Tool wear intelligent monitoring techniques in cutting: a review

Cheng, Yaonan; Gai, Xiaoyu; Guan, Rui; Jin, Yingbo; Lu, Mengda; Ding, Ya

doi:10.1007/s12206-022-1229-9

Cited by 29 publications

(7 citation statements)

References 49 publications

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“…Much of this heat generated in mechanical micro-drilling is conducted into the workpiece and tool; however, a portion remains in the chip [50]. A high temperature in the contact zone adversely affects thermally activated wear mechanisms, resulting in reduced tool life [51]. Thus, from the point of view of drill life, prior laser pre-drilling is advantageous.…”

Section: Energy In the Mechanical Drilling Processmentioning

confidence: 99%

An Investigation of the Sequential Micro-Laser Drilling and Conventional Re-Drilling of Angled Holes in an Inconel 625 Ni-Based Alloy

Szwajka,

Zielińska-Szwajka,

Żaba

et al. 2023

Lubricants

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The conventional (mechanical) micro-drilling of Inconel 625 alloys suffers from premature breakage of the drill bit due to its brittle nature and limited cutting tool life. Even greater problems are encountered when micro-drilling holes at an acute angle to the machining plane. In such a process, there are great difficulties associated with the low stiffness of the tool, which leads to the frequent breakage of the drill during machining. Therefore, in this type of mechanical drilling operation, the hole surface is usually milled with an end mill to provide a flat surface on the entry side of the drill bit. The aim of this article is to recognise the process of sequential micro-drilling and to assess the possibility of its use as an effective and efficient method of micro-drilling in hard-to-cut metals. The paper describes the process of initial laser drilling followed by final mechanical micro-drilling. Inconel 625 Ni-based alloy sheets were used as the test material. The shape and microstructure of pre-holes made with a laser, the volumetric efficiency of laser processing, the energy in the mechanical drilling process, and tool wear were analysed. The research results show that in the sequential drilling process, mechanical re-drilling eliminates the geometrical discrepancies resulting from the laser pre-drilling. In addition, it was found that, compared to mechanical micro-drilling, the use of sequential micro-drilling resulted in a two-fold increase in drill life. It has been also observed that sequential machining reduces the energy demand by 60% compared to mechanical micro-drilling. In addition, it was found that the edge of the drill bit is a key factor in deciding the target diameter of the laser-drilled pilot hole, and thus in selecting the micro-drilling parameters.

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Section: Energy In the Mechanical Drilling Processmentioning

confidence: 99%

An Investigation of the Sequential Micro-Laser Drilling and Conventional Re-Drilling of Angled Holes in an Inconel 625 Ni-Based Alloy

Szwajka,

Zielińska-Szwajka,

Żaba

et al. 2023

Lubricants

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“…TCM systems enable companies to indirectly monitor cutter conditions using various parameters such as temperature, vibration, and cutting forces [6]. In numerous investigations concerning the monitoring of tool wear through indirect measurement, the force sensor has emerged as the preferred choice among researchers due to its precision in detecting tool wear [7,8]. Nonetheless, the utilization of this sensor type is hindered by its high cost and impracticality within industrial settings [9].…”

Section: Introductionmentioning

confidence: 99%

Innovative Tool Condition Classification: Utilizing Time-Frequency Moments as Inputs for BiLSTM Networks in Milling Processes

Rahman,

Jauhari,

Huda

et al. 2024

Preprint

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Milling is one of the most important processes in the manufacturing industry, and it uses rotating cutting tools to sculpt raw materials into intricate shapes and structures. However, tool wear and breakage present significant challenges influenced by various factors, such as machining parameters and tool fatigue, which directly impact surface quality, dimensional accuracy, and production costs. Therefore, monitoring cutter wear conditions is essential for ensuring milling process efficiency. This study proposes applying BiLSTM networks to classify end mill tool conditions based on vibration signals. Significant improvements in classification accuracy are achieved by extracting features and utilizing spectrogram analysis. Specifically, utilizing dual spectral vibration signals increases the BiLSTM's average accuracy from 84.5–96.3%. These findings demonstrate the effectiveness of the proposed method for real-time tool condition monitoring in milling operations, offering potential benefits for manufacturing processes.

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“…Across multiple research endeavors focused on indirectly measuring tool wear, the force sensor is preferred due to its precision in detecting tool wear [3,4]. Nonetheless, its cost and impracticality in industrial settings pose significant drawbacks [5].…”

Section: Introductionmentioning

confidence: 99%

Enhancing Turbine Blade Manufacturing through MEMS-Based Milling Monitoring

Rahman,

Jauhari,

Huda

et al. 2024

IOP Conf. Ser.: Earth Environ. Sci.

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Manufacturing steam turbine blades with intricate shapes poses a substantial challenge. These blades significantly impact turbine efficiency, reliability, and productivity. Their precise formation through milling processes demands vigilant monitoring, especially concerning the cutting tool’s condition, which is responsible for shaping the blade profiles and ensuring high-quality outcomes. Direct tool monitoring, however, disrupts productivity, prompting the need for an indirect Tool Condition Monitoring (TCM) system. Such a system becomes essential for detecting tool wear and damage early, ensuring dimensional accuracy and surface smoothness. This experiment monitors tool conditions by analyzing vibrations generated by an endmill cutter while machining martensitic stainless steel (MSS) AISI 420. The setup employs a cost-effective MEMS vibration sensor, the ADXL 345, and Raspberry Pi for real-time online TCM functionality as the signal processor. This study delves into the sensor’s ability to capture vibrations representing actual tool conditions, focusing on the affordability and effectiveness of MEMS-based monitoring. The successful real-time implementation of MEMS-based monitoring could be an easily accessible gateway for manufacturing industries to embrace cloud-based monitoring systems, aligning with current technological trends. This research aims to underscore the viability and potential adoption of affordable MEMS sensors for comprehensive tool condition monitoring, offering a seamless transition toward cloud-integrated monitoring systems for manufacturing industries.

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Tool wear intelligent monitoring techniques in cutting: a review

Cited by 29 publications

References 49 publications

An Investigation of the Sequential Micro-Laser Drilling and Conventional Re-Drilling of Angled Holes in an Inconel 625 Ni-Based Alloy

An Investigation of the Sequential Micro-Laser Drilling and Conventional Re-Drilling of Angled Holes in an Inconel 625 Ni-Based Alloy

Innovative Tool Condition Classification: Utilizing Time-Frequency Moments as Inputs for BiLSTM Networks in Milling Processes

Enhancing Turbine Blade Manufacturing through MEMS-Based Milling Monitoring

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