Project Title:Supervisory Control and Monitoring of

Microblanking Using Acoustic Emission

Project Supervisor: Dr. A RosochowskiCo-Supervisor: Prof. R Balendra

Research Student: Hisham Hamid

Research Presentation

Drug delivery system

Microrelays

Injection nozzles

PacOptical switches

Lab on a chip

Magneto-optical heads

Projection light valves

Inclinometer

Micromotors

Anti collision

Microvalves

Mature Products

Accelerometers

Pressure sensors

Inkjet printer heads

Microsystem

Markets

Growth Products Emerging Products

Disk drive heads

Chemical sensors

Hearing aids

In-vitro diagnostics

Pace makers

Infrared images

Gyroscopes

Microspectrometers

MST Markets

Hairsprings for clocks and watches Dimension: strip thickness 0.015mm

strip width 1mm

Micro screws

Micro ball bearingMicro connectors

Microparts

Micro Product Development

How do we make microparts???

Silicon etching – 95%

New Technologies

Micromilling

Micro EDM

Micro injection moulding

Laser ablation

Microforming

Forming Technology

Microforming

Microblanking

Microblanking

The operation of shearing sub-milimeter parts of a complete outline of a workpiece to a predetermined shape by die cutting the outside shape of the parts

Project defined

Producing sheet metal circular blanks, 0.3 mm in diameter and thickness. To ensure that products are competitive, the produced parts should be consistently of high quality. The blank edge quality is influenced by numerous process parameters such as punch-die clearance, tool wear, punch-die state, types of material, punch velocity and lubrication. Controlling the part quality manually is inadequate.

A process monitoring system for microblanking is introduced based on the acoustic emission signal generated during the process. Should the system sense abnormalities, it will stop the machine or prompt the operator to take action.

Project defined

Aim: To develop a monitoring and quality control system for microblanking

Objectives: To develop/acquire an appropriate press machine for microforming

To design and develop suitable tool system for microblanking

To select suitable materials for microblanking

To implement a microblanking operation

To extract features of the microblanking process signatures

To develop a monitoring system for microblanking operation

Thank you

Methodology

Acquire Micro formingMachine-Analysis-Purchase-Installation & Commissioning

Acquire Microblanking Tooling System-Design-Manufacture

Microblanking TrialsSelection of Materials-Classical metals-Ultra-fine grain metals

X-Y Translation Feeding System

Capture Process Signature

Force-Displacement Signature

Acoustic Emission

Processing of AE signals

Correlation of AE Results With Tool State

Statistical DOE to Capture the Effect of Tool State on Product Quality

Development of an Automated Monitoring System

Project Overview

Produce sheet metal circular blanks

-size 300 micrometer diameter and thickness

- material 304L austenitic stainless steel

On-line quality control

Production continue

No

Yes

Stop machine

Or

Alert operator

Microblanking operation

Blank edge quality is influence by:

•Punch-die clearance

•Tool wear

•Punch-die state

•Material

•Punch velocity

•Lubrication

Acoustic Emission

Technique

Supervisory Control and Monitoring of

Microblanking

AE Sensor

Preamplifier

AE Signal acquisition board

Signal analysis

Feature extraction

Decision-making

Punch

Blank holder

Stock material

Die

Experiment set-up

Bose-EnduraTec ELF 3300

AE Sensor and AE Acquisition Board

X-Y Translation Stages

MICRO BLANKING

TOOL SETS

Drawn by: Hisham Hamid

MERG Dmem Uni of strathclyde

Title: Micro Blanking Tooling – Overview of the Punches, Die, Guides and Components

SIZE FSCM NO DWG NO REV

SCALE Not to scale SHEET 1 OF 1

Micro Blanking DieMaterial – sheet metal

Curve Spring (S1)

Blank Holder – Lower Guide (G1)

Spring (S2)

Upper Guide (G2)

Spring (S3)

Circlip

Slide Punch Guide (G3)

Slide Punch (P2)

UpperPlate

MiddlePlate

BasePlate

Stainless Socket Head Cap Screw – M3 X 4

Tool Sets

Quality Control

Machines

Tools

MaterialsProcesses

Microforming System

Microforming System

Thank you

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