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.

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.

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.

Grinding process monitoring based on electromechanical impedance measurements

Coordenação de Aperfeiçoamento de Pessoal de Nível Superior (CAPES)

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.

Evaluation of neural models applied to the estimation of tool wear in the grinding of advanced ceramics

Conselho Nacional de Desenvolvimento Cientifico e Tecnológico (CNPq)

IDENTIFYING AND MONITORING THE ROLES OF CAVITATION IN HEATING FROM HIGH-INTENSITY FOCUSED ULTRASOUND

For high-intensity focused ultrasound (HIFU) to continue to gain acceptance for cancer treatment it is necessary to understand how the applied ultrasound interacts with gas trapped in the tissue. The presence of bubbles in the target location have been thought to be responsible for shielding the incoming pressure and increasing local heat deposition due to the bubble dynamics. We lack adequate tools for monitoring the cavitation process, due to both limited visualization methods and understanding of the underlying physics. The goal of this project was to elucidate the role of inertial cavitation in HIFU exposures in the hope of applying noise diagnostics to monitor cavitation activity and control HIFU-induced cavitation in a beneficial manner. A number of approaches were taken to understand the relationship between inertial cavitation signals, bubble heating, and bubble shielding in agar-graphite tissue phantoms. Passive cavitation detection (PCD) techniques were employed to detect inertial bubble collapses while the temperature was monitored with an embedded thermocouple. Results indicate that the broadband noise amplitude is correlated to bubble-enhanced heating. Monitoring inertial cavitation at multiple positions throughout the focal region demonstrated that bubble activity increased prefocally as it diminished near the focus. Lowering the HIFU duty cycle had the effect of maintaining a more or less constant cavitation signal, suggesting the shielding effect diminished when the bubbles had a chance to dissolve during the HIFU off-time. Modeling the effect of increasing the ambient temperature showed that bubbles do not collapse as violently at higher temperatures due to increased vapor pressure inside the bubble. Our conclusion is that inertial cavitation heating is less effective at higher temperatures and bubble shielding is involved in shifting energy deposition at the focus. The use of a diagnostic ultrasound imaging system as a PCD array was explored. Filtering out the scattered harmonics from the received RF signals resulted in a spatially- resolved inertial cavitation signal, while the amplitude of the harmonics showed a correlation with temperatures approaching the onset of boiling. The result is a new tool for detecting a broader spectrum of bubble activity and thus enhancing HIFU treatment visualization and feedback.

Sinais de vibração no monitoramento do processo de retificação plana de cerâmicas avançadas

Conselho Nacional de Desenvolvimento Científico e Tecnológico (CNPq)

Plug Force Monitoring for the Control and Optimisation of the Thermoforming Process

Thermoforming processes generally employ sheet temperature monitoring as the primary means of process control. In this paper the development of an alternative system that monitors plug force is described. Tests using a prototype device have shown that the force record over a forming cycle creates a unique map of the process operation. Key process features such as the sheet modulus, sheet sag and the timing of the process stages may be readily observed, and the effects of changes in all of the major processing parameters are easily distinguished. Continuous, cycle-to-cycle tests show that the output is consistent and repeatable over a longer time frame, providing the opportunity for development of an on-line process control system. Further testing of the system is proposed.

Force modelling of the crankshaft pin grinding process.

A force model was developed for crankshaft pin grinding to predict the forces generated during grinding. The force model developed builds on the authors’ previously developed model, which predicted the out-of-roundness in crankshaft pin grinding. The model includes key grinding variables, such as the work removal parameter (WRP), system sti€ ness and Young’s modulus to determine the end forces produced. The model also includes the important geometrical relationships that are unique to this type of grinding. The model was veriŽ ed using an experiential set-up involving sophisticated strain gauge force measurements on a commercial Landis CP grinding machine, with close correlation between the results and the model.

Mathematical modelling of the crankshaft pin grinding process

Novel mathematical models to predict crankshaft pin grinding forces, out-of-roundness and thermal damage were developed as part of this thesis. The models were validated at a local automotive manufacturer's plant. The outcomes of this research have resulted in reduced scrap and warranty costs, improved manufacturing process quality and reduced lead times.

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.