Steel integrated thin film sensors for characterizing grinding processes

Dumstorff, Gerrit; Sarma, Mridusmita; Reimers, Marcel; Kolkwitz, B.; Brinksmeier, E.; Heinzel, Carsten; Lang, Walter

doi:10.1016/j.sna.2016.03.014

Cited by 11 publications

(5 citation statements)

References 16 publications

Supporting

Mentioning

Contrasting

Order By: Relevance

“…Dumstorff et al (2016) developed thin film force sensors which were integrated with steel in order to characterize grinding operations [178]. Luo et al measured the cutting forces in the milling process by using work tables that were integrated with polyvinylidene fluoride (PVDF) [179]. Similarly, Liu et al (2019) evaluated the cutting forces of milling operation using thin film sensors that were fitted into fixtures [7].…”

Section: Force Sensorsmentioning

confidence: 99%

A review on thin films, conducting polymers as sensor devices

Prabakaran

Vadivu

Mouliprasanth

2022

Mater. Res. Express

View full text Add to dashboard Cite

Thin film sensors are used to monitor environmental conditions by measuring the physical parameters. By using thin film technology, the sensors are capable of conducting precise measurements. Moreover, the measurements are stable and dependable. Furthermore, inexpensive sensor devices can be produced. In this paper, thin film technology for the design and fabrication of sensors that are used in various applications is reviewed. Further, the applications of thin film sensors in the fields of biomedical, energy harvesting, optical, and corrosion applications are also presented. From the review, the future research needs and future perspectives are identified and discussed.

show abstract

Section: Force Sensorsmentioning

confidence: 99%

A review on thin films, conducting polymers as sensor devices

Prabakaran

Vadivu

Mouliprasanth

2022

Mater. Res. Express

View full text Add to dashboard Cite

show abstract

“…Materials such as chromium are used to create thin-film sensors with a specific shape to allow measurement of the electrical resistance during changing external loads. Such sensors have been successfully applied in machining processes for temperature measurement of cutting inserts right on the rake face [6] as well as in grinding processes [7]. Novel application methods for the thin-film layer were studied in [8] and [9].…”

Section: Introductionmentioning

confidence: 99%

Analysis of tool heating in cold forging using thin-film sensors

Grötzinger

2023

Materials Research Proceedings

View full text Add to dashboard Cite

Abstract. Data acquisition and data analysis to gain a better process understanding are one of the most promising trends in manufacturing technology. Especially in cold forging processes, data acquisition close to the deformation zone seems challenging due to the high surface pressure. Thus far, process parameters such as die temperature are mainly measured with state-of-the-art sensors, including standard thermocouples, which are integrated into the tooling system. The application of thin-film sensors has been tested in hot forging processes for local die temperature measurement. However, the process conditions regarding tribology and tool load in cold forging are even more difficult. In this contribution, the use of thin-film sensors, applied on a cold forging punch for cup backward extrusion, is subjected. The aim is to investigate the applicability of such thin-film sensors in cold forging with special emphasis on temperature measurement in cyclic forming processes. The thin-film sensor system and its manufacturing procedure by vacuum coating technology combined with microstructuring are described. With these thin-film sensors the cup backward cold extrusion of steel billets was investigated experimentally. Cyclic tool heating simulations with thermal parameter variations were performed as a reference to experimental results.

show abstract

“…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

Self Cite

View full text Add to dashboard Cite

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.

show abstract

Steel integrated thin film sensors for characterizing grinding processes

Cited by 11 publications

References 16 publications

A review on thin films, conducting polymers as sensor devices

A review on thin films, conducting polymers as sensor devices

Analysis of tool heating in cold forging using thin-film sensors

Investigations on Material Loads during Grinding by Speckle Photography

Contact Info

Product

Resources

About