Sinais de vibração no monitoramento do processo de retificação plana de cerâmicas avançadas
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Data
2016-02-17
Autores
Conceição Junior, Pedro de Oliveira [UNESP]
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Editor
Universidade Estadual Paulista (Unesp)
Resumo
As cerâmicas estruturais avançadas, tais como o óxido de alumínio, nitreto de silício, alumina e a zircônia estão sendo cada vez mais utilizadas na engenharia e na medicina. No entanto, muitas destas características que fazem a cerâmica tão atrativa também dificultam a sua fabri-cação por métodos tradicionais de usinagem. Para obter a forma desejada na usinagem de ma-teriais é necessário o uso do processo de retificação. As características da retificação cerâmicas avançadas são muito diferentes das características dos metais. Portanto, é necessário efetuar outros estudos para alcançar uma compreensão mais abrangente e um melhor controle dos parâmetros. Novas alternativas para o monitoramento do processo de retificação de cerâmicas têm sido estudadas. O monitoramento por sinais de vibração é um dos métodos bem-sucedidos utilizados no processo de retificação, pois algumas características que descrevem o comportamento e a influência do processo nas peças retificadas somente são perceptíveis no estudo deste sinal. O presente trabalho tem como objetivo estudar o sinal de vibração, de for-ma a extrair características relacionadas com o acabamento de cerâmicas avançadas no pro-cesso de retificação plana. Foi utilizada uma máquina retificadora tangencial plana com rebolo diamantado e corpos de prova de cerâmica alumina. O sinal de vibração foi medido por um acelerômetro e coletado por um osciloscópio à taxa de amostragem de 2 MHz. Os ensaios foram realizados em diferentes profundidades de corte, adotando duas velocidades da peça (vw), obtendo condições de usinagem brandas às mais severas. Medições de microscopia con-focal foram realizadas após a retificação das peças com objetivo de caracterizá-las. A rugosi-dade Ra das peças usinadas foi medida em quatro pontos ao longo das mesmas, por meio de um rogosímetro portátil. O processamento digital do sinal de vibração foi realizado, aplicando ferramentas computacionais e estatísticas de análise em cada passada de usinagem, compa-rando com os valores da rugosidade medidos. A faixa de frequência entre 800 Hz e 2 kHz foi a mais interessante para o estudo, e que melhor se relacionou com a condição da cerâmica após a retificação. Foi encontrada uma correlação entre a vibração e a integridade da peça cerâmica, pois o aumento da vibração é diretamente proporcional à rugosidade em cada profundidade de corte utilizada. Infere-se que a vibração pode ser utilizada para monitorar a retificação de cerâmica, devido à sua relação com a condição das peças.
Advanced structural ceramics such as aluminum oxide, silicon, nitride, alumina and zirconia are increasingly being used in engineering and medicine. However, many of these features that make ceramics so attractive also make them difficult to manufacture by traditional machining methods. To obtain the desired shape in the machining of these materials is necessary to use grinding process. The characteristics of the grinding of advanced ceramics are very different from those of metals. Therefore, it is necessary to perform other studies to gain a broader understanding and better control of the parameters. New alternatives for monitoring of ceramic grinding process have been studied. Monitoring vibration signals is one of the successful methods used in the grinding process, as some characteristics that describe the behavior and influence the process in parts ground only are noticeable in the study of this signal. This research aims to study the vibration signal, searching for the extraction of features that best relate to the characterization of machined parts. A surface grinding machine with diamond grinding wheel and alumina ceramic workpieces was used. The vibration signal was measured by an accelerometer and collected by the oscilloscope, using 2 MHz of sample rate. Tests were conducted at different depths of cut, adopting two different feed speeds (vw), which ranged from low to severe grinding conditions. Confocal microscopy was performed after the grinded of the workpieces in order to characterized them. The surface roughness Ra of each finished workpiece was measured at four areas along its surface, using a portable roughness measurer. The vibration digital signal processing was performed by applying computational tools on each pass machining. The frequency range between 800 Hz and 2 kHz was the most interesting for the study, and which better was related to the condition of the ceramic after the grinding process. A correlation between the vibration and the integrity of the ceramic workpiece was found, because the increased vibration is directly proportional to the surface roughness at each depth of cut used. It is inferred that the vibration can be used to monitor the grinding process of ceramic because of its relationship with the condition of the workipiece.
Advanced structural ceramics such as aluminum oxide, silicon, nitride, alumina and zirconia are increasingly being used in engineering and medicine. However, many of these features that make ceramics so attractive also make them difficult to manufacture by traditional machining methods. To obtain the desired shape in the machining of these materials is necessary to use grinding process. The characteristics of the grinding of advanced ceramics are very different from those of metals. Therefore, it is necessary to perform other studies to gain a broader understanding and better control of the parameters. New alternatives for monitoring of ceramic grinding process have been studied. Monitoring vibration signals is one of the successful methods used in the grinding process, as some characteristics that describe the behavior and influence the process in parts ground only are noticeable in the study of this signal. This research aims to study the vibration signal, searching for the extraction of features that best relate to the characterization of machined parts. A surface grinding machine with diamond grinding wheel and alumina ceramic workpieces was used. The vibration signal was measured by an accelerometer and collected by the oscilloscope, using 2 MHz of sample rate. Tests were conducted at different depths of cut, adopting two different feed speeds (vw), which ranged from low to severe grinding conditions. Confocal microscopy was performed after the grinded of the workpieces in order to characterized them. The surface roughness Ra of each finished workpiece was measured at four areas along its surface, using a portable roughness measurer. The vibration digital signal processing was performed by applying computational tools on each pass machining. The frequency range between 800 Hz and 2 kHz was the most interesting for the study, and which better was related to the condition of the ceramic after the grinding process. A correlation between the vibration and the integrity of the ceramic workpiece was found, because the increased vibration is directly proportional to the surface roughness at each depth of cut used. It is inferred that the vibration can be used to monitor the grinding process of ceramic because of its relationship with the condition of the workipiece.
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Palavras-chave
Cerâmicas avançadas, Monitoramento do processo de retificação, Sinal de vibração, Rugosidade, Advanced ceramics, Monitoring the grinding process, Vibration signal, Surface roughness