CN101829951A - Outer circle grinding workpiece surface quality visualization real-time monitoring method - Google Patents
Outer circle grinding workpiece surface quality visualization real-time monitoring method Download PDFInfo
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Abstract
The invention relates to an outer circle grinding workpiece surface quality visualization real-time monitoring method, which comprises the following steps of: 1, arranging an acoustic emission sensor and acquiring data; 2, preprocessing an acoustic emission signal; 3, establishing a roughness relationship model between the root mean square (RMS) of the acoustic emission signal and the workpiece surface; and 4, realizing the visualization of the workpiece surface quality in the grinding process. The outer circle grinding workpiece surface quality visualization real-time monitoring method can realize the visual real-time monitoring of the workpiece grinding quality by using the acoustic emission signal, provides help for guiding a grinding machine operator to select technological parameters, and has significance for improving the grinding efficiency and the grinding quality.
Description
Technical field
The present invention relates to a kind of precision optical machinery processing method of real-time, especially a kind of outer circle grinding workpiece surface quality method of real-time.
Background technology
In ultraprecise/accurate grinding process, how to monitor workpiece surface quality and grinding situation in the grinding process in real time, to improving grinding quality and grinding efficiency with significant.If can realize the real-time monitoring of surface of the work grinding quality, can realize the FEEDBACK CONTROL of grinding process parameters, thereby realize the Based Intelligent Control of grinding process.Therefore, the workpiece surface quality of monitoring in real time in the grinding process is the key technology of accurate grinding technology.Although numerous researchers adopts current of electric, grinding force, acoustic emission signal and accelerometer etc. that the grinding Condition Monitoring Technology has been done a large amount of research work, but be limited to sensor reasons such as difficulty, signal interference and sensitivity are installed, still lack the method that in actual production, can effectively use so far.Because acoustic emission signal can avoid grinding process medium and low frequency noise region, highly sensitively in high-frequency range be subjected to environmental change little, so acoustic emission is a kind of method of being widely adopted of grinding status monitoring in recent years.Acoustic emission (AE) is that a kind of material is subjected to external force or endogenetic process and when producing distortion or fracture, the phenomenon that releases energy with the form of elastic wave.In the cylindrical grinding process, when emery wheel contacted with workpiece, its contact condition can reflect by the AE signal.
Summary of the invention
The present invention will provide a kind of outer circle grinding workpiece surface quality visualization real-time monitoring method that is applicable to, this method by setting up acoustic emission signal root mean square (RMS) and the relational model between the workpiece quality roughness, predict the workpiece surface roughness under the different technical parameters, and in conjunction with workpiece surface roughness numerical value and curve demonstration, workpiece surface quality is visual in the realization grinding process, offer help for the grinding machine operator repairs grinding process parameters, and help improving the grinding efficiency and the grinding quality of workpiece.
Technical scheme of the present invention is: a kind of outer circle grinding workpiece surface quality visualization real-time monitoring method, and concrete steps are:
2. the installation of calibrate AE sensor and data acquisition
In order to monitor the grinding state, with calibrate AE sensor be installed in cylindrical grinder grinding carriage or, on the headstock or the tailstock, acoustic emission signal is obtained by computer acquisition by data collecting system, and corresponding sample frequency is set;
3. the preliminary treatment of acoustic emission signal
In order to remove interfering signal, the acoustic emission signal of being gathered is carried out filtering to be handled: the interfering signal that adopts Qie Bixuefu II low pass filter filters out grinding process, filter cutoff frequency is determined according to the frequency range of grinding machine AE signal under no grinding state, when grinding wheel spindle and the rotation of workpiece drive shaft, and emery wheel and workpiece are when contactless, the signal that AE received is considered as interfering signal, analyzes by its radio-frequency component, determines the cut-off frequency of low pass filter;
4. set up the root mean square (RMS) of acoustic emission signal and the roughness relational model of surface of the work
Adopt orthogonal test method, carry out grinding test: after finishing each time grinding test, utilize the roughness on roughmeter measuring workpieces surface, after root-mean-square value is averaged, promptly obtain the relation of the roughness of acoustic emission signal root-mean-square value and surface of the work;
5. realize the visual of grinding process workpiece surface quality
According to the root mean square (RMS) of the acoustic emission signal that step 3 obtained and the roughness relational model of surface of the work, root-mean-square value by acoustic emission signal calculates acquisition workpiece surface roughness value, thereby realization shows the method for workpiece surface roughness change curve in real time or the method for workpiece surface roughness value with the numeral variation is simultaneously displayed on the screen of digital control system.
Useful tool effect of the present invention: by this invention, can utilize acoustic emission signal to realize the visualization real-time monitoring of workpiece grinding quality, offer help instructing the grinding machine operator to choose technological parameter, and significant to improving grinding efficiency and grinding quality.
Description of drawings
Fig. 1 is a calibrate AE sensor installation site schematic diagram;
Fig. 2 is workpiece surface roughness numerical value and change curve display mode schematic diagram.
The specific embodiment
The present invention is further illustrated below in conjunction with accompanying drawing and embodiment.
Outer circle grinding workpiece surface quality visualization real-time monitoring method of the present invention, in the workpiece grinding process, emery wheel and workpiece Elastic Contact, emery wheel bonding agent break, the emery wheel abrasive particle collapses broken, emery wheel abrasive particle and workpiece friction, surface of the work crackle etc. all can be launched elastic wave.The factors such as state of these factors and workpiece material, grinding condition, wheel face all have confidential relation.The change of these factors will inevitably cause that the aspects such as amplitude of acoustic emission signal change, and this just makes us to come the grinding state is differentiated by the variation that detects acoustic emission signal.The amplitude of variation of AE signal is directly proportional with the amplitude of variation of grinding force, and the amplitude of variation of grinding force is more little, and the amplitude of variation of AE signal is also more little, and the quality of surface of the work is just high more.Otherwise the amplitude of variation of grinding force is big more, and the amplitude of variation of AE signal is also big more, and the quality of surface of the work is just poor more.And the amplitude of variation of AE signal can be described by the root mean square of acoustic emission signal.Therefore, can predict the roughness of surface of the work, and show that workpiece surface quality is visual in the realization grinding process in conjunction with workpiece surface roughness numerical value and curve by the root mean square (RMS) of acoustic emission signal.Its concrete step is as follows:
1. the installation of calibrate AE sensor and data acquisition
In order to monitor the grinding state, calibrate AE sensor 4 generally can be installed on grinding carriage 1, the headstock 2 and the tailstock 3 on cylindrical grinder.Consider the sensitivity of detection signal, the present invention with calibrate AE sensor 4 be installed in tailstock 3 top on, as shown in Figure 1.Acoustic emission signal can be passed through data collecting system, is obtained by computer acquisition, and sample frequency can be taken as 1000Hz.
2. the preliminary treatment of acoustic emission signal
In order to remove interfering signal, need carry out filtering to the acoustic emission signal of being gathered and handle.Can adopt the interfering signal of Qie Bixuefu II low pass filter filters out grinding process, determining of filter cutoff frequency, need determine according to the frequency range of grinding machine AE signal under no grinding state, when grinding wheel spindle and the rotation of workpiece drive shaft, and emery wheel and workpiece are when contactless, the signal that AE received can be considered interfering signal, analyzes by its radio-frequency component, determines the cut-off frequency of low pass filter.
3. set up the root mean square (RMS) of acoustic emission signal and the roughness relational model of surface of the work
In grinding process, the root mean square of acoustic emission signal has reflected the amplitude that grinding force changes.Therefore, there is certain relation in the roughness of the root mean square of acoustic emission signal and surface of the work.But this relation is also relevant with workpiece material and abrasive grinding wheel.Need obtain the root mean square (RMS) of acoustic emission signal and the relational model of the roughness of surface of the work by grinding experiment.In order from experiment, more effectively to obtain relevant information, can adopt orthogonal experiment design method, finish grinding test.
If given cylindrical grinder, the grinding wheel speed scope is (P
Min, P
Max, the feed speed scope is (V
Min, V
Max), the stock removal scope is (S
Min, S
Max) and the general range of work speed be (G
Min, G
Max).According to orthogonal experiment design method, above-mentioned each selected factor can be divided four levels, as shown in table 1.According to above-mentioned factor and horizontal division, can select L
16(4
5) orthogonal test, the evaluation index of each test is workpiece surface roughness (Ra) and acoustic emission signal (RMS), and is as shown in table 2 with this orthogonal table arrangement test.Need to prove that also can adopt other orthogonal test scheme, test number (TN) is many more, the acoustic emission signal root mean square (RMS) that is obtained is accurate more with the relation of workpiece surface roughness.
Table 1 orthogonal test factor level table
Table 2 Orthogonal Experiment and Design table
When finishing the grinding test each time of table 2, all should gather acoustic emission signal simultaneously and calculate its root-mean-square value, when the acoustic emission signal sample frequency is taken as 1000Hz, root-mean-square value of desirable per 100 sample calculation, i.e. the frequency of root-mean-square value calculating is 10Hz.After finishing each time grinding test, utilize the roughness on roughmeter measuring workpieces surface, after root-mean-square value is averaged, promptly obtain the relation of the roughness of acoustic emission signal root-mean-square value and surface of the work.
By above work, can obtain the point of the roughness relation of several reflection acoustic emission signal root-mean-square values and surface of the work.At this moment, can adopt the curve fitting theory on the one hand, obtain the curve model of the roughness relation of acoustic emission signal root-mean-square value and surface of the work.On the other hand, also linear interpolation method be can adopt, other position acoustic emission signal root-mean-square value and the pairing value of workpiece surface roughness obtained.
4. realize the visual of grinding process workpiece surface quality
According to the root mean square (RMS) of the acoustic emission signal that step 3 obtained and the roughness relational model of surface of the work, can calculate by the root-mean-square value of acoustic emission signal and obtain the workpiece surface roughness value, thereby realize showing in real time the method for workpiece surface roughness change curve, certainly also the workpiece surface roughness value can be simultaneously displayed on the screen of digital control system, as shown in Figure 2 with the method that numeral changes.
Claims (1)
1. outer circle grinding workpiece surface quality visualization real-time monitoring method is characterized in that concrete steps are:
(1) installation of calibrate AE sensor and data acquisition
In order to monitor the grinding state, with calibrate AE sensor be installed in cylindrical grinder grinding carriage or, on the headstock or the tailstock, acoustic emission signal is obtained by computer acquisition by data collecting system, and corresponding sample frequency is set;
(2) preliminary treatment of acoustic emission signal
In order to remove interfering signal, the acoustic emission signal of being gathered is carried out filtering to be handled: the interfering signal that adopts Qie Bixuefu II low pass filter filters out grinding process, filter cutoff frequency is determined according to the frequency range of grinding machine AE signal under no grinding state, when grinding wheel spindle and the rotation of workpiece drive shaft, and emery wheel and workpiece are when contactless, the signal that AE received is considered as interfering signal, analyzes by its radio-frequency component, determines the cut-off frequency of low pass filter;
(3) set up the root mean square (RMS) of acoustic emission signal and the roughness relational model of surface of the work
Adopt orthogonal test method, carry out grinding test: after finishing each time grinding test, utilize the roughness on roughmeter measuring workpieces surface, after root-mean-square value is averaged, promptly obtain the relation of the roughness of acoustic emission signal root-mean-square value and surface of the work;
(4) realize the visual of grinding process workpiece surface quality
According to the root mean square (RMS) of the acoustic emission signal that step 3 obtained and the roughness relational model of surface of the work, root-mean-square value by acoustic emission signal calculates acquisition workpiece surface roughness value, thereby realization shows the method for workpiece surface roughness change curve in real time or the method for workpiece surface roughness value with the numeral variation is simultaneously displayed on the screen of digital control system.
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| CN102172892A (en) * | 2011-01-19 | 2011-09-07 | 天津大学 | On-line measurement device and method for grinding force for excircle honing |
| CN102275131A (en) * | 2011-06-28 | 2011-12-14 | 上海三一精机有限公司 | Monitoring method and monitoring system for detecting processing state of grinding machine |
| CN102501173A (en) * | 2011-11-21 | 2012-06-20 | 上海理工大学 | Method for measuring temperature of grinding region of surface grinding |
| CN102554780A (en) * | 2012-02-17 | 2012-07-11 | 上海理工大学 | Measuring device for grinding radial run-out of metal-bonded grinding wheels |
| CN102873638A (en) * | 2012-10-12 | 2013-01-16 | 上海理工大学 | Workpiece radius online detection method in excircle cutting in grinding feeding process |
| CN103273387A (en) * | 2013-06-18 | 2013-09-04 | 上海理工大学 | Stiffness-measurement-based optimization method for cylindrical grinding process parameters |
| CN103419130A (en) * | 2012-05-21 | 2013-12-04 | 昆山华辰重机有限公司 | Working table movable type numerical control roll grinder tail stock sleeve feeding mechanism |
| CN103659602A (en) * | 2012-09-25 | 2014-03-26 | 宁波工程学院 | Method and device for detecting cylindrical grinding surface roughness through data fusion technology |
| CN104589201A (en) * | 2014-12-27 | 2015-05-06 | 中国西电电气股份有限公司 | Method for controlling grinding size of outer circle of ceramic product |
| CN104669114A (en) * | 2013-12-02 | 2015-06-03 | 宁波宝新不锈钢有限公司 | Grinder flutter monitoring system and extracting and diagnostic method for grinding fault signal thereof |
| CN105051631A (en) * | 2013-03-29 | 2015-11-11 | 株式会社牧野铣床制作所 | Workpiece worked surface evaluation method, control device, and working machine |
| CN105058177A (en) * | 2015-08-31 | 2015-11-18 | 苏州柏德纳科技有限公司 | Clamping tool for high-precision cylindrical workpiece |
| CN106002495A (en) * | 2016-06-13 | 2016-10-12 | 李培培 | Magnetic grinding machine capable of observation of grinding conditions of workpiece |
| CN109277938A (en) * | 2017-07-21 | 2019-01-29 | 株式会社迪思科 | Grinding attachment |
| CN109605133A (en) * | 2018-11-22 | 2019-04-12 | 国网天津市电力公司电力科学研究院 | A kind of site intelligent polishing process suitable for tower material tissue |
| CN109855578A (en) * | 2019-02-28 | 2019-06-07 | 长沙理工大学 | A kind of inside workpiece defect inspection method based on surface topography roughness |
| CN110375938A (en) * | 2019-07-05 | 2019-10-25 | 上海理工大学 | Headstock for cylindrical grinding machine dynamic stiffness measurement device and method |
| CN110900454A (en) * | 2019-12-04 | 2020-03-24 | 长沙理工大学 | Grinding surface roughness real-time detection and intelligent control system |
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| CN102172892A (en) * | 2011-01-19 | 2011-09-07 | 天津大学 | On-line measurement device and method for grinding force for excircle honing |
| CN102172892B (en) * | 2011-01-19 | 2013-04-03 | 天津大学 | On-line measurement device and method for grinding force for excircle honing |
| CN102275131B (en) * | 2011-06-28 | 2013-03-20 | 上海三一精机有限公司 | Monitoring method and monitoring system for detecting processing state of grinding machine |
| CN102275131A (en) * | 2011-06-28 | 2011-12-14 | 上海三一精机有限公司 | Monitoring method and monitoring system for detecting processing state of grinding machine |
| CN102501173A (en) * | 2011-11-21 | 2012-06-20 | 上海理工大学 | Method for measuring temperature of grinding region of surface grinding |
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