Abstract
Advanced manufacturing processes require an in-line full inspection system. A nondestructive inspection system able to detect a contaminant such as tool chipping was utilized for the purpose of detecting a defective product as well as damaged machine tools used to fabricate the product. In a previous study, a system able to detect magnetic tool steel chipping in conductive material such as aluminum was developed and tested. In this study, a method of position and size estimation for magnetic chipping was investigated and is described. An experimental confirmation of the proposed method was also carried out using an actual prototype system.
Highlights
An array of the thin-film sensors was set in a strong and uniform magnetic field, with the sensing direction perpendicular to the magnetic field direction. This system can detect a magnetic field leaking from the contaminant with high sensitivity, simultaneously with the magnetization of the contaminant by a strong static magnetic field
If the static magnetic field present a non-uniformity in the sensing area, an eddy current is generated in the aluminum casting while feeding the measured work piece in it
Based on the equation of a magnetic field generated by a magnetic dipole, a simple equation for estimating position and size of magnetic contaminant was derived
Summary
A thin-film magneto-impedance (MI) sensor made of a single-layer amorphous film was designed and developed previously [12] It aims to realize a nondestructive detection of magnetic small contaminants in aluminum casting. In this system, an array of the thin-film sensors was set in a strong and uniform magnetic field, with the sensing direction perpendicular to the magnetic field direction. The excitation coil or magnet generates a magnetic field in the measurement area, and the sensing apparatus detects the 3-dimensional field and estimates the position of the marker or magnet [13,14] They use a convergence calculation using an iteration method.
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