Search query: Precision Manufacturing Process Monitoring with Acoustic Emission

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abstract: Current demands in high technology industries such as semiconductor, optics, MEMS, etc. have predicated the need for manufacturing processes that can fabricate increasingly smaller features reliably at very high tolerances. In situ monitoring systems that can be used to characterize, control, and improve the fabrication of these smaller features are therefore needed to meet increasing demands in precision and quality. This paper discusses the unique requirements of monitoring of precision manufacturing processes, and the suitability of acoustic emission (AE) as a monitoring technique at the precision scale. Details are then given on the use of AE sensor technology in the monitoring of precision manufacturing processes; grinding, chemical mechanical planarization (CMP) and ultraprecision diamond turning in particular. q 2005 Elsevier Ltd. All rights reserved.
author_names: D E Leea

I Hwanga

C M O Valenteb

Jeane Freitas de Oliveirab

D A Dornfelda
title: Precision manufacturing process monitoring with acoustic emission
year: 2005

abstract: Abstract Current demands in high technology industries such as semiconductor, optics, MEMS, etc. have predicated the need for manufacturing processes that can fabricate increasingly smaller features reliably at very high tolerances. In situ monitoring systems that can be used to characterize, control, and improve the fabrication of these smaller features are therefore needed to meet increasing demands in precision and quality. This paper discusses the unique requirements of monitoring of precision manufacturing processes, and the suitability of acoustic emission (AE) as a monitoring technique at the precision scale. Details are then given on the use of AE sensor technology in the monitoring of precision manufacturing processes; grinding, chemical mechanical planarization (CMP) and ultraprecision diamond turning in particular.
author_names: Dae-Eun Lee

Inkil Hwang

C M O Valente

Joao Fernando Gomes de Oliveira

David A Dornfeld
title: Precision manufacturing process monitoring with acoustic emission
year: 2006

abstract: Demands in high technology industries such as semiconductor, optics, MEMS, etc. have predicated the need for manufacturing processes that can fabricate increasingly smaller features reliably at very high tolerances. In situ monitoring systems that can be used to characterize, control, and improve the fabrication of these smaller features are therefore needed to meet increasing demands in precision and quality. This paper discusses the unique requirements of monitoring of precision manufacturing processes, and the suitability of acoustic emission (AE) as a monitoring technique at the precision scale. Details are then given on the use of AE sensor technology in the monitoring of precision manufacturing processes; grinding, chemical mechanical planarization (CMP) and ultraprecision diamond turning in particular.
author_names: Inkil Hwang

C M O Valente
title: Precision Manufacturing Process Monitoring with Acoustic Emission
year: 2006

abstract: International Journal of Machine Tools Manufacture 46 (2006) 176 188 www.elsevier.com/locate/ijmactool Precision manufacturing process monitoring with acoustic emission D.E. Lee a I. Hwang a C.M.O. Valente b J.F.G. Oliveira b D.A. Dornfeld a, a Laboratory for Manufacturing Automation, Department of Mechanical Engineering, University of California, Berkeley, CA 94720 1740, USA b University of Sao Paulo, Nucleus of Advanced Manufacturing, Sao Carlos, Brazil Received 27 January 2005; accepted 7 April 2005 Available online 13 June 2005 Abstract Current demands in high technology industries such as semiconductor, optics, MEMS, etc. have predicated the need for manufacturing processes that can fabricate increasingly smaller features reliably at very high tolerances. In situ monitoring systems that can be used to characterize, control, and improve the fabrication of these smaller features are therefore needed to meet increasing demands in precision and quality. This paper discusses the unique requirements of monitoring of precision manufacturing processes, and the suitability of acoustic emission (AE) as a monitoring technique at the precision scale. Details are then given on the use of AE sensor technology in the monitoring of precision manufacturing processes; grinding, chemical mechanical planarization (CMP) and ultraprecision diamond turning in particular. q 2005 Elsevier Ltd. All rights reserved. Keywords: Acoustic emission; Precision; Process monitoring 1. Introduction Current demands in high technology industries such as semiconductor, optics, MEMS, etc. have predicated the need for manufacturing processes that can fabricate increasingly smaller features reliably at very high toler ances. This increasing demand for the ability to fabricate features at smaller length scales and at greater precision can be represented in the Taniguchi curve (Fig. 1) which demonstrates that the smallest achievable accuracy (and, as a consequence, smallest reproducible feature) decreases as a function of time [1] In situ monitoring systems that can be used to characterize, control, and improve the fabrication of these smaller features are therefore needed to meet increasing demands in precision and quality. Sensor based monitoring yields valuable information about the manufacturing process that can serve the dual purpose of process control and quality monitoring, and will ultimately be the part of any fully automated manufacturing environment. However, a high degree of confidence and reliability in characterizing Corresponding author. Tel. C1 510 642 0906; fax: C1 510 643 7492. E mail addresses: cmov@sc.usp.br (C.M.O. Valente) dornfeld@me. berkeley.edu (D.A. Dornfeld) the manufacturing process is required for any sensor to be utilized as a monitoring tool. As demonstrated in a previous review paper by Dornfeld et al. [2] acoustic emission (AE) has demonstrated a high degree of confidence in character izing various phenomena related to material removal, particularly at the microscale, hence lending credence to its suitability for precision manufacturing process monitor ing. This work serves to demonstrate sensitivity of AE at the three different manufacturing regimes outlined in the Taniguchi curve; the normal/conventional, precision, and ultraprecision scales (Fig. 1) 2. Requirements for sensor technology at the precision scale In material removal processes at the precision scale, the undeformed chip thickness can be on the order of a few microns or less, and can approach the nanoscale in some cases. At these length scales, the surface, subsurface, and edge condition of machined features and the fundamental mechanism for chip formation are much more intimately affected by the material properties and microstructure of the workpiece material, such as ductile/brittle behavior, crystal lographic orientation of the material at the tool/chip interface, and microtopographical features such as voids, secondary phases, and interstitial particulates [3,4] 0890 6955/ see front matter q 2005 Elsevier Ltd. All rights reserved. doi:10.1016/j.ijmachtools.2005.04.001
author_names: D E Lee

Inkil Hwang

C M O Valente

J F G Oliviera

David A Dornfeld
title: Precision Manufacturing Process Monitoring with Acoustic Emission eScholarship
year: 2006

abstract: Current demands in high technology industries such as semiconductor, optics, MEMS, etc. have predicated the need for manufacturing processes that can fabricate increasingly smaller features reliably at very high tolerances. In situ monitoring systems that can be used to characterize, control, and improve the fabrication of these smaller features are therefore needed to meet increasing demands in precision and quality. This paper discusses the unique requirements of monitoring of precision manufacturing processes, and the suitability of acoustic emission (AE) as a monitoring technique at the precision scale. Details are then given on the use of AE sensor technology in the monitoring of precision manufacturing processes; grinding, chemical mechanical planarization (CMP) and ultraprecision diamond turning in particular. q 2005 Elsevier Ltd. All rights reserved.
author_names: D E Leea

I Hwanga

C M O Valenteb

Jeane Freitas de Oliveirab

D A Dornfelda
title: Green Manufacturing and Sustainable Manufacturing Partnership Title Precision Manufacturing Process Monitoring with Acoustic Emission Permalink
year: 2005

abstract: To ensure overall quality of a precision large scale component, a tool condition monitoring (TCM) technique for multi step form milling is presented. The form milling of fir tree slots for a steam turbine rotor is an appropriate example that requires a fine surface finish and high dimensional accuracy. Therefore, we propose a novel TCM system based on a multi sensor fusion strategy which utilises the combination of spindle motor current and acoustic emission (AE) as well as adaptive thresholding for multiple manufacturing steps (roughing, semi finishing and finishing) To investigate the tool deterioration process, tool longevity tests using a test piece are carried out for each step. With the aid of qualitative inspection, it is found that AE signals provide comprehensive tool state information regarding tool flank wear, crack propagation and severe adhesive wear. In addition, by intentionally adding a bundle of chips to the surface, bursts of AE of large amplitudes occur in finishing, which provides the possibility of discovering anomalous events related to surface quality. By careful consideration of such characteristics, provisional alert levels are determined using a two dimensional diagram with respect to both sensors. The strategy is verified throughout the actual manufacturing processes of the rotors. The proposed TCM system shows not only an excellent ability to prevent catastrophic tool failure and surface irregularities in form milling but also acceptable expendability for various groove specifications.
author_names: Masahiro Uekita

Yasuhiro Takaya
title: Tool condition monitoring for form milling of large parts by combining spindle motor current and acoustic emission signals
year: 2017

abstract: This paper considers the application of the method of acoustic emission (AE) for the control of welding quality in process of its manufacturing. Features AE method to detect in real time defects of weld joint during manual submerged arc welding and in cooling were studied. Set of informative AE parameters after the analysis of AE monitoring and data of arbitration methods of nondestructive testing was offered, which form a space of criteria for separating the signals from defects and interference that accompany the welding process. Determination of the coordinates of defects with high precision makes it possible to correct them in the operative welding process with a minimum of metal excision; reduces the volume of application of traditional testing methods.
author_names: Victor P Gomera

Evgeny J Nefedyev

Anatoly D Smirnov
title: On the Possibility of Producing Defect Free Welds under Acoustic Emission Monitoring
year: 2017

abstract: The use of fine micro structured rapidly solidified aluminium (RSA) alloys in manufacturing of optical mould inserts has recently increased because of the advantages these alloys offer at a relatively low cost. The fine microstructure of RSA imparts these alloys a high ultimate strength and thus make them suitable candidates as mould materials. As part of our research in the area of manufacture of optical mould inserts, this paper presents a monitoring technique established to identify the behaviour of diamond tool wear during the ultra high precision machining of RSA 905 for optical mould insert production. Acoustic emission (AE) is employed as a precision sensing technique and further processed to correlate AE rms feature with the process performance. The initial results of tool wear measurement indicate an adequate rise in amplitude of RMS. The setup for the AE sensor system exhibits excellent sensitivity to the cutting mechanism, especially for the detection of the initial engagement between the tool and workpiece.
author_names: Oluwole A Olufayo

Khaled A Abou-El-Hossein
title: Acoustic Emission Monitoring in Ultra High Precision Machining of Rapidly Solidified Aluminium
year: 2013

abstract: Current demands of machining hard and brittle materials at very small tolerances have predicated the need for precision and high efficiency grinding. In situ monitoring systems based on acoustic emission (AE) provide a new way to control the surface damage and integrality of the components. However, a high degree of confidence and reliability in characterizing the manufacturing process is required for AE to be utilized as a monitoring tool. The authors established AE based online monitoring system and studied technique parameters versus the waveforms of AE under different working conditions. The results show that there are obvious mapping relations between the technique parameters of grinding and the effective values of the AE signals. Grinding along different directions would result in different strength of AE signal. Comparing with grinding along first longitude, fewer AE signal is released when grinding along latitude and better surface quality is generated. Similar variation tendency is observed no matter between AE root mean square (RMS) and linear speed or between surface roughness and linear speed which justify some kind of correlation may exist between AE RMS and surface roughness. The distance between the AE transducer and the AE source should be less than 80 mm while monitoring the process of grinding composite ceramics.
author_names: Xuesong Han

Tianyu Wu
title: Analysis of acoustic emission in precision and high efficiency grinding technology
year: 2013

abstract: Tool wear is a complex phenomenon, it worsens surface quality, increases power consumption, and causes rejection of machined parts. Tool wear has a direct effect on the quality of the surface finish of the workpiece, dimensional precision and ultimately the cost of the parts produced. In modern automated manufacturing machines, tool monitoring system for automated machines should be capable of operating on line and interpret the working condition of machining process at a given point in time. Therefore, there is a need to develop a continuous tool monitoring systems that would notify operator the state of tool in order to avoid tool failure or undesirable circumstances. This study therefore uses acoustic emission (AE) sensing techniques, signal processing and Artificial Neural Networks (ANN) frameworks to model and validate the machining process. The AE showed effects of tool breakage and ANN predictions closest to the experimental cutting parameters were obtained. It was also shown that the ANN prediction model obtained is a useful, reliable and quite effective tool for modeling tool wear of carbide tools when working on stainless steel. Thus, the results of the present research can be successfully applied in the manufacturing industry to reduce the time, energy and high experimental costs.
author_names: Peter Babatunde Odedeyi

Khaled A Abou-El-Hossein

Muhammad Mukhtar Liman

Abubakar I Jumare

Abdulqadir N Lukman
title: Acoustic Emission in Stainless Steel End Milling with Carbide Tools
year: 2017