Friction Sensing for Manufacturing Process Analysis and Control

制造过程、操作和产品质量在很大程度上取决于刀具和工件表面之间的摩擦。由于缺乏对制造操作极端环境中存在的摩擦边界条件的准确描述，复杂的数值过程分析受到阻碍。制造过程控制是基于对过程状态的测量，但重要的摩擦条件不能直接测量。提出了一种能够测量材料变形过程中摩擦应力分布的传感器的研究工作。传感器将有足够的分辨率来测量工艺工具上分布区域上的非常局部的摩擦影响。它的设计将使其对过程的影响降至最低，并在生产过程中有用。传感器的使用将在过程控制应用中进行演示。传感器的基本配置是一组微型压电力传感元件，其结构适合于工艺工具的表面以下。

Manufacturing process operation and product quality are determined in large part by the friction which acts between the tooling and workpiece surfaces. Sophisticated numerical process analyses are hindered by a lack of accurate descriptions of the frictional boundary conditions which exist in the extreme environments of manufacturing operations. Manufacturing process control is based on measurements of the states of processes, but the important frictional conditions cannot be directly measured. Research work is proposed to develop a sensor capable of measuring friction stress distributions in material deformation processes. The sensor will have sufficient resolution to measure very local friction effects over a distributed area on the process tooling. It will be designed so as to have minimal effect on the process and to be useful in production processes. The use of the sensor will be demonstrated in a process control application. The basic sensor configuration is an array of miniature piezoelectric force sensing elements in a structure which fits below the surface of process tooling.