Presentation of Project Content - Lessons Learned · Presentation of Project Content FAA Project on Process Monitoring November 3rd 2009, Boston FAA Dipl.-Ing. Dražen Veselovac Department

Presentation of Project ContentFAA Project on Process Monitoring

November 3rd 2009, Boston FAA

Dipl.-Ing. Dražen Veselovac

Department of Process and Product Monitoring Chair of Manufacturing Technology WZL - RWTH Aachen

© WZL/Fraunhofer IPT

Outline

1

2

3

4

5

6

Introduction

Interest of Industrial Partners

State of the Art

Objectives and Main Goals

Scope of the Project

Risk Management

© WZL/Fraunhofer IPT Seite 2

Introduction

Introduction1

2

3

4

5

6


State of the Art



Risk Management


Needs for workpiece-oriented process monitoring

ACCIDENT

DL 1288, July 6, 1996 - Pensacola, Florida

Broaching and drilling are machining operations carried out to finalise discs’ geometry

Drilling is most critical and sensitive process due to difficult cutting tip engagement, complicated chip flow and unfavourable heat dissemination

Broaching is difficult because of one-stroke nature

Need for investigation and monitoring of these operations was expressed several times from ROMAN group based on their Lessons-Learned data base


.5

1000

Workpiece-oriented process monitoring

Stable manufacturing of critical Process monitoring / temperature control turbine engine discs are required to ensure components without

fatal thermal damages

Source: MTU, Rolls-Royce

0 2 5 7.5 10 12.5 15

Bohrweg [mm]

0

500

1000

1500

2000

2500

3000

Vor

schu

bkr a

ft [N

]

Kt x

a

ppl.

(MPa

)

10000 100000 1000000 Zahl der Lastwechsel

Correlation of induced thermal impact to LCF-tests of manufactured specimens


10 mm

Temperature Measurements in Drilling TiAl6V4d = 100 µm d = 200 µm d = 300 µm

d

tY

3D-Measurment device

After experimental investigations

Holes for fibres

Experiments


Temperature Distribution around the Cutting Edge

Dis

tanc

e0.6

mm

0.4

0.3

0.2

0.1

0.0

-0.1

-0.2

-0.3

-0.4

Max. Temperature [°C]

183

303 225

Holewall 432

Cutting edge

550

Tool 567

Main tip -0.8 -0.7 -0.6 -0.5 -0.4 -0.3 -0.2 -0.1 0.0 0.1 0.2 0.3 0.4

Position in direction of feed xrel [mm] © WZL/Fraunhofer IPT Seite 7

-0 4

-0 3

-0 2

-0 1

-0 8 -0 7 -0 6 -0 5 -0 4 -0 3 -0 2 0

-0

-0 1

2,5 7,5 12,5 17,5 22,5

Temperature Distribution along the whole Drilling Operation

Cutting parameter: D = 8 mm l = 25 mm

vc = 35 m/min f = 0.1 mm l/D = 3.125

Max. Temperature [°C]

,

,

,

,

0,0

0,1

0,2

0,3

0,4

0,5

0,6

, , , , , , , -0,1 0,0 0,1 ,2 0,3 0,4 -0,4

-0,3

-0,2

-0,1

0,0

0,1

0,2

0,3

0,4

0,5

0,6

-0,8 -0,7 -0,6 -0,5 -0,4 -0,3 -0,2 -0,1 0,0 0,1 0,2 0,3 0,4 -0,4

-0,3

-0,2

-0,1

0,0

0,1

0,2

0,3

0,4

0,5

0,6

-0,8 -0,7 -0,6 -0,5 -0,4 -0,3 -0,2 -0,1 0,0 0,1 0,2 0,3 0,4 -0,4

,3

-0,2

,

0,0

0,1

0,2

0,3

0,4

0,5

0,6

-0,8 -0,7 -0,6 -0,5 -0,4 -0,3 -0,2 -0,1 0,0 0,1 0,2 0,3 0,4 -0,4

-0,3

-0,2

-0,1

0,0

0,1

0,2

0,3

0,4

0,5

0,6

-0,8 -0,7 -0,6 -0,5 -0,4 -0,3 -0,2 -0,1 0,0 0,1 0,2 0,3 0,4

.

Cutting edge Holewall

567 550

432225

183

591 514

268

467192

225 154

652 573

289 217225

182

614 628

554 297

297 202

349 303

220

729

572 656

648

303

2.5 7.5 12.5

17.5

22.5

Measurement position – Depth of Hole [mm]


vc = 35 m/minf = 0.1 mmD = 8 mm

Temperature distribution in continuous measurements

-2 0 2 4 6 8 10 12 14 16 18 20 22 24 26 0

100

200

300

400

500

600

700

800

Tem

pera

ture

T [°

C]

Drilling depth [mm]

1

2

3

4 5

6

V-Slot

Drilling tool

vf

vf

v c

Fibre

Work piece

V-slot-base

Tem

pera

ture

T [°

C]

Zoom

Process Parameter:

Measurement distance d = 200 µm

800

700

600

500

400

300

200

100

0

21.6 21.8 22 22.2 22.4 22.6 22.8 0

100

200

300

400

500

600

700

800

0.1 mm = f

0.05 mm = ½ f

22.55 22.6 22.65 22.7 22.75 22.8

Drilling depth [mm]


0,05 mm/tooth

Analysis of Drilling Process

- Reground tool - Already used for 8 holes - Dry cut Feedforce - TiN coated

Process parameter:

vc = 35 m/min f = l/D = 3,125

AE-raw Signal

Seite 10 © WZL/Fraunhofer IPT

AE RMS Monitoring for Drilling TiAl6V4

AE _r

m s

(V )

Very clear indication of anomaly during the time and drilling depth, where LCF specimen 4 is located

7

6

5

4

3

2

1

0

Min_RMS400

Max_RMS400

Mean_RMS400

1 2 3 4 5

X1_X2 X3_X4 X5_X6 X7_X8 X9_X10

Distance (total 25mm)


Joint Time Frequency AE Raw Analysis


0

200

400

600

800

1000

1200

Torq

ue (N

m)

0

2

4

6

8

10

12

14

Anom

aly

(mic

rom

eter

s)

0

20

40

60

80

100

120

140

160

PM-Anomaly-LCF CorrelationWorn tool. TiN. No coolent. Wide margin.

0 5 10 15 20 25 30

Forc

e (N

)

Force Distance (mm)Torque 21 mmAmorphous layer Total deformation


Joint Drilling Depth-Frequency AE Raw Analysis


Design of a Slim-Line integrated face milling tool

Design and first prototype



Cutting Tip Slim-Line Sensor


Forc

e F

[N]


Force signal of dynanometer New designIndividual slim line signals

Ability to monitor individual

time t [s]

forc

e F

[N]

forc

e F

[N]

time t [s]

Force Signals in HS-Cutting

forc

e F

[N]

Individual signal not extractable

Individual signal not extractable

cutting edge signaltime t [s]


Accelerometric compensation with Slim-Line sensorsSlim-Line Sensors

Tool holder

Cutting tip

Tip-mounting and preload transfer device

Slim-Line Sensor

Tool-holder set-up with Slim-Line force sensor

Workpiece for high frequency force interaction


V

Slim-Line vs. Dynamomter force meausurements

Process Parameter: 20

Cut

ting

Forc

e [N

] C

uttin

g Fo

rce

[N]

Cut

ting

Forc

e [N

]

0 10 20 30 40 Time [s]

]

Slime-Line Sensor Dynamometervc = 532 m/min

ap = 0.1 mm

f = 0.05 mm/rev

10

0

-10

Coolant = no

Cal.slim = 2.4 pC/N 20

= 100 N/V

fEingr. = 1000 Hz

fgrenz = no Filter SL

fAbtast = 100 kS/s

Time-const. = Long 7.82 7.83 7.84 7.85 7.86 Time [s]

15 10 5 0

-5-10-15

20 15 10 5 0

-5 -10 -15

7.864 7.865 7.866 7.867 7.868 Time [s]


Interest of industrial partners

1 Introduction

Interest of Industrial Partners 2

3

4

5

6

State of the Art



Risk Management


Industrial partners from WZL

WZL has become a Center of Competence for MTU AERO Engines in Compressor Technologies

WZL is official Partner of Rolls-Royce plc. in Production Technology development for Integrative Aero Engine components

Main development axes are going to focus on 3 – 5 axis machining operations with machining centres

Blisk technology is going to be the main focus of technology development for military and commercial aeronautics


Support of industrial partners during the project

Support actions Support actions Support actions Opportunity to use broaching Conduction of trials on Supply work piece material

machine tools for testing broaching machine tools for testing series


State of the Art

1

2

Introduction


State of the Art 3

4

5

6



Risk Management


Application of Process Monitoring in Manufacturing Process Monitoring is seen

as effective control for production with little or no part variation (automotive, food processing)

In manufacture for critical aero engines PM is often seen as a burden rather than a benefit

Systems in use apply simple techniques e.g. simple gated process monitoring

These simple techniques fail to detect manufacturing induced anomalies in production, identified during MANHIRP Project

Source: ARMINES, SNECMA MOTEURS

without anomaly

smearings

minor thermal influence

high thermal influence

Kt x

a

ppl.

(MP

a)

1000 10000 100000 1000000 Zahl der Lastwechsel


Adressing state of the art in previous projects Initiated by the Pensacola

event in 1996, FAA sponsored the Roman Project, which introduced appropriate manufacturing controls

European aero engine makers formed project MANHIRP, which investigated use of PM for detection of anomalies, NDE, fatigue and probabilistic lifing models

MANHIRP delivered an anomaly definition and categorization and identification of characteristic process monitoring signals

Source: FAA

Information on achieved quality

Process qualification

Process Monitoring

NDE

Direct feedback

Information on special event


Addressing state of the art in this proposal

ability to manufacture critical rotating components whilst

Manufacturing needs offering better quality control will lead to increased levels of air safety

ability to demonstrate a higher level of quality manufacture in this most demanding and competitive global market

development of a product monitoring system will allow reduction of time required to approval

Design needs

Design intent higher stressesimproved performancemore frequent flights

New material introduction More difficult to machine More prone to machining abuse

Component introduction costs Process validation time Manufacturing change control Inspection time

Manufacturing Cost Multiple machine operation Automation New methods New tooling materials and coatings

Lead time

FutureToday



1

2

3

Introduction


State of the Art

Objectives and Main Goals 4

5

6


Risk Management


Process-Material Combinations Work of this project will refer to

Drilling Processes Broaching Processes

FAA will choose either one Titanium or Nickel Alloy to conduct trials with

Trials will be performed with same tools, materials and parameters as they are used in production of critical aero engine components

Analysis of the trials and evaluation of machined parts will lead to suitable sensor solutions for monitoring material defects

With regard to known specifications and FAA standards, borders and limits with regard to recorded signals will be defined

Drilling processes Broaching processes

Titanium or Nickelbased Alloy

source: MTUsource: Lycoming


Sensor and Mounting Location Selection

possible sensors

physical process and disturbance quantities

sensing principles

sensor specifications

sensor mounting restrictions

input:

OEM description of process conditions ex.: - tool

- cutting steps - disturbance def. - disturbance char. - process features - :

Sensing principles

- strain gauge - hall effect - structure-borne sound

- :

ex.: - piezoelectric

AE-Signal force torque

acceleration temperature power drive current

10

20

30

40

100

200

300

N

500

10,84

400

10,9 Zeit

10

20

v

Zeit -10

-20 10

20

30

40

V/°C

°C

10

20

30

40

Md

P

20 10

20

30

40

Weg

IHSP

Sensor specifications

- frequency response

- range - sensitivity

- :

ex.: - frequency band

Machine test bed

- machine 3, 5 axis - interfaces (mechanical, data) - process boundary conditions (lubricant, electro magnetic fields, etc.)

- :

ex.: - workpiece handling

- mounting space


Suited Sensors for Cutting Operations

vc

AE-Sensor

Cutting forces

Rotating Cutting force Dynamometer (RCD)

Mov

emen

t/Vib

ratio

n

Accerelation Sensor

Hall-Sensor

Structure born sound

Structure borne sound


Signal Analysis

Low frequency signals (20 kHz): - Force, torque and power analysis in time-domain

- Combination of AERMS and feed-force - Analysis of acceleration in frequency domain

High frequency signals (500 - 2000 kHz): - Analysis of AEraw-signal in frequency domain

- Time-Frequency analysis of AEraw-signal

Additional analysis of work pieces and tools:- SEM (WP and tools)- Surface roughness measurements- Micro hardness measurements

At WZL’s lab:- Work piece oriented temperature measurements


Main Goals of the Project- PM-Strategy: Development of a position oriented process monitoring strategy for the selected material and process combinations

- Data Basis: Creation of data basis of available monitoring systems on the free market and actual scientific work done in the area of process monitoring

- Software Tool: Development of a software tool for data aquisition of monitoring signals and feature extraction routines

- Correlation of identified anomalies to the determined signal pattern

- Reaction strategies: development of possible reaction strategies and measures to be taken for saving time and waste during manufacture



1

2

3

4

Introduction


State of the Art


Scope of the Project 5

6 Risk Management


Task 4:

Task 8:

Task Content and Interaction

Task 6: Preliminary study of

automated data/signal mining in

manufacturing

Task 1: Procurement of test

material

Task 2: Evaluation of the state of the art

Task 3: General review on

experiences with PM systems in production

PM techniques identification

Task 5: Sensor specification

and sensor developments for

specific applications

Task 7: Definition and design of a

suitable PM System Machining Experiments at demonstrator machines

Task 9: Intelligent signal analysis and

software development

Task 10: Feature extraction/selection

Task 11: Development of possible

reaction strategies


Task Description

prog

ress

Task 1: Procurement of test material

Material will be used for machining tests/production of test pieces for hole making and broaching trials

Task 2: Evaluation of state of the art

Review of PM techniques studied in MANHIRP project

Task 3: General review on experiences with PM Systems in production

Survey of current knowledge about PM in OEM’s shop floors

Analysis of assessment and benefit in terms of quality, production, safety and human factors


Task Description

prog

ress

Task 4: PM techniques identification

Definition of useful combination of sensor signals in order to detect anomalies and disturbances

Task 5: Sensor specification and sensor development for specific applications

Specification and development of special sensors to enable surface monitoring system

Task 6: Preliminary study of automated data/signal mining in manufacturing

Literature Study of data/signal mining for PM applications

Literature Study on models describing measurements considered in the project


Task Description

prog

ress

Task 7: Definition and design of a suitable PM System

Development of system with suitable sensors and database

Qualification of sensor system

Procurement of sensors and equipment

Task 8: Machining experiments at the demonstrator machines

Experiments based on DoE analysis

Task 9: Intelligent signal analysis and software development

Data collection from various PM sensors and conditions

Time frequency and statistical analysis of signals in normal and abnormal mode

Development of software tools based on LabView environment


Task Description

prog

ress

Task 10: Feature extraction/selection

Find features of PM signals for reliable detection

Perform analysis isolating the features that give reliable detection of an abnormal mode

Optimise computational efficiency for high data rate measurements

Task 11: Development of possible reaction strategies

Elaboration of reactions strategies, e.g. immediate stop of machining process, reduction of cutting parameters, warnings


Risk Management

1

2

3

4

5

Introduction


State of the Art



Risk Management 6


Identified Risks and Measures

Risk Action

No anomalies could be created during standard machining operations

Development of a anomaly creation procedure (analogy trials) which are inducing anomalies, similar to those which can occur during production

Machine tool availability is not big enough at the end-user sites as it was planned

Do fundamental analysis for system verification at the available machine tool at the WZL (hydraulic machine tool) on analogical set-ups


Documents

Presentation of Project Content - Lessons Learned · Presentation of Project Content FAA Project on Process Monitoring November 3rd 2009, Boston FAA Dipl.-Ing. Dražen Veselovac Department