A sobreposição de frequências ultrassônicas a uma ferramenta em operações de perfuração, utilizando transdutores piezelétricos, resulta em melhorias na usinagem de metais, garantindo melhor acabamento (ausência de rebarba), redução do tamanho do cavaco e menor desgaste ferramental. A utilização desse tipo de técnica na perfuração de rochas reduz a carga axial e aumenta a velocidade do processo, possibilitando maior profundidade de perfuração, podendo vir a ser muito útil em pesquisas aplicadas à perfuração de reservas petrolíferas e exploração mineral. Este trabalho teve como objetivo simular e aplicar um transdutor piezelétrico ultrassônico de potência para perfuração de rochas e metais. Para as simulações numéricas duas técnicas foram utilizadas: o método dos elementos finitos (MEF) e o método das matrizes em cadeia (MMC). O MEF permitiu análises harmônicas e modais de forma rápida e precisa enquanto o MMC resultou em expressão analítica, possibilitando melhor compreensão dos parâmetros físicos e geométricos envolvidos na performance do transdutor. Ambos os métodos nortearam o projeto do protótipo a ser usado em ensaios de perfuração. Para a construção do protótipo, foi projetado um mandril para a fixação da broca, que foi adaptado a um transdutor de potência de 20 kHz. Ensaios de perfuração de rochas e de discos de alumínio foram realizados com o protótipo. A aplicação do protótipo à perfuração de rochas carbonáticas demonstrou redução no tempo de furação, quando comparada ao método convencional (sem aplicação de ultrassom). Na furação de discos de alumínio, a redução de rebarbas, quebra do cavaco durante a operação e melhor acabamento da peça, são conclusões evidentes das melhorias proporcionadas pela sobreposição de frequências ultrassônicas à broca. / Superposition of high frequency vibration in the tool, driven by a piezoelectric actuator, in a drilling machining process of metals results in some improvements such as finishing quality (without burr), reduction of tool wear and chip dimensions. Similar techniques applied in rock perforation reduce the axial load in the tool, which enhances the process velocity, resulting in deeper perforation. This might be useful in oil and mineral exploration, opening the feasibility of researches in this field. The aim of this work is to simulate and implement an ultrasonic piezoelectric transducer to perforate rocks and metals. Concerning numerical simulation, two techniques were performed: finite element method (FEM) and chain matrix method (CMM). FEM simulations provide fast and effective modal and harmonic analysis. CMM provide mathematical expressions, analytically exposing geometrical and physical parameters involved in the transducer performance. Both methods were the guide and basement for the prototype project, able to perform perforation experiments. For the construction of the prototype, a drill chuck were designed and adapted for a 20 kHz power ultrasonic transducer. Aluminum drilling and rock perforation experiments were carried out with this prototype. A lower perforation time was achieved in carbonate rocks when the ultrasound-aided method was used as opposed to the conventional method. Results in aluminum disks presented burr reduction, better part finishing and breakage of chips during operation. Those results evidently appoint some improvements due to the power ultrasonic superposition in the drilling process.

Plusieurs industries manipulent des substances liquides et gazeuses qui circulent souvent dans de longues canalisations. La technique d'ondes guidées est couramment utilisée dans ce domaine. Cette technique est en progrès continu. Dans cette thèse, un système d'inspection a été conçu et développé. Il est basé sur des transducteurs piézoélectriques qui génèrent des ondes guidées de torsion pouvant se propager le long du tube testé. Les signaux réfléchis des défauts et singularités rencontrés sont détectés aussi par des capteurs piézoélectriques. Des simulations numériques utilisantpar la méthode d'éléments finis standard et la méthode Wave Finite Element(WFEM) ont été effectuées afin de vérifier et de visualiser le phénomène de propagation des ondes dans des tubes intacts et endommagés. Un ensemble de tests a été mis en place sur des tubes droits et courbés avec deux matériaux différents: PVC et acier. L'interaction entre les ondes générées et les défauts usinés a été prouvée.Les résultats numériques et expérimentaux confirment certaines caractéristiques spécifiques concernant le coefficient de réflexion de l'onde. Par la suite, un pipeline industriel d'environ soixante mètres de long et contenant plusieurs défauts et singularités a été testé par le système d'inspection. Les signaux enregistrés ont soumis certains traitements numériques afin de les rendre exploitables. Les signaux traités sont analysés afin d'identifier et de distinguer les réflexions des défauts de celles des singularités structurés. La méthode WFEM a été employée pour construire une base de données numérique des coefficients de réflexion en variant la profondeur et les extensions axiale et circonférentielle du défaut modélisé. Le calcul a été établi en fonction de la fréquence. La corrélation des tailles des défauts est effectuée en balayant la base de données numérique pour trouver la combinaison appropriée de dimensions pour un défaut donné. Les réflexions à partir des singularités structurées (coudes, blocs de béton, colliers, et les soudures) sont traitées ainsi en comparant des coefficients de réflexion obtenus par WFEM à ceux évalués expérimentalement. Enfin, on a étudié numériquement l'effet de la position angulaire d'un défaut sur les coefficients de réflexion et de transmission tout en excitant à différents types d'ondes. La méthode WFE est aussi utilisée pour effectuer le calcul. Cette étude donne un guide à la localisation circonférentielle des défauts dans les tubes. / Long pipelines are widely used in several industries transporting liquid or gas. The guided wave technique is commonly used in this field and it is under continuing progress. In this thesis, an inspection system has been designed and developed. Piezoelectric transducers are employed to generate torsional guided waves that could propagate along the tested pipe; and receive reflected signals from encountered features and damages. Numerical simulations using standard FE and Wave Finite Element methods have been carried out in order to verify and visualize the wave propagation phenomenon in both intact and damaged pipes. A set of tests has been performed on straight and curved pipes with two different materials: PVC and steel. The interaction between generated waves and machined defects has been proven. Numerical and experimental results confirm some specific features in the wave reflection coefficient. Thereafter, an industrial pipeline of about sixty meters long and containing several features has been tested by the inspection system.Recorded signals had submitted some numerical treatments in order to make them interpretable. Processed signals are analyzed to identify defects reflections from structured singularities echoes. The Wave Finite Element Method (WFEM) has been used to construct a numerical database of reflection coefficients from modelled defects by varying thickness, axial and circumferential extents. Calculation was made depending on frequency. The approximation of defect sizes is carried out by sweeping the numerical database to find the suitable combination of dimensions fora given defect. Reflections from structural singularities (elbows, concrete blocks,clamps, and welds) are treated as well by comparing reflection coefficients obtained by WFEM to those evaluated experimentally. Finally, a numerical investigation deals with the effect of defect angular-position on reflection and transmission coefficients while exciting by different types of waves. The spectral method Wave Finite Element has been used to carry out calculation. This study gives guidance to circumferential localization of defects in pipes.

<p align="justify">Many different active control techniques can be used to control the vibrations of a mechanical structure: they however require at least a sensitive signal amplifier (for the sensor), a power amplifier (for the actuator) and an analog or digital filter (for the controller). The use of all these electronic devices may be impractical in many applications and has motivated the use of the so-called shunt circuits, in which an electrical circuit is directly connected to a transducer embedded in the structure. The transducer acts as an energy converter: it transforms mechanical (vibrational) energy into electrical energy, which is in turn dissipated in the shunt circuit. No separate sensor is required, and only one, generally simple electronic circuit is used. The stability of the shunted structure is guaranteed if the electric circuit is passive, i.e. if it is made of passive components such as resistors and inductors.</p><p><p><p align="justify">This thesis compares the performances of the electric shunt circuits with those of classical active control systems. It successively considers the use of piezoelectric transducers and that of electromagnetic (moving-coil) transducers.</p><p><p><p align="justify">In a first part, the different damping techniques are applied on a benchmark truss structure equipped with a piezoelectric stack transducer. A unified formulation is found and experimentally verified for an active control law, the Integral Force Feedback (IFF), and for various passive shunt circuits (resistive and resistive-inductive). The use of an active shunt, namely the negative capacitance, is also investigated in detail. Two different implementations are discussed: they are shown to have very different stability limits and performances.</p><p><p><p align="justify">In a second part, vibration isolation with electromagnetic (moving-coil) transducers is introduced. The effects of an inductive-resistive shunt circuit are studied in detail; an equivalent mechanical representation is found. The performances are compared with that of resonant shunts and with that of active isolation with IFF. Next, the construction of a six-axis isolator based on a Stewart Platform is presented: the key parameters and the main limitations of the system are highlighted.</p> / Doctorat en Sciences de l'ingénieur / info:eu-repo/semantics/nonPublished

Ce manuscrit présente une méthode d’imagerie quantitative et sans état de référence, de défauts de corrosion d’une plaque mince, exploitant de manière passive un réseau embarqué de capteurs d’ondes élastiques guidées. Les applications visées sont le contrôle santé intégré (SHM) de structures critiques qui amènent de fortes contraintes à la fois d’intrusivité des capteurs et de fiabilité du diagnostic. Une solution prometteuse, permettant de multiplier la densité de points de mesure sans augmenter l’intrusivité du système, est offerte par les réseaux de Bragg sur fibre optique (FBG). Toutefois, contrairement aux transducteurs piézoélectriques (PZT) classiquement employés en SHM, les FBG ne permettent pas d’émettre d’ondes élastiques. L’idée consiste à utiliser des méthodes dites « passives » permettant de retrouver la fonction de Green entre deux capteurs à partir du bruit ambiant, naturellement présent dans la structure, mesuré simultanément entre ces deux capteurs. Nous étudions dans ce manuscrit deux méthodes passives : la corrélation de bruit et le filtre inverse passif. Nous verrons que ce dernier a plus de potentiel lorsqu’il est couplé à l’imagerie par tomographie. Différents algorithmes de tomographie sont évalués par simulation numérique puis lors d’expériences comparatives actives et passives à l’aide d’un réseau de PZT. Afin de rendre la tomographie passive robuste, nous présentons une méthode clé de détection de temps de vol, basée sur une représentation temps-fréquence. Enfin, nous décrivons une première démonstration expérimentale de mesures passives par FBG qui laisse à penser que la tomographie passive par FBG est prometteuse. / This manuscript presents a baseline-free quantitative method for the imaging of corrosion flaws present in thin plates. This method only requires an embedded guided waves sensors network in a fully passive way. The field ofapplications are Structural Health Monitoring (SHM) of critical structures with heavy constrains on both sensors intrusiveness and diagnostic reliability. A promising solution allowing to increase the number of measurement points without increasing the intrusiveness of the system is provided by the Fiber Bragg Gratings (FBGs). However, unlike piezoelectric transducers generally used in SHM, the FBGs cannot emit elastic waves. The idea consists in using passive methods in order to retrieve the Green function from elastic diffuse fields - naturally present in structures - measured simultaneously between two sensors. In this manuscript, two passive methods are studied: the ambient noise correlation and the passive inverse filter. It is shown that the latter gives better results when coupled with tomography. Several tomography algorithms are assessed with numerical simulations and then applied to active and passive datasets measured by a PZT network. In order to make passive tomography robust, a time of flight identification method is proposed, based on a time-frequency representation. Finally, a novel experimental demonstration of passive measurements with FBGs only is presented, suggesting high potential for FBGs passive tomography.

Ultra low power wireless sensors and sensor systems are of increasing interest in a variety of applications ranging from structural health monitoring to industrial process control. Electrochemical batteries have thus far remained the primary energy sources for such systems despite the finite associated lifetimes imposed due to limitations associated with energy density. However, certain applications (such as implantable biomedical electronic devices and tire pressure sensors) require the operation of sensors and sensor systems over significant periods of time, where battery usage may be impractical and add cost due to the requirement for periodic re-charging and/or replacement. In order to address this challenge and extend the operational lifetime of wireless sensors, there has been an emerging research interest on harvesting ambient vibration energy. Vibration energy harvesting is a technology that generates electrical energy from ambient kinetic energy. Despite numerous research publications in this field over the past decade, low power density and variable ambient conditions remain as the key limitations of vibration energy harvesting. In terms of the piezoelectric transducers, the open-circuit voltage is usually low, which limits its power while extracted by a full-bridge rectifier. In terms of the interface circuits, most reported circuits are limited by the power efficiency, suitability to real-world vibration conditions and system volume due to large off-chip components required. The research reported in this thesis is focused on increasing power output of piezoelectric transducers and power extraction efficiency of interface circuits. There are five main chapters describing two new design topologies of piezoelectric transducers and three novel active interface circuits implemented with CMOS technology. In order to improve the power output of a piezoelectric transducer, a series connection configuration scheme is proposed, which splits the electrode of a harvester into multiple equal regions connected in series to inherently increase the open-circuit voltage generated by the harvester. This topology passively increases the rectified power while using a full-bridge rectifier. While most of piezoelectric transducers are designed with piezoelectric layers fully covered by electrodes, this thesis proposes a new electrode design topology, which maximizes the raw AC output power of a piezoelectric harvester by finding an optimal electrode coverage. In order to extract power from a piezoelectric harvester, three active interface circuits are proposed in this thesis. The first one improves the conventional SSHI (synchronized switch harvesting on inductor) by employing a startup circuitry to enable the system to start operating under much lower vibration excitation levels. The second one dynamically configures the connection of the two regions of a piezoelectric transducer to increase the operational range and output power under a variety of excitation levels. The third one is a novel SSH architecture which employs capacitors instead of inductors to perform synchronous voltage flip. This new architecture is named as SSHC (synchronized switch harvesting on capacitors) to distinguish from SSHI rectifiers and indicate its inductorless architecture.

Structural Health Monitoring (SHM) systems for future structures and vehicles would involve a process of damage identification and prediction of certain quantities of interest that concerns the function and safety. This process provides SHM systems the ability to not only save cost but also enhance the service life, safety and reliability of the structures and vehicles. Integrated SHM system (ISHM) is an advancement of SHM system that has additional capability of predicting the component life/failure. ISHM system development involves detailed understanding of diagnostic waves, hardware components, signal processing paradigms and intelligent use of algorithms. Diagnostic waves like the guided waves are the elastic waves that propagate in a direction defined by the material boundaries. These waves have the capability of traveling large distance probing the entire thickness in plates/shells. Thus, they are widely used by SHM systems in monitoring the plate structures. Piezoelectric transducers are often employed in the interrogation using guided waves. Most SHM systems employing guided waves are designed for specific structures. Current paradigms of SHM systems are unable to enable the transition from simple or ideal structures to realistic and complicated structures. This is due to the challenges at the fundamental level involving transducer, wave propagation and phenomena of guided wave scattering with damages to evaluate the possible solutions through mathematical modeling and signal analysis capability required by ISHM systems. This thesis aims to develop understanding of these problems at a fundamental level. Complex system level understanding is still needed which is left out as open problem. A primary requirement in designing SHM system is the proper understanding of wave characteristics such as number of modes, wavelength and dispersiveness. Although three-dimensional elasticity solution and simplified theories are available to understand them, their applicability in SHM problem requires a much more detailed look. Effort toward this direction has led to the development of simpler models. However, mathematical models are not available for understanding the wave characteristics in complex structures involving stiffeners and adhesive joints. This problem is addressed in this thesis. There is a fair amount of understanding developed regarding transducer characteristics. This is accomplished by analytical and finite element models of transducers in the past. However, simplified transducer model that are computationally fast to suit SHM system requirements needs to be developed. The development of such model is presented in this thesis. Apart from modeling the transducers and wave scattering due to damage, signal correlation and calibration are needed for practical implementation in SHM. Characterization studies reported in published literature are limited to quasi-static and low frequencies applications. However, SHM of aerospace structures employ guided waves typically in the frequency range of 100-500 kHz. Methods to characterize the transducers at this frequency range needs to be developed, which is addressed in this thesis. Another major requirement of SHM system is the design and development of sensor-actuator network and appropriate algorithm. Techniques developed earlier involving transducer arrays in this regard have limitation due to complexity of geometry and signal interpretation that needs to be addressed. The network with suitable algorithm should ideally monitor large area including the critical areas of failure with minimum number of transducers. ISHM systems further require some capability to estimate the useful life of the damaged structure in order to take suitable decisions. Efficient techniques to achieve these are not developed. Overall, there is a need to improve highly interdisciplinary areas involving mathematical modeling, transducer design, fabrication and characterization, damage detection and monitoring strategies. In this thesis, various novel techniques to combine mathematical model with experimental signals to enhance the damage detection capability are presented. In this thesis, developments in the three main aspects of SHM systems are focused upon. They are (1) development of mathematical models of sensors/actuators, wave propagation and scattering due to damage (2) characterization and calibration of transducers and (3) development of technique to monitor wide variety of damages within the scope of ultrasonic guided wave based SHM. The thesis comprises of ten chapters. First chapter is devoted to the background and motivation for the problem addressed in this thesis. In second chapter, brief overview of available mathematical models and conventional damage monitoring strategy is presented. The significant contributions reported in the subsequent chapters in this thesis are outlined below In chapter 3, a reduced-order model of guided wave propagation in thick structures with reduced-order approximation of higher-order elasto-dynamic field is formulated. The surface normal and shear tractions of the thick structure are satisfied in a closed form. The time-frequency Fourier spectral finite element is developed and is validated using detailed and computationally intensive finite element simulations. Natural frequencies obtained from the developed spectral finite element and the detailed finite element simulations are compared. Transient response due to broad frequency band and narrow frequency band excitations given in the form of surface tractions are validated by comparing with the detailed finite element simulations. Using the developed spectral finite element, wave scattering from a free edge and a notch are simulated and validated by comparing with the detailed finite element simulations. In chapter 4, two-dimensional plane wave and flexural wave scattering models for more complicated features such as stiffener with delamination and stiffener with bolt failures in a stiffened panel are derived using ultrasonic ray tracing based approach combined with wave-field representation. Dispersion relations are reformulated for the base plate where it is bolted with the stiffener. Surface conditions due to contact stiffness and contact damping are modeled by introducing springs and dampers. Scattering coefficients for the bonded and bolted stiffeners are derived. The scattering coefficients are evaluated for various different frequencies. Results are compared for different stiffener parameters. In chapter 5, a simplified analytical model of a piezoelectric actuator with uniform electrodes is modeled. The problem is to determine the launched guided wave characteristics in the structure. The analytical model is derived considering two-dimensional elasticity based approach and Airy’s stress function. The actuator model is used to specify the displacement boundary conditions in the detailed finite element model. The radiated wave patterns in a plate due to actuation from transducers of different shapes are obtained and validated with experiments. Phased array actuators are modeled in the detailed finite element model using the displacements estimated from the actuator model. The radiated wave pattern from the detailed finite element simulations are validated with experiments. Chapter 6 is devoted to the design and characterization of transducers for ultrasonic guided wave applications. The characterization techniques involve the estimation of voltage response for the induced strain by the guided wave at various different frequencies. First, a novel removable bonding technique and a calibration technique are demonstrated and related advantages are discussed. Performance of the piezoelectric thin film under quasi-static, dynamic and transient impact loadings are analyzed first. Next, a guided wave technique is developed to characterize piezoelectric thin film sensors and actuators at ultrasonic frequencies. The transducers with inter digital electrodes are characterized for frequency tuning and directional sensitivity. This characterization study enables in the selection of optimal frequency bands for interrogation. Further, the characterization of transducers with thermal degradation is presented. In chapter 7, a novel guided wave technique to calibrate the thin film sensors for ultrasonic applications is presented. Calibration procedure involves the estimation of the piezoelectric coefficient at ultrasonic range of frequencies. Calibration is done by the measurement of voltage generated across thin films when guided waves are induced on them. With the proposed technique, piezoelectric coefficient can be estimated accurately at any frequency of the propagating wave. Similarly, the measurement of piezoelectric coefficient of thin films with inter digital electrodes is presented. The estimation of piezoelectric coefficient at various different directions using laser Doppler vibrometer is presented. Lastly, the degradation of piezoelectric coefficient is studied for increasing thermal fatigue. In chapter 8, toward SHM methodology development, a guided wave based technique to detect and monitor cracks in a structure is presented. To establish the methodology, a detailed study is carried out on the effect of crack and specimen size on the guided wave propagation characteristics. Using the wave characteristics, an analytical way of modeling Lamb wave propagation in the specimen with plastic zone is proposed. The feasibility to determine plastic zone and fatigue crack propagation with integrated piezoelectric transducers is demonstrated experimentally and the results are verified analytically. A method is further established to detect damage at initial stage and crack-tip plastic zone size along with crack length for a given stress amplitude or vice-versa. An approach to estimate fatigue life from the transducer signals is also proposed. In chapter 9, a compact circular array of sensor-actuator network and an algorithm is presented to monitor large plate structures. A method based on the wavelet transforms of transducer signals is established to localize and estimate the severity of damages. Experiments are conducted to demonstrate the capability of the circular array based method in the localization and quantification of various types of damages like debonding of stiffeners, failure of bolted joints, corrosion and hole-enlargement. A damage index is then computed from wavelet time-frequency map that indicates the severity of damage. Chapter 10 ends with the concluding remarks on the work done with simultaneous discussion on the future scope. The work reported in this thesis is interdisciplinary in nature and it aims to combine the modeling and simulation techniques with realistic data in SHM to impart higher confidence levels in the prediction of damages and its prognosis. The work also aims in incorporating various mathematical models of wave propagation and ray tracing based algorithm to optimize the detection scheme employed in SHM. The future direction based on this study could be aimed at developing intelligent SHM systems with high confidence levels so that statistical machine learning would be possible to deal with complex real-world SHM problems.