In-process grinding monitoring by acoustic emission

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. The acoustic emission signals were acquired from a fixed sensor placed on the workpiece holder. A high sampling rate data acquisition system at 2.5 MHz was used to collect the raw acoustic emission instead of root mean square value usually employed. Many statistics have shown effective to detect burn, such as the root mean square (RMS), correlation of the AE, constant false alarm (CFAR), ratio of power (ROP) and mean-value deviance (MVD). However, the CFAR, ROP, Kurtosis and correlation of the AE have been presented more sensitive than the RMS.

Surface finishing of flat pieces when submitted to lapping kinematics on abrasive disc dressed under several overlap factors

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

Material processing by plasma shock wave generated in an inverse Z-pinch plasma expander

The applicability of plasma shock wave for material processing was investigated using modified inverse Z-pinch device. Shock wave expanding speed and plasma spectral analysis were studied using an internal magnetic,probe and spatially collimated light spectroscopy. The material processing capability of the device was shown by many different surface analysis techniques such as AES, IRS, EPM and SEM. The interactions between a plasma shock wave of similar to4x10(6) cm/s speed with a Si substrate surface shows some ion implantation capability using a nitrogen plasma and thin film formation using a methane plasma.

Solitary waves on a free surface of a heated Maxwell fluid

Conselho Nacional de Desenvolvimento Científico e Tecnológico (CNPq)

Evolution equation for short surface waves on water of finite depth

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

Sensible and latent heat loss from the body surface of Holstein cows in a tropical environment

The general principles of the mechanisms of heat transfer are well known, but knowledge of the transition between evaporative and non-evaporative heat loss by Holstein cows in field conditions must be improved, especially for low-latitude environments. With this aim 15 Holstein cows managed in open pasture were observed in a tropical region. The latent heat loss from the body surface of the animals was measured by means of a ventilated capsule, while convective heat transfer was estimated by the theory of convection from a horizontal cylinder and by the long-wave radiation exchange based on the Stefan-Boltzmann law. When the air temperature was between 10 and 36 degrees C the sensible heat transfer varied from 160 to -30 W m(-2), while the latent heat loss by cutaneous evaporation increased from 30 to 350 W m(-2). Heat loss by cutaneous evaporation accounted for 20-30% of the total heat loss when air temperatures ranged from 10 to 20 degrees C. At air temperatures > 30 degrees C cutaneous evaporation becomes the main avenue of heat loss, accounting for approximately 85% of the total heat loss, while the rest is lost by respiratory evaporation.

Macrobenthic intertidal communities from wave to tide dominated beach environments. A case study in two Brazilian beaches

Modification showed by intertidal macrofaunal communities between two nearby sites that change from a wave to a tide dominated beach environment, was analyzed on the present study. At each site, eleven intertidal sampling stations were distributed along a transect, from the drift line to the spring low tide water level. Four macrofaunal samples one meter long-shore spaced were collected at, each station with an iron core of 0.05 m(2) surface area, taken to a depth of 20 cm. Major,differences on sediments between sites were the offshore decrease of mean particle size diameter and increase of kurtosis and water content at the tide dominated site. KIDS ordination showed major similarities between the lowest stations of this site, that represents the dissipative low tide-terrace portion of the beach. Two lower station of the wave dominated site presented similarities with this group. The other stations of the tide-dominated site, that represents the reflective high tide beach portion, grouped distant from the former. (canonical Correspondence Analysis (CCA) showed a similar spatial distribution of stations, suggesting the importance of environmental factors on the explanation of species distribution patterns. Sediment water content and water table depth, with the highest inertia value, seems to be the principal physical factor. Increase on water content affects the macrofaunal distribution by the expansion of typical infralitoral species, as was the case of Bathyporeiapus ruffoi, on the dissipative low tide terrace beach portion. A disrupted distribution with the lost of a gradate zonation along a physical gradient is one of the major modification presented by macrobenthic communities on the transition from a wave to a tide dominated beach environment.

Modulational instability analysis of surface-waves in the Bénard-Marangoni phenomenon

By using the long-wave approximation, a system of coupled evolutions equations for the bulk velocity and the surface perturbations of a Bénard-Marangoni system is obtained. It includes nonlinearity, dispersion and dissipation, and it is interpreted as a dissipative generalization of the usual Boussinesq system of equations. Then, by considering that the Marangoni number is near the critical value M = -12, we show that the modulation of the Boussinesq waves is described by a perturbed Nonlinear Schrödinger Equation, and we study the conditions under which a Benjamin-Feir instability could eventually set in. The results give sufficient conditions for stability, but are inconclusive about the existence or not of a Benjamin-Feir instability in the long-wave limit. © 1995.

A case study of the 9 August 1988 South Atlantic storm: Numerical simulations of the wave activity

During 9-11 August 1988, a cyclone developed over Uruguay in the lee of the Andes Mountains and moved over the South Atlantic Ocean, where it redeveloped into an intense storm. This storm was responsible for unusual wave activity along the Brazilian shoreline from 22° to 32°S. The Brazilian news media reported the loss of at least one life, waves of 3 m and higher, and the disappearance of a drainage pipe, which weighed 8000 kg, off the shores of Rio de Janeiro. In this paper, the evolution of this intense storm and the associated ocean wave response is studied through European Centre for Medium-Range Weather Forecasts analyses, a hydrostatic limited-area meteorological model, and a second-generation prognostic wave model. The atmospheric model results indicated the presence of a long-lived and large fetch with surface wind velocities higher than 12 m s -1 directed toward the coast. Some areas with velocities of 20 m s -1 were embedded in the fetch. The wave model forced by this wind field was able to simulate waves with a significant height of 8 m far from the coast and about 4 m in regions very close to the Brazilian coast in agreement with the occurrence reported at Rio de Janeiro. The swell propagation toward the coast of Rio de Janeiro was obstructed by a northeastward 10-m wind during the first 24-h period of the model's integration. During the second 24-h period, the fetch was still large and strong, but the obstacle was removed by a counterclockwise rotation of wind direction favoring the swell and windsea propagation toward the Rio de Janeiro coast.

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.

The use of shallow seismic reflection technique in near surface exploration of urban sites: An evaluation in the city of SãO Paulo, Brazil

In order to evaluate the use of shallow seismic technique to delineate geological and geotechnical features up to 40 meters depth in noisy urban areas covered with asphalt pavement, five survey lines were conducted in the metropolitan area of São Paulo City. The data were acquired using a 24-bit, 24-channel seismograph, 30 and 100 Hz geophones and a sledgehammer-plate system as seismic source. Seismic reflection data were recorded using a CMP (common mid point) acquisition method. The processing routine consisted of: prestack band-pass filtering (90-250 Hz); automatic gain control (AGC); muting (digital zeroin) of dead/noisy traces, ground roll, air-wave and refracted-wave; CMP sorting; velocity analyses; normal move-out corrections; residual static corrections; f-k filtering; CMP stacking. The near surface is geologically characterized by unconsolidated fill materials and Quaternary sediments with organic material overlying Tertiary sediments with the water table 2 to 5 m below the surface. The basement is composed of granite and gneiss. Reflections were observed from 40 milliseconds to 65 ms two-way traveltime and were related to the silt clay layer and fine sand layer contact of the Tertiary sediments and to the weathered basement. The CMP seismic-reflection technique has been shown to be useful for mapping the sedimentary layers and the bedrock of the São Paulo sedimentary basin for the purposes of shallow investigations related to engineering problems. In spite of the strong cultural noise observed in these urban areas and problems with planting geophones we verified that, with the proper equipment, field parameters and particularly great care in data collection and processing, we can overcome the adverse field conditions and to image reflections from layers as shallow as 20 meters.

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.

In-process grinding monitoring through acoustic emission

This work aims to investigate the efficiency of digital signal processing tools of acoustic emission signals in order to detect thermal damages in grinding processes. 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 Steel as work material. The acoustic emission signals were acquired from a fixed sensor placed on the workpiece holder. A high sampling rate data acquisition system working at 2.5 MHz was used to collect the raw acoustic emission instead of the root mean square value usually employed. Many statistical analyses have shown to be effective to detect burn, such as the root mean square (RMS), correlation of the AE, constant false alarm rate (CFAR), ratio of power (ROP) and mean-value deviance (MVD). However, the CFAR, ROP, Kurtosis and correlation of the AE have been presented more sensitive than the RMS. Copyright © 2006 by ABCM.

PTCa/PEEK composite acoustic emission sensors

Composites made of Calcium-modified lead titanate (PTCa) and poly (ether-etherketone) (PEEK) high performance polymer matrix were prepared in the film form using a hot press. The ceramic volume fraction reaches up to 60 percent providing a composite with 0-3 and 1-3 mixed connectivities due to the high ceramic content and the resulting materials could be considered PEEK-bonded PTCa particulate composite. The composites were characterized using piezoelectric spectroscopy and ultrasonic immersion techniques. Values up to 38.5 pC/N were obtained for the longitudinal d33 piezoelectric coefficient. The composite was surface-mounted on a carbon fiber plate-like specimen and the ability of the PTCa/PEEK composite to detect acoustic emission (AE) is reported. © 2006 IEEE.

Methodology for automatic selection of passes in surface grinding

The main purpose of this work is the development of computational tools in order to assist the on-line automatic detection of burn in the surface grinding process. Most of the parameters currently employed in the burning recognition (DPO, FKS, DPKS, DIFP, among others) do not incorporate routines for automatic selection of the grinding passes, therefore, requiring the user's interference for the choice of the active region. Several methods were employed in the passes extraction; however, those with the best results are presented in this article. Tests carried out in a surface-grinding machine have shown the success of the algorithms developed for pass extraction. Copyright © 2007 by ABCM.