Prof. Brinksmeier - Conference on Surface Integrity (CSI)

Process Signatures –
an Alternative Approach to
Predicting Functional Workpiece
Properties
Ekkard <strong>Brinksmeier</strong>
Ralf Gläbe
Fritz Klocke
Don A. Lucca
January 30 th , 2012
1 st CIRP <strong>Conference</strong> on Surface Integrity (CSI)
Glä 12/01/CIRP: 12/01/CIRP: 11

Machining is an energy based transformation process
INPUT PROCESS OUTPUT
machine
materials
(workpiece, tool)
lubricant
energy
many models
workpiece modification
macro geometry
surface‐/subsurface
f / b f
properties
very few models
some models
1 st CIRP <strong>Conference</strong> on Surface Integrity (CSI)
parts with
geometrical,
physical and
chemical h i l
properties
Glä 12/01/CIRP: 12/01/CIRP: 22

Evolution of manufacturing processes:
the early days
...
1950
1960
1970
1980
1990
2000
2010
2020
...
1956
O. Kienzle
geometrically driven concept
• the cornerstones of manufacturingg
O Kienzle: Die Grundpfeiler der Fertigungstechnik. in: VDI-
Zeitschrift 98, Nr. 23, Verein Deutscher Ingenieure, Düsseldorf,
1956: 1389–1395.
• consideration of geometrical properties
of components only
• workpiece material is considered as given by the designer
O Kienzle: Die Grundpfeiler der Fertigungstechnik. in: VDI-
Zeitschrift 98, Nr. 23, Verein Deutscher Ingenieure, Düsseldorf,
1956: 1389–1395.
Glä 12/01/CIRP: 3
1 st CIRP <strong>Conference</strong> on Surface Integrity (CSI)

Evolution of manufacturing processes:
late 1960ies: from macro‐ to micro‐geometry
...
1950
1960
1970
1980
1990
2000
2010
2020
...
late
1960ies
micro‐geometry of surfaces
• typology yp gy of surfaces
• measurement and characterization of surfaces
• functional behavior
• CIRP researchers
� H. von Weingraber
� R. van Hasselt
� W. de Bruin
� J. Peters
� D.J. Whitehouse
� P. Vanherck h k
D J Whitehouse, P Vanherck, W de Bruin, C A van Luttervelt.
Assessment of Surface Topology Analysis Technique in Turning .
CIRP Annals, Vol. 23, no. 2, 1974: 265-282.
Glä 12/01/CIRP: 12/01/CIRP: 44
1 st CIRP <strong>Conference</strong> on Surface Integrity (CSI)

Evolution of manufacturing processes:
view on Surface Integrity
...
1950
1960
1970
1980
1990
2000
2010
2020
...
M.Field investigations into surfaces and
functional properties
1971
J. Kahles
fti fatigue strength t th=
f (max. residual stress)
definition of Surface Integrity
Surface Integrity can be defined as the entirety of inherent and
enhanced properties of a surface. It involves a study and control of
topography and metallurgy of surfaces that can be generated by
machining or other operations.
M Field, J Kahles: Review of surface integrity of machined
components. CIRP Annals, 20(2),1971: 153-163.
Glä 12/01/CIRP: 12/01/CIRP: 55
1 st CIRP <strong>Conference</strong> on Surface Integrity (CSI)

Evolution of manufacturing processes:
focus on machining and functional properties
...
1950
1960
1970
1980
1990
2000
2010
2020
...
K. Tönshoff
driver: highly stressed components
• accumulated data showed that all manufacturing g
processes have certain effects on the workpiece material
• DFG priority program on “Manufacturing and
Performance of Components Components” (1980 (1980‐1983) 1983)
• permanent issue of the
CIRP Scientific Technical
1980s Committee “S“ in the
late 1980s and the 1990s:
“Surface and Function“
J.B. Bryan
M. Field
J. Kahles
W. König
P. Leskovar
J. Peters
GG. Byrne
G. Spur
• CIRP collaborative work
of STC "S" on "residual
stress measurement"
measurement
E <strong>Brinksmeier</strong>, J T Cammett, W König, P Leskovar, J Peters, H K
Tönshoff: Residual Stresses — Measurement and Causes in Machining
Processes. CIRP Annals, Volume 31, Issue 2, 1982: 491–510. Glä 12/01/CIRP: 12/01/CIRP: 66
1 st CIRP <strong>Conference</strong> on Surface Integrity (CSI)

Evolution of manufacturing processes:
progress of measuring techniques
...
1950
1960
1970
1980
1990
2000
2010
2020
...
� �,�
��m�� m �
sin2�
M A MH
H
advances in X‐ray stress measurement
• E. Macherauch
• V. Hauk
• U. Wolfstieg
• BB. Scholtes
E Macherauch, P Müller: Das sin2�-Verfahren
der röntgenographischen Spannungsmessung, Z.
angew. Physik 13, 1961: 305-312.
advances in micro‐magnetic analysis
• WA W.A. Theiner
• B. Karpuschewski
high resolution techniques
• D.A. Lucca
• G. Gochh
• C. Evans
1 st CIRP <strong>Conference</strong> on Surface Integrity (CSI)
G Goch, B Schmitz, B Karpuschewski, J Geerkens,
MM. RReigl, i l P SSprongl, l R Ritt Ritter: RReview i of f nondestructive
measuring methods for the assessment
of surface integrity: a survey of new measuring
methods for coatings, layered structures and
processed surfaces. Precision Engineering, Volume
23, Issue 1, January 1999: 9–33.
D A Lucca, K Herrmann, M J Klopfstein:
Nanoindentation: Measuring methods and
applications. CIRP Annals STC S, 59/2/2010:
803-819.
Glä 12/01/CIRP: 12/01/CIRP: 77

Evolution of manufacturing processes:
modeling of grinding processes
...
1950
1960
1970
1980
1990
2000
2010
2020
...
S. Malkin
replacement of machining parameters by
energy related parameters
• critical specific energy for
the onset of grinding burn
rgy u
• combination of thermal
ene
equations (Carslaw/Jaeger)
since and process parameters
ecific
1978 spe
W.B. Rowe
M.C. Shaw
• prevention of
grinding burn
higher
temperature
u o
B
d 1/4 a ‐3/4 v ‐1/2
d 1/4
e ae
3/4
vw
1/2
S Malkin: Burning Limit for Surface and Cylindrical Grinding of
Steels. CIRP Annals, 27/1 (1978): 233–236.
W B Rowe, J A Pettit, A Boyle, J L Moruzzi: Avoidance of Thermal
Damage in Grinding and Prediction of the Damage Threshold. CIRP
Annals, Volume 37, Issue 1, 1988: 327-330.
1 st CIRP <strong>Conference</strong> on Surface Integrity (CSI)
Glä 12/01/CIRP: 12/01/CIRP: 88

Evolution of manufacturing processes:
significance of energy and specific power for surface integrity
...
1950
1960
1970
1980
1990
2000
2010
2020
...
E. <strong>Brinksmeier</strong>
1980ies
K. Tönshoff
W. Hetz
B. Karpuschewski
W. Heuer
residual stress = f (specific power)
+ � process 1 process 2 process 3 process 4
residdual
stress
‐ �
� �
targeted residual
stress level
�� reduction of converted power
� modification of heat distribution
specific grinding power P c“
E <strong>Brinksmeier</strong>: Prozess- und Werkstückqualität in der Feinbearbeitung.
Habilitationsschrift, Universität Hannover, VDI Verlag, Fortschritts-
Berichte VDI Reihe 2 Nr. 234, Düsseldorf, 1991.
Glä 12/01/CIRP: 12/01/CIRP: 99
1 st CIRP <strong>Conference</strong> on Surface Integrity (CSI)

Evolution of manufacturing processes:
significance of energy dissipation for the process
...
1950
1960
1970
1980
1990
2000
2010
2020
...
D.J. Stephenson
R. Komanduri
2000
2003
heat partitioning in machining processes
• Stephenson: p deep p ggrindingg T. Jin, , D.J. Stephenson: Investigation of the heat
partitioning in high efficiency deep grinding. International
Journal of Machine Tools and Manufacture. Volume 43, Issue 11,
September 2003:1129–1134.
• Komanduri: orthogonal process
R. Komanduri, , Z.B. Hou: Thermal modeling of the metal
cutting process: Part I — Temperature rise distribution due to
shear plane heat source source. International Journal of Mechanical
Sciences, Volume 42, Issue 9, September 2000: 1715–1752.
1 st CIRP <strong>Conference</strong> on Surface Integrity (CSI)
Glä 12/01/CIRP: 10 10

Evolution of manufacturing processes:
extended modeling of surface integrity
...
1950
1960
1970
1980
1990
2000
2010
2020
...
C. Heinzel
I.S. Jahawir
J.C. Outeiro
RR. M'S M'Saoubi bi
2005 ‐
2011
classified grind‐hardening results
speciffic
grindingg
power Pc“ 1000
W
2
mm
10
Pc '
W / mm
' � 25 �0.
15
2
t 0.
* ( )
s
� 74 � 4
1
001 0.01 010 0.10 100 1.00 10 10.00 00 s 1000 1000.00 00
heat exposure time Δt
C Heinzel: Schleifprozesse verstehen: Zum Stand der Modellbildung
und Simulation sowie unterstützender Methoden. Habilitationsschrift,
Universität i i Bremen, Shaker Verlag, Aachen, 2009 2009.
I S Jawahir, E <strong>Brinksmeier</strong>, R M'Saoubi, D K Aspinwall, J C Outeiro,
D Meyer, D Umbrello, A D Jayal: Surface Integrity in Material
Removal Processes: Recent Advances. CIRP Annals 60/2, 2011: 603-626.
1 st CIRP <strong>Conference</strong> on Surface Integrity (CSI)
Glä 12/01/CIRP: 11 11

CIRP collaborative work 2010:
residual stress at surface
...
1950
1960
1970
1980
1990
2000
2010
2020
...
2010
round robin test: residual stress at surface
• 12 participating p p ginstitutes
residual
stressees
�II at surfaace
800
MPa
400
200
0
-200
-400
-600
-800
-1000
Milling
Turning
Grinding
EDM
Fine Grinding
sets
max/min
ttargett Jawahir, I. S.; <strong>Brinksmeier</strong>, E.; M'Saoubi, R.; Aspinwall, D. K.;
Outeiro, J.C.; Meyer, D.; Umbrello, D.; Jayal, A. D.: Surface
Integrity in Material Removal Processes: Recent Advances. Annals
of the CIRP 60/2, , 2011, ,
Seite 603-626.
Glä 12/01/CIRP: 12 12
1 st CIRP <strong>Conference</strong> on Surface Integrity (CSI)

Evolutionary view on Surface Integrity
progres p ss
visio on
focus
macro‐/micro‐
macro /micro
geometry
surface and sub‐
surface properties
energy
conversion,
specific power
?
1 st CIRP <strong>Conference</strong> on Surface Integrity (CSI)
"state‐of‐the‐art"
conformance to design tolerances
case studies, surface and functional
properties
modeling and simulation of functional
properties p p independent p from
machining parameters
characterization/prediction /p of surface
integrity independent from individual
processes
Glä 12/01/CIRP: 13

Similar surface modifications achievable
by completely different processes
HV
thermal mechanical
grinding
wheel
v s
workpiece
induction hardening grind hardening deep rolling grind strengthening
HV HV HV
z
z
z
0
0
0
0
‐� ‐� ‐� ‐�
• different processes: similar surface layer properties
• workpiece material: does not know processes
• material reacts on thermal and mechanical exposure, resulting from the energy signature and the
generating dynamics of the process
1 st CIRP <strong>Conference</strong> on Surface Integrity (CSI)
v ft
v c
z
Glä 12/01/CIRP: 14 14

What is needed for a reliable prediction
of surface integrity after machining?
knowledge (at different scales) on
• energy conversion
• energy dissipation
• heat partitioning
• material response to physical/chemical process impact
• fundamental material data
focus on
• physical/chemical impact resulting from tool/workpiece
interactions
• characterization and classification of processes
regarding physical/chemical influencing parameters
� process signature
1 st CIRP <strong>Conference</strong> on Surface Integrity (CSI)
Glä 12/01/CIRP: 15 15

Required information to form the process signature
input process
output
• material
• tool
• kinematics
• energy
• system
quantities
energy gy energy gy material
conversion dissipation modification
causal sequence
1 st CIRP <strong>Conference</strong> on Surface Integrity (CSI)
modified surface
and near surface
region
� near surface
functional
properties
Glä 12/01/CIRP: 16 16

v c
Different processes can be described
by the same causal principles
tool
cutting
initial surface and
boundary layer
applied energy
mechanical
chemical
thermal
...
energy conversion and
dissipation
dissipative energy
friction energy
chem. binding energy
� structural modification
modified
surface and
near surface region
�� surface/sub‐surface properties
�� functional performance
1 st CIRP <strong>Conference</strong> on Surface Integrity (CSI)
acid
laser
laser
etching
v f
Glä 12/01/CIRP: 17 17

Can we identify characteristic process signatures
based on physical/chemical descriptions?
workpiece
material
main process impact
load
mechanical, thermal,
mechanical, thermal,
chemical chemical
process
process process signature
signature
signature
modified
surface / near
surface
functional
properties
1 st CIRP <strong>Conference</strong> on Surface Integrity (CSI)
application
component
with
function(s)
performance of component
Glä 12/01/CIRP: 18 18

How to develop a process signature?
input output
...
• material
• tool
• kinematics
• energy
• system
quantities
possible approach
• combination of selected methods for
combining input and output quantities
• physically/chemically based descriptions
of tool‐workpiece interactions
...
...
... .
1 st CIRP <strong>Conference</strong> on Surface Integrity (CSI)
modified surface
and near surface
region
� near surface
functional
properties
characteristic number
regression / transfer function
semantic description
energetic based values/functions
in‐/output values
Glä 12/01/CIRP: 19 19

How to develop a process signature? input
...
degree of
abstraction
small mechanisms
• material
• tool
• kinematics
• energy
• system
quantities
...
...
...
output
modified surface
and near surface
region
� near surface
functional
properties
abstraction level approach method application area
di direct physical h i l/ /chemical h i l analytic, l i
modeling
FEM
small ll –
iindirect di tphysical h i l characteristic
h t i ti
mechanisms/system
medium
/chemical modeling number
medium mechanisms/system
high system
quantitative cause cause‐and‐ and
effect relationship
qualitative cause cause‐and‐ and
effect relationship
1 st CIRP <strong>Conference</strong> on Surface Integrity (CSI)
regression,
transfer
function
semantic
process analysis
process analysis, l i
process signature
Glä 12/01/CIRP: 20 20

Comparable mechanisms in machining and use of a component
workpiece
material
main process impact
mechanical, thermal,
chemical
process
process signature
modified
surface / near
surface
functional
properties p p
load
mechanical, thermal,
chemical
application
solution of "inverse inverse problem"? problem ?
1 st CIRP <strong>Conference</strong> on Surface Integrity (CSI)
component
with
function(s)
functional signature ?
Glä 12/01/CIRP: 21 21

Evolutionary view on Surface Integrity
progres p ss
visio on
focus
macro‐/micro‐
macro /micro
geometry
surface and sub‐
surface properties
energy
conversion,
specific power
process
signature
1 st CIRP <strong>Conference</strong> on Surface Integrity (CSI)
"state‐of‐the‐art"
conformance to design tolerances
case studies, surface and functional
properties
modeling and simulation of functional
properties p p independent p from
machining parameters
characterization/prediction /p of surface
integrity independent from individual
processes
Glä 12/01/CIRP: 22

Conclusion
progress
vision
input
• material
• tool
• kinematics
• energy
• system
quantities
workpiece
material
focus
macro‐/micro‐
geometry
surface and sub‐
surface properties
energy
conversion,
specific power
process
signature
"state‐of‐the‐art"
conformance to design tolerances
case studies, surface and functional
properties
modeling and simulation of functional
properties p p independent p from
machining parameters
description of surface integrity
independent from specific process
...
...
...
...
main process impact
load
mechanical, thermal,
mechanical, thermal,
chemical chemical
process
process signature
modified
surface / near
surface
functional
properties
application
output
modified surface
and near surface
region
� near surface
functional
properties g
component
with
function(s)
functional signature ?
solution of "inverse problem"?
• next step in machining process abstraction is required
• proposed approach: process signature
• requirements
• physical/chemical description of machining processes
• advanced d dmethods th d ffor iin‐process dt determination i ti of f
temperatures and forces
• innovative methods for modeling and for combining g
models (e.g. multi‐physical, multi‐scale)
• multi‐scale material characterization
• innovative methods for combining energy based
heterogeneous information
�� vision
inverse engineering of functional surfaces
1 st CIRP <strong>Conference</strong> on Surface Integrity (CSI)
Glä 12/01/CIRP: 23 23

Thank you!
1 st CIRP <strong>Conference</strong> on Surface Integrity (CSI)
Glä 12/01/CIRP: 24 24