Measuring strain during a cylindrical grinding process using embedded sensors in a workpiece

Sarma, Mridusmita; Borchers, Florian; Dumstorff, Gerrit; Heinzel, Carsten; Lang, Walter

doi:10.5194/jsss-6-331-2017

Cited by 4 publications

(1 citation statement)

References 11 publications

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“…Although external loads such as forces affecting the workpiece during material processing can be measured and analyzed in detail (e.g., with force dynamometers), there is currently no in-process measuring method that is capable of determining the strains in the contact zone. Steel integrated thin film sensors to measure the mechanical loads in test workpieces during the manufacturing process are subject of current scientific research [7][8][9]. However, this measurement approach is invasive and currently only allows single-point measurements with a limited spatial resolution in the millimeter range.…”

Section: Introductionmentioning

confidence: 99%

Investigations on Material Loads during Grinding by Speckle Photography

Tausendfreund

Borchers

Kohls

et al. 2018

JMMP

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The knowledge of the loads occurring during a manufacturing process (e.g., grinding) and of the modifications remaining in the material is used in the concept of process signatures to optimize the manufacturing process and compare it with others (e.g., laser processing). The prerequisite for creating a process signature is that the loads can be characterized during the running process. Due to the rough process conditions, until now there is no in-process technique to measure the loads in the form of displacements and strains in the machined boundary zone. For this reason, the suitability of speckle photography is demonstrated for in-process measurements of material loads in a grinding process without cooling lubricant and the measurement results are compared with finite element method (FEM) simulations. As working hypothesis for the simulation it is assumed, that dry grinding is a purely thermally driven process. Despite the approximation by a purely thermal model with a constant heat source, the measured displacements differ only by a maximum of approximately 20% from the simulations. In particular, the strain measurements in feed speed direction are in good agreement with the simulation and support the thesis, that the dry grinding conditions used here lead to a primarily thermally affecting process.

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Section: Introductionmentioning

confidence: 99%

Investigations on Material Loads during Grinding by Speckle Photography

Tausendfreund

Borchers

Kohls

et al. 2018

JMMP

Self Cite

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Development of Material‐Integrated Actuator‐Sensor‐Arrays for Obstacle Sensing

et al. 2018

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The specific manufacturing processes of fiber‐reinforced plastics (FRP) enable a seamless integration of sensors and actuators, allowing realization of tasks that are additional to the main load bearing functionality, for example, obstacle distance sensing. Through the integration of several distributed piezoelectric actuators into a FRP component and their time‐shifted actuation, a directional plate wave can be generated. The interaction of the plate wave with the surrounding medium induces a sound wave, which − reflected from an obstacle − returns toward the component and forms a plate wave, that is, detected by another integrated transducer array. Since the time between the generation of the initial wave and the reflected wave appearance is a linear function of the distance to the obstacle, an appropriate evaluation enables the realization of the obstacle distance sensing functionality. Presented experimental investigations are conducted to confirm the feasibility of the above described operational principle. It is shown that a directional generation of plate waves and their radiation in surrounding medium can be achieved using a suitable actuator‐sensor arrangement. The operating principle is successfully demonstrated for exemplary textile‐reinforced composite plate with integrated piezoceramic actuator‐sensor transducer arrays.

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