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.

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.

Calcium modified lead titanate/poly-ether-ether-ketone composite for acoustic emission sensors

Composites made of calcium modified lead titanate ceramic powder and poly (ether-ether-ketone) high performance polymer matrix were prepared in the film form using a hot press. The acoustic and electromechanical properties of the composites have been determined using the ultrasonic immersion technique and piezoelectric spectroscopy, respectively. The composite film with 60 - 40 vol.% PTCa/PEEK was tested as acoustic emission detector. Preliminary results shown that the piezo composite can be used as sensor to evaluate the behavior of materials.

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.

Thin-Film Sparse Boundary Array Design for Passive Acoustic Mapping During Ultrasound Therapy

A new 2-D hydrophone array for ultrasound therapy monitoring is presented, along with a novel algorithm for passive acoustic mapping using a sparse weighted aperture. The array is constructed using existing polyvinylidene fluoride (PVDF) ultrasound sensor technology, and is utilized for its broadband characteristics and its high receive sensitivity. For most 2-D arrays, high-resolution imagery is desired, which requires a large aperture at the cost of a large number of elements. The proposed array's geometry is sparse, with elements only on the boundary of the rectangular aperture. The missing information from the interior is filled in using linear imaging techniques. After receiving acoustic emissions during ultrasound therapy, this algorithm applies an apodization to the sparse aperture to limit side lobes and then reconstructs acoustic activity with high spatiotemporal resolution. Experiments show verification of the theoretical point spread function, and cavitation maps in agar phantoms correspond closely to predicted areas, showing the validity of the array and methodology.

A study of acoustic emission technique for concrete damage detection

The Acoustic emission (AE) technique, as one of non-intrusive and nondestructive evaluation techniques, acquires and analyzes the signals emitting from deformation or fracture of materials/structures under service loading. The AE technique has been successfully applied in damage detection in various materials such as metal, alloy, concrete, polymers and other composite materials. In this study, the AE technique was used for detecting crack behavior within concrete specimens under mechanical and environmental frost loadings. The instrumentations of the AE system used in this study include a low-frequency AE sensor, a computer-based data acquisition device and a preamplifier linking the AE sensor and the data acquisition device. The AE system purchased from Mistras Group was used in this study. The AE technique was applied to detect damage with the following laboratory tests: the pencil lead test, the mechanical three-point single-edge notched beam bending (SEB) test, and the freeze-thaw damage test. Firstly, the pencil lead test was conducted to verify the attenuation phenomenon of AE signals through concrete materials. The value of attenuation was also quantified. Also, the obtained signals indicated that this AE system was properly setup to detect damage in concrete. Secondly, the SEB test with lab-prepared concrete beam was conducted by employing Mechanical Testing System (MTS) and AE system. The cumulative AE events and the measured loading curves, which both used the crack-tip open displacement (CTOD) as the horizontal coordinate, were plotted. It was found that the detected AE events were qualitatively correlated with the global force-displacement behavior of the specimen. The Weibull distribution was vii proposed to quantitatively describe the rupture probability density function. The linear regression analysis was conducted to calibrate the Weibull distribution parameters with detected AE signals and to predict the rupture probability as a function of CTOD for the specimen. Finally, the controlled concrete freeze-thaw cyclic tests were designed and the AE technique was planned to investigate the internal frost damage process of concrete specimens.

Fabrication methods for creating flexible polymer substrate sensor tags

The authors describe the design, fabrication, and testing of a passive wireless sensor platform utilizing low-cost commercial surface acoustic wave filters and sensors. Polyimide and polyethylene terephthalate sheets are used as substrates to create a flexible sensor tag that can be applied to curved surfaces. A microfabricated antenna is integrated on the substrate in order to create a compact form factor. The sensor tags are fabricated using 315 MHz surface acoustic wave filters and photodiodes and tested with the aid of a fiber-coupled tungsten lamp. Microwave energy transmitted from a network analyzer is used to interrogate the sensor tag. Due to an electrical impedance mismatch at the SAW filter and sensor, energy is reflected at the sensor load and reradiated from the integrated antenna. By selecting sensors that change electrical impedance based on environmental conditions, the sensor state can be inferred through measurement of the reflected energy profile. Testing has shown that a calibrated system utilizing this type of sensor tag can detect distinct light levels wireless and passively. The authors also demonstrate simultaneous operation of two tags with different center passbands that detects light. Ranging tests show that the sensor tags can operate at a distance of at least 3.6 m.

Archive of the PASATA (PASsive Acoustic Tracking of Antarctic marine mammals) field documentation

Recordings from the PerenniAL Acoustic Observatory in the Antarctic ocean (PALAOA) show seasonal acoustic presence of 4 Antarctic ice-breeding seal species (Ross seal, Ommatophoca rossii, Weddell seal, Leptonychotes weddellii, crabeater, Lobodon carcinophaga, and leopard seal, Hydrurga leptonyx). Apart from Weddell seals, inhabiting the fast-ice in Atka Bay, the other three (pack-ice) species however have to date never (Ross and leopard seal) or only very rarely (crabeater seals) been sighted in the Atka Bay region. The aim of the PASATA project is twofold: the large passive acoustic hydrophone array (hereafter referred to as large array) aims to localize calling pack-ice pinniped species to obtain information on their location and hence the ice habitat they occupy. This large array consists of four autonomous passive acoustic recorders with a hydrophone sensor deployed through a drilled hole in the sea ice. The PASATA recordings are time-stamped and can therefore be coupled to the PALAOA recordings so that the hydrophone array spans the bay almost entirely from east to west. The second, smaller hydrophone array (hereafter referred to as small array), also consists of four autonomous passive acoustic recorders with hydrophone sensors deployed through drilled holes in the sea ice. The smaller array was deployed within a Weddell seal breeding colony, located further south in the bay, just off the ice shelf. Male Weddell seals are thought to defend underwater territories around or near tide cracks and breathing holes used by females. Vocal activity increases strongly during the breeding season and vocalizations are thought to be used underwater by males for the purpose of territorial defense and advertisement. With the smaller hydrophone array we aim to investigate underwater behaviour of vocalizing male and female Weddell seals to provide further information on underwater movement patterns in relation to the location of tide cracks and breathing holes. As a pilot project, one on-ice and three underwater camera systems have been deployed near breathing holes to obtain additional visual information on Weddell seal behavioural activity. Upon each visit in the breeding colony, a census of colony composition on the ice (number of animals, sex, presence of dependent pups, presence and severity of injuries-indicative of competition intensity) as well as GPS readings of breathing holes and positions of hauled out Weddell seals are taken.

Ultrasonic field and temperature sensor based on short in-fibre Bragg gratings

The authors demonstrate that in-fibre Bragg gratings may be successfully used to measure megahertz acoustic fields if the grating length is sufficiently short and the optical fibre is appropriately desensitised. A noise-limited pressure resolution of 4.5 × 10 –3 atm vHz was found. The capability to simultaneously act as a temperature sensor is also demonstrated.

Combined ultrasound and temperature sensor using a fibre Bragg grating

We demonstrate the feasibility of using in-fibre Bragg gratings to measure MHz acoustic fields and temperature simultaneously. We achieved a noise-limited pressure resolution of ˜4.5×10-4 Atm/vHz and a temperature resolution of 0.2°C.

Transient response in high-resolution Brillouin-based distributed sensing using probe pulses shorter than the acoustic relaxation time

We perform numerical simulations on a model describing a Brillouin-based temperature and strain sensor, testing its response when it is probed with relatively short pulses. Experimental results were recently published [e.g., Opt. Lett. 24, 510 (1999)] that showed a broadening of the Brillouin loss curve when the probe pulse duration is reduced, followed by a sudden and rather surprising reduction of the linewidth when the pulse duration gets shorter than the acoustic relaxation time. Our study reveals the processes responsible for this behavior. We give a clear physical insight into the problem, allowing us to define the best experimental conditions required for one to take the advantage of this effect.

A low-cost multimode fiber Bragg grating sensor system

A low-cost fiber optic sensor system based on multimode fiber and an LED light source is presented. A multimode fiber Bragg grating (MMFBG) element is used as a strain sensor. In a matched grating scheme, a MMFBG similar to the sensing one was used as a reference in the receiving unit. For detection of large wavelength shift we demonstrated the feasibility of MMFBG wavelength detection using a single mode fiber fused coupler edge filter. The high cost normally associated with wavelength interrogators for single mode fiber FBG sensors was overcome by the utilization of a low cost multimode fiber pigtailed LED light source. The multimode fiber sensing system has the potential of maintaining much of the advantages of its single mode FBG sensor system counterparts. The MMFBG sensing schemes could be used for short distance, high sensitivity, high speed, strain, temperature and acoustic sensing applications.

Acoustic emission detection using optical fibre sensors for aerospace applications

Structural Health Monitoring (SHM) ensures the structural health and safety of critical structures covering a wide range of application areas. This thesis presents novel, low-cost and good-performance fibre Bragg grating (FBG) based systems for detection of Acoustic Emission (AE) in aircraft structures, which is a part of SHM. Importantly a key aim, during the design of these systems, was to produce systems that were sufficiently small to install in an aircraft for lifetime monitoring. Two important techniques for monitoring high frequency AE that were developed as a part of this research were, Quadrature recombination technique and Active tracking technique. Active tracking technique was used extensively and was further developed to overcome the limitations that were observed while testing it at several test facilities and with different optical fibre sensors. This system was able to eliminate any low frequency spectrum shift due to environmental perturbation and keeps the sensor always working at optimum operation point. This is highly desirable in harsh industrial and operationally active environments. Experimental work carried out in the laboratory has proved that such systems can be used for high frequency detection and have capability to detect up to 600 kHz. However, the range of frequency depends upon the requirement and design of the interrogation system as the system can be altered accordingly for different applications. Several optical fibre configurations for wavelength detection were designed during the course of this work along with industrial partners. Fibre Bragg grating Fabry-Perot (FBG-FP) sensors have shown higher sensitivity and usability than the uniform FBGs to be used with such system. This was shown experimentally. The author is certain that further research will lead to development of a commercially marketable product and the use of active tracking systems can be extended in areas of healthcare, civil infrastructure monitoring etc. where it can be deployed. Finally, the AE detection system has been developed to aerospace requirements and was tested at NDT & Testing Technology test facility based at Airbus, Filton, UK on A350 testing panels.

Enhanced slotted aloha protocols for underwater sensor networks with large propagation delay

Recently underwater sensor networks (UWSN) attracted large research interests. Medium access control (MAC) is one of the major challenges faced by UWSN due to the large propagation delay and narrow channel bandwidth of acoustic communications used for UWSN. Widely used slotted aloha (S-Aloha) protocol suffers large performance loss in UWSNs, which can only achieve performance close to pure aloha (P-Aloha). In this paper we theoretically model the performances of S-Aloha and P-Aloha protocols and analyze the adverse impact of propagation delay. According to the observation on the performances of S-Aloha protocol we propose two enhanced S-Aloha protocols in order to minimize the adverse impact of propagation delay on S-Aloha protocol. The first enhancement is a synchronized arrival S-Aloha (SA-Aloha) protocol, in which frames are transmitted at carefully calculated time to align the frame arrival time with the start of time slots. Propagation delay is taken into consideration in the calculation of transmit time. As estimation error on propagation delay may exist and can affect network performance, an improved SA-Aloha (denoted by ISA-Aloha) is proposed, which adjusts the slot size according to the range of delay estimation errors. Simulation results show that both SA-Aloha and ISA-Aloha perform remarkably better than S-Aloha and P-Aloha for UWSN, and ISA-Aloha is more robust even when the propagation delay estimation error is large. © 2011 IEEE.