In an effort to increase machining efficiency and minimize costs, research into tool condition monitoring (TCM) systems has focused on developing methods to allow for unmanned machining. For drilling processes, such systems typically use indirect approaches to monitoring the tool condition by measuring spindle torque and feed force as well as vibrations including acoustic emission (AE – mechanical vibrations faster than 100 kHz). This project aimed to advance the state-of-the-art in the area of TCM by developing a method to detect sudden tool failures in large diameter (> 25 mm) indexable insert drills. This project was a continuation of the research conducted by Mr. R. Griffin (a former MSc student), who developed a model capable of predicting long term wear trends in indexable insert drills [1]. Notably, his model was unable to react to sudden tool breakage due to tool chipping, which was addressed by this project as presented in this thesis. In order to develop and train models able to detect sudden tool failure, an experiment was developed and installed in the field of the industry partner of this project. The experiment’s main feature was a pair of AE sensors added to the existing torque and force sensors. On this setup, experiments were conducted by drilling 2251 holes in workpieces using indexable insert drills with or without the insert breaking. When drilling holes without the insert breaking, the holes were named as good ones; and when drilling holes with the insert breaking they were named as bad holes. During the drilling process, data was collected from current sensors attached to the spindle motor and feed motor as well as from an AE sensor on the spindle and on the workpiece. From the signals from the spindle motor current and feed motor current sensors, algorithms were developed to identify and divide the signals of drilling a hole into different sections of the drilling cycle (i.e. entrance, steady-state, exit, etc.). Steady-state time-domain features were extracted from the sensor signals measured for all holes drilled in the experiments and the extracted features were used to train and test the classifier models. These models were cross validated to determine which type of model was the best fit for the drilling data collected. The results from the classifier models show that most of the classifiers tested have the ability to identify sudden tool breakage based on the data recorded in the present study, with varying degrees of success. The naïve Bayes classifier was able to detect the most failures but suffered from a large number of falsely detected failures. Both the classification tree and linear discriminant analysis classifiers had lower failure detection rates than the naïve Bayes classifier, but did not suffer from the same amount of false positives; as such, these two classifiers had higher overall classification rates than the naïve Bayes. These results suggest that classification tree and linear discriminant analysis methods are better suited for the drilling application and that the time-domain features should be complemented by others, such as the features extracted from the frequency domain, to accurately diagnose the tool condition. Future research should focus on extracting frequency and time-frequency domain features as these features might contain more information on tool condition. In addition, methods of examining features at the entrance and exit of the holes should be investigated as these two points in the drilling cycle are the most prone to sudden tool failure.

This dissertation develops a robust, data-driven localization methodology based on the integration of matched field processing with compressed sensing ℓ1 recovery techniques and scale transform signal processing. The localization methodology is applied to an ultrasonic guided wave structural health monitoring system for detecting, locating, and imaging damage in civil infrastructures. In these systems, the channels are characterized by complex, multi-modal, and frequency dispersive wave propagation, which severely distort propagating signals. Acquiring the characteristics of these propagation mediums from data represents a difficult inverse problem for which, in general, no readily available solution exists. In this dissertation, we build data-driven models of these complex mediums by integrating experimental guided wave measurements with theoretical wave propagation models and ℓ1 sparse recovery methods from compressed sensing. The data-driven models are combined with matched field processing, a localization framework extensively studied for underwater acoustics, to localize targets in complex, guided wave environments. The data-driven matched field processing methodology is then refined, through the use of the scale transform, to achieve robustness to environmental variations that distort guided waves. Data-driven matched field processing is experimentally applied to an ultrasound structural health monitoring system to detect and locate damage in aluminum plate structures.

Multiphase flow is the simultaneous flow of two or several phases through a system such as a pipe. This common phenomenon can be found in the petroleum and chemical engineering industrial fields. Transport of sand particles in multiphase production has attracted considerable attention given sand production is a common problem especially to the oil and gas industry. The sand production causes loss of pipe wall thickness which can lead to expensive failures and loss of production time. Build-up of sand in the system can result in blockage and further hamper production. Monitoring of multiphase flow is a process that has been established over several decades. This thesis reports an assessment of the application of Acoustic Emission (AE) technology as an alternative online technique to monitoring of sand particles under multiphase flow conditions in a horizontal pipe. The research was conducted on a purpose built test rig with the purpose of establishing a relation between AE activity and sand concentration under different multiphase flow conditions. The investigation consisted of five experimental tests. The initial experiment was performed to provide a basis for the application of AE technology to detect sand particle impact prior to performing tests in multiphase flow conditions. Further investigations are reported on two phase air-sand, water-sand and air- water-sand three-phase flows in a horizontal pipe for different superficial gas velocities (VSG), superficial liquid velocities (VSL) and sand concentrations (SC). The experimental findings clearly showed a correlation exists between AE energy levels and multiphase flow parameters, such as superficial liquid velocity (VSL), superficial gas velocity (VSG), sand concentration and sand minimum transport condition (MTC).

To evaluate the state of health of the composite, a real-time, in-situ acoustic emission (AE) damage detection system has been developed, where the monitoring of AE activity emitted from within a carbon/epoxy composite material (CFRP) is achieved using an all-fibre Mach-Zehnder interferometric sensor. The basic Mach-Zehnder configuration was modified to achieve the sensitivity needed to detect the low amplitude signals associated with AE. An active homo dyne feedback loop was employed to maintain quadrature, whereas polarisation controllers ensured that the state of polarisation of the guided beams were equal. Two additional components were included in the AE detection system; fibre collimators and a demountable composite test section. The fibre collimators adjusted the optical path length in one of the arms of the interferometer to help maintain system sensitivity from test to test. The demountable test section ensured ease of testing, without the need for continual fusion splicing. The characterisation of the fibre optic sensor was achieved by an analysis of its response to known acoustic disturbances. The fibre optic sensors response to continuous and transient acoustic excitation sources demonstrated the feasibility of using an embedded fibre optic Mach-Zehnder interferometric sensor for the evaluation of composite materials. The sensor's potential for non-destructive evaluation (NDE) was investigated by placing CFRP specimens with the embedded sensors under sufficient tension to cause damage. Signal analysis was performed on the detected AE data, using the time domain parameters and the cumulative event count. The change in the slope of the cumulative count curve coincided with the point where the accumulated damage seriously compromised the structural integrity of the sample. As a damage detection system the fibre optic sensor was adequate, however, the correlation of the time domain parameters with specific damage mechanisms proved inconclusive. Specially designed samples were manufactured to help the fibre optic sensor differentiate between mechanisms. Fibre optic sensor component failure resulted in the testing and analysis using the piezoelectric transducer only. Amplitude and frequency distribution analysis of the piezoelectrically detected signals from these specially designed composite samples was attempted. From the results, it was evident that a correlation could be made between some of the damage mechanisms and the detected AE signals. However, it was apparent that a mixing of distribution occurred in some of the tests. Despite this, the results obtained using the piezoelectric transducer highlighted the benefits of attempting these specially designed tests in future fibre optic sensor work.

The combined finite-discrete element method (FEM/DEM) has been used to simulate processes of brittle fracturing and associated seismicity. With the newly extended FEM/DEM algorithm, two topics involving rock mechanics and geophysics are investigated. In the first topic, a velocity-weakening law is implemented to investigate the initiation of frictional slip, and an innovative method that incorporates surface roughness with varying friction coefficients is introduced to examine the influences of surface roughness. Simulated results revealed detailed responses of stresses to the propagation of the slip front. In the second topic, acoustic activities induced in confined compression tests are simulated and quantitatively studied using the internal monitoring algorithm in FEM/DEM. It is shown that with increasing confinement, AE events are spatially more concentrated and temporally more separated, accompanied by a decreasing b-value. Moreover, interesting correlation between orientations of cracks and the mechanical behavior of the rock was observed.

The combined finite-discrete element method (FEM/DEM) has been used to simulate processes of brittle fracturing and associated seismicity. With the newly extended FEM/DEM algorithm, two topics involving rock mechanics and geophysics are investigated. In the first topic, a velocity-weakening law is implemented to investigate the initiation of frictional slip, and an innovative method that incorporates surface roughness with varying friction coefficients is introduced to examine the influences of surface roughness. Simulated results revealed detailed responses of stresses to the propagation of the slip front. In the second topic, acoustic activities induced in confined compression tests are simulated and quantitatively studied using the internal monitoring algorithm in FEM/DEM. It is shown that with increasing confinement, AE events are spatially more concentrated and temporally more separated, accompanied by a decreasing b-value. Moreover, interesting correlation between orientations of cracks and the mechanical behavior of the rock was observed.

Thesis (Ph. D.)--Auburn University. / Abstract. Vita. Includes bibliographical references (p. 202-209).

Mémoire (M.Ing.)--Université du Québec à Chicoutimi, 2000. / Document électronique également accessible en format PDF. CaQCU

Η παρούσα διπλωματική εργασία αποτελεί βιβλιογραφική έρευνα πάνω στο επιστημονικό αντικείμενο της Ακουστικής Εκπομπής (ΑΕ) σαν μια από τις μεθόδους του Μη Καταστροφικού Ελέγχου (ΜΚΕ) και υλοποίηση της μεθόδου εντοπισμού της θέσης πηγής ΑΕ στο προγραμματιστικό περιβάλλον Matlab. Στην εργασία γίνεται αναφορά στις πιο διαδεδομένες μεθόδους του ΜΚΕ, στα πλεονεκτήματα της ΑΕ έναντι των άλλων μεθόδων. Γίνεται παρουσίαση των τεχνικών της ΑΕ, με βάση την ιστορική εξέλιξή της, από την συμβατική τεχνική που αξιοποιεί κάποιες παραμέτρους του σήματος, για την «ποιοτική» εκτίμηση της καταπόνησης του υλικού, μέχρι τις σύγχρονες τεχνικές που αξιοποιούν τις υπολογιστικές ικανότητες που προσφέρουν οι Θ/Τ δίνοντας τη δυνατότητα για μια περισσότερο «ποσοτική» εκτίμηση του μεγέθους και του είδους της αστοχίας. Γίνεται αναφορά στη θεωρία της διάδοσης των κυμάτων σε λεπτές πλάκες, ακρογωνιαίο λίθο της επεξεργασίας των σημάτων με πιο εξελιγμένες υπολογιστικές μεθόδους στο πεδίο του χρόνου και της συχνότητας. Παρουσιάζεται η εφαρμογή της θεωρίας της διάδοσης των κυμάτων στα σύνθετα υλικά, των προβλημάτων που παρουσιάζει η τεχνική της ΑΕ σε αυτά, καθώς και η αξιοποίηση των νευρωνικών δικτύων, στην χωρίς επίβλεψη αναγνώριση του είδους της αστοχίας σε σύνθετα υλικά. Γίνεται αναφορά στον μετασχηματισμό κυματιδίου σαν τεχνική ανάλυσης των κυματομορφών της ΑΕ. Τέλος παρουσιάζεται το πρόβλημα του εντοπισμού της θέσης της πηγής της ΑΕ, όπου υλοποιείται η μέθοδος που αξιοποιεί τους χρόνους άφιξης του σήματος στους αισθητήρες για τον υπολογισμό της θέσης της πηγής. Αναφέρονται οι σημαντικότερες και πιο πρόσφατες εργασίες της διεθνούς βιβλιογραφίας και σχολιάζονται οι τεχνικές που χρησιμοποιούνται για την εξαγωγή συμπερασμάτων για το είδος και την θέση της αστοχίας. / The thesis is a search about the techniques of acoustic emission. It refers to algorithms for finding the source location af acoustis emission. Finally, a new algorithm made on MATLAB environment is introduced.

Στα πλαίσια της παρούσας διπλωματικής εργασίας πραγματοποιείται μελέτη και υλοποίηση μεθοδολογιών εντοπισμού Ακουστικής Εκπομπής (ΑΕ) στα πλαίσια του Μη Καταστροφικού Ελέγχου (ΜΚΕ). Αρχικά παρουσιάζονται οι γενικότερες κατηγορίες μεθόδων ΜΚΕ και γίνεται μια κριτική ανάλυση των δημοφιλέστερων. Επίσης γίνεται αναφορά στο φαινόμενο του πιεζοηλεκτρισμού καθώς και των βασικότερων χαρακτηριστικών των πιεζοηλεκτρικών αισθητήρων που χρησιμοποιούνται ευρέως για την μέτρηση σημάτων ΑΕ. Εν συνεχεία πραγματοποιείται μια εκτενής αναφορά στη μέθοδο της ΑΕ, παρουσιάζοντας τα πλεονέκτημα και μειονεκτήματα της μεθόδου, τον τρόπο παραγωγής και διάδοσης των ακουστικών κυμάτων, τα φαινόμενα της εξασθένισης και της ταχύτητας διάδοσης καθώς και τον απαραίτητο εξοπλισμό για την μέτρηση των σημάτων ΑΕ. Αναφέρονται τα είδη σημάτων ΑΕ, οι βασικές παράμετροι που χρησιμοποιούνται παραδοσιακά για τον εντοπισμό και ανάλυση αστοχιών καθώς και θεωρητικά μοντέλα για την προσομοίωση τέτοιων σημάτων στο Η/Υ. Εν συνεχεία αναλύεται το σημαντικό θέμα του εντοπισμού της θέσης της ακουστικής εκπομπής εξετάζοντας διάφορες μεθοδολογίες που έχουν αναπτυχθεί στην βιβλιογραφία. Οι μέθοδοι χρησιμοποιούν τους χρόνους άφιξης των σημάτων ή κάποιων χαρακτηριστικών αυτών για να υπολογίσουν την απόσταση αισθητήρων – πηγής και τελικά την θέση της πηγή. Τέλος παρουσιάζεται και αξιολογείται μεθοδολογία εντοπισμού της θέσης της ΑΕ υπολογίζοντας τους διαφορετικούς χρόνους άφιξης των φασματικών συνιστωσών του σήματος σε ένα αριθμό αισθητήρων. Αρχικά αναπτύχθηκε αλγόριθμος για τον υπολογισμό των χρόνων άφιξης των φασματικών χαρακτηριστικών χρησιμοποιώντας τα φίλτρα Goertzel. Ο αλγόριθμος υλοποιήθηκε σε υπολογιστικό μοντέλο (μέσω του λογισμικού MATLAB ) και αξιολογήθηκε για διαφορετικές θέσεις της πηγής. Σε κάθε περίπτωση η μέθοδος υπολογίζει με μεγάλη ακρίβεια τους χρόνους άφιξης των χαρακτηριστικών . Έχοντας μετρήσει τους χρόνους άφιξης οι κανονικοποιημένες αποστάσεις υπολογίζονται ελαχιστοποιώντας την συνάρτηση τετραγωνικού σφάλματος μεταξύ των πραγματικών χρόνων και των μετρούμενων χρόνων των φασματικών συνιστωσών και τέλος η ακριβής θέση της πηγής υπολογίζεται αναλυτικά ελαχιστοποιώντας την συνάρτηση τετραγωνικού σφάλματος μετρούμενων και πραγματικών αποστάσεων πηγής και αισθητήρων. Οι παραπάνω αλγόριθμοι υλοποιήθηκαν σε υπολογιστικά μοντέλα και αξιολογήθηκαν σε διάφορα υπολογιστικά πειράματα. Στα παραπάνω πειράματα δοκιμάζονται οι αλγόριθμοι για διαφορετικές θέσεις πηγής και αισθητήρων στο επίπεδο και τον χώρο. Επίσης αναλύεται η επίδραση του θορύβου των μετρήσεων προσθέτοντας λευκό Γκαουσιανό θόρυβο στις αρχικές παραμέτρους.Εδώ πρέπει να εξεταστεί η τροποποίηση του αλγορίθμου και η χρήση παραπάνω αισθητήρων για την μείωση της επίδρασης του θορύβου. / The objective of this thesis is the study and implementation of several methods for the Acoustic Emission (AE) source location. The thesis starts with a critical survey of several Non Destructive Testing (NDT) techniques as well as with a presentation of the basic characteristics of piezoelectric sensors. An extensive presentation of the AE method follows, including topics as the advantages and disadvantages of the method, acoustic emission sources and propagation of AE waves, attenuation and wave velocity, instrumentation. The different types of AE source signals as well as their basic parameters used to detect and identify several structural faults are reported. The methods of AE source location are analyzed. Most of methods use AE signals or signal characteristics Time of Arrival (TOA) to estimate the distances between the source and the sensors and finally the exact source location. Finally, an algorithm for calculation of TOA of several frequencies on different sensors is developed. The algorithm uses Goertzel filters on a moving window of the original signal to identify the TOA of different frequencies. Algorithm is implemented in MATLAB and its performance is evaluated using different source – sensors configurations. In all cases algorithm estimates with high accuracy the TOA . Based on the estimated TOA the normalized distances are estimated by minimizing the Sum of Square Errors (SSE) between the calculated and the real TOA and finally, the AE source location is estimated by minimizing the SSE between the calculated and the real distances between sensors and the AE source. The above algorithms are implemented in MATLAB as well, and their performance is evaluated for different configurations and noise levels.