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Characterization of the physical origins of acoustic emission (AE) from natural fiber reinforced polymers (NFRPs) machining processes

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Abstract

Natural fiber reinforced polymers (NFRPs) are environmentally friendly and are receiving growing attention in the industry. However, the multi-scale structure of natural fibers and the random distribution of the fibers in the matrix material severely impede the machinability of NFRPs, and real-time monitoring is essential for quality assurance. This paper reports a synchronous in situ imaging and acoustic emission (AE) analysis of the NFRP machining process to connect the temporal features of AE to the underlying dynamics and process instability, all happen within milliseconds during the NFRP cutting. This approach allows directly observing the surface modification and chip formation from a high-speed camera (HSC) during NFRP cutting processes. The analysis of the HSC images suggests that the complex fiber structure and the random distribution introduce an unsteady, almost a freeze-and-release type motion pattern of the cutting tool with varying depths of cut at the machining interface. More pertinently, a prominent burst pattern of AE from time domain was found to emanate due to the sudden penetration of the tool into the surface of the NFRP workpiece (increasing the depth of cut), as well as a release motion of the tool from its momentary freeze position. These findings open the possibility of tracking AE signals to assess the effective specific energy and surface quality that are affected by these unsteady motion patterns.

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Availability of data and material

The datasets generated during and/or analyzed during the current study are available from the corresponding author on reasonable request.

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Funding

This research is supported by the National Science Foundation (NSF) (S&AS: INT #1849085), X-grant program at TEES.

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Authors and Affiliations

  1. Department of Systems Science and Industrial Engineering, State University of New York at Binghamton, Binghamton, NY, USA

    Zimo Wang & Qiyang Ma

  2. Department of Industrial and Systems Engineering, Texas A&M University, College Station, TX, USA

    Ruiqi Guo, Faissal Chegdani & Satish T. S. Bukkapatnam

  3. Arts et Métiers ParisTech, MSMP Laboratory/EA7350, Rue Saint Dominique BP508, 51006, Châlons-en-Champagne, France

    Faissal Chegdani & Mohamed El Mansori

  4. Department of Mechanical Engineering, Texas A&M University, College Station, TX, USA

    Bruce Tai

Authors
  1. Zimo Wang
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  2. Ruiqi Guo
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  3. Qiyang Ma
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  4. Faissal Chegdani
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  5. Bruce Tai
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  6. Mohamed El Mansori
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  7. Satish T. S. Bukkapatnam
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Contributions

Zimo Wang conducted experiments, collected experiment results, developed data analysis, and wrote and edited the manuscript; Ruiqi Guo analyzed experiment results and contributed the analysis of the microdynamics and its relationship with AE signal nature; Qiyang Ma edited paper and analyzed the data and visualized the results; Faissal Chegdani designed and conducted experiments; Bruce Tai realized the hardware setup and designed experiments; Mohamed El Mansori and Satish T.S. Bukkapatnam supervised the work and edited the paper. All the authors reviewed and edited the final document.

Corresponding author

Correspondence to Zimo Wang.

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Wang, Z., Guo, R., Ma, Q. et al. Characterization of the physical origins of acoustic emission (AE) from natural fiber reinforced polymers (NFRPs) machining processes. Int J Adv Manuf Technol 118, 865–879 (2022). https://doi.org/10.1007/s00170-021-07956-w

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  • DOI: https://doi.org/10.1007/s00170-021-07956-w

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