Tool condition monitoring of aluminum oxide grinding wheel in dressing operation using acoustic emission and neural networks

The grinding operation gives workpieces their final finish, minimizing surface roughness through the interaction between the abrasive grains of a tool (grinding wheel) and the workpiece. However, excessive grinding wheel wear due to friction renders the tool unsuitable for further use, thus requiring the dressing operation to remove and/or sharpen the cutting edges of the worn grains to render them reusable. The purpose of this study was to monitor the dressing operation using the acoustic emission (AE) signal and statistics derived from this signal, classifying the grinding wheel as sharp or dull by means of artificial neural networks. An aluminum oxide wheel installed on a surface grinding machine, a signal acquisition system, and a single-point dresser were used in the experiments. Tests were performed varying overlap ratios and dressing depths. The root mean square values and two additional statistics were calculated based on the raw AE data. A multilayer perceptron neural network was used with the Levenberg-Marquardt learning algorithm, whose inputs were the aforementioned statistics. The results indicate that this method was successful in classifying the conditions of the grinding wheel in the dressing process, identifying the tool as "sharp''(with cutting capacity) or "dull''(with loss of cutting capacity), thus reducing the time and cost of the operation and minimizing excessive removal of abrasive material from the grinding wheel.

Density and Spatial Distribution of Buffy-tufted-ear Marmosets (Callithrix aurita) in a Continuous Atlantic Forest

Fundação de Amparo à Pesquisa do Estado de São Paulo (FAPESP)

How to not inflate population estimates? Spatial density distribution of white-lipped peccaries in a continuous Atlantic forest

Fundação de Amparo à Pesquisa do Estado de São Paulo (FAPESP)

Dressing monitoring with a digital signal processor

Grinding is a finishing process in machining operations, and the topology of the grinding tool is responsible for producing the desired result on the surface of the machined material The tool topology is modeled in the dressing process and precision is therefore extremely important This study presents a solution in the monitoring of the dressing process, using a digital signal processor (DSP) operating in real time to detect the optimal dressing moment To confirm the monitoring efficiency by DSP, the results were compared with those of a data acquisition system (DAQ) and offline processing The method employed here consisted of analyzing the acoustic emission and electrical power signal by applying the DPO and DPKS parameters The analysis of the results allowed us to conclude that the application of the DPO and DPKS parameters can be substituted by processing of the mean acoustic emission signal, thus reducing the computational effort

Continuous wave ultraviolet frequency upconversion due to triads of Nd3+ ions in fluoroindate glass

We have observed ultraviolet upconversion fluorescence from the 4D3/2 and 2P3/2 levels of Nd3+ in fluoroindate glass under infrared pumping. It was found that the excitation of a large population in the 4F3/2 metastable level allows to achieve strong upconversion emissions at 354 and 382 nm. A simple rate equation model reproduces the temporal behavior of the upconverted emission and allows us to estimate the energy transfer rate among three Nd3+ ions participating in the process. © 1997 American Institute of Physics.

Confronting particle emission scenarios with strangeness data

We show that a hadron gas model with continuous particle emission instead of freeze-out may solve some of the problems (high values of the freeze-out density and specific net charge) that one encounters in the latter case when studying strange particle ratios such as those from the experiment WA85. This underlines the necessity to understand better particle emission in hydrodynamics to be able to analyze data. It also reopens the possibility of a quark-hadron transition occurring with phase equilibrium instead of explosively.

White light emission of Eu3+-based hybrid xerogels

The luminescence spectra and extended x-ray-absorption fine-structure (EXAFS) measurements of a series of Eu3+-based organic/inorganic xerogels were reported and related to the local coordination of the lanthanide cations. The hybrid matrix of these organically modified silicates, classed as U(2000) ureasils, is a siliceous network to which short organic chains containing oxyethylene units are covalently grafted by means of urea bridges. The luminescent centers were incorporated as europium triflate, Eu(CF3SO3)3, and europium bromide, EuBr3, with concentrations 200≥n≥20 and n=80, 40, and 30, respectively - where n is the number of ether oxygens in the polymer chains per Eu3+ cation. EXAFS measurements were carried out in some of the U(2000)nEu(CF3SO3)3 xerogels (n=200, 80, 60, and 40). The obtained coordination numbers N ranging from 12.8, n=200, to 9.7, n=40, whereas the average Eu3+ first neighbors distance R is 2.48-2.49 Å. The emission spectra of these multiwavelength phosphors superpose a broad green-blue band to a series of yellow-red narrow 5D0→7F0-4 Eu3+ lines and to the eye the hybrids appeared to be white, even at room temperature. The ability to tune the emission of the xerogels to colors across the chromaticity diagram is achieved by changing the excitation wavelength and the amount of salt incorporated in the hybrid host. The local environment of Eu3+ is described as a continuous distribution of closely similar low-symmetry network sites. The cations are coordinated by the carbonyl groups of the urea moieties, water molecules, and, for U(2000)nEu(CF3SO3)3, by the SO3 end groups of the triflate anions. No spectral evidences have been found for the coordination by the ether oxygens of the polyether chains. A mean radius for the first coordination shell of Eu3+ is calculated on the basis of the emission energy assignments. The results obtained for U(2000)nEu(CF3SO3)3, 2.4 Å for 90 ≥n≥40 and 2.6 and 2.5 Å for n=30 and 20, respectively, are in good agreement with the values calculated from EXAFS measurements. The energy of the intraconfigurational charge-transfer transitions, the redshift of the 5D0→7F0 line, with respect to the value calculated for gaseous Eu3+, and the hypersensitive ratio between the 5D0→7F2 and 5D0→7F1 transitions, point out a rather low covalency nature of the Eu3+ first coordination shell in these xerogels, comparing to the case of analogous polymer electrolytes modified by europium bromide. ©1999 The American Physical Society.

Production grinding burn detection using acoustic emission and electric power signals

This work uses a monitoring system based on a PC platform, where the acoustic emission and electric power signals generated during the grinding process are used to investigate superficial burning occurrence in a surface grinding operation using two types of steel, three grinding conditions and an Al203 vitrified grinding wheel. Acoustic emission signals on the workpiece and grinding power were measured during a surface plunge operation until the grinding burn happened. From the results the standard deviation of the acoustic emission signal and the maximum electric power were calculated for each grinding pass. The proposed DPO parameter is the product between the power level and acoustic emission standard deviation. The results show that both signals can be used for burning detection, and the parameter DPO is the best indicator for the burning studied in this work. This can be explained by the high dispersion of the acoustic emission RMS level associated to the high power consumption when the grinding wheel lose its sharpness.

In-process thermal damage detection in grinding with monitoring via Internet

This work aims the development of a dedicated system for detection of burning in surface grinding process, where the process will constantly be monitored through the acoustic emission and electric power of the induction motor drive. Acquired by an analog-digital converter, algorithms process the signals and a control signal is generated to inform the operator or interrupt the process in case of burning occurrence. Moreover, the system makes possible the process monitoring via Internet. Additionally, a comparative study between parameters DPO and FKS is carried through. In the experimental work one type of. steel (ABNT-1020 annealed) and one type of grinding wheel referred to as TARGA, model ART 3TG80.3 NVHB, were employed.

Control of thermal damage in grinding by digital signal processing of raw acoustic emission

Grinding process is usually the last finishing process of a precision component in the manufacturing industries. This process is utilized for manufacturing parts of different materials, so it demands results such as low roughness, dimensional and shape error control, optimum tool-life, with minimum cost and time. Damages on the parts are very expensive since the previous processes and the grinding itself are useless when the part is damaged in this stage. This work aims to investigate the efficiency of digital signal processing tools of acoustic emission signals in order to detect thermal damages in grinding process. To accomplish such a goal, an experimental work was carried out for 15 runs in a surface grinding machine operating with an aluminum oxide grinding wheel and ABNT 1045 e VC131 steels. The acoustic emission signals were acquired from a fixed sensor placed on the workpiece holder. A high sampling rate acquisition system at 2.5 MHz was used to collect the raw acoustic emission instead of root mean square value usually employed. In each test AE data was analyzed off-line, with results compared to inspection of each workpiece for burn and other metallurgical anomaly. A number of statistical signal processing tools have been evaluated.

Automatic system for thermal damage detection in manufacturing process with Internet monitoring

This work involved the development of a smart system dedicated to surface burning detection in the grinding process through constant monitoring of the process by acoustic emission and electrical power signals. A program in Visual Basic® for Windows® was developed, which collects the signals through an analog-digital converter and further processes them using burning detection algorithms already known. Three other parameters are proposed here and a comparative study carried out. When burning occurs, the newly developed software program sends a control signal warning the operator or interrupting the process, and delivers process information via the Internet. Parallel to this, the user can also interfere in the process via Internet, changing parameters and/or monitoring the grinding process. The findings of a comparative study of the various parameters are also discussed here. Copyright © 2006 by ABCM.

Induction of chromosome aberrations in the Allium cepa test system caused by the exposure of seeds to industrial effluents contaminated with azo dyes

Numerous potentially mutagenic chemicals have been studied mainly because they can cause damaging and inheritable changes in the genetic material. Several tests are commonly used for biomonitoring pollution levels and to evaluate the effects of toxic and mutagenic agents present in the natural environment. This study aimed at assessing the potential of a textile effluent contaminated with azo dyes to induce chromosomal and nuclear aberrations in Allium cepa test systems. A continuous exposure of seeds in samples of the textile effluent in different concentrations was carried out (0.3%, 3%, 10%, and 100%). Cells in interphase and undergoing division were examined to assess the presence of chromosome aberrations, nuclear changes, and micronuclei. Our results revealed a mutagenic effect of the effluent at concentrations of 10% and 100%. At lower concentrations, the effluent (3% and 0.3%) did not induce mutagenic alterations in the test organism A. cepa. These findings are of concern, since cell damage may be transmitted to subsequent generations, possibly affecting the organism as a whole, as well as the local biota exposed to the effluent discharge. If the damage results in cell death, the development of the organism may be affected, which could also lead to its death. © 2008 Elsevier Ltd. All rights reserved.

Monitoring the dressing operation in the grinding process

This work was based on a methodology of development and experimentation, and involved monitoring the dressing operation by processing the acoustic emission and electric power signals to detect the optimal dressing moment. Dressing tests were performed in a surface grinding machine with an aluminium grinding wheel. Dressing analysis software was developed and used to process the signals collected earlier in order to analyse not only the dressing parameters but also the software's ability to indicate the instant when the dressing operation could be concluded. Parameters used in the study of burn in grinding were implemented in order to ascertain if they would also prove efficient in monitoring dressing. A comparative study revealed that some parameters are capable of monitoring the dressing operation. It was possible to verify the parameters effectiveness that today are utilised in burning to monitor dressing as well as to create new parameters for monitoring this operation. Copyright © 2009, Inderscience Publishers.

Piezoelectric composite film for acoustic emission detection

The continuous technological advances require materials with properties that conventional material cannot display. Material property combinations are being the focus to the development of composite materials, which are considered a multiphase material that exhibits properties of the constituent phases. One interesting material to be studied as sensing material is the composite made of ferroelectric ceramic and polymeric matrix as a two-phases composite material. In that case, the combinations properties intended are the high piezo and pyroelectric activities of the dense ceramic with the impact resistance, flexibility, formability and low densities of the polymer. Using the piezoelectric property of the composite film, it can be used to detect acoustic emission (AE), which is a transient elastic wave generated by sudden deformation in materials under stress. AE can be applied for evaluating the health of structures in a nondestructive way and without any lapse of time. The preliminary result indicates that the composite Pz34/PEEK can be used as sensing material for nondestructive evaluation. ©2009 IEEE.

Aerosols monitoring in Rio Claro, Brazil: Using lidar and air pollution analyzers

Brazil has an important role in the biomass burning aerosol activity. During the Dry Season (June-September) of 2009 an aerosol profiling campaign was carried out using a backscattering and Raman lidar system in Rio Claro-SP, Brazil (22°23'S and 47°32'W). The main goal of this campaign was to observe the biomass burning aerosol load due to sugarcane crops and also study the air dispersion conditions, planetary boundary and mixed layer daily evolution. In this paper we aim to present the preliminary results of the influence of this type of aerosol over the city of Rio Claro-SP, Brazil and one case study to evaluate the aerosol profile in a biomass burning episode that occurred in July, 2009. On July 15 an intense burning was observed about 300 m away from the lidar location. Throughout the measurements it was observed that the plumes reached up to 900 m, and that there was a time gap between the plumes. The gas analyzers showed a strong influence of this burning as it was noticed in the measurements of CO, NO x and nephelometer, whereas the PM10 did not have due to this burning, possibly because the particulate was deposited further from the emission source, not being detected by the equipment. © Sociedad Española de Óptica.