Force Sensors Embedded in Surfaces for Manufacturing and Other Tribological Process Monitoring

Du, H. C.; Klamecki, Barney E.

doi:10.1115/1.2833131

Cited by 26 publications

(11 citation statements)

References 12 publications

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“…Although ultrasonic metal welding (USMW) was invented in 1940s, its bonding mechanism is still not fully understood [10][11][12][13]. There are a few different theories proposed so far.…”

Section: Introductionmentioning

confidence: 99%

Transient Temperature and Heat Flux Measurement in Ultrasonic Joining of Battery Tabs Using Thin-Film Microsensors

Li¹,

Choi²,

Ma³

et al. 2013

Journal of Manufacturing Science and Engineering

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Process physics understanding, real time monitoring, and control of various manufacturing processes, such as battery manufacturing, are crucial for product quality assurance. While ultrasonic welding has been used for joining batteries in electric vehicles (EVs), the welding physics, and process attributes, such as the heat generation and heat flow during the joining process, is still not well understood leading to time-consuming trial-and-error based process optimization. This study is to investigate thermal phenomena (i.e., transient temperature and heat flux) by using micro thin-film thermocouples (TETC) and thin-film thermopile (TETP) arrays (referred to as microsensors in this paper) at the very vicinity of the ultrasonic welding spot during joining of three-layered battery tabs and Cu buss bars (i.e., battery interconnect) as in General Motors's (GM) Chevy Volt. Microsensors were first fabricated on the buss bars. A series of experiments were then conducted to investigate the dynamic heat generation during the welding process. Experimental results showed that TETCs enabled the sensing of transient temperatures with much higher spatial and temporal resolutions than conventional thermocouples. It was further found that the TETPs were more sensitive to the transient heat generation process during welding than TETCs. More significantly, the heat flux change rate was found to be able to provide better insight for the process. It provided evidence indicating that the ultrasonic welding process involves three distinct stages, i.e., friction heating, plastic work, and diffusion bonding stages. The heat flux change rate thus has significant potential to identify the insitu welding quality, in the context of welding process monitoring, and control of ultrasonic welding process. The weld samples were examined using scanning electron microscopy (SEM) and energy dispersive X-ray spectroscopy (EDS) to study the material interactions at the bonding interface as a function of weld time and have successfully validated the proposed three-stage welding theory.

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“…Although ultrasonic metal welding (USMW) was invented in 1940s, its bonding mechanism is still not fully understood [10][11][12][13]. There are a few different theories proposed so far.…”

Section: Introductionmentioning

confidence: 99%

Transient Temperature and Heat Flux Measurement in Ultrasonic Joining of Battery Tabs Using Thin-Film Microsensors

Li¹,

Choi²,

Ma³

et al. 2013

Journal of Manufacturing Science and Engineering

View full text Add to dashboard Cite

show abstract

“…As the first step, using the RGB factor in a pixel inside the target object, the values of R RG and R RB , which is the ratio of green and red and the ratio of blue and red, respectively, are obtained using equation (1). These obtained values are referred to as the reference ratio, (R RG ) ref and (R RB ) ref .…”

Section: Object Image Extractionmentioning

confidence: 99%

Rapid and non-invasive surface crack detection for pressed-panel products based on online image processing

Jung

Park

2019

Structural Health Monitoring

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Crack detection during the manufacturing process of pressed-panel products is an important aspect of quality management. Traditional approaches for crack detection of those products are subjective and expensive because they are usually performed by experienced human inspectors. Therefore, the development and implementation of an automated and accurate inspection system is required for the manufacturing process. In this article, a crack detection technique based on image processing is proposed that utilizes the images of panel products captured by a regular camera system. First, the binary panel object image is extracted from various backgrounds after considering the color factor. Edge lines are then generated from a binary image using a percolation process. Finally, crack detection and localization is performed with a unique edge-line evaluation. In order to demonstrate the capability of the proposed technique, lab-scale experiments were carried out with a thin aluminum plate. In addition, a test was performed with the panel images acquired at an actual press line. Experimental results show that the proposed technique could effectively detect panel cracks at an improved rate and speed. The experimental results also demonstrate that the proposed technique could be an extension of structural health monitoring frameworks into a new manufacturing application.

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“…Structural embedding of microthin film sensors into tools could provide efficient sensor protection by avoiding direct contact with the chip or workpiece while allowing for sensing very close to the tool-workpiece interface. Sensor embedding has been studied for composite materials [9][10][11][12] as well as metal structures [13][14][15][16]. An earlier study proved the feasibility of sensor embedding into ceramic substrates [17] using a diffusion bonding technique.…”

Section: Introductionmentioning

confidence: 99%

Tool Embedded Thin Film Microsensors for Monitoring Thermal Phenomena at Tool-Workpiece Interface During Machining

Werschmoeller

Ehmann

2011

Journal of Manufacturing Science and Engineering

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Existing thermal sensors for machining processes are having difficulties to reliably provide high spatial and temporal resolutions for monitoring and control of the dynamic thermal phenomena at the tool-workpiece interface during machining. This paper presents a novel approach to obtain transient tool internal temperature data reliably from a very close di.stance to the tool-workpiece interface. An array of nine microthin film thermocouples, fabricated using standard microfabrication methods, has been embedded into polycrystalline cubic boron nitride (PCBN) cutting inserts by means of diffusion bonding. Scanning electron microscopy was performed to examine thin film sensor and host material interactions at the bonding interface and to determine optimal bonding parameters. The thin film microthermal sensors were statically and dynamically characterized by heating in a tube furnace and application of pulsed laser radiation. The embedded thin film thermal sensors exhibit good linearity, sensitivity, and extremely fast response time. The instrumented PCBN inserts were applied in machining of aluminum alloy 6061 disks at various cutting speeds and feed rates. Embedded into the PCBN inserts at numerous distances of 75-450 fim from tool rake face and 100-500 fim from tool fiank face, these microsensors enabled the sensing of transient cutting temperature fields with high spatial and temporal resolutions. The temperature data obtained during cutting demonstrate the functionality of the tool embedded microthermal sensors and their value for fast, accurate, and reliable monitoring, which will be of .significance for both fundamental study and in-process control of machining operations.

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Force Sensors Embedded in Surfaces for Manufacturing and Other Tribological Process Monitoring

Cited by 26 publications

References 12 publications

Transient Temperature and Heat Flux Measurement in Ultrasonic Joining of Battery Tabs Using Thin-Film Microsensors

Transient Temperature and Heat Flux Measurement in Ultrasonic Joining of Battery Tabs Using Thin-Film Microsensors

Rapid and non-invasive surface crack detection for pressed-panel products based on online image processing

Tool Embedded Thin Film Microsensors for Monitoring Thermal Phenomena at Tool-Workpiece Interface During Machining

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