Underlying Mechanisms for Developing Process Signatures in Manufacturing

Brinksmeier, E.; Reese, Stefanie; Klink, Andreas; Langenhorst, L.; Lübben, Th.; Meinke, Matthias; Meyer, Daniel; Riemer, Oltmann; Sölter, Jens

doi:10.1007/s41871-018-0021-z

Cited by 42 publications

(14 citation statements)

References 40 publications

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“…To understand the material modification, the local process load on the machined part has to be determined. The interdisciplinary Transregional Collaborative Research Center (SFB TRR) 136 “Process Signatures” strives to investigate various machining processes and to analyze the process loads and material modification mechanisms that mainly determine the surface integrity of machined parts [ 2 , 3 , 4 ]. To accommodate for the solution of the inverse problem and prediction of surface properties, the temperature and the local and temporal temperature gradient were identified as a local material load.…”

Section: Introductionmentioning

confidence: 99%

An Investigation on High-Resolution Temperature Measurement in Precision Fly-Cutting

Gräbner

Zielinski

Vovk

et al. 2021

Sensors

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The loads acting on a workpiece during machining processes determine the modification of the surface of the final workpiece and, thus, its functional properties. In this work, a method that uses thermocouples to measure the temperature in precision fly-cutting machining with high spatial and temporal resolution is presented. Experiments were conducted for various materials and machining parameters. We compare experimental measurement data with results from modern and advanced machining process simulation and find a good match between experimental and simulation results. Therefore, the simulation is validated by experimental data and can be used to calculate realistic internal loads of machining processes.

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Section: Introductionmentioning

confidence: 99%

An Investigation on High-Resolution Temperature Measurement in Precision Fly-Cutting

Gräbner

Zielinski

Vovk

et al. 2021

Sensors

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show abstract

“…In order to avoid these laborious and tedious methods, it is necessary to understand and describe mechanisms of material modification with respect to machining. The interdisciplinary Transregional Collaborative Research Center (SFB TRR) 136 “Process Signatures” strives to investigate the process loads and material modification mechanisms in various machining processes in order to predict surface integrity [ 2 , 3 , 4 ]. Prior to this investigation, the material model was validated regarding temperature development and process forces in fly-cutting experiments [ 5 ].…”

Section: Introductionmentioning

confidence: 99%

An Investigation on Internal Material Loads and Modifications in Precision Turning of Steel 42CrMo4

et al. 2021

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The functional properties of a workpiece are determined by a modification of the surface and subsurface materials. In this work, the correlation between thermo-mechanical material loads and the modification of the residual stresses is presented. While the resulting residual stresses were measured by X-ray diffraction after machining experiments, the material loads were determined using a process simulation. The experimental data (measured process forces and results from previous experiments) are used to validate the simulation, which is then applied to calculate the internal thermo-mechanical loads of the maximal temperature and the equivalent von-Mises-stresses per volume element during the machining experiments. In conclusion, a higher depth impact of mechanical loads compared to a lower depth impact of thermal loads in precision machining is observed. For the sake of novelty, the thermo-mechanical loads were plotted and interpreted in a three-dimensional fashion. Finally, cross sections of this mutual representation at certain constant material loads—thermal and mechanical—result in a process signature, which can prospectively improve the prediction of functional workpiece properties.

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“…The overall roughness modification M Sa is then proportional to the number of passes N. By differentiation of Equation (6) after N and inserting Equation (5), one receives the following ordinary differential equation for a multi-cycle PSC according to: Figure 10. Schematic illustration of Process Signatures in accordance to [28], (a) applied on the laserinduced electrochemical polishing process, and (b) the concept of a multiple, recurring loading of the same constant amount of energy within one process (multi-cycle load). Figure 10.…”

Section: Notation For Process Signatures Of Multi-cycle Loadsmentioning

confidence: 99%

“…Figure 10. Schematic illustration of Process Signatures in accordance to [28], (a) applied on the laser-induced electrochemical polishing process, and (b) the concept of a multiple, recurring loading of the same constant amount of energy within one process (multi-cycle load).…”

Section: Notation For Process Signatures Of Multi-cycle Loadsmentioning

confidence: 99%

Multi-Cycle Process Signature of Laser-Induced Thermochemical Polishing

Eckert

2019

JMMP

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Laser-induced thermochemical polishing (LCP) is a non-conventional processing technique that uses laser radiation to smooth the surface of self-passivated metallic parts by initiating a localized anodic material dissolution. This technology can be used to selectively micro-polish without the need for masking or thermal and mechanical stress. However, there is still a lack in understanding the surface quality depending on the applied laser machining parameters. This paper takes up the concept of Process Signatures and interprets the surface smoothing as result of multiple, recurring internal material loads of a constant energy amount. The laser-induced thermal impact is identified as the relevant internal material load and is correlated with the surface roughness. This derives an empirical-based functional relation as multi-cycle Process Signature. The experiment results show an exponential decay in surface roughness with increasing cycle loads for titanium, Ti6Al4V, Nitinol, Stellite 21, and metallic glass. The Process Signature of LCP is a solution to a differential equation with respect to the cycle loads. The paper demonstrates how the multi-cycle Process Signature helps determine suitable machining parameters to predict the surface roughness, as well as to scale the polishing rate.

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Underlying Mechanisms for Developing Process Signatures in Manufacturing

Cited by 42 publications

References 40 publications

An Investigation on High-Resolution Temperature Measurement in Precision Fly-Cutting

An Investigation on High-Resolution Temperature Measurement in Precision Fly-Cutting

An Investigation on Internal Material Loads and Modifications in Precision Turning of Steel 42CrMo4

Multi-Cycle Process Signature of Laser-Induced Thermochemical Polishing

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