A review on multi sensor data fusion technique in CNC machining of tailor-made nanocomposites

Mouli, K. V. V. N. R. Chandra; Prasad, Balla Srinivasa; Sridhar, Annavarapu Venkata; Alanka, Sandeep

doi:10.1007/s42452-020-2739-7

Cited by 9 publications

(4 citation statements)

References 71 publications

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“…This adaptive controller controls the milling process parameters in real-time and maintains vibration under a preset safety threshold value by means of driver interfacing for adaptation of machining parameters. Applicability of the method for the adaptive alteration of milling parameters is demonstrated and tested on a 3-axis CNC milling machine with experimental trails [23]. Results of the end milling experiments with adaptive controller strategy display that the established in house controller has great sturdiness and steadiness.…”

Section: Discussionmentioning

confidence: 99%

Development of in-situ adaptive controller for end milling based on vibration feedback

Reddy

Prasad

Raghuram³

et al. 2021

SN Appl. Sci.

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This study establishes a tool condition monitoring methodology builds on the vibration signal attained via data acquisition system which is integrated with the in house developed adaptive controller for an end milling. As the quality of the products and the machine tool performance are the key parameters in maintaining machine stability. Proposed Adaptive control optimization system is validated with the experimentation trials and data analysis on 3 axis CNC milling machine. The rotational speed of the spindle and vibration signals is found to be reactive to milling cutter condition and therefore capable of sustaining the set-out methodology. A novel hybrid transformation, coupled with FFT and HHT is proposed to distinguish between a source of variation for adaptive control optimization, cutting region with the non-cutting region. In this study, decisions are made to evaluate the tool condition by combining all related information into a rule base. The investigation trajectories unveil the established system be able to accomplish the mechanism properly as anticipated.

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Section: Discussionmentioning

confidence: 99%

Development of in-situ adaptive controller for end milling based on vibration feedback

Reddy

Prasad

Raghuram³

et al. 2021

SN Appl. Sci.

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“…19 Surface stability is an essential aspect of manufacturing for a variety of industries, including aerospace, automotive, and defense. Chatter tremors are affected by cutting characteristics such as speed, 20 feed, 21 and depth of cut, 22 and these tremors increase as the workpiece's hardness increases. 23 Therefore, using tools with higher hardness and greater resistance to heat damage, such as PCD and PCBN, may help minimize noise when cutting through difficult materials.…”

Section: Introductionmentioning

confidence: 99%

An experimental approach to characterize the performance of PCD and PCBN tools in milling nano Al-8081-Zr/Mg/TiO2 metal matrix composites using multi-sensor data fusion

Mouli,

Reddy,

Prakash

2024

Proceedings of the Institution of Mechanical Engineers, Part C:

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To prevent the quality of the finished product from declining, precision manufacturing procedures need reliable cutting tool wear detection. Cutting tool material, workpiece attributes, cutting conditions and conditions, and excessive cutting forces creating vibrations causing chatter impacting tool wear finally leading to tool failure all have an impact on tool performance. This paper presents a multisensory data fusion approach that assigns sensors at nearfield sites during the machining process to monitor the tool condition. The study investigates the performance of polycrystalline diamond (PCD) and Polycrystalline Cubic Boron Nitride (PCBN) cutting tools during the machining of nano metal matrix composites reinforced with Zr/Mg/TiO2 (15%). The method correlates signal features with experimental results to provide a reliable empirical approach to monitor the cause of tool flank wear and displacement, leading to failure. The experimental investigation it is found the cutting forces showed significant effect on flank wear affecting surface finish and tool life. Tool performance was successful monitoring and predicted instantly based on the signature analysis of vibrations and forces during machining helped accurately analyzed factors affecting tool wear at uncertain cutting conditions using FDA analysis. The study provides insights into the PCD and PCBN tools’ performance characteristics.

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“…18 This methodology for implementing the concept of real-time monitoring of the machining process yielded cost-effective outcomes . 19 The current research focusses on not only developing a cost-effective real-time in-situ system for estimating the elements that affect the machining process, but also on recent advances in advanced nano metal matrix composites. Surface roughness is known to be influenced by the cutting tool material, which leads to chatter .…”

Section: Introductionmentioning

confidence: 99%

“…18 This methodology for implementing the concept of real-time monitoring of the machining process yielded cost-effective outcomes . 19…”

Section: Introductionmentioning

confidence: 99%

Surface morphology and microstructural analysis of al 8081-mg/zr/tio₂ nano metal matrix composite – A base for performance evaluation of polycrystalline diamond and poly cubic boron nitride tools

Prasad

KarakaVVNR

Annavarapu

2021

Proceedings of the Institution of Mechanical Engineers, Part C:

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The investigation of surface roughness in machined materials/products has proven to be a difficult undertaking. The surface quality is determined not only by the parameters but also by the cutting conditions. Surprisingly, a study indicated that when analysing the quality of machining processes currently being done, surface morphology has a significant impact on tool performance. PCD (Polycrystalline diamond) and PCBN (Poly cubic boron nitride) cutting tools produce a better surface finish, which is explored in the machining of Al-Mg/Zr/TiO2 (15%), nano metal matrix composites (NMMC). The study primarily focuses on determining the best parameters for end milling NMMCs in tests for long-term production sustainability. Using scanning electron microscopy, microstructural study of the machined surface will aid in finding the parameters responsible for the cause of surface integrity. The work focusses on analysing tool performance by monitoring the machining process in real time using signal characteristics, forecasting vibrations (displacement) and machine outputs using surface topography and chip analysis. The tool failure was acquired by establishing a correlation between displacement (vibrations) and post machining outcome of experimental study, as a result, the evolution of displacement in the PCBN tool is 24.7 μm, which is better compared to 34.3 μm in the PCD tool at 3000 r/min. PCBN outperformed PCD with a 1.82 μm surface roughness, resulting in longer tool life. Thus, this economical reliable empirical method the problem of finding difficulty identifying the causing of tool wear and failure by correlating sensor signals features with experimental results.

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A review on multi sensor data fusion technique in CNC machining of tailor-made nanocomposites

Cited by 9 publications

References 71 publications

Development of in-situ adaptive controller for end milling based on vibration feedback

Development of in-situ adaptive controller for end milling based on vibration feedback

An experimental approach to characterize the performance of PCD and PCBN tools in milling nano Al-8081-Zr/Mg/TiO2 metal matrix composites using multi-sensor data fusion

Surface morphology and microstructural analysis of al 8081-mg/zr/tio₂ nano metal matrix composite – A base for performance evaluation of polycrystalline diamond and poly cubic boron nitride tools

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A review on multi sensor data fusion technique in CNC machining of tailor-made nanocomposites

Cited by 9 publications

References 71 publications

Development of in-situ adaptive controller for end milling based on vibration feedback

Development of in-situ adaptive controller for end milling based on vibration feedback

An experimental approach to characterize the performance of PCD and PCBN tools in milling nano Al-8081-Zr/Mg/TiO2 metal matrix composites using multi-sensor data fusion

Surface morphology and microstructural analysis of al 8081-mg/zr/tio2 nano metal matrix composite – A base for performance evaluation of polycrystalline diamond and poly cubic boron nitride tools

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Product

Resources

About

Surface morphology and microstructural analysis of al 8081-mg/zr/tio₂ nano metal matrix composite – A base for performance evaluation of polycrystalline diamond and poly cubic boron nitride tools