Detection of surface damages in ground spur gears by non-destructive micromagnetic methods

Sackmann, Daniel; Karpuschewski, Bernhard; Épp, Jérémy; Jedamski, Rahel

doi:10.1007/s10010-019-00368-z

Cited by 17 publications

(13 citation statements)

References 5 publications

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“…Figure 2a presents examples of a normal RS depth profile (A), a moderate grinding burn (B) with a 300 MPa tensile stress peak below the surface and a more severe grinding burn (C) with a 600 MPa tensile stress peak below the surface. Similar results were obtained in [2,7,8,20], where almost similar high surface compressive residual stress values were obtained in samples having tensile residual stress peaks beneath the surface and where BN was sensitive to the sub-surface tensile stresses. Figure 2b…”

Section: Residual Stress Measurementssupporting

confidence: 83%

Sub-Surface Analysis of Grinding Burns with Barkhausen Noise Measurements

et al. 2022

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Barkhausen noise (BN) measurements are commonly used for surface characterisation. However, often there is also a need to verify the sub-surface region because detrimental tensile stresses may be present after different manufacturing steps. Especially in a grinding burn, the surface stress may be compressive, but it changes quickly into tensile stress below the surface. The aim of this study was to find out whether regular surface-sensitive BN measurement is also sensitive to the stresses below the surface caused by grinding burns. More specifically, the aim was to study the relationship between BN features and sub-surface stresses and to identify a model that estimates sub-surface stresses. Real samples were collected from an actual process. The samples were cylindrical samples manufactured from commercial alloyed AISI/SAE L6 steel that was through-hardened prior to grinding. Barkhausen noise measurements were carried out for 42 grinding burn locations followed by X-ray diffraction-based residual stress surface measurements and residual stress depth profiles. Depth information was obtained through step-by-step electrolytic removal of thin layers. The stress profiles were pre-processed through interpolation and averaged stress was calculated as a function of depth below the surface. Correlation analysis was carried out to evaluate the relationships between BN features and stress at different depths and among BN features. The main outcome of the analysis was that BN measurement is dominated by the sub-surface tensile stresses rather than the compressive stress at the surface. It was also noticed that BN features form two groups, corresponding to average Barkhausen activity and magnetising field strength leading to maximum Barkhausen activity. Models for stress at different steps were identified systematically. The performance of the models for sub-surface stresses was reasonable with R2 values of around 0.85 and root mean squared error (RMSE) values of around 95 MPa. Based on the results, it is concluded that BN measurement provides information about sub-surface stresses and that stress can be evaluated through straightforward modelling, allowing fast detection of grinding burns.

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Section: Residual Stress Measurementssupporting

confidence: 83%

Sub-Surface Analysis of Grinding Burns with Barkhausen Noise Measurements

et al. 2022

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“…Da an einigen Werkstoffzuständen keine Neuhärtungszonen aufgetreten sind, wird deren Einfluss auf das Barkhausenrauschen im Rahmen dieser Untersuchungen nicht im Detail evaluiert. Aus der Literatur ist jedoch bekannt, dass eine zunehmende Ausbildung von Neuhärtungszonen mit einer weiteren Abnahme des RMS-Werts bis auf das Grundniveau des schädigungsfreien Referenzzustands verbunden ist [23]. In Tabelle 6 ist eine Übersicht über die mit diesem Vorgehen ermittelten RMS-Werte in Abhängigkeit vom Rand-und Werkstoffzustand gegeben.…”

Section: Evaluation and Discussion Of Materialspecific Influences On unclassified

“…The corresponding RMS-value is therefore used for temper etching class D. Since no rehardening zones occurred on some material states, their influence on the Barkhausen noise is not evaluated in detail within the scope of these investigations. However, it is known from the literature that an increasing formation of rehardening zones is associated with a further decrease of the RMS-value down to the base level of the damage-free reference state [23]. Table 6 provides an overview of the RMS-values determined using this approach as a function of the surface integrity and material state.…”

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

confidence: 99%

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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“…This describes the position of the maximum BN and, thus, the coercivity H cM . Further information about the micromagnetic parameters of the Rollscan device are provided in Reference [21].…”

Section: Micromagnetic Barkhausen Noise Analysismentioning

confidence: 99%

Micromagnetic Analysis of Thermally Induced Influences on Surface Integrity Using the Burning Limit Approach

Heinzel

Sackmann

Karpuschewski

2019

JMMP

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Particularly for highly stressed components, it is important to have precise knowledge of the surface and subsurface properties and, thus, of the functional properties after final grinding at the end of a complex process chain in order to avoid rejected parts. Therefore, non-destructive testing methods have been the subject of research for several years. The Barkhausen noise analysis, as a micromagnetic measuring method, has the potential to characterize the subsurface area up to an analyzing depth δ non-destructively with micromagnetic parameters. In addition to micromagnetic multiparameter approaches, which allow post-process mode clear statements about the subsurface area state, the present research work deals with the concept of a connection of a single Barkhausen noise parameter with grinding process parameters. In combination with the analytical approach of Malkin for the thermal surface and subsurface area influence, which is based on the process parameters of grinding processes, a distinction between good and rejected ground parts can be achieved. The results show that, by post-process measurements of the Barkhausen noise on case-hardened workpieces made of steel 18CrNiMo7-6 (No. 1.6587, AISI 4820) and machined by a cylindrical grinding process, incipient changes in the residual stress state up to industrial-relevant limits, which distinguish between good and rejected parts, is possible. In the future, a combination of the Malkin grinding burning limit and sufficient condition monitoring based on in-process measurements of Barkhausen noise will be investigated. The application limits of the analytical approach of Malkin as well as the measurement of the Barkhausen noise in-process have to be determined.

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Detection of surface damages in ground spur gears by non-destructive micromagnetic methods

Cited by 17 publications

References 5 publications

Sub-Surface Analysis of Grinding Burns with Barkhausen Noise Measurements

Sub-Surface Analysis of Grinding Burns with Barkhausen Noise Measurements

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

Micromagnetic Analysis of Thermally Induced Influences on Surface Integrity Using the Burning Limit Approach

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