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Project Title: Supervisory Control and Monitoring of Microblanking Using Acoustic Emission

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.

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Project Title: Supervisory Control and Monitoring of Microblanking Using Acoustic Emission

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  1. 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

  2. MST Markets Microsystem Markets Mature Products Growth Products Emerging Products • Accelerometers • Pressure sensors • Inkjet printer heads • Disk drive heads • Chemical sensors • Hearing aids • In-vitro diagnostics • Pace makers • Infrared images • Gyroscopes • Microspectrometers • Drug delivery system • Microrelays • Injection nozzles • PacOptical switches • Lab on a chip • Magneto-optical heads • Projection light valves • Inclinometer • Micromotors • Anti collision • Microvalves

  3. Microparts Hairsprings for clocks and watches Dimension: strip thickness 0.015mm strip width 1mm Micro screws Micro connectors Micro ball bearing

  4. Micro Product Development How do we make microparts??? Silicon etching – 95%

  5. New Technologies • Micromilling • Micro EDM • Micro injection moulding • Laser ablation • Microforming

  6. Forming Technology • Microforming • Microblanking

  7. 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

  8. 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.

  9. 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

  10. Methodology Acquire Micro forming Machine -Analysis -Purchase -Installation & Commissioning Acquire Microblanking Tooling System -Design -Manufacture Selection of Materials -Classical metals -Ultra-fine grain metals X-Y Translation Feeding System Microblanking Trials Thank you Force-Displacement Signature Capture Process 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

  11. Microblanking operation Acoustic Emission Technique Supervisory Control and Monitoring of Microblanking Project Overview • Produce sheet metal circular blanks • size 300 micrometer diameter and thickness • material 304L austenitic stainless steel • Blank edge quality is influence by: • Punch-die clearance • Tool wear • Punch-die state • Material • Punch velocity • Lubrication Stop machine Or Alert operator On-line quality control No Yes Production continue

  12. Punch Preamplifier AE Sensor Blank holder AE Signal acquisition board Stock material Signal analysis Die Decision-making Feature extraction Experiment set-up

  13. Bose-EnduraTec ELF 3300

  14. AE Sensor and AE Acquisition Board

  15. X-Y Translation Stages

  16. Tool Sets

  17. Machines Quality Control Tools Materials Processes Microforming System Microforming System

  18. Thank you -end-

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