Improved examination and test procedure of tapping torque tests according to ASTM D5619 using coated forming taps and water-mixed metalworking fluids

Demmerling, Anna Lena; Söffker, Dirk

doi:10.1016/j.triboint.2019.106151

Cited by 11 publications

(4 citation statements)

References 16 publications

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“…The experiment is designed and conducted by the Chair of Dynamics and Control and Rhenus Lub GmbH & Co KG, the measurements are taken at Rhenus Lub. Details about the test rig and measurement procedure are reported in (Demmerling & Söffker, 2020). To reduce chip effects for AE signals in metalworking process as much as possible, thread forming is chosen as metalworking process.…”

Section: Experiments Designmentioning

confidence: 99%

New Data Processing Method for Acoustic Emission Signals for Metalworking Fluid Classification

Wei

Söffker²

2022

PHM_CONF

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Metalworking fluid (MWF) differentiating is of important significance as their additives affect metalworking process extremely so the evaluation of MWF should be suitable conducted. Acoustic Emission (AE) measurements can be easily taken as process-close measures for evaluating cutting and forming processes as well as MWFs performance. In thread forming process, AE measurements from different kinds of MWFs could be – related to the position of the tool - divided into different process phases: air, forward, and reverse phases. From physical view, forward part contains most useful AE data. Therefore, extracting forward part data from the overall signal is significant for MWFs classification. Because boundaries among different parts in time domain of AE signals are not clear, in this contribution, a new data processing method is proposed to abstract the forward part data from non-related parts of the whole measurement signal. For the first time, scalogram is applied to find the boundaries in time domain as an aid. Firstly, the intact measurement signal is transformed from time domain to time-frequency domain by continuous wavelet transform (CWT) and scalogram is acquired. As boundaries among different phases are obvious in scalogram, by reverse calculation, boundaries’ location in time domain could be defined and forward part data of each measurement are picked out. Afterwards, data in forward phase are divided into different samples and each sample contains data of one round. Finally, samples’ features are extracted and classified by convolutional neural network (CNN). By adjusting CNN structure and hyperparameters with cross validation method, features in time domain could be distinguished well. For five kinds of testing MWF, the classification accuracy is as high as 98.11 %. For reference, oil-based, and water-based MWF classification, the results can reach to 98.94 %. Accuracy for water-based MWF distinction is 97.55 % while for oil-based MWF distinction is 98.29 %. Comparing with results using the whole AE measurements, these results improve significantly. Good results show that the proposed data processing method could extract most useful information from the whole AE measurements in time domain for MWF distinction. Besides, the proposed method also provides an effective way for data analysis in the future.

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Section: Experiments Designmentioning

confidence: 99%

New Data Processing Method for Acoustic Emission Signals for Metalworking Fluid Classification

Wei

Söffker²

2022

PHM_CONF

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“…The nanoparticles in the forming process were studied by the authors in [ 10 ], with a tremendous effect on the forming process of metal containers. All of these works and many others [ 11 , 12 , 13 , 14 , 15 , 16 , 17 , 18 , 19 , 20 , 21 ] inspired the authors of the paper to thoroughly study the effect of polymers in a forming technology from several aspects. The selection resulted in the production of thread by forming taps.…”

Section: Introductionmentioning

confidence: 99%

Exquisite Energy Savings at Cold Metal Forming of Threads through the Application of Polymers

et al. 2022

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One of the global problems today is energy—its production and distribution. As the human population grows, the consumption of energy rises simultaneously. However, the natural sources are limited, and so the focus on power savings becomes more and more important. One of the ways to reduce consumption is the use of effective lubricants and tribological fluids in industry, especially in processes with high demands on energy but high quality of products as well. Forming is a typical example of such technology, and the application of polymers seems to be a very important challenge, because the application of straight oils or lubricant with extreme pressure additives seems to be prevailing in that field. Nevertheless, the polymer lubricant should fulfill all European standards as well as the environmental and ecological limitations with respect to health and the natural environment and its recycling and disposal. This paper is focused on the forming technology of threads and the application of selected polymers to the forming process. The measured and quantified criteria are torque and force loadings, energy consumption, and quality of the produced surfaces. Kistler dynamometers, scanning electron microscopy, and advanced surface topography with the use of Alicona IF-G5 were applied to assess all aspects of the tribological and energy aspects of six modern process fluids, three lubricating pastes, and two fluid modifications. The results show that the polymer synthetic lubricant (at volume concentration 20% in water) can reduce the total energy consumption by up to 40% per forming cycle (in mean values) at average surface roughness below 0.8 μm.

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“…Finally, a torque value to cut or form a thread is obtained. Smaller torque values indicate better metal working performance (Demmerling, & Söffker, 2020). In this study, metal working performance of vegetable oils and PEs were evaluated with Tapping Torque test method.…”

Section: Introductionmentioning

confidence: 99%

Comparison of the Effects of Vegetable Oils such as Castor and Canola Oil and Polyol Esters on the Metalworking Performance of AL 6061 and Al 7075 Metal Alloys by Tapping Torque Method

KAVUT¹,

GULEN-TOM²,

OZPERCIN³

2022

EPSTEM

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Improved examination and test procedure of tapping torque tests according to ASTM D5619 using coated forming taps and water-mixed metalworking fluids

Cited by 11 publications

References 16 publications

New Data Processing Method for Acoustic Emission Signals for Metalworking Fluid Classification

New Data Processing Method for Acoustic Emission Signals for Metalworking Fluid Classification

Exquisite Energy Savings at Cold Metal Forming of Threads through the Application of Polymers

Comparison of the Effects of Vegetable Oils such as Castor and Canola Oil and Polyol Esters on the Metalworking Performance of AL 6061 and Al 7075 Metal Alloys by Tapping Torque Method

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