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.

Application of the Minimum Quantity Lubrication (MQL) Technique in the Plunge Cylindrical Grinding Operation

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

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.

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.

Operator's manual : grinding machine, cylinder head (Cedar Rapids Engineering model 860), FSN 4910-889-2051.

"February 1969."

Operator's manual : grinding kit, valve seat, electric 35 degree angle type concentric drive, 1/4 horsepower, AC/DC, single phase, 115-volt, 14000 RPM rated no load speed (K.O. Lee Company model P300BB) (4910-060-9983) and (K.O. Lee Company model P300BB-M2) (4910-473-6437).

"February 1965."

Operator's manual : grinding kit, valve seat, electric, 35 degree angle, concentric drive, driver, AC/DC, 115-volt, 7,500 RPM rated no load speed (Albertson and Company model 1712-M) (4910-060-9983).

"June 1965."

Operator's manual : grinding machine, machine tool attachment, internal and external grinding, 5" maximum external diameter wheel, 1/4" minimum internal diameter wheel, 4,600 to 42,400 rpm spindle speed, 1/2 hp, AC/DC, 115 V, 60-C, single phase (Dumore series 5) ...

"October 1967."

Operator's manual : grinding machine, machine tool attachment (U.S. Electrical Tool Co. model HLGE-12) (3460-243-9607).

"November 1965."

Operator's manual : grinding machine, valve face, bench mounting, 9/32 inch to 11/16 inch chuck, 0 to 45 degree valve, face angle adjustment, 115-volt, AC/DC, 60-cycle, single phase (Cedar Rapids model "KWIK-WAY" KK) (4910-540-4679).

"6 October 1967."

Isolation of Shiga toxigenic Escherichia coli from butcheries in Taquaritinga city, State of São Paulo, Brazil

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

Presence of extraintestinal pathogenic Escherichia coli in butcheries in Taquaritinga, SP, Brazil

The study was conducted in twenty-three butcheries in the city of Taquaritinga, State of São Paulo, Brazil, surveyed during a 10 months period. Among two hundred and eighty-seven Escherichia coli strains isolated from samples of ground beef, meat-grinding-machines and the hands of manipulators, five were recognized as extraintestinal pathogenic E. coli (ExPEC), showing virulence factors (P and S fimbriae, hemolysin and aerobactin) and presenting multidrug resistance. Retail-sold food may constitute an important vehicle for the dissemination of ExPEC in communities, giving rise to reasons for concern.

Finishing of flat parts led by lapping kinematics on abrasive disc dressed in agreement with overlap factors

This paper discusses the investigation of an abrasive process for finishing flat workpieces, based on the combination of important grinding and lapping characteristics. Instead of loose abrasive grains between the workpiece and the lapping plate, a resinoid grinding wheel of hot-pressed silicon carbide is placed on the plate of a device resembling a lapping machine. The resin bond grinding wheel is dressed with a single-point diamond. In addition to keeping the plate flat, dressing also plays the role of interfering in the behavior of the process by varying the overlap factor (Ud). It was found that the studied process simplify the set-up and can be controlled more easily than in lapping, whose is a painstaking process. The surface roughness and flatness deviation proved comparable to those of lapping, or even finer than it, with the additional advantage of a less contaminated workpiece surface with a shiny appearance. The process was also monitored by acoustic emission (AE), which indicates to be a promissing and suitable technique for use in this process. Copyright © 2008 by ASME.