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A non-contact method for part-based process performance monitoring in end milling operations

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Abstract

Surface response to excitation (SuRE) method was originally developed for structural health monitoring (SHM) applications. SuRE was used to evaluate the performance of completed milling operations. The method generates surface waves on the plate and studies the spectrum changes at selected points to detect defects and change of compressive forces. In this study, the length, depth, and width of a slot were changed step by step. The surface of the aluminum plate was excited in the 20–400 kHz range with a piezoelectric element. A laser scanning vibrometer was used to monitor the vibrations at the predetermined grid points after the dimensions of the slot were changed methodically. The frequency spectrums of measured vibrations were calculated by using the Fast Fourier Transformation (FFT). The sums of the squares of the differences (SSD) of the spectrums were calculated to evaluate the change of the spectrums. The SuRE method was able to determine if the dimensions were changed in each case at all the selected points. The scanning laser vibrometer is not feasible to be used at the shop floor. However, the study demonstrated that a piezoelectric element attached to any of the grid points would be able to evaluate the completed machining process.

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Authors and Affiliations

  1. Mechatronics Research Laboratory, Mechanical and Materials Engineering Department, Florida International University, 10555 W Flagler Street EC3420, Miami, FL, USA

    Hadi Fekrmandi, Amin Baghalian, Shervin Tashakori, Kathleen Oyola, Abdullah Alsenawi & Ibrahim Nur Tansel

  2. Department of Electronics & Computer Education, Marmara University, Goztepe Campus, Kadikoy, Istanbul, Turkey

    Muhammad Unal

Authors
  1. Hadi Fekrmandi
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  2. Muhammad Unal
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  3. Amin Baghalian
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  4. Shervin Tashakori
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  5. Kathleen Oyola
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  6. Abdullah Alsenawi
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  7. Ibrahim Nur Tansel
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Correspondence to Hadi Fekrmandi.

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Fekrmandi, H., Unal, M., Baghalian, A. et al. A non-contact method for part-based process performance monitoring in end milling operations. Int J Adv Manuf Technol 83, 13–20 (2016). https://doi.org/10.1007/s00170-015-7523-2

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  • DOI: https://doi.org/10.1007/s00170-015-7523-2

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