Abstract
The interest of the scientific community for ultrasound techniques has increased in recent years due to its wide range of applications. A continuous effort of researchers and industries has been made in order to improve and increase the applicability of non-destructive evaluations (NDE). In this context, the monitoring of manufacturing processes, such as the grinding process, arises. This work proposes a novel technique of ultrasound monitoring (chirp-through-transmission) through low-cost piezoelectric diaphragms and digital signal processing. The proposed technique was applied to the monitoring of material removal during the grinding process. The technique is based on changes in ultrasonic waves when propagated through the material under study, with the difference that this technique does not use traditional parameters of ultrasonic techniques but digital signal processing (RMS and Counts). Furthermore, the novelty of the proposed technique is also the use of low-cost piezoelectric diaphragms in the emission and reception of ultrasonic waves, enabling the implementation of a low-cost monitoring system. The results show that the monitoring technique proposed in this work, when used in conjunction with the frequency band selection, is sensitive to the material removal in the grinding process and therefore presents an advance for monitoring the grinding processes.
Highlights
The manufacturing processes convert raw materials into finished products, often employing machines or machine tools [1]
The results showed that the low-cost sensor has low sensitivity when compared to the conventional acoustic emission sensor, for the application studied, the collected signals from both sensors had similar behavior, which characterizes its application in the detection of partial discharges in power transformers
The results and discussion of the workpiece assessment and the digital signal. In this the results andfocus discussion the workpiece assessment and the of digital signal processing willsection, be presented, which on theofcorrelation of the material removal the grinding processing will be presented, which focus on the correlation of the material removal of the grinding process with the statistics applied to the ultrasound signals
Summary
The manufacturing processes convert raw materials into finished products, often employing machines or machine tools [1]. Among the finishing processes, grinding is considered one of the most important processes because it is applied in the final stage of the production line, providing the final finishing of the part [2]. The material removal mechanism is performed by the contact between the abrasive surface of the grinding wheel, which is composed of thousands of abrasive grains with undefined cutting geometries randomly distributed [3], with the workpiece surface, which makes grinding a highly stochastic process [4]. The monitoring of the grinding process allows a better understanding of the interaction between the grinding wheel abrasive grains and the workpiece surface [5]. A better understanding of the material removal mechanism can help in the control of the grinding wheel wear and the workpiece surface quality [6].
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