerged in artificial soft tissue to imitate the influence of anatomical soft tissue. The FRAC appeared overall more sensitive than the PCC. In the presence of the artificial soft tissue the technique yielded higher PCC and FRAC values earlier in the insertion process. The measurements with artificial soft tissue produced FRFs with fewer peaks, lower resonance frequencies, and overall higher damping factors. The soft tissue appears to limit the fixation-change detection capabilities of the system and a promising potential remedy to this limitation is suggested. Full article