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Development of a sensor integrated 'intelligent' grinding wheel for in-process monitoring of ceramic grinding.

机译：集成了传感器的“智能”砂轮的开发，用于陶瓷磨削的过程监控。

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摘要

A sensor integrated “intelligent” diamond grinding wheel was designed and developed for in-process monitoring of ceramic grinding processes. The system is capable of monitoring normal force, acoustic emission, gap elimination and wheel rounding process in real-time. The prototype wheel consisted of an aluminum core integrated with piezo-ceramic sensors and diamond abrasive segments bonded on the periphery. A DSP based telemetric data acquisition was employed to acquire, process and transmit data from the rotating wheel to a remote receiver. Software was developed for data interception, processing and presentation of process information.; The mechanical design of the “intelligent” grinding wheel was evaluated both by numerical simulations and static experiments. Prior to system integration, experiments were conducted on each sub-component of the system to ascertain its performance and mechanical integrity. The capabilities of the “intelligent” grinding wheel was verified through grinding and wheel preparation experiments. The DSP was programmed to implement application specific algorithms for process monitoring. Wheel roundness during truing was monitored by comparing the outputs from all eleven force sensors located on the outer periphery of the wheel. Normal force monitored by the “intelligent” grinding wheel showed a close match with that measured by a commercial dynamometer. Furthermore, it was shown that acoustic emission signal monitored by this system can identify Wheel-workpiece contact, thereby serving as useful gap elimination tool. In addition, it was demonstrated that the acoustic signal is sensitive to grinding parameters and can provide corroborative evidence to normal force measurements. Finally, the “intelligent” grinding wheel was used to study contact length and normal force distribution in the grinding zone.; The prototype wheel used diamond abrasives for grinding of ceramic components. This same approach can also be applied to CBN wheels for grinding of ferrous and nickel based alloys. The results of this investigation provide the scientific and technological basis for commercial development of a new generation of monitoring systems for machining.
机译：设计并开发了传感器集成的“智能”金刚石砂轮，用于陶瓷磨削过程的过程中监控。该系统能够实时监控法向力，声发射，间隙消除和车轮倒圆过程。原型轮由铝芯和压电陶瓷传感器组成，并在外围粘合金刚石磨片。采用基于DSP的遥测数据采集来采集，处理数据并将数据从转轮传输到远程接收器。开发用于数据拦截，处理和过程信息表示的软件。通过数值模拟和静态实验对“智能”砂轮的机械设计进行了评估。在进行系统集成之前，先对系统的每个子组件进行实验，以确定其性能和机械完整性。 “智能”砂轮的功能已通过磨削和砂轮制备实验进行了验证。对DSP进行编程，以实现针对过程监控的专用算法。通过比较位于车轮外圆周上的所有十一个力传感器的输出，可以监控整车过程中的车轮圆度。 “智能”砂轮监测的法向力与商用测功机测得的法向力非常接近。此外，已表明，通过该系统监视的声发射信号可以识别轮-工件接触，从而成为有用的间隙消除工具。另外，已经证明，声信号对磨削参数敏感，并且可以为法向力测量提供确凿的证据。最后，使用“智能”砂轮研究磨削区的接触长度和法向力分布。原型轮使用金刚石磨料研磨陶瓷组件。同样的方法也可以应用于研磨铁和镍基合金的CBN砂轮。该调查的结果为新一代机加工监控系统的商业开发提供了科学和技术基础。

著录项

  • 作者

    Varghese, Biju.;

  • 作者单位

    University of Massachusetts Amherst.;

  • 授予单位 University of Massachusetts Amherst.;
  • 学科 Engineering Mechanical.
  • 学位 Ph.D.
  • 年度 1999
  • 页码 128 p.
  • 总页数 128
  • 原文格式 PDF
  • 正文语种 eng
  • 中图分类 机械、仪表工业;
  • 关键词

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