A new technique to detect damages in surface grinding of steel workpieces based on ultrasound signals generated by piezoelectric transducer

Abstract

The grinding process is one of the last stage of the manufacturing chain, and responsible to provide finish and precision to the parts. Scraps at this phase is unacceptable, since the part underwent previous machining processes and then has a high value-added. The grinding process monitoring of steel workpieces through piezoelectric transducer signal is presented as an alternative for diagnosis of the surface workpiece. Recent researches have shown that this signal has great potential to monitor the grinding process. The goal of this work is to develop a new technique based on ultrasound signals generated by piezoelectric transducer to detect damages in the parts of steels during the grinding process. Grinding tests will be conducted through a setup properly designed and built, and signals from piezoelectric diaphragms and acoustic emission sensor will be acquired. The characteristics that represent the condition of the workpiece surface will be measured by tests of hardness, surface roughness, metallography and scanning electron microscopy. Digital signal processing techniques will be used, and then features related to the workpiece damage extracted. Thus, a non-destructive and non-invasive detection system based on low-cost sensors will be attained, which will provide a more reliable and robust damage detection in grinding of steel parts and, in turn, the automation, control and optimization of the process achieved as important contributions of this research. Publications of scientific papers in high standard conferences and journals will also be significant results.