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D. Grandy, P. Koshy McMaster University, Canada F. Klocke RWTH Aachen, Germany

Pneumatic Non-Contact Roughness Assessment of Moving Surfaces. D. Grandy, P. Koshy McMaster University, Canada F. Klocke RWTH Aachen, Germany. www.taylor-hobson.com. www.taylor-hobson.com. Development towards in-process roughness estimation

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D. Grandy, P. Koshy McMaster University, Canada F. Klocke RWTH Aachen, Germany

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  1. Pneumatic Non-Contact Roughness Assessment of Moving Surfaces D. Grandy, P. Koshy McMaster University, Canada F. Klocke RWTH Aachen, Germany

  2. www.taylor-hobson.com www.taylor-hobson.com • Development towards in-process roughness estimation • Issues with machining debris and cutting fluid • Development of a pneumatic sensor Pneumatic Non-contact Roughness Assessment of Moving Surfaces D. Grandy, P. Koshy, F. Klocke 59th CIRP General Assembly Boston, August 26, 2009

  3. Principle of pneumatic gauging ps pressure transducer air ps P control orifice pb pb xi work xi • Back pressure pbdepends on xi • Primarily quasi-static applications Pneumatic Non-contact Roughness Assessment of Moving Surfaces D. Grandy, P. Koshy, F. Klocke 59th CIRP General Assembly Boston, August 26, 2009

  4. Surface porosity detection in machined castings piezoelectric pressure transducer Menzies & Koshy (2009) air • Sensor integrated into the cutting tool holder for in-process application, in the presence of a flood coolant 5 mm work Pneumatic Non-contact Roughness Assessment of Moving Surfaces D. Grandy, P. Koshy, F. Klocke 59th CIRP General Assembly Boston, August 26, 2009

  5. Reliability of pneumatic gauging deteriorates as the peak-to-valley height of the surface exceeds about 3 µm US patent 2,417,988 (1947) • Related previous work • Nicolau (1937) • Hamouda (1979) • Tanner (1982) • Wang & Hsu (1987) • Woolley (1992) • Nozzle is in contact with workpiece, and is hence not suitable for in-process application US patent 7,325,445 (2004) Pneumatic Non-contact Roughness Assessment of Moving Surfaces D. Grandy, P. Koshy, F. Klocke 59th CIRP General Assembly Boston, August 26, 2009

  6. The present work pertains to non-contact roughness assessment of moving surfaces • Roughness is related to the frequency content of the back pressure signal air frequency decomposition P pb xi work Pneumatic Non-contact Roughness Assessment of Moving Surfaces D. Grandy, P. Koshy, F. Klocke 59th CIRP General Assembly Boston, August 26, 2009

  7. Working principle nozzle nozzle traverse Pneumatic Non-contact Roughness Assessment of Moving Surfaces D. Grandy, P. Koshy, F. Klocke 59th CIRP General Assembly Boston, August 26, 2009

  8. Experiments on plane surfaces piezo pressure transducer nozzle Pneumatic Non-contact Roughness Assessment of Moving Surfaces D. Grandy, P. Koshy, F. Klocke 59th CIRP General Assembly Boston, August 26, 2009

  9. Comparison of stylus and pneumatic signals from milled and turned surfaces of roughness 3.2 µm Ra milled surface turned surface Height (µm) stylus Voltage (V) pneumatic Distance (mm) Distance (mm) Pneumatic Non-contact Roughness Assessment of Moving Surfaces D. Grandy, P. Koshy, F. Klocke 59th CIRP General Assembly Boston, August 26, 2009

  10. Frequency domain comparison of stylus and pneumatic signals milled surface turned surface Amplitude (µm) stylus Amplitude (V) pneumatic Frequency (mm-1) Frequency (mm-1) Pneumatic Non-contact Roughness Assessment of Moving Surfaces D. Grandy, P. Koshy, F. Klocke 59th CIRP General Assembly Boston, August 26, 2009

  11. Frequency spectra corresponding to milled surfaces of various roughness values 5 plots shown for each roughness ?? Pneumatic Non-contact Roughness Assessment of Moving Surfaces D. Grandy, P. Koshy, F. Klocke 59th CIRP General Assembly Boston, August 26, 2009

  12. Correlation of pneumatic indices to roughness measured using a stylus instrument • Area under the frequency plot • Amplitude of dominant frequency 0.45 1.5 0.30 1.0 Area (V/mm) Amplitude (V) 0.15 0.5 0.00 0.0 0 3 6 9 12 15 0 3 6 9 12 15 Roughness Ra (µm) Roughness Ra (µm) Pneumatic Non-contact Roughness Assessment of Moving Surfaces D. Grandy, P. Koshy, F. Klocke 59th CIRP General Assembly Boston, August 26, 2009

  13. Effect of supply pressure ps dn 9 air 6 P Normalized amplitude dc pb 3 xi 0 work 0 100 200 300 400 Supply pressure (kPa) Pneumatic Non-contact Roughness Assessment of Moving Surfaces D. Grandy, P. Koshy, F. Klocke 59th CIRP General Assembly Boston, August 26, 2009

  14. Effect of control orifice diameter dc ps 3 experimental 2 dn 1 air 0 Normalized amplitude 3 dc analytical pb 2 dc = 0.84 mm xi dc = 0.84 mm 1 work 0 dc = 0.50 mm dc = 0.50 mm 0 50 100 150 200 250 300 Stand-off distance (µm) Pneumatic Non-contact Roughness Assessment of Moving Surfaces D. Grandy, P. Koshy, F. Klocke 59th CIRP General Assembly Boston, August 26, 2009

  15. Experiments on rotating cylindrical surfaces nozzle nozzle quenchant hardness nozzle workpiece turned surface Pneumatic Non-contact Roughness Assessment of Moving Surfaces D. Grandy, P. Koshy, F. Klocke 59th CIRP General Assembly Boston, August 26, 2009

  16. Effect of increasing roughness increasing roughness quenched end of Jominy specimen 1 mm 1 mm Amplitude (V) 1.2 µm Ra 3.8 µm Ra Frequency (Hz) Frequency (Hz) Pneumatic Non-contact Roughness Assessment of Moving Surfaces D. Grandy, P. Koshy, F. Klocke 59th CIRP General Assembly Boston, August 26, 2009

  17. Effect of relative speed between nozzle and work • Sensor response can be improved by minimizing the volume of the variable pressure chamber Pneumatic Non-contact Roughness Assessment of Moving Surfaces D. Grandy, P. Koshy, F. Klocke 59th CIRP General Assembly Boston, August 26, 2009

  18. Effect of application of cutting fluid • Flood coolant application has minimal influence on sensor performance Pneumatic Non-contact Roughness Assessment of Moving Surfaces D. Grandy, P. Koshy, F. Klocke 59th CIRP General Assembly Boston, August 26, 2009

  19. Recent work on extension to fine surfaces 0.1 µm Ra ground 0.1 µm Ra lapped • Back pressure signals are noisy, and are affected by vibration  Pneumatic Non-contact Roughness Assessment of Moving Surfaces D. Grandy, P. Koshy, F. Klocke 59th CIRP General Assembly Boston, August 26, 2009

  20. Principal Components Analysis Variables Observations X2 P t2 … t1 S X1 X3 20/23 Pneumatic Non-contact Roughness Assessment of Moving Surfaces D. Grandy, P. Koshy, F. Klocke 59th CIRP General Assembly Boston, August 26, 2009

  21. Application of principal components analysis • Filled symbols refer to test data not considered when building the model Pneumatic Non-contact Roughness Assessment of Moving Surfaces D. Grandy, P. Koshy, F. Klocke 59th CIRP General Assembly Boston, August 26, 2009

  22. Conclusions • Proof-of-concept of pneumatic non-contact roughness assessment of moving surfaces has been established • In its present state of development, the system is best suited for in-situ process monitoring based on appropriate calibration • The system exhibits potential for in-process application in the presence of machining debris and cutting fluid that generally obscure the measurement process when using optical instruments • Future work will focus on the physics of jets impinging on laterally moving surfaces, taking roughness into consideration Pneumatic Non-contact Roughness Assessment of Moving Surfaces D. Grandy, P. Koshy, F. Klocke 59th CIRP General Assembly Boston, August 26, 2009

  23. Thank you for your attention! Natural Sciences & Engineering Research Council of Canada For more details please see: D. Grandy, P. Koshy, F. Klocke, Pneumatic non-contact roughness assessment of moving surfaces, CIRP Annals 58 (2009) 515-518. Pneumatic Non-contact Roughness Assessment of Moving Surfaces D. Grandy, P. Koshy, F. Klocke 59th CIRP General Assembly Boston, August 26, 2009

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