Article
Engineering, Manufacturing
Eckart Uhlmann, Tobias Holznagel
Summary: This paper presents a reliable process monitoring approach for milling fibre-reinforced plastics, which utilizes acoustic emission signals and signal processing techniques to detect and distinguish tool wear and workpiece damages.
CIRP JOURNAL OF MANUFACTURING SCIENCE AND TECHNOLOGY
(2022)
Article
Engineering, Mechanical
Enrique Caso, Alberto Diez-Ibarbia, Pablo Garcia, Javier Sanchez-Espiga, Alfonso Fernandez-del-Rincon
Summary: Acoustic emission (AE) technology has been used to monitor the wire drawing process in an industrial environment. The correlation between AE measurements and process parameters, such as drawing speed, die temperature, lubricant type, wire diameter, and die status, has been studied to develop a reliable monitoring system. The results show that AE amplitude is correlated with lubricant chemical composition and die temperature, and variations in AE spectra reflect slight changes in the process when different wire materials or die sets are used.
MECHANICAL SYSTEMS AND SIGNAL PROCESSING
(2023)
Article
Automation & Control Systems
Maznah Iliyas Ahmad, Yazid Saif, Yusri Yusof, Md Elias Daud, Kamran Latif, Aini Zuhra Abdul Kadir
Summary: The article presents a case study on monitoring and inspection based on the Internet of Things for milling process. The proposed solution can work on both G-code and STEP-NC-based controllers and demonstrated the capabilities of the controller. The IoT-based monitoring architecture showed high accuracy in detecting machining process conditions and measuring machined parts.
INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY
(2022)
Article
Engineering, Manufacturing
Eckart Uhlmann, Tobias Holznagel, Robin Clemens
Summary: Acoustic emission-based monitoring of the milling process is capable of detecting undesired damages of fibre-reinforced plastic workpieces and can also detect wear, tool breakage, and coating failures. Proper signal processing and frequency-dependent amplification enable the extraction of meaningful information from the raw measurement data.
JOURNAL OF MANUFACTURING AND MATERIALS PROCESSING
(2022)
Article
Automation & Control Systems
Valentin Dambly, Edouard Riviere-Lorphevre, Francois Ducobu, Olivier Verlinden
Summary: In the Industry 4.0 era, the modelling of machining operations plays a crucial role in the production sector. A robust method is proposed for the computation of cutter-workpiece engagement (CWE) in dynamic simulations, considering machining forces and the resulting machined surface. An accurate estimation of uncut chip thickness is achieved through a hybrid dexel-based-analytic method. The impact of operational parameters on parts can be assessed through a simulation-based evaluation using dexel networks.
INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY
(2023)
Article
Automation & Control Systems
Yuanhao Fan, Junxue Ren, Zihua Hu, Yiran Tang
Summary: This paper discusses the causes of thread milling error and establishes the machining error model. The model is proven through thread milling experiments, showing good agreement with the experimental results.
INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY
(2022)
Article
Engineering, Manufacturing
Daniel Gauder, Michael Biehler, Johannes Goelz, Volker Schulze, Gisela Lanza
Summary: This paper presents an in-process pore detection method for machining operations using a structure-borne acoustic sensor. By detecting the defects in-process, the machining operation can be stopped immediately if those defects are detected. Experimental results show that pores can be detected during a milling process using the applied methodology with quantified uncertainty.
CIRP JOURNAL OF MANUFACTURING SCIENCE AND TECHNOLOGY
(2022)
Article
Automation & Control Systems
Sangil Han, Ferdinando Salvatore, Christophe Claudin, Joel Rech, Fabio Wosniak, Patrick Matt
Summary: Abrasive flow machining (AFM) is an effective and widely used method for superfinishing internal channel surfaces. Monitoring the evolution of surface roughness during AFM is crucial due to its sensitivity to AFM medium variables. Acoustic emission (AE) has shown potential in detecting microscale deformation mechanisms caused by abrasion. This research demonstrates a close correlation between the evolution of surface roughness and AE signals, such as AE root mean square (RMS) and AE fast Fourier transform (FFT), during AFM with different media. Furthermore, AE signals are associated with wear mechanisms, such as plowing and cutting.
INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY
(2023)
Article
Engineering, Industrial
R. Teti, D. Mourtzis, D. M. D'Addona, A. Caggiano
Summary: This keynote paper focuses on the advancements of machining technology and systems, particularly in terms of enhanced performance, increased system integration, and augmented machine intelligence. The key enabling technologies of Industry 4.0, such as robust and reconfigurable sensing systems, play a crucial role in transforming conventional manufacturing concepts into digital manufacturing paradigms. The paper presents application examples, future challenges, and upcoming trends in machining monitoring.
CIRP ANNALS-MANUFACTURING TECHNOLOGY
(2022)
Article
Engineering, Electrical & Electronic
Hao Li, Fei Gao, Jinyang Jiao, Zongyang Liu, Dingcheng Ji, Jing Lin
Summary: This paper proposes a method for wire arc additive manufacturing (WAAM) health monitoring based on acoustic emission (AE) signal, using a bi-classifier and orthogonal constraints jointly guided domain adaptation. By optimizing the strategy and introducing orthogonal loss, the method adapts different domain features and captures remote dependence relationships in AE signals. Experimental results demonstrate the effectiveness and superiority of the proposed method.
IEEE TRANSACTIONS ON INSTRUMENTATION AND MEASUREMENT
(2023)
Article
Automation & Control Systems
Zhengzhong Zhang, Yonglin Cai, Xiaolin Xi, Haitong Wang
Summary: This study proposes a non-uniform allowance planning method for thin-walled parts based on the workpiece deformation constraint, which can reduce the deformation and improve the machining accuracy of thin-walled parts during milling.
INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY
(2023)
Article
Automation & Control Systems
Guilherme Serpa Sestito, Giuliana Sardi Venter, Kandice Suane Barros Ribeiro, Alessandro Roger Rodrigues, Maira Martins da Silva
Summary: This paper proposes an in-process chatter detection method for micro-milling operations. A sliding window algorithm is used to extract datasets from acoustic emissions and derive nine statistical-based features. These features are then used by machine learning classifiers during the training and testing phases to achieve in-process chatter detection.
INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY
(2022)
Article
Automation & Control Systems
Maojun Li, Dingxiao Huang, Xujing Yang
Summary: In high-speed robotic milling process, acoustic emission technique combined with root mean square value and fast Fourier transform method were used to analyze chatter phenomenon. A stability lobe diagram was proposed for predicting chatter occurrence, along with the establishment of underlying mechanism and theoretical analysis of chatter stability.
INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY
(2021)
Article
Environmental Sciences
Tarik Zarrouk, Jamal-Eddine Salhi, Samir Atlati, Mohammed Nouari, Merzouki Salhi, Najim Salhi
Summary: The machining of Nomex honeycomb structures is a technical and scientific challenge for aeronautical applications. This study used finite element calculation code ABAQUS-EXPLICIT to optimize and analyze the milling of Nomex honeycomb structures, focusing on the influence of machining conditions on cutting forces and chip morphology.
ENVIRONMENTAL SCIENCE AND POLLUTION RESEARCH
(2022)
Article
Engineering, Manufacturing
Mark J. Eaton, Davide Crivelli, Robert Williams, Carlton Byrne
Summary: This study aims to monitor the drilling process in carbon fibre laminates using Acoustic Emission. Continuous data acquisition and analysis were conducted to study the periodic phenomena during the cutting process and their correlation with cutting regime, tool wear, and hole quality.
PROCEEDINGS OF THE INSTITUTION OF MECHANICAL ENGINEERS PART B-JOURNAL OF ENGINEERING MANUFACTURE
(2023)