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Development and Analysis of AE Signal Generation Model for Tool Wear Monitoring in Turning
|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||引用:||【1】 H. Ernst, M.E. Merchant, 1941, “Chip Formation, Friction and High Quality Machined Surfaces,” Surface Treatment of Metals, vol. 29, American Society of Metals, New York, pp. 229-378. 【2】 M. Merchant, 1945, “Mechanics of the metal cutting process 1：orthogonal cutting and a type 2 chip,” Journal of Applied Physics, 16（5）, pp.267-275. 【3】 M. Merchant, 1945, “Mechanics of the metal cutting process 2：plasticity conditions in orthogonal cutting,” Journal of Applied Physics, 16（5）, pp.318-324. 【4】 M.C. Shaw, 2005, “Metal Cutting Principles,” second ed., Oxford Series on Advanced Manufacturing, Oxford University Press. 【5】 L. Alting, F. Kimura, H.N. Hansen, G. Bissacco, 2003, “Micro engineering,” Annals of CIRP Keynote, STC-O. 【6】 X. Liu, R.E. DeVor, S.G. Kapoor, K.F. 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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。
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.
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