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.

Studies on the cooling minimum quantity and conventional cooling at hardened steels in grinding process

The purpose of this work is to explain the concept of cutting fluids reasonable usage through the fluid minimum quantity in grinding processes. on that purpose, the development of a new nozzle and an own and adequate methodology should be required in order to obtain good results and compare them to the conventional methods. The analysis of the grinding wheel/cutting fluid performance was accomplished from the following input parameters: flow rate variation by nozzle diameter changes (three diameters values: 3mm, 4mm and 5mm), besides the conventional round nozzle already within the machine. Integral oil and a synthetic emulsion were used as cutting fluids and a conventional grinding wheel was employed. The workpieces were made of steel VC 131, tempered and quenched with 60HRc. Thus, as the flow rate and the nozzle diameter changes, keeping steady fluid jet velocity (equal to cutting velocity), attempted to find the best machining conditions, with the purpose to obtain a decrease on the cutting fluid volume, taking into consideration the analysis of the process output variables such as cutting strength, cutting specific energy, grinding wheel wear and surface roughness. It was verified that the 3mm diameter optimized nozzle and the integral oil, in general, was the best combination among all proposed.

Towards the prediction of essential genes by integration of network topology, cellular localization and biological process information

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

Relax and fix heuristics to solve one-stage one-machine lot-scheduling models for small-scale soft drink plants

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

Line based camera calibration in machine vision dynamic applications

The problem of dynamic camera calibration considering moving objects in close range environments using straight lines as references is addressed. A mathematical model for the correspondence of a straight line in the object and image spaces is discussed. This model is based on the equivalence between the vector normal to the interpretation plane in the image space and the vector normal to the rotated interpretation plane in the object space. In order to solve the dynamic camera calibration, Kalman Filtering is applied; an iterative process based on the recursive property of the Kalman Filter is defined, using the sequentially estimated camera orientation parameters to feedback the feature extraction process in the image. For the dynamic case, e.g. an image sequence of a moving object, a state prediction and a covariance matrix for the next instant is obtained using the available estimates and the system model. Filtered state estimates can be computed from these predicted estimates using the Kalman Filtering approach and based on the system model parameters with good quality, for each instant of an image sequence. The proposed approach was tested with simulated and real data. Experiments with real data were carried out in a controlled environment, considering a sequence of images of a moving cube in a linear trajectory over a flat surface.

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.

Global analysis of aerodynamics deflectors efficiency in the grinding process

The conventional, grinding methods in some cases are not very efficient because the arising of thermal damages in the pieces is very common. Optimization methods of cutting fluid application in the grinding zone are essential to prevent thermal problems from interaction of the wheel grains with the workpiece. surface. The optimization can happen through the correct selection of the cut parameters and development of devices that eliminate air layer effects generated around the grinding wheel. This article will collaborate with the development of an experimentation methodology which allows evaluating, comparatively, the performance of the deflectors in the cutting region to minimize the air layer effect of the high speed of the grinding wheel. The air layers make the cutting fluid jet to dissipate in the machine. An optimized nozzle was used in order to compare the results with the conventional method (without baffles or deflectors) of cutting fluid application. The results showed the high eficciency of the deflectors or baffles in the finish results. Copyright © 2006 by ABCM.

Classification of petroleum well drilling operations using Support Vector Machine (SVM)

During the petroleum well drilling operation many mechanical and hydraulic parameters are monitored by an instrumentation system installed in the rig called a mud-logging system. These sensors, distributed in the rig, monitor different operation parameters such as weight on the hook and drillstring rotation. These measurements are known as mud-logging records and allow the online following of all the drilling process with well monitoring purposes. However, in most of the cases, these data are stored without taking advantage of all their potential. On the other hand, to make use of the mud-logging data, an analysis and interpretationt is required. That is not an easy task because of the large volume of information involved. This paper presents a Support Vector Machine (SVM) used to automatically classify the drilling operation stages through the analysis of some mud-logging parameters. In order to validate the results of SVM technique, it was compared to a classification elaborated by a Petroleum Engineering expert. © 2006 IEEE.

Estimation of electrical machine speed using sensorless technology and neural networks

The use of sensorless technologies is an increasing tendency on industrial drivers for electrical machines. The estimation of electrical and mechanical parameters involved with the electrical machine control is used very frequently in order to avoid measurement of all variables related to this process. The cost reduction may also be considered in industrial drivers, besides the increasing robustness of the system, as an advantage of the use of sensorless technologies. This work proposes the use of a recurrent artificial neural network to estimate the speed of induction motor for sensorless control schemes using one single current sensor. Simulation and experimental results are presented to validate the proposed approach. ©2008 IEEE.

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.

Digital system design process automation using place/transition petri nets

The constant increase in digital systems complexity definitely demands the automation of the corresponding synthesis process. This paper presents a computational environment designed to produce both software and hardware implementations of a system. The tool for code generation has been named ACG8051. As for the hardware synthesis there has been produced a larger environment consisting of four programs, namely: PIPE2TAB, AGPS, TABELA, and TAB2VHDL. ACG8051 and PIPE2TAB use place/transition net descriptions from PIPE as inputs. ACG8051 is aimed at generating assembly code for the 8051 micro-controller. PIPE2TAB produces a tabular version of a Mealy type finite state machine of the system, its output is fed into AGPS that is used for state allocation. The resulting digital system is then input to TABELA, which minimizes control functions and outputs of the digital system. Finally, the output generated by TABELA is fed to TAB2VHDL that produces a VHDL description of the system at the register transfer level. Thus, we present here a set of tools designed to take a high-level description of a digital system, represented by a place/transition net, and produces as output both an assembly code that can be immediately run on an 8051 micro-controller, and a VHDL description that can be used to directly implement the hardware parts either on an FPGA or as an ASIC.

Monitoring in precision metal drilling process using multi-sensors and neural network

This paper presents a new method to estimate hole diameters and surface roughness in precision drilling processes, using coupons taken from a sandwich plate composed of a titanium alloy plate (Ti6Al4V) glued onto an aluminum alloy plate (AA 2024T3). The proposed method uses signals acquired during the cutting process by a multisensor system installed on the machine tool. These signals are mathematically treated and then used as input for an artificial neural network. After training, the neural network system is qualified to estimate the surface roughness and hole diameter based on the signals and cutting process parameters. To evaluate the system, the estimated data were compared with experimental measurements and the errors were calculated. The results proved the efficiency of the proposed method, which yielded very low or even negligible errors of the tolerances used in most industrial drilling processes. This pioneering method opens up a new field of research, showing a promising potential for development and application as an alternative monitoring method for drilling processes. © 2012 Springer-Verlag London Limited.

Hot turning of a difficult-to-machine steel (sae xev-f) aided by infrared radiation

A possible way for increasing the cutting tool life can be achieved by heating the workpiece in order to diminish the shear stress of material and thus decrease the machining forces. In this study, quartz electrical resistances were set around the workpiece for heating it during the turning. In the tests, heat-resistant austenitic alloy steel was used, hardenable by precipitation, mainly used in combustion engine exhaustion valves, among other special applications for industry. The results showed that in the hot machining the cutting tool life can be increased by 340% for the highest cutting speed tested and had a reduction of 205% on workpiece surface roughness, accompanied by a force decrease in relation to conventional turning. In addition, the chips formed in hot turning exhibited a stronger tendency to continuous chip formation indicating less energy spent in material removal process. Microhardness tests performed in the workpieces subsurface layers at 5 m depth revealed slightly higher values in the hot machining than in conventional, showing a tendency toward the formation of compressive residual stress into plastically deformed layer. The hot turning also showed better performance than machining using cutting fluid. Since it is possible to avoid the use of cutting fluid, this machining method can be considered better for the environment and for the human health.