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Description
(Short description)
Major objective of this thesis was the attempt to find an answer to the question, if underspecified boundary conditions signals generated with state of the art monitoring solutionsallow an interpretation of the generated part quality during the manufacture of criticalaero engine components. It is shown in the state of the art of this thesis, that process monitoringsystems are widely used in modern production systems. Their major focus is setonto cutting and machine tool condition monitoring solutions. Various sensor solutionsare on the market to monitor manufacturing and production system, but up to now nodirect link to the parts quality with the aid of sensor and monitoring systems has beenmade. Following the need that sensor and monitoring solutions have to be implementedinto a rather rough production environment, it is asked, how these environmental issuesare influencing the robustness and reliability of the process monitoring system. This questionis discussed in this work, where first non-machining related key process variables aredefined and analyzed. Following this, the question is raised if major machining characteristicsof a drilling process can be monitored and interpreted in such a way, that a correlationto the machined components quality is possible. To answer this, pure machiningrelated anomalies and their influence on sensor signals are discussed. This is undertakenon drilling processes for the two relevant alloys of this thesis, TiAl6V4 and Inconel 718.A broad range of process characteristics and abnormal behavior during a drilling processis identified and described with corresponding sensor signals. A possible evaluation forthe creation of signal features is given as an example. Furthermore, an attempt is madeto create a correlation of sensor signals to the life of components. As component life isusually evaluated by the use of LCF experiments, this has also been carried out within thethesis work. Various typical anomalies were machined into test blocks, monitored and LCFtested. A monitoring strategy based on this evaluation is also presented. As it was foundthat temperature evolution within the drilling process is critical a new temperature measurementmethod has been developed and based on these measurements a temperaturemodel has been derived from the results for drilling the titanium alloy TiAl6V4.
