ProcessMonitoringandControlforPrecision-GRACO.docVIP

Process Monitoring and Control for Precision Manufacturing David A. Dornfeld Abstract: New demands are being placed on monitoring systems in precision manufacturing because of recent developments and trends in machining technology and machine tool design. This paper first discusses the requirements for sensor technology for precision manufacturing process monitoring in general. Then, background and details are given about acoustic emission (AE) and the application of AE sensing to process characterization and monitoring in ultraprecision machining. A review of the research on AE in machining (including, polishing, lapping and diamond turning) and signal processing at the University of California at Berkeley is included. Keywords: Production Process, Precision Machining, Sensors Introduction In-process sensors play a significant role in assisting manufacturing systems in producing quality products at a reasonable cost and are used to generate control signals to improve both the control and productivity of manufacturing systems [1]. Numerous different sensor types are available for monitoring and control of the manufacturing and machining environments [2]. This paper first discusses the requirements for sensor technology for precision manufacturing process monitoring and control in general. Then, background and details are given about acoustic emission (AE) and the application of AE sensing to process characterization and monitoring, primarily in material removal processes at the Laboratory for Manufacturing Automation at Berkeley. Requirements for Sensor Technology for Precision Manufacturing Precision machining takes place at the sub-micron to nano scale dimensions (with respect to the uncut chip thickness, for example.) Critical sensor information in precision machining is required mostly for assessing material removal at the sub-micron level, surface finish and subsurface damage. In addition, it is of interest to track for control purposes the variation in proce