Abstract
In the concept of the process signature, the relationship between a material load and the modification remaining in the workpiece is used to better understand and optimize manufacturing processes. The basic prerequisite for this is to be able to measure the loads occurring during the machining process in the form of mechanical deformations. Speckle photography is suitable for this in-process measurement task and is already used in a variety of ways for in-plane deformation measurements. The shortcoming of this fast and robust measurement technique based on image correlation techniques is that out-of-plane deformations in the direction of the measurement system cannot be detected and increases the measurement error of in-plane deformations. In this paper, we investigate a method that infers local out-of-plane motions of the workpiece surface from the decorrelation of speckle patterns and is thus able to reconstruct three-dimensional deformation fields. The implementation of the evaluation method enables a fast reconstruction of 3D deformation fields, so that the in-process capability remains given. First measurements in a deep rolling process show that dynamic deformations underneath the die can be captured and demonstrate the suitability of the speckle method for manufacturing process analysis.
Highlights
The functionality of technical surfaces is significantly influenced by the manufacturing process [1,2,3]
Due to the expectedthat strong out-of-plane movement the edge area(∆ξ,∆ψ) of theis linearly machined related to the displacement (∆x,∆y) of the maximum of the cross-correlation via the scaling surface, the deep rolling process was selected as the manufacturing process to investigate factor A (Equations (11) and (12)), it is shown by Equation (16) that a linear relationship
Contrary to the intuitive idea, the setup is upside down and the rolling surface, the deep rolling process was selected as the manufacturing process to investigate tool presses on the workpiece frommanufacturing below
Summary
The functionality of technical surfaces is significantly influenced by the manufacturing process [1,2,3]. This applies in particular to processes which aim to change the surface layer properties of the workpiece in a suitable manner. A remedy can be provided by the introduced concept of process signatures [7], which focuses on the internal mechanisms and the influencing quantities [8], leading to a material change to describing the workpiece modification. To gain a deeper understanding of the manufacturing process, the study of process signatures, which correlate the material changes occurring with the acting internal mechanical material loads, is ongoing. The use of process signatures enables a better understanding of the process, and allows a comparison of seemingly different manufacturing processes
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