project title: supervisory control and monitoring of microblanking using acoustic emission
DESCRIPTION
Research Presentation. Project Title: Supervisory Control and Monitoring of Microblanking Using Acoustic Emission. Project Supervisor: Dr. A Rosochowski Co-Supervisor: Prof. R Balendra Research Student: Hisham Hamid. MST Markets. Microsystem Markets. Mature Products. Growth Products. - PowerPoint PPT PresentationTRANSCRIPT
Project Title:Supervisory Control and Monitoring of
Microblanking Using Acoustic Emission
Project Supervisor: Dr. A RosochowskiCo-Supervisor: Prof. R Balendra
Research Student: Hisham Hamid
Research Presentation
Drug delivery system
Microrelays
Injection nozzles
PacOptical switches
Lab on a chip
Magneto-optical heads
Projection light valves
Inclinometer
Micromotors
Anti collision
Microvalves
Mature Products
Accelerometers
Pressure sensors
Inkjet printer heads
Microsystem
Markets
Growth Products Emerging Products
Disk drive heads
Chemical sensors
Hearing aids
In-vitro diagnostics
Pace makers
Infrared images
Gyroscopes
Microspectrometers
MST Markets
Hairsprings for clocks and watches Dimension: strip thickness 0.015mm
strip width 1mm
Micro screws
Micro ball bearingMicro connectors
Microparts
Micro Product Development
How do we make microparts???
Silicon etching – 95%
New Technologies
Micromilling
Micro EDM
Micro injection moulding
Laser ablation
Microforming
Forming Technology
Microforming
Microblanking
Microblanking
The operation of shearing sub-milimeter parts of a complete outline of a workpiece to a predetermined shape by die cutting the outside shape of the parts
Project defined
Producing sheet metal circular blanks, 0.3 mm in diameter and thickness. To ensure that products are competitive, the produced parts should be consistently of high quality. The blank edge quality is influenced by numerous process parameters such as punch-die clearance, tool wear, punch-die state, types of material, punch velocity and lubrication. Controlling the part quality manually is inadequate.
A process monitoring system for microblanking is introduced based on the acoustic emission signal generated during the process. Should the system sense abnormalities, it will stop the machine or prompt the operator to take action.
Project defined
Aim: To develop a monitoring and quality control system for microblanking
Objectives: To develop/acquire an appropriate press machine for microforming
To design and develop suitable tool system for microblanking
To select suitable materials for microblanking
To implement a microblanking operation
To extract features of the microblanking process signatures
To develop a monitoring system for microblanking operation
Thank you
Methodology
Acquire Micro formingMachine-Analysis-Purchase-Installation & Commissioning
Acquire Microblanking Tooling System-Design-Manufacture
Microblanking TrialsSelection of Materials-Classical metals-Ultra-fine grain metals
X-Y Translation Feeding System
Capture Process Signature
Force-Displacement Signature
Acoustic Emission
Processing of AE signals
Correlation of AE Results With Tool State
Statistical DOE to Capture the Effect of Tool State on Product Quality
Development of an Automated Monitoring System
Project Overview
Produce sheet metal circular blanks
-size 300 micrometer diameter and thickness
- material 304L austenitic stainless steel
On-line quality control
Production continue
No
Yes
Stop machine
Or
Alert operator
Microblanking operation
Blank edge quality is influence by:
•Punch-die clearance
•Tool wear
•Punch-die state
•Material
•Punch velocity
•Lubrication
Acoustic Emission
Technique
Supervisory Control and Monitoring of
Microblanking
AE Sensor
Preamplifier
AE Signal acquisition board
Signal analysis
Feature extraction
Decision-making
Punch
Blank holder
Stock material
Die
Experiment set-up
Bose-EnduraTec ELF 3300
AE Sensor and AE Acquisition Board
X-Y Translation Stages
MICRO BLANKING
TOOL SETS
Drawn by: Hisham Hamid
MERG Dmem Uni of strathclyde
Title: Micro Blanking Tooling – Overview of the Punches, Die, Guides and Components
SIZE FSCM NO DWG NO REV
SCALE Not to scale SHEET 1 OF 1
Micro Blanking DieMaterial – sheet metal
Curve Spring (S1)
Blank Holder – Lower Guide (G1)
Spring (S2)
Upper Guide (G2)
Spring (S3)
Circlip
Slide Punch Guide (G3)
Slide Punch (P2)
UpperPlate
MiddlePlate
BasePlate
Stainless Socket Head Cap Screw – M3 X 4
Tool Sets
Quality Control
Machines
Tools
MaterialsProcesses
Microforming System
Microforming System
Thank you
-end-