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On use of acoustic emission in monitoring of under and over abrasion during a water jet milling process

Mikler J.

Journal of Machine Engineering

2014

Vol. 14, No. 2

104--115

Water jet milling process is a new emerging technology with many interesting applications. Low cutting forces, no thermal distortion, process flexibility and ability to machine difficult to cut materials make it very attractive for many technological operations. However, its wider application is hindered by lack of proper solutions of process monitoring that would allow accurate control of the material removal process. The research contributions so far focused on use of acoustic emission, thus the purpose of this paper is an evaluation of the proposed strategies and analysis of applicability of acoustic emission for this purpose. An extensive amount of AE data was collected during waterjet machining with various feed rates, abrasive flows, and pump pressures, and analyzed with the aim to determine whether there exists any feature of the AE signal correlated with under- and over abrasion. Monitoring and control of removal rate is possible only if it is possible to discriminate between AE signal samples originating from different states of the abrasive process. In this paper I present results based on extensive one-way ANOVA study of the AE samples, showing, that the standard AE signal features proposed in the literature the energy and statistics of the AE signal do not allow such discrimination, and are not suitable to monitor abnormalities of the abrasive process. The research covers also principle component analysis of the AE signal energy performed in the aim to study if there exists any subset of the energy allowing better discrimination between the investigated process states.