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標題: 車削刀具磨耗偵測之聲射訊號產生模型建立與分析
Development and Analysis of AE Signal Generation Model for Tool Wear Monitoring in Turning
作者: 田仲凱
Tian, Jhong-Kai
關鍵字: orthogonal cutting;正交切削;tool wear;Acoustic Emission signal;turning;刀具磨耗;聲射訊號;車削加工
出版社: 機械工程學系所
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在切削加工中,刀具磨耗而產生之各種訊號變化可藉由感測器加以偵測,其中聲射訊號屬於高頻訊號,分布範圍在數十kHz 到數十MHz 之間。本研究針對正交車削並以理想化之正交切削模型整合刀腹磨耗之理論模型建立高頻聲射訊號產生機制與刀具磨耗間之關係模型,探討刀具磨耗與聲射訊號之關係。
模型建立方面,先使用有限元素分析軟體模擬正交切削時,剪切區的應力及應變率分布情形,同時整合Waldorf利用滑線場(Slip-Line Field)理論建立的犁切力模型及Zorev提出的切屑與刀具接觸面的摩擦力模型,以得到刀腹與工件接觸面及刀面與切屑接觸面之應力及應變率分佈,再將其數據利用利用歐羅萬定律計算出材料內的差排密度,並利用高斯機率密度函數以及波動方程式求得聲射訊號源分布及聲射訊號傳遞模型,最後模擬聲射訊號隨著刀具磨耗變化的變化情形。以正交車削實驗擷取之聲射訊號與模擬之聲射訊號做驗證比較。

In Machining, tool wear condition can be detected by the Acoustic Emission (AE) signal, which is ranged from 1 kHz to 10 MHz in frequency domain. In order to study the relationship between tool wear and AE signal on theoretical base, a model was developed to analyze the effect of tool wear on the AE signal generation and propagation.
In the model development, shear strain and strain rate on the shear plane was first obtained by the FEM software based on orthogonal cutting, integrated with the generated strain on the flank surface based on the Waldorf model and on the rake surface based on the Zorev model. After calculating the dislocation density on shear plane, flank surface, and chip-tool contact surface, the distribution of AE source was generated. Following the development of the AE signal generation, the one dimension propagation model was developed as well to simulate the propagation of AE signal to the sensor location. Finally, the experiment was implemented to simulate the orthogonal cutting in turning to verify the model developed in this study.
In the simulation results, the AE signal was observed to be dominated by the AE signal generated from the shear plane and chip-tool contact surface with sharp tool installation. As the tool wear increases, the contribution from the AE signal generated from the flank surface increases. In which, the signal energy increase and move to the higher frequency range.
By observing the experiment results, signals obtained from the two locations show the same trend as simulation results, the signal energy increases and the signal in the high frequency range increases as well. However, the experimental results show that the AE signals concentrates on the specific frequency, rather than the more wide distribution over a span of frequency range in the simulation results.
其他識別: U0005-2508201104574700
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