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.
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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