Acoustic Emission Specifics while Conventional Cutting and Machining by the Concentrated Energy Flows

Mechanical Engineering and Machine Science


Аuthors

Migranov M. S.*, Kozochkin M. P., Mustafaev E. S., Ostrikov E. A., Fedorov S. V.**

Moscow State University of Technology "STANKIN", 1, Vadkovsky lane, Moscow, 127994, Russia

*e-mail: migmars@mail.ru
**e-mail: sv.fedorov@icloud.com

Abstract

Critical products manufacturing technological processes diagnostics and monitoring in the aviation industry, particularly in aircraft industry, helicopter industry, aircraft engine-building, avionics manufacturing, constituent parts etc. are indispensable tools for reliability, safety quality and endurance ensuring of the product being made. The role of the quality formed while producing complex parts of the state-of the-art gas turbine engines and other power plants is the most pronounced while manufacturing the products being operated under conditions of sharply changing temperatures, aggressive media, under the impact of high dynamic loading, which frequency varies over a wide range. Among the methods for various technological processes operational monitoring and appropriate equipment for aircraft engine building, acoustic diagnostics has long since won its place as a non-destructive control tool. However, even now, all capabilities of the method are not fully revealed, despite the expanding possibilities of the computing technology application. The presented article draws parallels between changes in the acoustic emission (AE) signals parameters while conventional cutting tool machining of difficult-to-machine, aviation-oriented high alloys and relatively new technologies employing concentrated energy flows.
The article presents the results of the experimental research that studied the relationships of the AE signal parameters with the modes of laser, electrical discharge machining (EDM) and mechanical processing. Much attention is given to the relations between the AE amplitude spectrum variations and the power density of the impact on the surface of the machined heat-proof and heat-resistant alloys and steels under different processing technologies. It is emphasized that the tendencies in the AE spectrum changes with varying power density are similar, regardless of the nature of the energy impact. The article adduces experimental data for mechanical processing, where power density varied with the tool wear, as well as with the EDM, where power density decreased with the of erosion products concentration increase. As the result, A conclusion was made that the AE parameters monitoring allows tracking qualitative changes in technological processes of different natures and implementing timely control actions.
The second part of the work presents the results of experiments involving the laser pulse modes varying, the AE signals recording, and morphology studying of the machined surface. Information processing by the experiments planning allowed to establishing relationships between the acoustic parameters and processing performance, changes in power density, and the shift of the material removal process towards sublimation or melt formation. Special attention is given to the laser probing of materials, where it was demonstrated that the AE signals reflected such phenomena as the vapor-plasma plume forming, the internal bond energy of the material structure, and laser radiation self-focusing. To assess resistance of the material to the destructive factors, the concept of the specific AE amplitude was introduced, which corresponds to the ratio of the AE amplitude and the volume of the hole formed by the laser pulses. This ratio growth indicates the material greater ability to withstand destructive factors. The article presents experimental data on the specific amplitude for various tool materials, including synthetic diamonds, and high-entropy alloys options, demonstrating a clear advantage of the ultrahard tool materials. Further study of the method capabilities will allow employing it as a tool for rapid analysis of the qualitative characteristics of innovative alloy options for power section components of modern aircraft gas turbine engines (GTE), as well as wear-resistant coatings, without lengthy full-scale experiments involving significant working time and financial resources.
The objectives of this work included experimental studies of the relationships between the AE signal parameters and processing modes in different technological processes, and assessing the possibility of using these parameters for monitoring in automated production environments and as a tool for understanding the processing processes kinetics. The research results demonstrate that the AE parameters may serve as indicators of the processing performance, the resulting surface quality, and the properties of new materials. This opens up prospects for the acoustic diagnostics application in industry, such as for operational monitoring of GTE component processing, properties evaluating of the new alloys, and optimizing technological modes.

Keywords:

cutting tool machining, laser processing, technological process monitoring, acoustic emission, concentrated energy flows, power density, vapor-plasma plume, ultrahard materials

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