Articles | Volume 6, issue 2
J. Sens. Sens. Syst., 6, 331–340, 2017
J. Sens. Sens. Syst., 6, 331–340, 2017

Regular research article 15 Sep 2017

Regular research article | 15 Sep 2017

Measuring strain during a cylindrical grinding process using embedded sensors in a workpiece

Mridusmita Sarma1, Florian Borchers2, Gerrit Dumstorff1, Carsten Heinzel2, and Walter Lang1 Mridusmita Sarma et al.
  • 1Institute for Microsensors Actuators and Systems (IMSAS), University of Bremen, 28359, Bremen, Germany
  • 2Foundation Institute for Materials Science (IWT) and MAPEX Centre for Materials and Processes, University of Bremen, Bremen 28359, Germany

Abstract. This paper presents the results of using a sensor-integrated workpiece for in situ measurement of strain during an outer-diameter cylindrical grinding process. The motivation of this work is to measure in situ process parameters using integrated sensors in a workpiece in order to characterize the manufacturing process. Resistive sensors that operate on the same principle as conventional strain gauges were fabricated on wafers made of steel using standard microtechnology and later the wafers were diced to form unique sensor-integrated steel components (sensor inlays). These inlays are embedded into a groove on the top surface of a cylindrical workpiece using epoxy adhesive. The workpiece is also made of the same steel as the sensor wafers and has similar properties due to a heat treatment process, thereby maintaining the homogeneity of the material over the whole contact area. The sensor-integrated workpiece was used to perform experiments in a Studer S41 high-performance cylindrical grinding machine. The sensor response to the internal strain was recorded during every grinding step starting from a depth of 1 mm down to 2 mm from the top surface. Such an application of sensor integration in materials for in situ process monitoring can be used in other manufacturing processes as well and this can help to observe internal loads (mechanical or thermal) in manufacturing processes.

Short summary
In this work, we measured strain during a cylindrical grinding process in real time and in situ during the process. For this, we integrated strain sensors in a standard workpiece using microfabrication technology and performed grinding experiments on the so-called sensorial workpiece to characterize the manufacturing process. The approach can be used for measuring strain and temperature in other manufacturing processes, to characterize them.