Method for determining edge chipping in milling based on tool holder vibration measurements

Bleicher, Friedrich; Ramsauer, Christoph; Oswald, Ralf; Leder, Norbert; Schoerghofer, Paul

doi:10.1016/j.cirp.2020.04.100

Cited by 27 publications

(10 citation statements)

References 8 publications

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“…Another model available in the market has been developed by Schunk GmbH that can measure only the cutting vibrations using a MEMS accelerometer [ 111 ]. This sensor node was employed in a TCM system to monitor the cutting tool edge chipping events in the milling process [ 112 ]. In terms of the system stiffness and the quantities measured, the developed designs are still limited, and further improvements are necessary.…”

Section: Sensing and Data Acquisitionmentioning

confidence: 99%

Tool Condition Monitoring for High-Performance Machining Systems—A Review

Mohamed

Hassan

M’Saoubi³

et al. 2022

Sensors

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In the era of the “Industry 4.0” revolution, self-adjusting and unmanned machining systems have gained considerable interest in high-value manufacturing industries to cope with the growing demand for high productivity, standardized part quality, and reduced cost. Tool condition monitoring (TCM) systems pave the way for automated machining through monitoring the state of the cutting tool, including the occurrences of wear, cracks, chipping, and breakage, with the aim of improving the efficiency and economics of the machining process. This article reviews the state-of-the-art TCM system components, namely, means of sensing, data acquisition, signal conditioning and processing, and monitoring models, found in the recent open literature. Special attention is given to analyzing the advantages and limitations of current practices in developing wireless tool-embedded sensor nodes, which enable seamless implementation and Industrial Internet of Things (IIOT) readiness of TCM systems. Additionally, a comprehensive review of the selection of dimensionality reduction techniques is provided due to the lack of clear recommendations and shortcomings of various techniques developed in the literature. Recent attempts for TCM systems’ generalization and enhancement are discussed, along with recommendations for possible future research avenues to improve TCM systems accuracy, reliability, functionality, and integration.

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Section: Sensing and Data Acquisitionmentioning

confidence: 99%

Tool Condition Monitoring for High-Performance Machining Systems—A Review

Mohamed

Hassan

M’Saoubi³

et al. 2022

Sensors

View full text Add to dashboard Cite

show abstract

“…A fast response and a specific adaption of the process are required for a feedback loop, so that a control system can cover stochastic process effects. The instrumented tool holder has been proven capable of chatter detection and mitigation [85,86], as well as cutting edge chipping detection [87]. In the case, that a process is classified to be unstable, an automated adaption of spindle speed and feed rate can be applied in the real-time control loop.…”

Section: Heavy Duty Millingmentioning

confidence: 99%

Tooling systems with integrated sensors enabling data based process optimization

Bleicher¹,

Ramsauer²,

Leonhartsberger³

et al. 2021

Journal of Machine Engineering

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Sensor integration into machining equipment has become an important factor for gaining deep process insights mainly driven by increasingly smaller and cheaper sensors and transmitters. Due to advances in microelectronics and communication technology, a broader field of applications in production processes and machine tools can be addressed using sensing devices and their implementation potentials. Ensuring a sensitive but robust data stream from close to the actual process allows not only reliable monitoring but also process and quality control based on sensor information. This paper provides an overview of the utilization of sensor data for the purpose of condition monitoring, model fitting and real-time control coping with stochastic effects. Examples of sensor integration in fields of injection molding, roll forming and heavy-duty milling comprise the state of the art of sensor implementation, data evaluation and possible feedback loops in the respective application scenarios.

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“…Many already existing measurement systems rely on deflection of strain gauges or piezoelectric components to directly sense and visualize force components. The instrumented tool holder has battery and a wireless Bluetooth transmission system implemented and senses acceleration [9]. The design is depicted in Fig.…”

Section: Mechanical Model Of Oscillation Systemmentioning

confidence: 99%

“…y). (9) where: QTheoryquality index according to theory, knatural number as counter, XITH,kinstrumented tool holder's signal in frequency domain in x direction evaluated at certain frequencies, znumber of cutting edges, ωSprotational speed of spindle.…”

Section: Derived Model For Detection Of Uneven Wear In Milling Operatmentioning

confidence: 99%

See 1 more Smart Citation

New method for determining single cutting edge breakage of a multi-tooth milling tool based on acceleration measurements by an instrumented tool holder

Ramsauer¹,

Bleicher²

2021

Journal of Machine Engineering

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In machining applications predominantly for automated machining cells, tool life is often not used to its full extend and cutting tools are exchanged prematurely to avoid tool breakage and thus machine downtime or even damage at work piece or machine. Both effective process monitoring and adequate process control require reliable data from sensors and derived indicators that enable meaningful evaluation. Acceleration measurement by the instrumented tool holder provides signals with high quality from close to the cutting zone. Using the monitoring system, the gained data of the instrumented tool holder can be analyzed especially for the use case of unexpected tool wear, chipping of the cutting edge or breakouts at end mills. This paper describes the data analysis based on the rotational sensor and the corresponding effects on the measurement, an advanced assessment of the spectral distribution in the frequency domain and the experimental results of a test series.

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Method for determining edge chipping in milling based on tool holder vibration measurements

Cited by 27 publications

References 8 publications

Tool Condition Monitoring for High-Performance Machining Systems—A Review

Tool Condition Monitoring for High-Performance Machining Systems—A Review

Tooling systems with integrated sensors enabling data based process optimization

New method for determining single cutting edge breakage of a multi-tooth milling tool based on acceleration measurements by an instrumented tool holder

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