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Analysis of grind-hardening process monitoring and control possibilities using AE and force sensors

The reliability of grinding processes can be increased by process control using Acoustic Emission Sensors. AE signals correlate to force signals and therefore also to the heat induced into the workpiece. In Task 2.5, it was discovered that grind-hardening processes cannot be controlled in this way due to following reasons:

- AE monitoring is not possible in continuous dressing processes. Dressing AE signals have much higher vibration amplitude than the grind hardening process itself
- Force and AE signals do not correlate, especially at the beginning of the grind-hardening process.
- Neither AE nor force signals stay constant at a process with constant parameter and grind-hardening result
- There is no clear correlation between the increase of the AE signal and the grinding wheel wear
- Thermal material structure changes cause different signal level
- No correlation between the AE signals and the process result was found
- Friction coefficient and feed speed do not correlate to feed speed, so they cannot be used for control purposes

Coiflet wavelet transformation of third order and four levels of detail might offer a post process quality monitoring possibility. The increase of the detail frequency bands could be used as a feature for input to a neuronal network. A certain uncertainty probably will remain.

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