Effect of Acoustic Emission Sensor Location on the Detection of Grinding Wheel Deterioration in Cylindrical Grinding
Abstract
:1. Introduction
2. Grinding Experiments
2.1. Experimental Setup
2.2. Experimental Procedure
2.3. Signal Analysis for AE Waves
3. Experimental Results
3.1. Surface Roughness Deterioration with an Increasing Number of Grinding Cycles
3.2. Analysis of AE Signals Acquired from AE Sensors at Different Locations
4. Discussion
5. Conclusions
- The RMS values derived from the AE signals acquired from the AE sensor placed on the hydrostatic bearing decreased with the increase in the number of grinding cycles. Furthermore, they exhibited a small variation for each cycle and were less affected by the grinding position than those for the AE sensor placed on the tailstock spindle.
- A comparison between the AE sensors located on the hydrostatic bearing and the tailstock spindle, respectively, facilitated by a frequency domain analysis showed differences at frequencies below 0.3 MHz and above 1 MHz. It can be concluded that the difference in frequency response below 0.3 MHz is due to the AE sensor located on the tailstock spindle detecting AE signals caused by crack propagation, breakage, and the deformation of the workpiece, whereas the AE sensor on the hydrostatic bearing detected AE signals generated by cracks, friction, and the fractures of bonds and the cBN on the grinding wheel surface.
- To realize an effective method for monitoring grinding wheel deterioration using AE, the location of the AE sensor is an important factor. Acquiring an AE signal by positioning a sensor on the hydrostatic bearing is effective because it can extract information on grinding wheel deterioration despite the reduced signal intensity.
6. Patents
Author Contributions
Funding
Data Availability Statement
Conflicts of Interest
References
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Diameter of grinding wheel, mm | 350 |
Width of grinding wheel, mm | 20 |
Abrasive grain | cBN |
Bond material | Vitrified |
Grain size | #120 |
Concentration | 150 |
Wheel peripheral speed, m/s | 45 |
Work rotational speed, min−1 | 100 |
Grinding stock removal rate Z’, mm3/(mm·s) | 10 |
Stock removal in one plunge grinding, mm3 | 722.4 |
Roughing feed, mm/min | 3.23 |
Semi–finishing feed, mm/min | 0.170 |
Finishing feed, mm/min | 0.0213 |
AE Sensor Location | ||
---|---|---|
Tailstock Spindle | Hydrostatic Bearing | |
Number of interfaces | 6 | 7 |
Details of interface | Workpiece ↓ Lubricating grease ↓ Tailstock spindle ↓ Vacuum grease ↓ Separate shaft holder ↓ Thermoplastic adhesive ↓ AE sensor | cBN ↓ Vitrified ↓ Base metal ↓ Grinding wheel shaft ↓ Lubricating oil (Mobil Velocite 3) ↓ Hydrostatic bearing ↓ Instant adhesive ↓ AE sensor |
AE Signal Characteristic | AE Sensor Location | |
---|---|---|
Tailstock Spindle | Hydrostatic Bearing Supporting Grinding Wheel Spindle | |
Intensity | Large | Medium |
Variation in amplitude at same grinding position | Large | Very small |
Effect of grinding position on skewer-like workpiece | Large | Very small |
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Kon, T.; Mano, H.; Iwai, H.; Ando, Y.; Korenaga, A.; Ohana, T.; Ashida, K.; Wakazono, Y. Effect of Acoustic Emission Sensor Location on the Detection of Grinding Wheel Deterioration in Cylindrical Grinding. Lubricants 2024, 12, 100. https://doi.org/10.3390/lubricants12030100
Kon T, Mano H, Iwai H, Ando Y, Korenaga A, Ohana T, Ashida K, Wakazono Y. Effect of Acoustic Emission Sensor Location on the Detection of Grinding Wheel Deterioration in Cylindrical Grinding. Lubricants. 2024; 12(3):100. https://doi.org/10.3390/lubricants12030100
Chicago/Turabian StyleKon, Tomohiko, Hiroki Mano, Hideki Iwai, Yoshiaki Ando, Atsushi Korenaga, Tsuguyori Ohana, Kiwamu Ashida, and Yoshio Wakazono. 2024. "Effect of Acoustic Emission Sensor Location on the Detection of Grinding Wheel Deterioration in Cylindrical Grinding" Lubricants 12, no. 3: 100. https://doi.org/10.3390/lubricants12030100