Project Details
Projekt
Intelligent sensor system for the disturbance variable invariant conditioning of residual stresses during machining of Ti-6Al-4V - Phase 2
Subject Area
Metal-Cutting and Abrasive Manufacturing Engineering
Measurement Systems
Measurement Systems
Term
since 2018
Project identifier
Deutsche Forschungsgemeinschaft (DFG) - Project number 402129590
In the planned research project the residual stress state of Ti-6Al-4V should be set reliable and independent from any tool wear during longitudinal turning. Therefore, a sensor system consisting of acoustic sensors, which measure the chip segmentation frequency as an indicator for the tool wear state, is implemented. The tool wear as disturbance value is compensated by controlling the following process variables: cutting speed, feed, rake angle and entering angle. By using a soft sensor, the acoustic signal in combination with a FE-simulation based process knowledge is processed and the thermo-mechanic load spectrum which effects the component’s surface layer states is determined. The aim is to keep the component behavior under cyclic loading on a consistently high level despite a wear-induced tool geometry alteration, by controlling the mentioned process variables.The first objective of the second project phase is the improvement of the process model performance being able to model the chip formation process using industrial cutting tools with more complex geometry. The second objective is the enhancing of the signal processing method to real-time processing and evaluation (soft sensor). The soft sensor is reliable and can identify interfering noises such as chip collisions, noises caused by metal cutting fluids and tool infeed and outfeed and can separate them from the signals relevant for the soft sensors. The third objective is the process control to regulate residual stress states after machining. By an AI-supported system identification the dynamic behavior of the soft sensor and the initial material and tool condition are identified in real time. With this information and using the process model the process parameters (cutting speed and feed) and, with the help of piezoelectric actuators, the rake and entering angles are controlled and adjusted to obtain the desired residual stresses in the final part.
DFG Programme
Priority Programmes
Subproject of
SPP 2086:
Surface Conditioning in Machining Processes
Co-Investigator
Dr.-Ing. Jens Gibmeier
