Wall-thickness eccentricity is a major dimensional deviation problem in seamless steel tube production. Although eccentricity is mainly caused by abnormal process conditions in the cross-roll piercing mill, most seamless tube plants lack the monitoring at the hot piercing stage but only inspect the quality of finished tubes using ultrasonic testing (UT) at the end of all manufacturing processes. This paper develops an online monitoring technique to detect abnormal conditions in the cross-roll piercing mill. Based on an image-sensing technique, process operation condition can be extracted from the vibration signals. Optimal frequency features that are sensitive to tube wall-thickness variation are then selected through the formulation and solution of a set-covering optimization problem. Hotelling T2 control charts are constructed using the selected features for online monitoring. The developed monitoring technique enables early detection of eccentricity problems at the hot piercing stage, which can facilitate timely adjustment and defect prevention. The monitoring technique developed in this paper is generic and can be widely applied to the hot piercing process of various products. This paper also provides a general framework for effectively analyzing image-based sensing data and establishing the linkage between product quality information and process information.
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April 2015
Research-Article
Online Eccentricity Monitoring of Seamless Tubes in Cross-Roll Piercing Mill
Weihong Guo,
Weihong Guo
1
Department of Industrial and
Operations Engineering,
e-mail: graceguo@umich.edu
Operations Engineering,
The University of Michigan
,Ann Arbor, MI 48109
e-mail: graceguo@umich.edu
1Corresponding author.
Search for other works by this author on:
Rui Chen,
Rui Chen
Manufacturing Engineering Program of
Integrative Systems and Design Division,
College of Engineering,
e-mail: ruichen@umich.edu
Integrative Systems and Design Division,
College of Engineering,
The University of Michigan
,Ann Arbor, MI 48109
e-mail: ruichen@umich.edu
Search for other works by this author on:
Jionghua (Judy) Jin
Jionghua (Judy) Jin
Fellow ASME
Department of Industrial and
Operations Engineering,
e-mail: jhjin@umich.edu
Department of Industrial and
Operations Engineering,
The University of Michigan
,Ann Arbor, MI 48109
e-mail: jhjin@umich.edu
Search for other works by this author on:
Weihong Guo
Department of Industrial and
Operations Engineering,
e-mail: graceguo@umich.edu
Operations Engineering,
The University of Michigan
,Ann Arbor, MI 48109
e-mail: graceguo@umich.edu
Rui Chen
Manufacturing Engineering Program of
Integrative Systems and Design Division,
College of Engineering,
e-mail: ruichen@umich.edu
Integrative Systems and Design Division,
College of Engineering,
The University of Michigan
,Ann Arbor, MI 48109
e-mail: ruichen@umich.edu
Jionghua (Judy) Jin
Fellow ASME
Department of Industrial and
Operations Engineering,
e-mail: jhjin@umich.edu
Department of Industrial and
Operations Engineering,
The University of Michigan
,Ann Arbor, MI 48109
e-mail: jhjin@umich.edu
1Corresponding author.
Contributed by the Manufacturing Engineering Division of ASME for publication in the JOURNAL OF MANUFACTURING SCIENCE AND ENGINEERING. Manuscript received April 21, 2014; final manuscript received August 22, 2014; published online December 12, 2014. Assoc. Editor: Robert Gao.
J. Manuf. Sci. Eng. Apr 2015, 137(2): 021007 (10 pages)
Published Online: April 1, 2015
Article history
Received:
April 21, 2014
Revision Received:
August 22, 2014
Online:
December 12, 2014
Citation
Guo, W., Chen, R., and Jin, J. (. (April 1, 2015). "Online Eccentricity Monitoring of Seamless Tubes in Cross-Roll Piercing Mill." ASME. J. Manuf. Sci. Eng. April 2015; 137(2): 021007. https://doi.org/10.1115/1.4028440
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