TY - GEN
T1 - Process monitoring during micro-drilling via acoustic emission, ultrasonic sound, and spindle load sensors
AU - Bourne, Keith A.
AU - Kapoor, Shiv G.
PY - 2012
Y1 - 2012
N2 - Careful monitoring of conditions during micro-drilling is important for insuring production of consistent high-quality holes. In this study, acoustic emission, ultrasonic sound, and electric spindle load were used to monitor micro-drilling performed using a micro-scale machine tool (mMT). Experiments were conducted where 0.508 mm diameter holes were drilled in polyetheretherketone (PEEK) polymer and 316 stainless steel. It was found that spindle load significantly increased when tool gumming occurred during drilling of PEEK. Increased spindle load when cutting 316 stainless steel was found to correspond to increased incidences of tool breakage, and a large reduction in spindle load was present during additional drilling operations following a breakage event. It was found that elevated acoustic emission levels were always present during drilling and that a lack of sufficient acoustic emission generation during retraction of a tool indicated tool breakage. The ultrasonic sound spectra were found to change in a manner that is a function of depth of cut and hence a function of depth of cut dependent tool dynamics.
AB - Careful monitoring of conditions during micro-drilling is important for insuring production of consistent high-quality holes. In this study, acoustic emission, ultrasonic sound, and electric spindle load were used to monitor micro-drilling performed using a micro-scale machine tool (mMT). Experiments were conducted where 0.508 mm diameter holes were drilled in polyetheretherketone (PEEK) polymer and 316 stainless steel. It was found that spindle load significantly increased when tool gumming occurred during drilling of PEEK. Increased spindle load when cutting 316 stainless steel was found to correspond to increased incidences of tool breakage, and a large reduction in spindle load was present during additional drilling operations following a breakage event. It was found that elevated acoustic emission levels were always present during drilling and that a lack of sufficient acoustic emission generation during retraction of a tool indicated tool breakage. The ultrasonic sound spectra were found to change in a manner that is a function of depth of cut and hence a function of depth of cut dependent tool dynamics.
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U2 - 10.1115/MSEC2012-7341
DO - 10.1115/MSEC2012-7341
M3 - Conference contribution
AN - SCOPUS:84883089595
SN - 9780791854990
T3 - ASME 2012 International Manufacturing Science and Engineering Conference Collocated with the 40th North American Manufacturing Research Conference and in Participation with the Int. Conf., MSEC 2012
SP - 781
EP - 790
BT - ASME 2012 International Manufacturing Science and Engineering Conference Collocated with the 40th North American Manufacturing Research Conf. and in Participation with the Int. Conf., MSEC 2012
T2 - ASME 2012 International Manufacturing Science and Engineering Conference, MSEC 2012 Collocated with the 40th North American Manufacturing Research Conference and in Participation with the International Conference
Y2 - 4 June 2012 through 8 June 2012
ER -