This paper presents a tool wear monitoring strategy based on a large number of signal features in the rough turning of Inconel 625. Signal features (SFs) were extracted from time domain signals as well as from frequency domain transforms and their wavelet coefficients (time-frequency domain). All of them were automatically evaluated regarding their relevancy for tool wear monitoring based on a determination coefficient between the feature and its low-pass-filtered course as well as the repeatability. The selected SFs were used for tool wear estimation. The accuracy of this estimation was then used to evaluate the sensor and signal usability.
Nickel-based superalloys are widely used in the aircraft industry since they are exceptionally thermal resistant, retaining their mechanical properties at temperatures of up to 700 • C. On the other hand, since they are very difficult to machine, tool life is typically short and can finish abruptly. As catastrophic tool failure can destroy an expensive workpiece, automatic tool condition monitoring (TCM) has become particularly critical. This paper presents an application of the wavelet packet transform (WPT) for extracting useful TCM features from the cutting forces and acoustic emission (AE) signals during rough turning of Inconel 625. New, improved methods of signal feature (SF) relevancy evaluation were proposed based on determination and correlation coefficients. Out of several SFs calculated from bandpass signals, the most useful for TCM were automatically selected. The selected features were used for tool condition monitoring.
StreszczenieW artykule przedstawiono wyniki badań eksperymentalnych czterech postaci odkształceń spawalniczych panelu I-core. Panel ten jest częścią węzła hybrydowego. Badania przeprowadzono wg zasad teorii planowania eksperymentu w warunkach laboratoryjnych, zbliżonych do warunków panujących w przemyśle. Przedstawiona analiza postaci deformacyjnych uwzględnia parametry technologiczno-konstrukcyjne wpływające na przydatność montażową wielkogabarytowej konstrukcji stalowej. Omówiona metoda oceny wyników eksperymentalnych umożliwia wykorzystanie wzorów aproksymacyjnych w celu prognozowania analizowanych postaci odkształceń w konstrukcjach wielkogabarytowych.
AbstractThe paper presents the results of experimental research on four types of welding distortions of I-core panel. This panel is a part of a hybrid node. The research has been carried out according to design of experiment technique in laboratory conditions near-real-life production conditions. The presented analysis of deformation picture accounts for technological-constructional parameters influencing the suitability for assembly of large-size steel construction. The presented appraisal method used for experiment results features implementation of approximation formulas in order to predict analysed types of distortions in large-size constructions. Fig. 1. Hybrid node [2]
Rys. 1. Węzeł hybrydowy [2]
The paper presents the results of experimental studies on distortion of the fixed plate edge due to formation of a butt joint. This is a hidden form of weld distortion present in structural nodes and identified at the ship hull pre-fabrication stages. The investigations were performed according to a design of experiment (DoE) approach in laboratory conditions resembling those encountered in the shipbuilding industry. The presented analysis includes the technological–construction parameters influencing the evaluated distortion shape. The implemented method of experimental results evaluation allows the utilisation of the approximation dependence to predict the fixed plate edge distortion in large-scale steel structures.
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