Min Soo-Hong, Lee Tae Hun, Lee Gil-Yong, Zontar Daniel, Brecher Christian, Ahn Sung-Hoon
Department of Mechanical Engineering, Seoul National University, Seoul 08826, Korea.
Department of Production Machines, Fraunhofer Institute for Production Technology IPT, Aachen 52074, Germany.
Materials (Basel). 2020 Jun 29;13(13):2920. doi: 10.3390/ma13132920.
A real-time, accurate, and reliable process monitoring is a basic and crucial enabler of intelligent manufacturing operation and digital twin applications. In this study, we represent a novel vibration measurement method for workpiece during the milling process using a low-cost nanoparticle vibration sensor. We directly printed the vibration sensor based on silver nanoparticles positioned onto a polyimide substrate using an aerodynamically-focused nanomaterials printing system, which is a direct printing technique for inorganic nanomaterials positioned onto a flexible substrate. Since it does not require any post-process such as chemical etching and heat treatment, a highly sensitive vibration sensor composed of a microscale porous structure was fabricated at a cost of several cents each. Furthermore, accurate and reliable vibration data was obtained by simple and direct attachment to a workpiece. In this study, we discussed the performance of vibration measurement of a fabricated sensor in comparison to a commercial vibration sensor. Using frequency and power spectrum analysis of obtained data, we directly measured the vibration of workpiece during the milling process, according to a process parameter. Lastly, we applied a fabricated sensor for the digital twins of turbine blade manufacturing in which vibration greatly affects the quality of the product to predict the process defects in real-time.
实时、准确且可靠的过程监测是智能制造运行和数字孪生应用的基本且关键的推动因素。在本研究中，我们展示了一种使用低成本纳米颗粒振动传感器在铣削过程中对工件进行振动测量的新方法。我们使用空气动力学聚焦纳米材料打印系统，将基于银纳米颗粒的振动传感器直接打印在聚酰亚胺基板上，这是一种将无机纳米材料直接打印到柔性基板上的技术。由于它不需要诸如化学蚀刻和热处理等任何后处理，因此以每个几美分的成本制造了由微尺度多孔结构组成的高灵敏度振动传感器。此外，通过简单直接地附着在工件上即可获得准确可靠的振动数据。在本研究中，我们讨论了与商用振动传感器相比，所制造传感器的振动测量性能。通过对所得数据进行频率和功率谱分析，我们根据工艺参数直接测量了铣削过程中工件的振动。最后，我们将所制造的传感器应用于涡轮叶片制造的数字孪生中，其中振动对产品质量有很大影响，以实时预测工艺缺陷。
