Investigations on the Potential of 5G for the Detection of Wear in Industrial Roller-Burnishing Processes
Roller burnishing represents an economical alternative to conventional surface-finishing processes, such as fine turning or honing. In contrast to the well-known wear mechanisms of chip-forming processes, the wear behavior in roller-burnishing is strongly based on the experience of the machine opera...
| Main Authors: | , , , , , , , , , , , |
|---|---|
| Format: | Article |
| Language: | English |
| Published: |
MDPI AG
2022-05-01
|
| Series: | Electronics |
| Subjects: | |
| Online Access: | https://www.mdpi.com/2079-9292/11/11/1678 |
| _version_ | 1797493708651757568 |
|---|---|
| author | Maximilian Kosel Tobias Schippers Aziz Abdul Kristina Ishii Jacek Mainczyk Jürgen Mansel Kai Milnikel Bünyamin Nurkan Ralf Löschner Konstantin Haefner Daniel Zontar Christian Brecher |
| author_facet | Maximilian Kosel Tobias Schippers Aziz Abdul Kristina Ishii Jacek Mainczyk Jürgen Mansel Kai Milnikel Bünyamin Nurkan Ralf Löschner Konstantin Haefner Daniel Zontar Christian Brecher |
| author_sort | Maximilian Kosel |
| collection | DOAJ |
| description | Roller burnishing represents an economical alternative to conventional surface-finishing processes, such as fine turning or honing. In contrast to the well-known wear mechanisms of chip-forming processes, the wear behavior in roller-burnishing is strongly based on the experience of the machine operators. The nature of the finishing process makes roller-burnishing very sensitive to surface defects, as it is often not possible to rework the last step in a process chain. In the present work, a prototype for a smart roller-burnishing tool with 5G communication is presented, which serves as an inline-monitoring tool to detect tool wear. A suitable metric to monitor the tool wear of the manufacturing roll is suggested, and the potentials of 5G communication for the described use-case are evaluated. Based on the signal-to-noise ratio of the process-force, a metric is found that distinguishes new rolls from worn rolls with very small defects on the micrometer scale. Using the presented approach, it was possible to distinguish the signal-to-noise ratio of a roll with very small wear marks by 3.8% on average. In the case of stronger wear marks, on the order of 20 µm, the difference increased to up to 15.6%. |
| first_indexed | 2024-03-10T01:23:56Z |
| format | Article |
| id | doaj.art-7aca153da56741e6b0d18feadf8ca37b |
| institution | Directory Open Access Journal |
| issn | 2079-9292 |
| language | English |
| last_indexed | 2024-03-10T01:23:56Z |
| publishDate | 2022-05-01 |
| publisher | MDPI AG |
| record_format | Article |
| series | Electronics |
| spelling | doaj.art-7aca153da56741e6b0d18feadf8ca37b2023-11-23T13:54:05ZengMDPI AGElectronics2079-92922022-05-011111167810.3390/electronics11111678Investigations on the Potential of 5G for the Detection of Wear in Industrial Roller-Burnishing ProcessesMaximilian Kosel0Tobias Schippers1Aziz Abdul2Kristina Ishii3Jacek Mainczyk4Jürgen Mansel5Kai Milnikel6Bünyamin Nurkan7Ralf Löschner8Konstantin Haefner9Daniel Zontar10Christian Brecher11Fraunhofer Institute for Production Technology IPT, 52074 Aachen, GermanyR&D Steuerungstechnik GmbH & Co. KG, 41189 Mönchengladbach, GermanyFraunhofer Institute for Production Technology IPT, 52074 Aachen, GermanyFraunhofer Institute for Production Technology IPT, 52074 Aachen, GermanyR&D Steuerungstechnik GmbH & Co. KG, 41189 Mönchengladbach, GermanyR&D Steuerungstechnik GmbH & Co. KG, 41189 Mönchengladbach, GermanyR&D Steuerungstechnik GmbH & Co. KG, 41189 Mönchengladbach, GermanyWenaroll GmbH Tools and Systems, 42799 Leichlingen, GermanyWenaroll GmbH Tools and Systems, 42799 Leichlingen, GermanyWenaroll GmbH Tools and Systems, 42799 Leichlingen, GermanyFraunhofer Institute for Production Technology IPT, 52074 Aachen, GermanyFraunhofer Institute for Production Technology IPT, 52074 Aachen, GermanyRoller burnishing represents an economical alternative to conventional surface-finishing processes, such as fine turning or honing. In contrast to the well-known wear mechanisms of chip-forming processes, the wear behavior in roller-burnishing is strongly based on the experience of the machine operators. The nature of the finishing process makes roller-burnishing very sensitive to surface defects, as it is often not possible to rework the last step in a process chain. In the present work, a prototype for a smart roller-burnishing tool with 5G communication is presented, which serves as an inline-monitoring tool to detect tool wear. A suitable metric to monitor the tool wear of the manufacturing roll is suggested, and the potentials of 5G communication for the described use-case are evaluated. Based on the signal-to-noise ratio of the process-force, a metric is found that distinguishes new rolls from worn rolls with very small defects on the micrometer scale. Using the presented approach, it was possible to distinguish the signal-to-noise ratio of a roll with very small wear marks by 3.8% on average. In the case of stronger wear marks, on the order of 20 µm, the difference increased to up to 15.6%.https://www.mdpi.com/2079-9292/11/11/1678roller-burnishingburnishing5Gsurface finishing |
| spellingShingle | Maximilian Kosel Tobias Schippers Aziz Abdul Kristina Ishii Jacek Mainczyk Jürgen Mansel Kai Milnikel Bünyamin Nurkan Ralf Löschner Konstantin Haefner Daniel Zontar Christian Brecher Investigations on the Potential of 5G for the Detection of Wear in Industrial Roller-Burnishing Processes Electronics roller-burnishing burnishing 5G surface finishing |
| title | Investigations on the Potential of 5G for the Detection of Wear in Industrial Roller-Burnishing Processes |
| title_full | Investigations on the Potential of 5G for the Detection of Wear in Industrial Roller-Burnishing Processes |
| title_fullStr | Investigations on the Potential of 5G for the Detection of Wear in Industrial Roller-Burnishing Processes |
| title_full_unstemmed | Investigations on the Potential of 5G for the Detection of Wear in Industrial Roller-Burnishing Processes |
| title_short | Investigations on the Potential of 5G for the Detection of Wear in Industrial Roller-Burnishing Processes |
| title_sort | investigations on the potential of 5g for the detection of wear in industrial roller burnishing processes |
| topic | roller-burnishing burnishing 5G surface finishing |
| url | https://www.mdpi.com/2079-9292/11/11/1678 |
| work_keys_str_mv | AT maximiliankosel investigationsonthepotentialof5gforthedetectionofwearinindustrialrollerburnishingprocesses AT tobiasschippers investigationsonthepotentialof5gforthedetectionofwearinindustrialrollerburnishingprocesses AT azizabdul investigationsonthepotentialof5gforthedetectionofwearinindustrialrollerburnishingprocesses AT kristinaishii investigationsonthepotentialof5gforthedetectionofwearinindustrialrollerburnishingprocesses AT jacekmainczyk investigationsonthepotentialof5gforthedetectionofwearinindustrialrollerburnishingprocesses AT jurgenmansel investigationsonthepotentialof5gforthedetectionofwearinindustrialrollerburnishingprocesses AT kaimilnikel investigationsonthepotentialof5gforthedetectionofwearinindustrialrollerburnishingprocesses AT bunyaminnurkan investigationsonthepotentialof5gforthedetectionofwearinindustrialrollerburnishingprocesses AT ralfloschner investigationsonthepotentialof5gforthedetectionofwearinindustrialrollerburnishingprocesses AT konstantinhaefner investigationsonthepotentialof5gforthedetectionofwearinindustrialrollerburnishingprocesses AT danielzontar investigationsonthepotentialof5gforthedetectionofwearinindustrialrollerburnishingprocesses AT christianbrecher investigationsonthepotentialof5gforthedetectionofwearinindustrialrollerburnishingprocesses |