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Electrostatic induction–based online monitoring of grinding wheel wear

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Abstract

Grinding is an important part of precision manufacturing, and grinding wheel wear is a crucial factor affecting the processing quality. It will be of great significance to monitor the grinding wheel wear status in real-time and provide timely warnings during processing. To realize the real-time and effective monitoring of grinding wheel wear, a new grinding wheel wear state monitoring method based on the principle of electrostatic induction is proposed. The principle of electrostatic induction in the machining process is analyzed, and two methods of grinding wheel wear surface monitoring and chip-abrasive grain monitoring are proposed. The time domain signal is processed by Fourier transform and noise reduction, and the influence of grinding wheel wear on the electrostatic signals of grinding wheel, abrasive grains, and chips is analyzed. The results of titanium alloy grinding show that with the increase in the wear degree of the grinding wheel, the electrostatic quantity of the grinding wheel increases by 5.6 times, and the number of electrostatic pulses of abrasive grains decreases by 74%. The degree of grinding wheel wear can be characterized by the electrostatic quantity of the grinding wheel and the number of electrostatic pulses of abrasive grains. In contrast, the number of electrostatic pulses of chips, the electrostatic pulse peaks of abrasive grains, and chips have no apparent relationship with grinding wheel wear. The electrostatic monitoring method can effectively monitor the grinding wheel wear state in real time and provide a new solution for the online monitoring of grinding wheel wear.

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Data availability

The authors declared that the data and material used and analyzed in this research could be obtained on reasonable request from the corresponding author.

Abbreviations

q :

Measured charge

E 1 :

The electric field strength at point M

E 1┴ :

The component of electric field strength E1

E 2 :

The electric field strength at point N

E 2┴ :

The component of electric field strength E2

ε 0 :

The dielectric constant of vacuum

Q 1 :

The amount of charge on the sensor end face

Q 2 :

The amount of charge on the sensor side face

Q :

The total induced charge of the sensor

ΔQ :

The variation of electrostatic induction of grinding wheel

A 1 :

The induced charge variation of the chip

R :

The radius of the sensor end face

L :

The length of the sensor

ω :

The angle of the effective sensing area of the probe

s :

Grinding wheel speed

f :

Feed rate

a p :

Depth of grinding

CBN:

The cubic boron nitride grinding wheel

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Funding

The work was supported by National Natural Science Foundation of China (Nos. U1933202 and U2133202) and the Aeronautical Science Foundation of China (NO.2020Z065052001).

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Authors and Affiliations

  1. College of Civil Aviation, Nanjing University of Aeronautics and Astronautics, Nanjing, 211100, Jiangsu, China

    Pengtao Li, Heng Jiang, Hongfu Zuo, Juan Xu & Jiachen Guo

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  1. Pengtao Li
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  2. Heng Jiang
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  3. Hongfu Zuo
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  4. Juan Xu
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Contributions

Pengtao Li: methodology, software, validation, formal analysis, writing-original draft. Heng Jiang: methodology, investigation, writing-review and editing. Hongfu Zuo: supervision, funding acquisition, project administration. Juan Xu: investigation, editing. Jiachen Guo: software, editing.

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Correspondence to Hongfu Zuo.

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Li, P., Jiang, H., Zuo, H. et al. Electrostatic induction–based online monitoring of grinding wheel wear. Int J Adv Manuf Technol 129, 3875–3887 (2023). https://doi.org/10.1007/s00170-023-12307-y

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  • DOI: https://doi.org/10.1007/s00170-023-12307-y

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