keynote presentation brinksmeier

ProcessSignatures

an Alternative Approach toanAlternativeApproachtoPredictingFunctionalWorkpiecePropertiesProperties

Ekkard BrinksmeierRalf Glbe

Fritz KlockeFritz Klocke

Don A. Lucca

Gl 12/01/CIRP: 1

January 30th, 2012

1st CIRPConferenceonSurfaceIntegrity(CSI)

Gl 12/01/CIRP:1

Machiningisanenergybasedtransformationprocess

INPUT PROCESS OUTPUT

machinematerials

(workpiece,tool)

lubricant

workpiecemodificationmacrogeometry

f / b f

partswithgeometrical,physicaland

h i llubricantenergy

surface/subsurfaceproperties

chemicalproperties

manymodels

somemodels

veryfewmodels

Gl 12/01/CIRP: 2


Gl 12/01/CIRP:2

Evolutionof manufacturing processes:the early days

...geometricallydrivenconcept

thecornerstonesofmanufacturing

19561960

1950g

O Kienzle: Die Grundpfeiler der Fertigungstechnik. in: VDI-Zeitschrift 98, Nr. 23, Verein Deutscher Ingenieure, Dsseldorf, 1956: 13891395.

consideration of geometrical propertiesO.Kienzle

1980

1970

considerationofgeometricalpropertiesofcomponentsonly

workpiecematerialisconsideredasgivenbythedesigner

2000

1990

2010

2000

Gl 12/01/CIRP: 3

2020

...O Kienzle: Die Grundpfeiler der Fertigungstechnik. in: VDI-Zeitschrift 98, Nr. 23, Verein Deutscher Ingenieure, Dsseldorf, 1956: 13891395.


Gl 12/01/CIRP:3

Evolutionofmanufacturingprocesses:late1960ies:frommacro tomicrogeometry

microgeometryofsurfaces

typologyofsurfaces...

yp gy measurementandcharacterizationofsurfaces functionalbehavior

1960

1950

CIRPresearchers H.vonWeingraber R.vanHasselt

late1960ies

1980

1970

W.deBruin J.Peters D.J.Whitehouse

h k2000

1990

P.Vanherck2010

2000

Gl 12/01/CIRP: 4

D J Whitehouse, P Vanherck, W de Bruin, C A van Luttervelt. Assessment of Surface Topology Analysis Technique in Turning . CIRP Annals, Vol. 23, no. 2, 1974: 265-282.

2020

...


Gl 12/01/CIRP:4

Evolutionofmanufacturingprocesses:view onSurfaceIntegrity

M.Field investigationsintosurfacesandfunctionalproperties...

f ti t th1960

1950

1971J.Kahles

fatiguestrength=f (max.residualstress)

1980

1970

definition of Surface Integrity2000

1990

definitionofSurfaceIntegritySurfaceIntegritycanbedefinedastheentiretyofinherentandenhancedpropertiesofasurface.Itinvolvesastudyandcontrolof

2010

2000

Gl 12/01/CIRP: 5

topographyandmetallurgyofsurfacesthatcanbegeneratedbymachiningorotheroperations.M Field, J Kahles: Review of surface integrity of machinedcomponents. CIRP Annals, 20(2),1971: 153-163.

2020

...


Gl 12/01/CIRP:5

Evolutionofmanufacturingprocesses:focusonmachiningandfunctionalproperties

driver: highlystressedcomponents

accumulateddatashowedthatallmanufacturingK.Tnshoff...

gprocesseshavecertaineffectsontheworkpiecematerial

DFGpriorityprogramonManufacturingandPerformance of Components (1980 1983)

1960

1950

PerformanceofComponents (19801983)

permanentissueoftheCIRPScientificTechnical1980

1970

1980s CommitteeSinthelate1980sandthe1990s:SurfaceandFunctionJ.B.BryanM.Field

2000

1990

CIRPcollaborativeworkofSTC"S"on"residualstress measurement"

J.KahlesW.KnigP.LeskovarJ.PetersG Byrne

2010

2000

Gl 12/01/CIRP: 6

stressmeasurement

E Brinksmeier, J T Cammett, W Knig, P Leskovar, J Peters, H K Tnshoff: Residual Stresses Measurement and Causes in Machining Processes. CIRP Annals, Volume 31, Issue 2, 1982: 491510.

G.ByrneG.Spur2020

...


Gl 12/01/CIRP:6

Evolutionofmanufacturingprocesses:progressofmeasuringtechniques

advancesinXraystressmeasurement E.Macherauch E Macherauch, P Mller: Das sin2-Verfahren

der rntgenographischen Spannungsmessung, Z.m,

...

V.Hauk U.Wolfstieg B Scholtes

der rntgenographischen Spannungsmessung, Z. angew. Physik 13, 1961: 305-312.

sin2

m

1960

1950

B.Scholtes

advancesinmicromagneticanalysis WA Theiner G Goch, B Schmitz, B Karpuschewski, J Geerkens, M R i l P S l R Ritt R i f

M AMH1980

1970

W.A.Theiner

B.KarpuschewskiM. Reigl, P Sprongl, R Ritter: Review of non-destructive measuring methods for the assessment of surface integrity: a survey of new measuring methods for coatings, layered structures and processed surfaces. Precision Engineering, Volume 23, Issue 1, January 1999: 933.

H

2000

1990

highresolutiontechniques D.A.Lucca

h

D A Lucca, K Herrmann, M J Klopfstein: Nanoindentation: Measuring methods and

2010

2000

Gl 12/01/CIRP: 7

G.Goch C.Evans

applications. CIRP Annals STC S, 59/2/2010: 803-819.2020

...


Gl 12/01/CIRP:7

Evolutionofmanufacturingprocesses:modelingofgrindingprocesses

S.Malkin

replacementofmachiningparametersbyenergyrelatedparameters...

criticalspecificenergyfortheonsetofgrindingburn

r

g

y

u

highertemperature1960

1950

combinationofthermalequations(Carslaw/Jaeger)andprocessparameterssince

e

c

i

f

i

c

e

n

e

1980

1970

preventionofgrindingburnW.B.Rowe

M.C.Shaw

1978 s pe

d 1/4 a 3/4 v 1/2

B

uo

2000

1990

S Malkin: Burning Limit for Surface and Cylindrical Grinding of Steels. CIRP Annals, 27/1 (1978): 233236.

de1/4 ae 3/4vw 1/2

2010

2000

Gl 12/01/CIRP: 8

W B Rowe, J A Pettit, A Boyle, J L Moruzzi: Avoidance of Thermal Damage in Grinding and Prediction of the Damage Threshold. CIRP Annals, Volume 37, Issue 1, 1988: 327-330.

2020

...


Gl 12/01/CIRP:8

Evolutionofmanufacturingprocesses:significanceofenergyandspecificpowerforsurfaceintegrity

residualstress=f (specificpower)...

E.Brinksmeier

+ process1 process2 process3 process41960

1950

d

u

a

l

s

t

r

e

s

s

1980

1970

1980ies

K.TnshoffW.Hetz

r

e

s

i

d

reduction of converted power

targetedresidualstresslevel

2000

1990

B.KarpuschewskiW.Heuer

specific grinding powerPc

reductionofconvertedpower modificationofheatdistribution

2010

2000

Gl 12/01/CIRP: 9

E Brinksmeier: Prozess- und Werkstckqualitt in der Feinbearbeitung. Habilitationsschrift, Universitt Hannover, VDI Verlag, Fortschritts-Berichte VDI Reihe 2 Nr. 234, Dsseldorf, 1991.

2020

...


Gl 12/01/CIRP:9

Evolutionofmanufacturingprocesses:significanceofenergydissipationfortheprocess

heatpartitioninginmachiningprocesses

Stephenson:deepgrinding

D.J.Stephenson

...p p g g

T. Jin, , D.J. Stephenson: Investigation of the heat partitioning in high efficiency deep grinding. International Journal of Machine Tools and Manufacture. Volume 43, Issue 11, September 2003:11291134.1960

1950

Komanduri:orthogonalprocessR. Komanduri, , Z.B. Hou: Thermal modeling of the metal cutting process: Part I Temperature rise distribution due to shear plane heat source International Journal of Mechanical

R.Komanduri

1980

1970

shear plane heat source. International Journal of Mechanical Sciences, Volume 42, Issue 9, September 2000: 17151752.

20002000

1990

20002003

2010

2000

Gl 12/01/CIRP: 10

2020

...


Gl 12/01/CIRP:10

Evolutionofmanufacturingprocesses:extendedmodelingofsurfaceintegrity

classifiedgrindhardeningresults1000

474)(*/

'' 15.025.02 tW

Pc...

g

p

o

w

e

r

P

c

/ 2 smmW

2mmW

C.Heinzel1960

1950

10

f

i

c

g

r

i

n

d

i

n

g

1980

1970

10 01 0 10 1 00 10 00 s 1000 00

s

p

e

c

i

f

I.S.JahawirJ.C.OuteiroR M'S bi2000

1990

20052011

0.01 0.10 1.00 10.00 s 1000.00

heat exposure timetC Heinzel: Schleifprozesse verstehen: Zum Stand der Modellbildung und Simulation sowie untersttzender Methoden. Habilitationsschrift,

i i 2009

R.M'Saoubi

2010

2000

Gl 12/01/CIRP: 11

Universitt Bremen, Shaker Verlag, Aachen, 2009.I S Jawahir, E Brinksmeier, R M'Saoubi, D K Aspinwall, J C Outeiro, D Meyer, D Umbrello, A D Jayal: Surface Integrity in Material Removal Processes: Recent Advances. CIRP Annals 60/2, 2011: 603-626.

2020

...


Gl 12/01/CIRP:11

CIRPcollaborativework2010:residualstressatsurface

roundrobintest:residualstressatsurface

12participatinginstitutes...

MPa

800MillingTurning

max/min

a

c

e

p p g

1960

1950

0

200

400 GrindingEDMFine Grinding

e

s

I

I

a

t

s

u

r

f

a

1980

1970

-600

-400

-200i

d

u

a

l

s

t

r

e

s

s

e

t t2000

1990

-1000

-800

sets

r

e

s target

20102010

2000

Gl 12/01/CIRP: 12

Jawahir, I. S.; Brinksmeier, E.; M'Saoubi, R.; Aspinwall, D. K.; Outeiro, J.C.; Meyer, D.; Umbrello, D.; Jayal, A. D.: Surface Integrity in Material Removal Processes: Recent Advances. Annals of the CIRP 60/2, 2011, Seite 603-626.

2020

...


Gl 12/01/CIRP:12, ,

EvolutionaryviewonSurfaceIntegrity

focus

macro/micro

"stateoftheart"

macro /microgeometry

conformancetodesigntolerances

s

s

surfaceandsubsurfaceproperties

casestudies,surfaceandfunctionalproperties

p

r

o

g

r

e

s

energyconversion,

modelingandsimulationoffunctionalpropertiesindependentfrom

p

specificpowerp p p

machiningparameters

?characterization/predictionofsurface

o

n

Gl 12/01/CIRP: 13

?/p

integrityindependentfromindividualprocessesv

i

s

i

o


Gl 12/01/CIRP:13

Similarsurfacemodificationsachievablebycompletelydifferentprocesses

thermalthermal mechanicalmechanicalworkpiece

vsvft

vc

grindingwheel

HV

inductionhardening grindhardening deeprolling grindstrengthening

HV HV HV

vc

0z

0z

0z

0z

differentprocesses:similarsurfacelayerproperties

Gl 12/01/CIRP: 14

workpiecematerial:doesnotknowprocesses materialreactsonthermalandmechanicalexposure,resultingfromtheenergysignatureandthegeneratingdynamicsoftheprocess


Gl 12/01/CIRP:14

Whatisneededforareliablepredictionofsurfaceintegrityaftermachining?

knowledge(atdifferentscales)on

energyconversion

energydissipation

heatpartitioning

material response to physical/chemical process impact materialresponsetophysical/chemicalprocessimpact

fundamentalmaterialdata

focuson

physical/chemicalimpactresultingfromtool/workpieceinteractions

characterizationandclassificationofprocessesregardingphysical/chemicalinfluencingparameters

Gl 12/01/CIRP: 15

processsignature


Gl 12/01/CIRP:15

Requiredinformationtoformtheprocesssignature

input outputprocess

material tool kinematics

modifiedsurfaceandnearsurfaceregionenergy energy materialkinematics

energy systemquantities

region

nearsurfacefunctional

gyconversion

gydissipation modification

causal sequence

properties

causal sequence

Gl 12/01/CIRP: 16


Gl 12/01/CIRP:16

Differentprocessescanbedescribedbythesamecausalprinciples

initialsurfaceandboundarylayer

laser

vf

appliedenergymechanicalchemicalthermal

acid

vc

...

energyconversionanddissipation

dissipativeenergyfrictionenergy

chem.bindingenergy structuralmodification

tool

modifiedsurfaceand

nearsurfaceregion

Gl 12/01/CIRP: 17

surface/subsurfaceproperties functionalperformance

cuttinglaser

etching


Gl 12/01/CIRP:17

Canweidentifycharacteristicprocesssignaturesbasedonphysical/chemicaldescriptions?

mainprocessimpactmechanical,thermal,

loadmechanical,thermal,

chemical chemical

componentwithapplicationprocessworkpiece

modifiedsurface/nearsurface with

function(s)applicationprocess

material functionalproperties

performance of componentperformance of componentprocess signatureprocess signatureprocess signature

Gl 12/01/CIRP: 18

performanceofcomponentperformanceofcomponentprocesssignatureprocesssignatureprocesssignature


Gl 12/01/CIRP:18

Howtodevelopaprocesssignature?

...input output

.

... material tool kinematics

modifiedsurfaceandnearsurfaceregion

.

.

.

...

energy systemquantities

nearsurfacefunctionalpropertiesproperties

possible approach

characteristicnumberregression/transferfunctionsemantic description

possibleapproach

combinationofselectedmethodsforcombininginputandoutputquantities

Gl 12/01/CIRP: 19

semanticdescriptionenergeticbasedvalues/functionsin/outputvalues

physically/chemicallybaseddescriptionsoftoolworkpiece interactions


Gl 12/01/CIRP:19

Howtodevelopaprocesssignature? ...input material tool

output

modifiedsurfaceandnearsurface

.

.

.

...

...

kinematics energy systemquantities

region

nearsurfacefunctionalproperties

degree ofabstraction

abstraction level approach method application area

di h i l / h i l l ismall mechanisms

direct physical /chemicalmodeling

analytic,FEM

process analysis

ll i di t h i l h t i tismall medium

mechanisms/systemindirect physical/chemical modeling

characteristicnumber

l iquantitative cause andregression,

process analysis,process signature

medium mechanisms/systemquantitativecauseandeffect relationship

transferfunction

qualitative cause and

Gl 12/01/CIRP: 20

high systemqualitativecauseandeffect relationship

semantic


Gl 12/01/CIRP:20

Comparablemechanismsinmachininganduseofacomponent


chemical


chemical


chemical


chemical

modifiedmodified

componentwith

function(s)applicationprocessworkpiece

material

modifiedsurface/nearsurface

functionalproperties

componentwith

function(s)applicationprocessworkpiece

material


functionalpropertiesp pp p

solution of "inverse problem"?

functionalsignature?processsignature

Gl 12/01/CIRP: 21

solutionof inverseproblem ?


Gl 12/01/CIRP:21

EvolutionaryviewonSurfaceIntegrity

focus

macro/micro

"stateoftheart"

macro /microgeometry


s

s



p

r

o

g

r

e

s

energyconversion,

modelingandsimulationoffunctionalpropertiesindependentfrom

p

specificpowerp p p

machiningparameters

process characterization/predictionofsurface

o

n

Gl 12/01/CIRP: 22

processsignature

/pintegrityindependentfromindividual

processesvi

s

i

o


Gl 12/01/CIRP:22

Conclusion

nextstepinmachiningprocessabstractionisrequired proposedapproach:processsignature

macro/microgeometry


energyconversion,

focus



modelingandsimulationoffunctionalpropertiesindependent from

p

r

o

g

r

e

s

s

"stateoftheart"

requirements physical/chemicaldescriptionofmachiningprocesses

d d th d f i d t i ti f

conversion,specificpower

processsignature

p p pmachiningparameters

descriptionofsurfaceintegrityindependent fromspecificprocess

v

i

s

i

o

n

advancedmethodsforinprocessdeterminationoftemperaturesandforces

innovativemethodsformodelingandforcombining

.

.

.

...

...

...

input

material tool kinematics energy systemquantities

output

modifiedsurfaceandnearsurfaceregion

nearsurfacefunctionalproperties g g

models(e.g.multiphysical,multiscale)

multiscalematerialcharacterizationmainprocessimpactmechanical,thermal,

chemical


chemical innovativemethodsforcombiningenergybasedheterogeneousinformation

visioncomponent

withfunction(s)

chemical chemical

applicationprocessworkpiecematerial


functionalproperties

functionalsignature?processsignature

Gl 12/01/CIRP: 23

visioninverseengineeringoffunctionalsurfaces

solutionof"inverseproblem"?


Gl 12/01/CIRP:23

Thank you!

Gl 12/01/CIRP: 24


Gl 12/01/CIRP:24

keynote presentation brinksmeier

Documents

cirp annals

j peters

debruin j

j kahles

j t cammett

d j whitehouse

peters d

p vanherck