Process monitoring to assist the workpiece surface quality in machining

The paper reports on research which attempts to correlate the quality of the machined surface after broaching and the output signals obtained from multiple sensors, namely acoustic emission, vibration, and cutting forces. The quality of the machined surface was estimated in terms of geometrical accuracy, burr formation, chatter marks and surface anomalies. Cutting conditions were varied based on an orthogonal array with cutting speed, coolant conditions, and tool settings as factors. Each orthogonal array was repeated at three levels of the tool wear.The results show that the cutting force signals are sensitive enough to detect the geometrical deviation of the machined profile, burr formation and to a lesser extent the chatter marks. The vibration signals were found sensitive to detect the chatter marks while the acoustic emission signal proved to be efficient for the detection of small surface anomalies such as pluckings, laps, and smeared material. However, up to now, no clear distinction between the different types of the surface anomalies could be made using the analysis of the acoustic emission signal.Time and frequency domain analysis of the output signals were carried out in order to develop appropriate techniques for qualitative/quantitative evaluation of the machined surface quality.It was found that each sensory signal is rather limited to a narrow field of application where certain surface features are detectable. The limitations of the employed sensory signals/analysis methodologies used to assess the workpiece surface quality, and their applicability in the industrial machining conditions are also discussed.     

Development of an on-line tool-life monitoring system using acoustic emission signals in gear shaping

Sensing techniques for monitoring machining processes have been one of the focuses of research on process automation. This paper presents the development of on-line tool-life monitoring system for gear shaping that uses acoustic emission (AE). Characteristics of the AE signals are related to the cutting condition, tool material and tool geometry in the cutting of metals. The relationship between AE signal and tool wear was investigated experimentally. Experiments were carried out on the gear shaping of SCM 420 material with a pinion cutter having 44 teeth. Root-mean-square (RMS) AE voltages increase regularly according to tool wear. It is suggested that the maximum value of RMS AE voltage is an effective parameter to monitor tool life. In this study, not only the acquisition method of AE signals for rotating objects but also the signal-processing technique were developed in order to realize the in-process monitoring system for gear shaping. The on-line tool-life monitoring system developed has been successfully applied to gear machining processes.     

A quick method for evaluating the thresholds of workpiece surface damage in machining

This paper proposes a Pendulum-Based Cutting Test (PBCT) methodology which allows quick cutting tests for surface integrity evaluation along with providing cutting energies associated with particular level of workpiece surface damage, this is backed by an unified cutting energy model that links damage level of machined surface with energy partition in the cutting area. PBCT method could rapidly define the energy transferred to the workpiece that incurs particular magnitude of surface damage without using conventional machine tools and monitor the cutting process while only limited amount of materials is required. A demonstration of the proposed method is presented for Inconel718.     

Inspection of power plant headers utilizing acoustic emission monitoring

Fossil power plant high energy, high temperature steam headers have been found to be susceptible to thermal fatigue assisted creep degradation. These mechanisms initiate and grow cracks in chrome molybdenum headers, from the bore hole edges and stub tube-to-header welds. Linking up of multiple cracks can lead to explosive expulsion of tubes and severe shorting of the header life. In order to extend the header life and operate safely, a better understanding of crack growth that may occur during specific plant operating conditions is needed. With that understanding, harsh operating conditions that may be causing excessive crack propagation and header damage can be curtailed. Acoustic emission monitoring of headers was performed to assist in identifying operating conditions that lead to header damage. This Electric Power Research Institute (EPRI) sponsored program found acoustic emission activity levels correlated to identified crack growth and analytically calculated stresses. Utilizing these results, draft EPRI guidelines have been developed to aid electric utilities in performing acoustic emission monitoring on superheater headers.     

The application of acoustic emission for precision drilling process monitoring

Precision drilling is a process where a close tolerance hole can be produced with a special drill bit without subsequent reaming. Producing a hole without reaming results in less overall processing time during hole preparation. Precision drilling is best accomplished by a robot with a computer controlled drilling end effector due to the high degree of process control required. Some aspects of the process, such as spindle speed, feed rate, and peck cycles, can easily be controlled by a computer controlled end effector. Other variables, such as drill bit wear, chipping, and point geometry variation, cannot be controlled with the end effector. These variables affect the diameter of the hole but cannot be detected unless the hole or the drill bit is manually inspected. It is not practical to stop the process and check the diameter after every hole. Therefore, a means to perform real time drilling process monitoring is required to detect if an oversized hole is being drilled. The primary objective of this research was to correlate the diameter of a hole drilled in steel with any acoustic emission (AE) signal measurement parameter. The secondary objective was to correlate drill bit lip height variation, which has a significant influence on the diameter of a hole, with any AE signal measurement parameter. The results of this study showed that acoustic emission could only be correlated to hole diameter variations if those variations were related to the lip height variations. However, AE energy and RMS were correlated to lip height variations under a wide variety of conditions.     

Evaluation of fatigue damage in reinforced concrete slab by acoustic emission

The applicability of acoustic emission (AE) technique for evaluation of fatigue damage in reinforced concrete (RC) slabs under cyclic loadings in both laboratory and as a structure in service is studied. The fundamental test performed in laboratory shows that the cracking process can be practically monitored by the measurement of AE signals. Analysis of the relationship between loading phase and AE activity indicates that the final stages of the fracture process can be evaluated by detecting AE signals generated near the minimum loading phase. Comparison of the results from the structure and that from the laboratory specimen demonstrates that AE energy can be an effective parameter for the evaluation of fatigue damage in RC slabs in service.     

Post-impact damage characterisation on natural fibre reinforced composites using acoustic emission

The present study aims to characterise damage due to low velocity impact on jute fibre reinforced polyester composites. To attain this goal, a number of post-impact mechanical tests have been carried out, including tensile tests, three-point bending and indentation, using either a staircase or a continuous loading programme. On all these tests acoustic emission activity (AE) was monitored. The results, compared with damage observed under an optical microscope, show that AE is able to perform a reliable measurement of the level of damage also, on a natural fibre reinforced laminate. The main limitations of this study are owing to the rather low ultimate stress of the material and to the need to apply a loading to evaluate the damage produced by the impact event.     

Efficient machining of complex-shaped seal slots for turbomachinery

Complex sealing arrangement in turbomachinery can increase turbine efficiency by reducing leakage of high-pressure cooling flows into the hot gas path. While die-sinking EDM is widely used to machine straight seal slots, electrode preparation and wear make it less efficient for complex shapes. This paper presents research on optimisation of a variant of EDM milling using process control and fluid dynamics simulation to exploit optimal machining conditions. The analysis demonstrates a stable process to machine complex shaped slots by focusing on the key requirements for large-scale turbomachinery component manufacture, namely productivity, surface integrity and process monitoring.     

An integrated monitoring method to supervise waterjet machining

The paper reports on development, calibration and exploitation of an integrated energy-based monitoring method for waterjet machining. The main advantage of the method resides in its ability to simultaneously monitor the level of output (at nozzle), active (cutting through) and passive (not cutting) waterjet energy thus enabling its budgeting. Relying on multiple acoustic emission sensors, the monitoring solution was implemented on the harsh waterjet environment to detect process malfunctions (e.g. jet penetration, nozzle clogging) and by adjust cutting conditions (e.g. feed speed) to result in improved accuracy and quality of machined surfaces.     

SCC damage evolution on martensitic stainless steel by using acoustic emission technique

Abstract

In the present work, acoustic emission testing (AE) technique was successfully applied to identify damage phenomena occurred during stress corrosion cracking (SCC) in chloride-containing environment of a precipitation hardening martensitic stainless steel. Through the use of multi-variable statistical analysis [by coupling principal component analysis (PCA) and self-organising map (SOM)], the different stages of SCC mechanisms (i.e. activation, growth and propagation of cracks) have been identified and analysed. In particular each mechanism was related to specific and significant AE patterns allowing its univocal recognition.     

Observations on chip formation and acoustic emission in machining Ti–6Al–4V alloy

Orthogonal cutting tests were undertaken to investigate the mechanisms of chip formation for a Ti–6Al–4V alloy and to assess the influences of such on acoustic emission (AE). Within the range of conditions employed (cutting speed, v_c=0.25–3.0 m/s, feed, f=20–100 μm), saw-tooth chips were produced. A transition from aperiodic to periodic saw-tooth chip formation occurring with increases in cutting speed and/or feed. Examination of chips formed shortly after the instant of tool engagement, where the undeformed chip thickness is slightly greater than the minimum undeformed chip thickness, revealed a continuous chip characterised by the presence of fine lamellae on its free surface. In agreement with the consensus that shear localisation in machining Ti and its alloys is due to the occurrence of a thermo-plastic instability, the underside of saw-tooth segments formed at relatively high cutting speeds, exhibiting evidence of ductile fracture. Chips formed at lower cutting speeds suggest that cleavage is the mechanism of catastrophic failure, at least within the upper region of the primary shear zone. An additional characteristic of machining Ti–6Al–4V alloy at high cutting speeds is the occurrence of welding between the chip and the tool. Fracture of such welds appears to be the dominant source of AE. The results are discussed with reference to the machining of hardened steels, another class of materials from which saw-tooth chips are produced.     

Surface integrity in finish hard turning of case-hardened steels

Highly stressed steel components, e.g., gears and bearing parts, are appropriate applications for hard turning. Therefore, the process effects on significant engineering properties of work materials have to be carefully analyzed. Roughness, residual stresses, and white layers as parts of surface integrity, are functions of the machining parameters and of the cuttability of the cutting edge, i.e. of the tool wear.The aim of this work was to study the influence of feed rate, cutting speed, and tool wear on the effects induced by hard turning on case-hardened 27MnCr5 gear conebrakes and to point out the technical limitations in mass production.     

Fast X-ray tomography and acoustic emission study of damage in metals during continuous tensile tests

Model AA-2124 matrix composites with two different reinforcement sizes were pulled with a strain rate of 10⁻⁵ using a dedicated tensile rig suitable for in situ tomography. Two main novelty aspects characterize the present study. First, tomography provides a new approach towards understanding the significance of AE signals, recorded simultaneously, during image acquisition on the same sample. The number of acoustic emission events is found to be in good agreement with the number of cracks as detected by image analysis and the energy of the signals is proportional to the dimension of the cracks. Secondly, fast tomography was used to perform the first continuous in situ tensile test. The continuous procedure is compared in the paper with the standard step by step procedure.     

Effect of fiber orientation in uni-directional glass epoxy laminate using acoustic emission monitoring

Acoustic emission(AE) can be used for in situ structural health monitoring of the composite laminates. One of the main issues of AE is to characterize different dam-age mechanisms from the detected AE signals. In the present work,pure resin and GFRP composites laminates with different stacking sequences such as 0,90,angle ply[±45 ],cross-ply [0 /90 ] are used to trigger different failure mechanisms when subjected to tensile test with AE monitoring. The study of failure mechanisms is facilitated by the choic...     

A critical analysis of effectiveness of acoustic emission signals to detect tool and workpiece malfunctions in milling operations

The industrial demands for automated machining systems to increase process productivity and quality in milling of aerospace critical safety components requires advanced investigations of the monitoring techniques. This is focussed on the detection and prediction of the occurrence of process malfunctions at both of tool (e.g. wear/chipping of cutting edges) and workpiece surface integrity (e.g. material drags, laps, pluckings) levels. Acoustic emission (AE) has been employed predominantly for tool condition monitoring of continuous machining operations (e.g. turning, drilling), but relatively little attention has been paid to monitor interrupted processes such as milling and especially to detect the occurrence of possible surface anomalies.This paper reports for the first time on the possibility of using AE sensory measures for monitoring both tool and workpiece surface integrity to enable milling of “damage-free” surfaces. The research focussed on identifying advanced monitoring techniques to enable the calculation of comprehensive AE sensory measures that can be applied independently and/or in conjunction with other sensory signals (e.g. force) to respond to the following technical requirements: (i) to identify time domain patterns that are independent from the tool path; (ii) ability to “calibrate” AE sensory measures against the gradual increase of tool wear/force signals; (iii) capability to detect workpiece surface defects (anomalies) as result of high energy transfer to the machined surfaces when abusive milling is applied.Although some drawbacks exist due to the amount of data manipulation, the results show good evidence that the proposed AE sensory measures have a great potential to be used in flexible and easily implementable solutions for monitoring tool and/or workpiece surface anomalies in milling operations.     

A comparative study of hard turned and cylindrically ground white layers

Compared with grinding, hard turning is competitive in many cases, with substantial benefits. However, hard turning applications are not preferred, due to the existence of the process-induced white layer on the component surface, which is often assumed to be detrimental to component life. Nevertheless, white layer properties have not been well understood or clearly defined, especially the properties of the white layer induced in hard turning as against grinding. A clear understanding of white layer properties will provide a solid physics basis for product performance analysis and useful data for process selection. In this study, benchmark hard turning and cylindrical grinding experiments were conducted to generate thick white layers for reliable measurement. It was found that the properties of white and dark layers by hard turning and grinding are fundamentally different in four aspects: surface structure characteristics, microhardness, microstructures, and chemical composition. A white layer is not untempered martensite in terms of retained austenite. Additionally, a thick white layer can be produced in grinding under certain conditions.     

White layers and thermal modeling of hard turned surfaces

White layers in hard turned surfaces are identified, characterized and measured as a function of tool flank wear and cutting speed. White layer depth progressively increases with flank wear. It also increases with speed, but approaches an asymptote. A thermal model based on Jaeger's moving heat source problems (J.C. Jaeger, Moving source of heat and the temperature at sliding contacts, in: Proceedings of the Royal Society, NSW, vol. 56, pp. 203–224) is applied to simulate the temperature field in machined surfaces and to estimate white layer depth in terms of the penetration depth for a given critical temperature. The analysis shows good agreement with the trend in experimental results. White layer formation seems to be dominantly a thermal process involving phase transformation of the steel, possibly plastic strain activated; flank wear land rubbing may be a primary heat source for white layer formation. A strong material dependence of surface alteration is also observed.     

Wavelet transform analysis of acoustic emission in monitoring friction stir welding of 6061 aluminum

In this paper, acoustic emission (AE) signals are detected and preliminarily analyzed in order to investigate the possibility of applying the AE technique for the in-process monitoring of an entire friction-stir-welding (FSW) process. Experimental tests are carried out using a high-speed rotating tool traversing on two, butted 6061 aluminum alloy plates with three equally spaced gaps made of two notches aligned along the butting joint of the parts. The wavelet transform (WT) is used to decompose the AE signal into various discrete series of sequences over different frequency bands. There are significant sudden changes in the band energy at the moment when the probe penetrates into and pulls out of the weld joint, as well as when the shoulder makes contact with or detaches from the plates. The band energy variation during the traversing of the tool over the defected region reflects the existence, location, and size of the weld defects. A three-dimensional representation of band energy vs time and scale gives valuable information on the potential weld defects during friction stir welding. Coupled with a contour mapping, the representation can be effectively utilized for monitoring the transient welding state and quickly identifying gap defects.     

A numerical model incorporating the microstructure alteration for predicting residual stresses in hard machining of AISI 52100 steel

Residual stresses induced by machining processes are a consequence of thermo-mechanical and microstructural phenomena generated during the machining operation. Hard machining of AISI 52100 bearing steel is a typical case where the microstructural phenomena associated with white and dark layers formation influences the residual stress distribution. Unfortunately, very limited physical models are available for residual stress prediction including the microstructural effects. This paper presents an experimental and numerical approach to predict residual stresses by incorporating the microstructural phase transformations induced during machining of AISI 52100 steel.     

A study on initial contact detection for precision micro-mold and surface generation of vertical side walls in micromachining

The surface quality and the dimensional accuracy are important criteria for micro-mold production, specially for micro-fluidic devices. Important cutting parameters that affect the quality of vertical side walls created by the peripheral cutting edge in micro-end-milling operations were identified. Surface roughness and form error were used to define the quality of side walls on stainless steel and aluminum workpieces. An acoustic emission sensor was used to detect initial contact between a tool and a workpiece for higher dimensional accuracy where the referencing is a critical element for precision micromachining feature creation.