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A sensor-integrated ‘intelligent’ grinding wheel was developed for wireless in-process monitoring of normal forces and acoustic emission

Development of a Sensor-Integrated “Intelligent” Grinding Wheel for In-Process Monitoring

CIRP Annals, no. 1 (2000): 231-234

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摘要

A sensor integrated ‘intelligent’ grinding wheel was developed for in-process monitoring of wheel preparation and grinding processes for machining of ceramics. The ‘intelligent’ grinding wheel consists of an aluminum core embedded with piezoceramic sensors and fitted with diamond abrasive segments on its periphery. Multiple sensors equall...更多

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简介
  • Machining of structural ceramic components to their final shape necessitates the use of grinding with diamond abrasive wheels.
  • Machining costs for ceramic grinding typically comprise about 60% of the total component cost [l].
  • The high machining cost has inhibited the more widespread utilization of ceramics for structural components.
  • A critical issue that needs to be addressed is how to monitor the grinding process in order to achieve cost-effective machining of ceramics.
  • An alternate approach is to instrument the grinding wheel, which can preclude the need for an instrumented machine tool [5-71
重点内容
  • Machining of structural ceramic components to their final shape necessitates the use of grinding with diamond abrasive wheels
  • Digitization of the analog signal is by an analog-to-digital converter (ADC) which is an integral part of the digital signal processor (DSP)
  • A sensor-integrated ‘intelligent’ grinding wheel was developed for wireless in-process monitoring of normal forces and acoustic emission (AE)
  • The normal forces monitored by the ‘intelligent’ grinding wheel were consistent with measurements from a platform dynamometer
  • Further miniaturization of the electronics and machine soldering of the electrical connections will allow for safe operation at much higher wheel velocities
方法
  • The 'intelligent' grinding wheel system illustrated in Figure 1 consists of a sensor-integrated diamond wheel supplemented with data acquisition circuitry for on-line signal processing and transmission to an external receiver.
  • Digitization of the analog signal is by an analog-to-digital converter (ADC) which is an integral part of the digital signal processor (DSP).
  • The DSP facilitates real time data acquisition, sub-system control, advanced signal processing routines, and interfacing to a radio frequency transmitter (RFT) for wireless data transmission to a remote host computer
结果
  • For wet grinding with a soluble oil, the mean AE RMS was about 20% lower than for dry grinding.
结论
  • A sensor-integrated ‘intelligent’ grinding wheel was developed for wireless in-process monitoring of normal forces and AE.
  • The normal forces monitored by the ‘intelligent’ grinding wheel were consistent with measurements from a platform dynamometer.
  • Force monitoring was successfully applied to identifying wheel rounding during truing.
  • The AE signal was found to be sensitive to grinding and truing parameters, and could identify initial wheel-workpiece contact during gap elimination.
  • Further miniaturization of the electronics and machine soldering of the electrical connections will allow for safe operation at much higher wheel velocities
基金
  • Funding was provided by the United States Department of Energy, Grant DE-FGO5 960R22524
引用论文
  • Malkin, S. and Hwang, T.W., 1996, Grinding Mechanisms for Ceramics, Annals of the CIRP, 45/2:569-580.
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  • Malkin, S., 1989, Grinding Technology: Theory and Applications of Machining with Abrasives, Ellis Horwood, Chichester. Reprinted by SME.
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  • Beattie, A. G., 1983, Acoustic Emission, Principles and Instrumentation, Journal of Acoustic Emission, 211: 95-128.
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  • Varghese, B., 1999, Development of a Sensor Integrated ‘Inteliigent‘ Grinding Wheel for In-Process Monitoring of Ceramic Grinding, Ph.D. Thesis, University of Massachusetts, Amherst.
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作者
S. Pathare
S. Pathare
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