Tool condition monitoring in an end-milling operation based on the vibration signal collected through a microcontroller-based data acquisition system

Zhang, Julie Z.; Chen, Joseph C.

doi:10.1007/s00170-007-1186-6

Cited by 83 publications

(25 citation statements)

References 12 publications

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“…The analysis of vibration data by sensing the typical changes in the signal measures tool wear in the milling process. The vibration amplitudes in the frequency domain (i.e., fast Fourier transform) and time domain (i.e., crest factor) can be used to detect the instability in the end milling process [10].…”

Section: Methodsmentioning

confidence: 99%

IEEE 1451-based Intelligent Computer Numerical Control Tool Holder

Tsai

Kuo

2012

2012 International Symposium on Computer, Consumer and Control

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The performance of a machine cutting tool has a significant effect on the processing quality. Thus, it is essential to design a robust system for monitoring and predicting failures of a machine tool by using its working parameters. In this study, a wireless sensor system has been developed for monitoring the processing state of the machine cutting tool. The proposed sensor system architecture is based on the IEEE 1451 smart transducer interface standard. This IEEE 1451-based sensor system is integrated within the tool holder. The collected data are wirelessly transmitted to an external embedded device in real time, thereby enhancing the processing quality. These acquired sensor data are preprocessed and parsed for feature extraction. The experimental results show that the proposed IEEE 1451-based sensor system successfully detects the vibration instability in a CNC milling operation.Keywords-machine monitoring; intelligent sensors; network capable application processor (NCAP); smart transducer interface module (STIM); transducer electronic data sheet (TEDS); transducer independent interface (TII)

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Section: Methodsmentioning

confidence: 99%

IEEE 1451-based Intelligent Computer Numerical Control Tool Holder

Tsai

Kuo

2012

2012 International Symposium on Computer, Consumer and Control

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“…In contrast to the aforementioned variables, vibration signal offers better characteristics such as the following: (1) periodic shape that resembles the cutting force, (2) enough information regarding tool condition, (3) robustness, (4) reliability, (5) applicability, (6) low-cost, and (7) ease in measurement implementation without requiring any machine tool modification. For this reason, the vibration signal has also been used for TCM in conventional machining [7][8][9].…”

Section: Introductionmentioning

confidence: 99%

FPGA-based reconfigurable system for tool condition monitoring in high-speed machining process

et al. 2015

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“…However, keeping the implementation cost effective and robust has become difficult. For a hardware cost of less than $200, Zhang and Chen (2007) used a microcontroller-based data acquisition system which examined vibrations. Kang et al (2005) used a piezo load cell attached to the feed system to measure the cutting forces.…”

Section: Introductionmentioning

confidence: 99%

Condition Monitoring for Indexable Carbide End Mill Using Acceleration Data

Milner

Roth

2010

Machining Science and Technology

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In order to automate machining operations, it is necessary to develop robust tool condition monitoring techniques. In this paper, a tool monitoring strategy for indexable tungsten carbide end milling tools is presented based on the Fourier transform and statistical analysis of the vibrations of the tool during the machining operations. Using a low-cost, tri-axial piezoelectric accelerometer, the presented algorithm demonstrates the ability to accurately monitor the condition of the tools as the wear increases during linear milling operations. One benefit of using accelerometer signals to monitor the cutting process is that the sensor does not limit the machine's capabilities, as a workpiece mounted dynamometer does. To demonstrate capabilities of the technique, four tool wear life tests were conducted under various conditions. The indirect method discussed herein successfully tracks the tool's wear and is shown to be sensitive enough to provide sufficient time to replace the insert prior to damage of the machine tool, cutter, and/or workpiece.

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Tool condition monitoring in an end-milling operation based on the vibration signal collected through a microcontroller-based data acquisition system

Cited by 83 publications

References 12 publications

IEEE 1451-based Intelligent Computer Numerical Control Tool Holder

IEEE 1451-based Intelligent Computer Numerical Control Tool Holder

FPGA-based reconfigurable system for tool condition monitoring in high-speed machining process

Condition Monitoring for Indexable Carbide End Mill Using Acceleration Data

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