Process-integrated measuring and control system for the determination and reliable generation of functionally relevant properties in surface edge zones during BTA deep-hole-drilling

机加工工艺会影响部件的表面层，而表面层又决定了其在工作载荷下的性能。因此，期望知道由制造过程引起的金属材料中的表面层的状态，并且另外期望具体地控制它，以便产生改进的部件使用寿命或可靠性。这将在BTA深孔钻削工艺的项目中实现。因此，在该研究项目的第二阶段，计划开发基于巴克豪森噪声分析的微磁传感器系统，并将其应用于BTA钻头。在第一阶段成功地进行了测量方法的鉴定和升级。通过将传感器技术与回归模型相结合，在软传感器中，该回归模型尤其基于来自第一阶段的过程知识，正在开发和测试鲁棒过程控制。该过程控制允许以可再现的方式调节孔壁中的表面完整性。为此，应分析过程中出现的影响和干扰变量，并在控制中加以考虑。回归模型是基于实验获得的数据，以及从2D和3D-FEM的数据，以及分析模拟。此外，具体调整的功能特性的控制深孔进行了分析，在准静态和循环调查。为此，计划根据应力和载荷循环次数记录表层中的材料反应，以便能够对受控制造试样的残余应力和疲劳行为进行面向机制的表征。

Machining processes influence the surface layer of a component, which in turn determines its properties under operating loads. Therefore, it is desirable to know the state of the surface layer in metallic materials caused by the manufacturing process and, in addition, to control it specifically in order to produce an improved component service life or reliability. This is to be achieved within the project for the BTA deep hole drilling process. In the second phase of this research project, it is therefore planned, to develop a micromagnetic sensor system based on the analysis of Barkhausen noise and to implement it in the BTA drilling head. The qualification and upgrading of the measurement method were successfully carried out in the first phase. By combining the sensor technology with a regression model, which is based among other things on the process knowledge from the first phase, in a soft sensor, a robust process control is being developed and tested. This process control allows the adjustment of the surface integrity in bore walls in a reproducible manner. For this purpose, influencing and disturbance variables that occur in-process are to be analysed and taken into account in the control. The regression model is based on experimentally obtained data as well as on data resulting from 2D- and 3D- FEM-based as well as on analytical simulations. Furthermore, the specifically adjusted functional properties of the controlled deep holes are analysed in quasi-static and cyclic investigations. For this purpose, it is planned to record the material reactions in the surface layer depending on the stress and number of load cycles in order to enable a mechanism-oriented characterisation of the residual stress and fatigue behaviour of the controlled manufactured test specimens.