Abstract
During turning of quenched and tempered AISI4140 surface layer states can be generated, which degrade the lifetime of manufactured parts. Such states may be brittle rehardened layers or tensile residual stresses. A soft sensor concept is presented in this work, in order to identify relevant surface modifications during machining. A crucial part of this concept is the measurement of magnetic characteristics by means of the 3MA-testing (Micromagnetic Multiparameter Microstructure and Stress Analysis). Those measurements correlate with the microstructure of the material, only take a few seconds and can be processed on the machine. This enables a continuous workpiece quality control during machining. However specific problems come with the distant measurement of thin surface layers, which are analyzed here. Furthermore the scope of this work is the in-process-measurement of the tool wear, which is an important input parameter of the thermomechanical surface load. The availability of the current tool wear is to be used for the adaption of the process parameters in order to avoid detrimental surface states. This enables new approaches for a workpiece focused process control, which is of high importance considering the goals of Industry 4.0.
Zusammenfassung
Beim Außenlängsdrehen von vergütetem 42CrMo4 können Randschichtzustände entstehen, welche die Lebensdauer von gefertigten Bauteilen beeinträchtigen. Beispiele für solche Zustände sind spröde Neuhärtezonen und Zugeigenspannungen. In dieser Arbeit wird ein Softsensor-Konzept vorgestellt, mit dem relevante Randschichtmodifikationen während der Zerspanung vorhergesagt werden sollen. Ein wesentlicher Teil des Konzepts ist die Messung magnetischer Kenngrößen mit der 3MA-Prüftechnik (Mikromagnetische Multiparametrische Mikrostruktur- und Spannungs-Analyse). Diese Messungen korrelieren mit der materiellen Mikrostruktur, nehmen nur wenige Sekunden in Anspruch und können im Bearbeitungsraum der Maschine erfolgen. Dies eröffnet die Möglichkeit einer 100-prozentigen Prüfung des Werkstücks bei der Zerspanung. Jedoch gibt es spezifische Probleme bei der berührungsfreien Messung dünner Randschichten, die hier analysiert werden. Darüber hinaus liegt der Fokus dieser Arbeit auf der prozessparallelen Ermittlung des Werkzeugverschleißes, der eine wichtige Einflussgröße für die thermomechanische Randschichtlast ist. Die Kenntnis des Verschleißes soll genutzt werden, um die Stellgrößen des Zerspanungsprozesses anzupassen und so schädliche Randschichtzustände zu vermeiden. Damit ergeben sich neue Ansätze für eine werkstückorientierte Prozessregelung, die im Zeitalter von Industrie 4.0 eine immer größere Bedeutung erlangen.
Funding statement: The scientific work has been supported by the DFG within the research priority program SPP 2086 (SCHU 1010/65-1, LA 2351/46-1, WO 903/4-1). The authors thank the DFG for this funding and intensive technical support.
About the authors
David Böttger has studied mechatronics with specialization in the field of sensor technology at University of Applied Sciences in Saarbruecken. During his bachelor and master studies he was working as a research assistant in the field of laser welding processes, air- and structure-borne ultrasound emissions. Since 2017 he is working as a scientific associate in the department “Production integrated NDT” with focus in multidimensional sensor technologies for process monitoring applications such as high frequency acoustic and micromagnetic NDT-techniques.
Benedict Stampfer has been a research associate of the research group ‘manufacturing and materials technology’ at wbk Institute of Production Science since 2017. His research areas include cooling strategies and control concepts of machining processes as well as surface engineering.
Daniel Gauder is research associate at the Institute for Production Science (wbk) at the Karlsruhe Institute of Technology (KIT) in the area of quality assurance.
Benjamin Straß studied mechanical engineering with specialization in automotive engineering at University of Kaiserslautern. In 2015 he received a doctoral degree at the Institute of Materials Science and Engineering (University of Kaiserslautern) for his research in the interface area between material science and production technology, especially joining of metals. Since October 2015 Dr. Straß is working at the department “Production Integrated NDT” at Fraunhofer IZFP where he is leading the group “Processing”. The focus of this group is on the monitoring of manufacturing processes (e.g. metal-cutting processes, joining processes and additive manufacturing) using innovative NDT technologies.
Benjamin Häfner is team leader at the Institute for Production Science (wbk) at Karlsruhe Institute of Technology (KIT) for the areas of global production strategies and quality assurance.
Prof. Dr.-Ing. Gisela Lanza is member of the management board at the Institute of Production Science (wbk) of the Karlsruhe Institute of Technology (KIT). She heads the Production Systems division dealing with the topics of global production strategies, production system planning, and quality assurance in research and industrial practice.
Volker Schulze has been a full professor for Manufacturing and Materials Technology at the Institute for Production Science at Karl- sruhe Institute of Technology (KIT) since April 2010. Parallelly, he is director at the Institute of Applied Materials at KIT. He is mem- ber of CIRP International Academy for Production Engineering and Spokesperson of the Research Priority Program 2086 of DFG. Re- search Interests include machining, additive manufacturing, heat treatment and mechanical surface treatments.
Bernd Wolter studied Material Science at University of Saarland. He made his PhD in Applications of One-Sided Nuclear Magnetic Res- onance for Material Characterization. In 2001 he was awarded with the Berthold Prize of the DGZfP (German Society for Non-Destructive Testing). Since 2002 he is head of department for Production Inte- grated NDT at the Fraunhofer-Institute for Nondestructive Testing. His research is focussed to sensor-based quality monitoring and control in production.
Acknowledgment
Special thanks for the inspiring collaboration of the department Production-Integrated NDT of Fraunhofer IZFP and the involved research assistants of wbk Institute of Production Science at Karlsruhe Institute of Technology KIT.
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