CN101829951B - Outer circle grinding workpiece surface quality visualized real-time monitoring method - Google Patents
Outer circle grinding workpiece surface quality visualized real-time monitoring method Download PDFInfo
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- CN101829951B CN101829951B CN201010168306XA CN201010168306A CN101829951B CN 101829951 B CN101829951 B CN 101829951B CN 201010168306X A CN201010168306X A CN 201010168306XA CN 201010168306 A CN201010168306 A CN 201010168306A CN 101829951 B CN101829951 B CN 101829951B
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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.The workpiece surface quality of therefore, 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 reasons such as sensor difficult installation, signal interference and sensitivity, 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 receive environmental change little, so acoustic emission be in recent years the grinding status monitoring by a kind of method that extensively adopts.Acoustic emission (AE) is that a kind of material receives 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 through 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; Root mean square (RMS) and relational model workpiece quality roughness between of this method through setting up acoustic emission signal; Predict the workpiece surface roughness under the different technical parameters; And combine workpiece surface roughness numerical value and curve to show; Workpiece surface quality is visual in the realization grinding process, offers help for the grinding machine operator repairs grinding process parameters, and helps 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 through data collecting system, and corresponding sample frequency is set;
3. the preliminary treatment of acoustic emission signal
In order to remove interfering signal; Acoustic emission signal to being gathered is carried out Filtering Processing: adopt the interfering signal of Qie Bixuefu II low pass filter filters out grinding process, filter cutoff frequency is confirmed according to the frequency range of grinding machine AE signal under no grinding state, when grinding wheel spindle and the rotation of workpiece driving main shaft; And emery wheel and workpiece are when contactless; The signal that AE received is regarded as interfering signal, analyzes through its radio-frequency component, confirms 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 accomplishing 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 through 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 digital variation is simultaneously displayed on the screen of digital control system.
Useful tool effect of the present invention: through this invention, acoustic emission signal capable of using realizes the visualization real-time monitoring of workpiece grinding quality, offers help to 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 sketch map;
Fig. 2 is workpiece surface roughness numerical value and change curve display mode sketch map.
The specific embodiment
Below in conjunction with accompanying drawing and embodiment the present invention is further described.
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 through 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 through the root mean square of acoustic emission signal.Therefore, can predict the roughness of surface of the work through the root mean square (RMS) of acoustic emission signal, and combine workpiece surface roughness numerical value and curve to show, workpiece surface quality is visual in the realization grinding process.Its concrete step is following:
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 Processing to the acoustic emission signal of being gathered.Can adopt the interfering signal of Qie Bixuefu II low pass filter filters out grinding process; Confirming of filter cutoff frequency need be confirmed according to the frequency range of grinding machine AE signal under no grinding state, when grinding wheel spindle and the rotation of workpiece driving main shaft; And emery wheel and workpiece are when contactless; The signal that AE received can be considered interfering signal, analyzes through its radio-frequency component, confirms 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 to obtain the root mean square (RMS) of acoustic emission signal and the relational model of the roughness of surface of the work through grinding experiment.In order from experiment, more effectively to obtain relevant information, can adopt orthogonal experiment design method, accomplish 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, can above-mentioned each selected factor 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 accomplishing 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 accomplishing 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.
Through 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 through 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 can the workpiece surface roughness value be simultaneously displayed on the screen of digital control system with the method that numeral changes, as shown in Figure 2.
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, calibrate AE sensor is installed on the grinding carriage or the headstock or tailstock of cylindrical grinder, acoustic emission signal is obtained by computer acquisition through data collecting system, and corresponding sample frequency is set;
(2) preliminary treatment of acoustic emission signal
In order to remove interfering signal; Acoustic emission signal to being gathered is carried out Filtering Processing: adopt the interfering signal of Qie Bixuefu II low pass filter filters out grinding process, filter cutoff frequency is confirmed according to the frequency range of grinding machine AE signal under no grinding state, when grinding wheel spindle and the rotation of workpiece driving main shaft; And emery wheel and workpiece are when contactless; The signal that AE received is regarded as interfering signal, analyzes through its radio-frequency component, confirms 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 accomplishing 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 through 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 digital variation is simultaneously displayed on the screen of digital control system.
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Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN103395001A (en) * | 2013-07-25 | 2013-11-20 | 王晋生 | System and method for diagnosing and intelligently optimizing grinding processes |
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| 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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| CN114734306B (en) * | 2022-05-10 | 2023-03-24 | 山东理工大学 | Method for grinding and polishing magnetic particles on surface of workpiece |
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