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ProcessSignatures
an Alternative Approach toanAlternativeApproachtoPredictingFunctionalWorkpiecePropertiesProperties
Ekkard BrinksmeierRalf Glbe
Fritz KlockeFritz Klocke
Don A. Lucca
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January 30th, 2012
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Machiningisanenergybasedtransformationprocess
INPUT PROCESS OUTPUT
machinematerials
(workpiece,tool)
lubricant
workpiecemodificationmacrogeometry
f / b f
partswithgeometrical,physicaland
h i llubricantenergy
surface/subsurfaceproperties
chemicalproperties
manymodels
somemodels
veryfewmodels
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Evolutionof manufacturing processes:the early days
...geometricallydrivenconcept
thecornerstonesofmanufacturing
19561960
1950g
O Kienzle: Die Grundpfeiler der Fertigungstechnik. in: VDI-Zeitschrift 98, Nr. 23, Verein Deutscher Ingenieure, Dsseldorf, 1956: 13891395.
consideration of geometrical propertiesO.Kienzle
1980
1970
considerationofgeometricalpropertiesofcomponentsonly
workpiecematerialisconsideredasgivenbythedesigner
2000
1990
2010
2000
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2020
...O Kienzle: Die Grundpfeiler der Fertigungstechnik. in: VDI-Zeitschrift 98, Nr. 23, Verein Deutscher Ingenieure, Dsseldorf, 1956: 13891395.
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Evolutionofmanufacturingprocesses:late1960ies:frommacro tomicrogeometry
microgeometryofsurfaces
typologyofsurfaces...
yp gy measurementandcharacterizationofsurfaces functionalbehavior
1960
1950
CIRPresearchers H.vonWeingraber R.vanHasselt
late1960ies
1980
1970
W.deBruin J.Peters D.J.Whitehouse
h k2000
1990
P.Vanherck2010
2000
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D J Whitehouse, P Vanherck, W de Bruin, C A van Luttervelt. Assessment of Surface Topology Analysis Technique in Turning . CIRP Annals, Vol. 23, no. 2, 1974: 265-282.
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Evolutionofmanufacturingprocesses:view onSurfaceIntegrity
M.Field investigationsintosurfacesandfunctionalproperties...
f ti t th1960
1950
1971J.Kahles
fatiguestrength=f (max.residualstress)
1980
1970
definition of Surface Integrity2000
1990
definitionofSurfaceIntegritySurfaceIntegritycanbedefinedastheentiretyofinherentandenhancedpropertiesofasurface.Itinvolvesastudyandcontrolof
2010
2000
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topographyandmetallurgyofsurfacesthatcanbegeneratedbymachiningorotheroperations.M Field, J Kahles: Review of surface integrity of machinedcomponents. CIRP Annals, 20(2),1971: 153-163.
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Evolutionofmanufacturingprocesses:focusonmachiningandfunctionalproperties
driver: highlystressedcomponents
accumulateddatashowedthatallmanufacturingK.Tnshoff...
gprocesseshavecertaineffectsontheworkpiecematerial
DFGpriorityprogramonManufacturingandPerformance of Components (1980 1983)
1960
1950
PerformanceofComponents (19801983)
permanentissueoftheCIRPScientificTechnical1980
1970
1980s CommitteeSinthelate1980sandthe1990s:SurfaceandFunctionJ.B.BryanM.Field
2000
1990
CIRPcollaborativeworkofSTC"S"on"residualstress measurement"
J.KahlesW.KnigP.LeskovarJ.PetersG Byrne
2010
2000
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stressmeasurement
E Brinksmeier, J T Cammett, W Knig, P Leskovar, J Peters, H K Tnshoff: Residual Stresses Measurement and Causes in Machining Processes. CIRP Annals, Volume 31, Issue 2, 1982: 491510.
G.ByrneG.Spur2020
...
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Evolutionofmanufacturingprocesses:progressofmeasuringtechniques
advancesinXraystressmeasurement E.Macherauch E Macherauch, P Mller: Das sin2-Verfahren
der rntgenographischen Spannungsmessung, Z.m,
...
V.Hauk U.Wolfstieg B Scholtes
der rntgenographischen Spannungsmessung, Z. angew. Physik 13, 1961: 305-312.
sin2
m
1960
1950
B.Scholtes
advancesinmicromagneticanalysis WA Theiner G Goch, B Schmitz, B Karpuschewski, J Geerkens, M R i l P S l R Ritt R i f
M AMH1980
1970
W.A.Theiner
B.KarpuschewskiM. Reigl, P Sprongl, R Ritter: Review of non-destructive measuring methods for the assessment of surface integrity: a survey of new measuring methods for coatings, layered structures and processed surfaces. Precision Engineering, Volume 23, Issue 1, January 1999: 933.
H
2000
1990
highresolutiontechniques D.A.Lucca
h
D A Lucca, K Herrmann, M J Klopfstein: Nanoindentation: Measuring methods and
2010
2000
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G.Goch C.Evans
applications. CIRP Annals STC S, 59/2/2010: 803-819.2020
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Evolutionofmanufacturingprocesses:modelingofgrindingprocesses
S.Malkin
replacementofmachiningparametersbyenergyrelatedparameters...
criticalspecificenergyfortheonsetofgrindingburn
r
g
y
u
highertemperature1960
1950
combinationofthermalequations(Carslaw/Jaeger)andprocessparameterssince
e
c
i
f
i
c
e
n
e
1980
1970
preventionofgrindingburnW.B.Rowe
M.C.Shaw
1978 s pe
d 1/4 a 3/4 v 1/2
B
uo
2000
1990
S Malkin: Burning Limit for Surface and Cylindrical Grinding of Steels. CIRP Annals, 27/1 (1978): 233236.
de1/4 ae 3/4vw 1/2
2010
2000
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W B Rowe, J A Pettit, A Boyle, J L Moruzzi: Avoidance of Thermal Damage in Grinding and Prediction of the Damage Threshold. CIRP Annals, Volume 37, Issue 1, 1988: 327-330.
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Evolutionofmanufacturingprocesses:significanceofenergyandspecificpowerforsurfaceintegrity
residualstress=f (specificpower)...
E.Brinksmeier
+ process1 process2 process3 process41960
1950
d
u
a
l
s
t
r
e
s
s
1980
1970
1980ies
K.TnshoffW.Hetz
r
e
s
i
d
reduction of converted power
targetedresidualstresslevel
2000
1990
B.KarpuschewskiW.Heuer
specific grinding powerPc
reductionofconvertedpower modificationofheatdistribution
2010
2000
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E Brinksmeier: Prozess- und Werkstckqualitt in der Feinbearbeitung. Habilitationsschrift, Universitt Hannover, VDI Verlag, Fortschritts-Berichte VDI Reihe 2 Nr. 234, Dsseldorf, 1991.
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Evolutionofmanufacturingprocesses:significanceofenergydissipationfortheprocess
heatpartitioninginmachiningprocesses
Stephenson:deepgrinding
D.J.Stephenson
...p p g g
T. Jin, , D.J. Stephenson: Investigation of the heat partitioning in high efficiency deep grinding. International Journal of Machine Tools and Manufacture. Volume 43, Issue 11, September 2003:11291134.1960
1950
Komanduri:orthogonalprocessR. Komanduri, , Z.B. Hou: Thermal modeling of the metal cutting process: Part I Temperature rise distribution due to shear plane heat source International Journal of Mechanical
R.Komanduri
1980
1970
shear plane heat source. International Journal of Mechanical Sciences, Volume 42, Issue 9, September 2000: 17151752.
20002000
1990
20002003
2010
2000
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2020
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Evolutionofmanufacturingprocesses:extendedmodelingofsurfaceintegrity
classifiedgrindhardeningresults1000
474)(*/
'' 15.025.02 tW
Pc...
g
p
o
w
e
r
P
c
/ 2 smmW
2mmW
C.Heinzel1960
1950
10
f
i
c
g
r
i
n
d
i
n
g
1980
1970
10 01 0 10 1 00 10 00 s 1000 00
s
p
e
c
i
f
I.S.JahawirJ.C.OuteiroR M'S bi2000
1990
20052011
0.01 0.10 1.00 10.00 s 1000.00
heat exposure timetC Heinzel: Schleifprozesse verstehen: Zum Stand der Modellbildung und Simulation sowie untersttzender Methoden. Habilitationsschrift,
i i 2009
R.M'Saoubi
2010
2000
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Universitt Bremen, Shaker Verlag, Aachen, 2009.I S Jawahir, E Brinksmeier, R M'Saoubi, D K Aspinwall, J C Outeiro, D Meyer, D Umbrello, A D Jayal: Surface Integrity in Material Removal Processes: Recent Advances. CIRP Annals 60/2, 2011: 603-626.
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CIRPcollaborativework2010:residualstressatsurface
roundrobintest:residualstressatsurface
12participatinginstitutes...
MPa
800MillingTurning
max/min
a
c
e
p p g
1960
1950
0
200
400 GrindingEDMFine Grinding
e
s
I
I
a
t
s
u
r
f
a
1980
1970
-600
-400
-200i
d
u
a
l
s
t
r
e
s
s
e
t t2000
1990
-1000
-800
sets
r
e
s target
20102010
2000
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Jawahir, I. S.; Brinksmeier, E.; M'Saoubi, R.; Aspinwall, D. K.; Outeiro, J.C.; Meyer, D.; Umbrello, D.; Jayal, A. D.: Surface Integrity in Material Removal Processes: Recent Advances. Annals of the CIRP 60/2, 2011, Seite 603-626.
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EvolutionaryviewonSurfaceIntegrity
focus
macro/micro
"stateoftheart"
macro /microgeometry
conformancetodesigntolerances
s
s
surfaceandsubsurfaceproperties
casestudies,surfaceandfunctionalproperties
p
r
o
g
r
e
s
energyconversion,
modelingandsimulationoffunctionalpropertiesindependentfrom
p
specificpowerp p p
machiningparameters
?characterization/predictionofsurface
o
n
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?/p
integrityindependentfromindividualprocessesv
i
s
i
o
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Similarsurfacemodificationsachievablebycompletelydifferentprocesses
thermalthermal mechanicalmechanicalworkpiece
vsvft
vc
grindingwheel
HV
inductionhardening grindhardening deeprolling grindstrengthening
HV HV HV
vc
0z
0z
0z
0z
differentprocesses:similarsurfacelayerproperties
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workpiecematerial:doesnotknowprocesses materialreactsonthermalandmechanicalexposure,resultingfromtheenergysignatureandthegeneratingdynamicsoftheprocess
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Whatisneededforareliablepredictionofsurfaceintegrityaftermachining?
knowledge(atdifferentscales)on
energyconversion
energydissipation
heatpartitioning
material response to physical/chemical process impact materialresponsetophysical/chemicalprocessimpact
fundamentalmaterialdata
focuson
physical/chemicalimpactresultingfromtool/workpieceinteractions
characterizationandclassificationofprocessesregardingphysical/chemicalinfluencingparameters
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processsignature
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Requiredinformationtoformtheprocesssignature
input outputprocess
material tool kinematics
modifiedsurfaceandnearsurfaceregionenergy energy materialkinematics
energy systemquantities
region
nearsurfacefunctional
gyconversion
gydissipation modification
causal sequence
properties
causal sequence
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Differentprocessescanbedescribedbythesamecausalprinciples
initialsurfaceandboundarylayer
laser
vf
appliedenergymechanicalchemicalthermal
acid
vc
...
energyconversionanddissipation
dissipativeenergyfrictionenergy
chem.bindingenergy structuralmodification
tool
modifiedsurfaceand
nearsurfaceregion
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surface/subsurfaceproperties functionalperformance
cuttinglaser
etching
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Canweidentifycharacteristicprocesssignaturesbasedonphysical/chemicaldescriptions?
mainprocessimpactmechanical,thermal,
loadmechanical,thermal,
chemical chemical
componentwithapplicationprocessworkpiece
modifiedsurface/nearsurface with
function(s)applicationprocess
material functionalproperties
performance of componentperformance of componentprocess signatureprocess signatureprocess signature
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performanceofcomponentperformanceofcomponentprocesssignatureprocesssignatureprocesssignature
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Howtodevelopaprocesssignature?
...input output
.
... material tool kinematics
modifiedsurfaceandnearsurfaceregion
.
.
.
...
energy systemquantities
nearsurfacefunctionalpropertiesproperties
possible approach
characteristicnumberregression/transferfunctionsemantic description
possibleapproach
combinationofselectedmethodsforcombininginputandoutputquantities
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semanticdescriptionenergeticbasedvalues/functionsin/outputvalues
physically/chemicallybaseddescriptionsoftoolworkpiece interactions
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Howtodevelopaprocesssignature? ...input material tool
output
modifiedsurfaceandnearsurface
.
.
.
...
...
kinematics energy systemquantities
region
nearsurfacefunctionalproperties
degree ofabstraction
abstraction level approach method application area
di h i l / h i l l ismall mechanisms
direct physical /chemicalmodeling
analytic,FEM
process analysis
ll i di t h i l h t i tismall medium
mechanisms/systemindirect physical/chemical modeling
characteristicnumber
l iquantitative cause andregression,
process analysis,process signature
medium mechanisms/systemquantitativecauseandeffect relationship
transferfunction
qualitative cause and
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high systemqualitativecauseandeffect relationship
semantic
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Comparablemechanismsinmachininganduseofacomponent
mainprocessimpactmechanical,thermal,
chemical
loadmechanical,thermal,
chemical
mainprocessimpactmechanical,thermal,
chemical
loadmechanical,thermal,
chemical
modifiedmodified
componentwith
function(s)applicationprocessworkpiece
material
modifiedsurface/nearsurface
functionalproperties
componentwith
function(s)applicationprocessworkpiece
material
modifiedsurface/nearsurface
functionalpropertiesp pp p
solution of "inverse problem"?
functionalsignature?processsignature
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solutionof inverseproblem ?
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EvolutionaryviewonSurfaceIntegrity
focus
macro/micro
"stateoftheart"
macro /microgeometry
conformancetodesigntolerances
s
s
surfaceandsubsurfaceproperties
casestudies,surfaceandfunctionalproperties
p
r
o
g
r
e
s
energyconversion,
modelingandsimulationoffunctionalpropertiesindependentfrom
p
specificpowerp p p
machiningparameters
process characterization/predictionofsurface
o
n
Gl 12/01/CIRP: 22
processsignature
/pintegrityindependentfromindividual
processesvi
s
i
o
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Conclusion
nextstepinmachiningprocessabstractionisrequired proposedapproach:processsignature
macro/microgeometry
surfaceandsubsurfaceproperties
energyconversion,
focus
conformancetodesigntolerances
casestudies,surfaceandfunctionalproperties
modelingandsimulationoffunctionalpropertiesindependent from
p
r
o
g
r
e
s
s
"stateoftheart"
requirements physical/chemicaldescriptionofmachiningprocesses
d d th d f i d t i ti f
conversion,specificpower
processsignature
p p pmachiningparameters
descriptionofsurfaceintegrityindependent fromspecificprocess
v
i
s
i
o
n
advancedmethodsforinprocessdeterminationoftemperaturesandforces
innovativemethodsformodelingandforcombining
.
.
.
...
...
...
input
material tool kinematics energy systemquantities
output
modifiedsurfaceandnearsurfaceregion
nearsurfacefunctionalproperties g g
models(e.g.multiphysical,multiscale)
multiscalematerialcharacterizationmainprocessimpactmechanical,thermal,
chemical
loadmechanical,thermal,
chemical innovativemethodsforcombiningenergybasedheterogeneousinformation
visioncomponent
withfunction(s)
chemical chemical
applicationprocessworkpiecematerial
modifiedsurface/nearsurface
functionalproperties
functionalsignature?processsignature
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visioninverseengineeringoffunctionalsurfaces
solutionof"inverseproblem"?
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Thank you!
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