An approach for a reliable detection of grinding burn using the Barkhausen noise multi-parameter analysis

Sackmann, Daniel; Heinzel, Jonas; Karpuschewski, Bernhard

doi:10.1016/j.procir.2020.02.076

Cited by 22 publications

(19 citation statements)

References 5 publications

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“…Thus, the selective application of active and passive Barkhausen noise can help to identify surface characteristics under different machining conditions. Nevertheless, it remains challenging to reliably identify different levels of thermal workpiece damage, e.g., shift of residual stresses, light tempering, strong tempering and rehardening, due to the multiple mechanical and microstructural parameters, influencing the Barkhausen noise [42]. Hence the measurements are to be complemented by process knowledge, which is derived from the model-based grinding burn limit of Malkin and allows to avoid visible tempering and rehardening in the surface and subsurface area of the workpiece [43,44].…”

Section: Measurement Of Surface Layer Statesmentioning

confidence: 99%

The Present State of Surface Conditioning in Cutting and Grinding

Stampfer

González

Gerstenmeyer

et al. 2021

JMMP

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All manufacturing processes have an impact on the surface layer state of a component, which in turn significantly determines the properties of parts in service. Although these effects should certainly be exploited, knowledge on the conditioning of the surfaces during the final cutting and abrasive process of metal components is still only extremely limited today. The key challenges in regard comprise the process-oriented acquisition of suitable measurement signals and their use in robust process control with regard to the surface layer conditions. By mastering these challenges, the present demands for sustainability in production on the one hand and the material requirements in terms of lightweight construction strength on the other hand can be successfully met. In this review article completely new surface conditioning approaches are presented, which originate from the Priority Program 2086 of the Deutsche Forschungsgemeinschaft (DFG).

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Section: Measurement Of Surface Layer Statesmentioning

confidence: 99%

The Present State of Surface Conditioning in Cutting and Grinding

Stampfer

González

Gerstenmeyer

et al. 2021

JMMP

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“…The characterization of the surface integrity resulting from the grinding process was mainly carried out on the basis of residual stress depth profiles and metallographic cross-sections. Figure 3 shows characteristic residual stress depth profiles on the BGH_1.0_0.6 material state [21]. The simple standard deviation σ is basically low and ranges from 7.6 MPa to 29.2 MPa.…”

Section: Characterization Of the Thermo-mechanical Influence On The Smentioning

confidence: 99%

“…Further increasing material removal rates lead to high- Bild 3. Charakteristische Eigenspannungstiefenverläufe am Werkstoffzustand BGH_1,0_0,6 [21] er residual tensile stresses up to values of 750 MPa at a specific material removal rate of 24 mm³/mm × s. In addition, the occurring tensile stress maximum shifts to deeper material regions with increasing thermo-mechanical loads on the material surface. For a comparison between individual material states, Figure 4 shows the residual stress depth profiles of all material states after machining with the specific material removal rates Q' w = 1 mm³/ mm × s and 24 mm³/mm × s, respectively.…”

Section: Characterization Of the Thermo-mechanical Influence On The Smentioning

confidence: 99%

“…In addition to the residual stress depth profiles, metallographic micrographs were prepared. Figure 5 shows cross-sections of the surface near area after grinding with the specific material removal rates 1, 12 and 24 mm³/mm × s based on the material state BGH_1.0_0.6 [21]. Grinding with a specific material removal rate Q' w of 1 mm³/mm × s did not significantly influence the microstructure.…”

Section: Characterization Of the Thermo-mechanical Influence On The Smentioning

confidence: 99%

“…Mögliche Unterschiede in den Signalen des Barkhausenrauschens an verschiedenen Werkstoffzuständen lassen sich demnach nicht auf ein variierendes Schleifverhalten zurückführen und werden somit direkt durch den Werkstoffzustand bedingt.Die Charakterisierung des aus der Schleifbearbeitung resultierenden Randzonenzustands wurde vorwiegend anhand von Eigenspannungstiefenverläufen und metallografischen Schliffbildern durchgeführt. In Bild 3 sind charakteristische Eigenspannungstiefenverläufe am Werkstoffzustand BGH_1,0_0,6 dargestellt[21]. Die einfache Standardabweichung σ ist grundsätzlich gering und befindet sich in einem Bereich von 7,6 MPa bis 29,2 MPa.Bis zu einem bezogenen Zeitspanvolumen Q' w von 2 mm³/mm × s ist zunächst kein signifikanter Einfluss durch die zunehmende thermo-mechanische Belastung während des Schleifprozesses festzustellen.…”

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Influence of the Material State of Ground, Case-Hardened Steels on the Barkhausen Noise Depending on the Surface Integrity*

Sackmann

Heinzel

Karpuschewski

2021

HTM Journal of Heat Treatment and Materials

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The manufacturing process of grinding generally leads to a thermo-mechanical influence on the surface integrity. In addition to the intended development of residual compressive stresses due to the finishing process, disturbances in the grinding process can lead to negative effects such as tensile residual stresses, tempering and even rehardening zones and significantly reduce the component lifetime. In industrial applications, the analysis of Barkhausen noise is becoming increasingly important for the detection of this unwanted thermo-mechanically influenced surface integrity. The non-destructive method reacts sensitively to changes in, for example, the residual stress state as well as the hardness. In addition, other material-, process- and metrology-related influences are described in literature. The investigations presented in this paper deal with the influence of different material states (case-hardening depth, surface carbon content and alloy composition) on the signals of the Barkhausen noise as a function of the surface integrity. It is shown that the signal level is significantly influenced by the material condition and thus individual limit values must be used for evaluation of the surface integrity. ◼

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Residual stress evolution and surface morphology in grinding of hardened steel following carburizing and quenching processes

Yang¹,

Chen²,

Wu³

et al. 2022

Materialwissenschaft Werkst

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In this paper, the residual stress evolution and surface morphology of quenched 20Cr2Ni4A steel after surface grinding with alumina grinding wheel was investigated. The initial compressive residual stress in the surface layer evolved into tensile stress after grinding. Since thermal stress was the dominated factor, the effect of grinding speed and grinding depth showed significant effects on the level of residual stress. The tensile stress on the ground surface increased by more than 50 % when grinding speed increased from 26 m/s to 34 m/s at the feed speed of 0.19 m/s to 0.26 m/s. The increase of grinding depth from 0.02 mm to 0.03 mm resulted in the increase rate of tensile stress varying between 54 % and 85 % at specific feed speed and grinding speed. Due to the extrusion and cutting of abrasive particles, plastic deformation and grooves were found on the machined surface. The influence of grinding heat and grinding force caused a plastic deformation layer and grinding burn layer within 20 μm.

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An approach for a reliable detection of grinding burn using the Barkhausen noise multi-parameter analysis

Cited by 22 publications

References 5 publications

The Present State of Surface Conditioning in Cutting and Grinding

The Present State of Surface Conditioning in Cutting and Grinding

Influence of the Material State of Ground, Case-Hardened Steels on the Barkhausen Noise Depending on the Surface Integrity*

Residual stress evolution and surface morphology in grinding of hardened steel following carburizing and quenching processes

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