New demands are being placed on monitoring systems in the manufacturing environment because of recent developments and trends in machining technology and machine tool design (high speed machining and hard turning, for example). In-process sensors play a significant role in assisting manufacturing systems in producing products at a cost affordable to the mass consumer market. In-process sensors are used to generate control signals to improve both the control and productivity of manufacturing systems. For example, acoustic emission sensors are used in many precision metal cutting processes to monitor the degree of tool wear, chip formation, surface features, etc., and in precision grinding, acoustic emission sensors are used to detect both the near approach of the grinding wheel to the work surface, and the initial wheel contact with the work. In particular, in-process sensors are needed in precision manufacturing systems, because human oversight of the manufacturing process is inadequate to achieve the performance levels necessary in precision manufacturing processes. In the precision grinding example just mentioned, stock removal can be just a few tens of microns, and a human operator has a poor ability to monitor and control material removal in this regime.
KeywordsAcoustic Emission Root Mean Square Tool Wear Material Removal Rate Flank Wear
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