Virtual Sensors for On-line Wheel Wear and Part Roughness Measurement in the Grinding Process

Grinding is an advanced machining process for the manufacturing of valuable complex and accurate parts for high added value sectors such as aerospace, wind generation, etc. Due to the extremely severe conditions inside grinding machines, critical process variables such as part surface finish or grinding wheel wear cannot be easily and cheaply measured on-line. In this paper a virtual sensor for on-line monitoring of those variables is presented. The sensor is based on the modelling ability of Artificial Neural Networks (ANNs) for stochastic and non-linear processes such as grinding; the selected architecture is the Layer-Recurrent neural network. The sensor makes use of the relation between the variables to be measured and power consumption in the wheel spindle, which can be easily measured. A sensor calibration methodology is presented, and the levels of error that can be expected are discussed. Validation of the new sensor is carried out by comparing the sensor's results with actual measurements carried out in an industrial grinding machine. Results show excellent estimation performance for both wheel wear and surface roughness. In the case of wheel wear, the absolute error is within the range of microns (average value 32 mu m). In the case of surface finish, the absolute error is well below R-a 1 mu m (average value 0.32 mu m). The present approach can be easily generalized to other grinding operations.

Estudio del rectificado de Inconel 718

[ES]Cada vez más industrias como las aeronáuticas o espaciales buscan nuevos materiales con excelentes propiedades hoy en día. Sin embargo, estos materiales suelen presentar hándicaps como por ejemplo su maquinabilidad. Mediante este TFG, se estudiará el rectificado de uno de estos materiales, el Inconel 718. Para conseguir los objetivos, este TFG se elaborará en varias etapas. Primero es necesario conocer las propiedades del Inconel 718 y analizarlas. Tras esto, se realizará el mismo proceso con el proceso de rectificado, haciendo hincapié en el desgaste de muelas; para finalmente, encontrar soluciones y alternativas que optimicen el proceso de rectificado. La ejecución de este TFG permitirá comprender y minimizar el desgaste de las muelas durante el proceso de rectificado.

A comprehensive method for the elastic calculation of the two-point wheel-rail contact

This work shows the method developed to solve the wheel-rail contact problem via a look-up table with a three-dimensional elastic model. This method enables introduction of the two contact point effect on vehicle movement using three-dimensional analysis of surfaces including the influence of the angle of attack. This work presents several dynamic simulations and studies the impact that the introduction of the two contact points on three dimensions has on wear indexes and derailment risk against traditional bidimensional analysis. Furthermore, it studies advantages and disadvantages of using a look-up table against an on-line resolution of the problem.

A rational fraction polynomials model to study vertical dynamic wheel-rail interaction

This paper presents a model designed to study vertical interactions between wheel and rail when the wheel moves over a rail welding. The model focuses on the spatial domain, and is drawn up in a simple fashion from track receptances. The paper obtains the receptances from a full track model in the frequency domain already developed by the authors, which includes deformation of the rail section and propagation of bending, elongation and torsional waves along an infinite track. Transformation between domains was secured by applying a modified rational fraction polynomials method. This obtains a track model with very few degrees of freedom, and thus with minimum time consumption for integration, with a good match to the original model over a sufficiently broad range of frequencies. Wheel-rail interaction is modelled on a non-linear Hertzian spring, and consideration is given to parametric excitation caused by the wheel moving over a sleeper, since this is a moving wheel model and not a moving irregularity model. The model is used to study the dynamic loads and displacements emerging at the wheel-rail contact passing over a welding defect at different speeds.

Design of an optimised wheel profile for rail vehicles operating on two track gauges

This paper sets out an optimum synthesis methodology for wheel profiles of railway vehicles in order to secure good dynamic behaviour with different track configurations. Specifically, the optimisation process has been applied to the case of rail wheelsets mounted on double gauge bogies, that move over two different gauges, which also have different types of rail: the Iberian gauge (1668 mm) and the UIC gauge (1435 mm). Optimisation is performed using Genetic Algorithms and traditional optimisation methods in a complementary way. The objective function used is based on an ideal equivalent conicity curve which ensures good stability on straight sections and also proper negotiation of curves. To this end the curve is constructed in such a way that it is constant with a low value for small lateral wheelset displacements (with regard to stability), and increases as the displacements increase (to facilitate negotiation of curved sections). Using this kind of ideal conicity curve also enables a wheel profile to be secured where the contact points have a larger distribution over the active contact areas, making wear more homogeneous and reducing stresses. The result is a wheel profile with a conicity that is closer to the target conicity for both gauges studied, producing better curve negotiation while maintaining good stability on straight sections of track. The paper shows the resultant wheel profile, the contact curves it produces, and a number of dynamic analyses demonstrating better dynamic behaviour of the synthesised wheel on curved sections with respect to the original wheel.

Dynamic optimization of track components to minimize rail corrugation

In this paper, the influence on corrugation of the most significant track parameters has been examined. After this parametric study, the optimization of the track parameters to minimize the undulatory wear growth has been achieved. Finally, the influence of the dispersion of the track and contact parameters on corrugation growth has been studied. A method has been developed to obtain an optimal solution of the track parameters which minimizes corrugation growth, thus ensuring that this solution remains optimum despite dispersion of track parameters and wheel-rail contact uncertainties. This work is based on the computer application RACING (RAil Corrugation INitiation and Growth) which has been developed by the authors to predict rail corrugation features.

La cerámica de la Segunda Edad del Hierro en el País Vasco: Estudio tecnológico, funcional y social

670 p. Capítulos de introducción, metodología, discusión y conclusiones en castellano e inglés.

Comparación de la rugosidad media y máxima obtenida mediante diferentes instrumentos: análisis del filtro y Lc empleados

[ES]Este trabajo pretende analizar la influencia que tiene la longitud de corte elegida y el filtro empleado en la medida de la rugosidad. Se realizan medidas de rugosidad en tres probetas que han sido sometidas a diferentes procesos de fabricación (fresado, rectificado y electroerosión). Además, se utilizan tres instrumentos diferentes para la medición. Tras realizar las medidas, se comparan los resultados y se extraen las conclusiones

Diseño de sistema de suspensión progresiva Pro-Link

[ES]Mediante este trabajo se va a diseñar un mecanismo para crear un sistema de suspensión progresiva para la suspensión trasera de una motocicleta a partir de un muelle lineal. El muelle introducido en la suspensión será lineal, por lo tanto, tendrá una sola rigidez, constante y la cual delimita el muelle, pero gracias a un mecanismo diseñado especialmente para la suspensión trasera de una moto, se va conseguir que la rigidez varíe. El mecanismo utilizado para este trabajo se llama Pro-Link y la empresa que lo emplea es Honda. Para ello, se creará un esquema del mecanismo en sí y tras un análisis cinemático mediante el programa Creo Parametric, y haciendo varios cambios en el sistema para ajustarlo a la mejor progresividad posible, se obtendrá la gráfica en la que se observará la curva que marca la rigidez progresiva. Esto es, se verá la evolución de la nueva rigidez dependiendo de la oscilación vertical de la rueda. Por otra parte, gracias a un análisis dinámico del mismo programa se conseguirán las reacciones del sistema y se calcularán los elementos auxiliares de éste para el buen funcionamiento del mismo. Finalmente, se creará el diseño del triángulo y un diseño preliminar del basculante mediante el método de elementos finitos del programa.

Sistema metal-organiko hedatuak

Lan honetan, kobre(II) katioiak zenbait estekatzaile organikoekin eratzen dituen haize-errota (paddle-wheel) itxurako egiturak aztertuko dira. Entitate hauek sistema solidoari zurruntasuna ematen diote eta koordinazio-polimeroaren hazkundearen norabideak finkatzen dituzte.