scholarly journals Application of Wavelet Analysis in Tool Wear Evaluation Using Image Processing Method

2018 ◽  
Vol 7 (4.36) ◽  
pp. 426
Author(s):  
Lee Woon Kiow ◽  
Syed Mohamad Aiman Tuan Muda ◽  
Ong Pauline ◽  
Sia Chee Kiong ◽  
Norfazillah Talib ◽  
...  
Keyword(s):  
Wavelet Analysis ◽  
Tool Wear ◽  
Cutting Tool ◽  
Wavelet Coefficient ◽  
Surface Profile ◽  
Machining Process ◽  
Machining Parameters ◽  
Continuous Wavelet ◽  
Monitoring Methods ◽  
Machined Surface

Tool wear plays a significant role for proper planning and control of machining parameters to maintain the product quality. However, existing tool wear monitoring methods using sensor signals still have limitations. Since the cutting tool operates directly on the workpiece during machining process, the machined surface provides valuable information about the cutting tool condition. Therefore, the objective of present study is to evaluate the tool wear based on the workpiece profile signature by using wavelet analysis. The effect of wavelet families, scale of wavelet and statistical features of the continuous wavelet coefficient on the tool wear is studied. The surface profile of workpiece was captured using a DSLR camera. Invariant moment method was applied to extract the surface profile up to sub-pixel accuracy. The extracted surface profile was analyzed by using continuous wavelet transform (CWT) written in MATLAB. The results showed that average, RMS and peak to valley of CWT coefficients at all scale increased with tool wear. Peak to valley at higher scale is more sensitive to tool wear. Haar was found to be more effective and significant to correlate with tool wear with highest R2 which is 0.9301.   

scholarly journals Experimental Study on Tool Wear and Delamination in Milling CFRPs with TiAlN- and TiN-Coated Tools

Coatings ◽  
2020 ◽  
Vol 10 (7) ◽  
pp. 623 ◽  
Author(s):  
Dervis Ozkan ◽  
Peter Panjan ◽  
Mustafa Sabri Gok ◽  
Abdullah Cahit Karaoglanli
Keyword(s):  
Tool Wear ◽  
Cutting Tool ◽  
Failure Mechanisms ◽  
Cutting Tools ◽  
Machining Process ◽  
Dynamic Loads ◽  
Fiber Reinforced Polymers ◽  
Machining Parameters ◽  
Coated Tool ◽  
Cfrp Composite

Carbon fiber-reinforced polymers (CFRPs) have very good mechanical properties, such as extremely high tensile strength/weight ratios, tensile modulus/weight ratios, and high strengths. CFRP composites need to be machined with a suitable cutting tool; otherwise, the machining quality may be reduced, and failures often occur. However, as a result of the high hardness and low thermal conductivity of CFRPs, the cutting tools used in the milling process of these materials complete their lifetime in a short cycle, due to especially abrasive wear and related failure mechanisms. As a result of tool wear, some problems, such as delamination, fiber breakage, uncut fiber and thermal damage, emerge in CFRP composite under working conditions. As one of the main failure mechanisms emerging in the milling of CFRPs, delamination is primarily affected by the cutting tool material and geometry, machining parameters, and the dynamic loads arising during the machining process. Dynamic loads can lead to the breakage and/or wear of cutting tools in the milling of difficult-to-machine CFRPs. The present research was carried out to understand the influence of different machining parameters on tool abrasion, and the work piece damage mechanisms during CFRP milling are experimentally investigated. For this purpose, cutting tests were carried out using a (Physical Vapor Deposition) PVD-coated single layer TiAlN and TiN carbide tool, and the abrasion behavior of the coated tool was investigated under dry machining. To understand the wear process, scanning electron microscopy (SEM) equipped with energy-dispersive X-ray spectroscopy (EDS) was used. As a result of the experiments, it was determined that the hard and abrasive structure of the carbon fibers caused flank wear on TiAlN- and TiN-coated cutting tools. The best machining parameters in terms of the delamination damage of the CFRP composite were obtained at high cutting speeds and low feed rates. It was found that the higher wear values were observed at the TiAlN-coated tool, at the feed rate of 0.05 mm/tooth.

Designing and implementation of a novel online adaptive control with optimization technique in hard turning

2020 ◽  
pp. 095965182095219
Author(s):  
Vahid Pourmostaghimi ◽  
Mohammad Zadshakoyan
Keyword(s):  
Adaptive Control ◽  
Tool Wear ◽  
Hard Turning ◽  
Cutting Tool ◽  
Optimization Technique ◽  
Cutting Parameters ◽  
Numerical Control ◽  
Machining Process ◽  
Machining Parameters ◽  
Optimization Methodology

Determination of optimum cutting parameters is one of the most essential tasks in process planning of metal parts. However, to achieve the optimal machining performance, the cutting parameters have to be regulated in real time. Therefore, utilizing an intelligent-based control system, which can adjust the machining parameters in accordance with optimal criteria, is inevitable. This article presents an intelligent adaptive control with optimization methodology to optimize material removal rate and machining cost subjected to surface quality constraint in finish turning of hardened AISI D2 considering the real condition of the cutting tool. Wavelet packet transform of cutting tool vibration signals is applied to estimate tool wear. Artificial intelligence techniques (artificial neural networks, genetic programming and particle swarm optimization) are used for modeling of surface roughness and tool wear and optimization of machining process during hard turning. Confirmatory experiments indicated that the efficiency of the proposed adaptive control with optimization methodology is 25.6% higher compared to the traditional computer numerical control turning systems.

scholarly journals A Novel Finite Element Method Approach in the Modelling of Edge Trimming of CFRP Laminates

2021 ◽  
Vol 11 (11) ◽  
pp. 4743
Author(s):  
Fernando Cepero-Mejias ◽  
Nicolas Duboust ◽  
Vaibhav A. Phadnis ◽  
Kevin Kerrigan ◽  
Jose L. Curiel-Sosa
Keyword(s):  
Finite Element ◽  
Tool Wear ◽  
Cutting Tool ◽  
Machining Process ◽  
Machining Forces ◽  
General Terms ◽  
Numerical Predictions ◽  
Composite Damage ◽  
Edge Trimming ◽  
Optimal Cutting Parameters

Nowadays, the development of robust finite element models is vital to research cost-effectively the optimal cutting parameters of a composite machining process. However, various factors, such as the high computational cost or the complicated nature of the interaction between the workpiece and the cutting tool significantly hinder the modelling of these types of processes. For these reasons, the numerical study of common machining operations, especially in composite machining, is still minimal. This paper presents a novel approach comprising a mixed multidirectional composite damage mode with composite edge trimming operation. An ingenious finite element framework which infer the cutting edge tool wear assessing the incremental change of the machining forces is developed. This information is essential to replace tool inserts before the tool wear could cause severe damage in the machined parts. Two unidirectional carbon fibre specimens with fibre orientations of 45∘ and 90∘ manufactured by pre-preg layup and cured in an autoclave were tested. Excellent machining force predictions were obtained with errors below 10% from the experimental trials. A consistent 2D FE composite damage model previously performed in composite machining was implemented to mimic the material failure during the machining process. The simulation of the spring back effect was shown to notably increase the accuracy of the numerical predictions in comparison to similar investigations. Global cutting forces simulated were analysed together with the cutting tool tooth forces to extract interesting conclusions regarding the forces received by the spindle axis and the cutting tool tooth, respectively. In general terms, vertical and normal forces steadily increase with tool wear, while tangential to the cutting tool, tooth and horizontal machining forces do not undergo a notable variation.

Surface Roughness and Cutting Force Components Evaluation in Hard Turning by Differently Shaped Cutting Tools

2016 ◽  
Vol 862 ◽  
pp. 26-32 ◽  
Author(s):  
Michaela Samardžiová
Keyword(s):  
Surface Roughness ◽  
Cutting Force ◽  
Hard Turning ◽  
Cutting Tool ◽  
Single Point ◽  
Machining Process ◽  
Tool Geometry ◽  
Machined Surface ◽  
Cutting Force Components ◽  
Force Components

There is a difference in machining by the cutting tool with defined geometry and undefined geometry. That is one of the reasons of implementation of hard turning into the machining process. In current manufacturing processes is hard turning many times used as a fine finish operation. It has many advantages – machining by single point cutting tool, high productivity, flexibility, ability to produce parts with complex shapes at one clamping. Very important is to solve machined surface quality. There is a possibility to use wiper geometry in hard turning process to achieve 3 – 4 times lower surface roughness values. Cutting parameters influence cutting process as well as cutting tool geometry. It is necessary to take into consideration cutting force components as well. Issue of the use of wiper geometry has been still insufficiently researched.

scholarly journals Effects of the Tribological Behaviour of h-BN MQL Nano Cutting Fluid (NCF-MQL) on Turning Inconel 625

2019 ◽  
Vol 11 (4) ◽  
pp. 107-121 ◽  
Author(s):  
Chinmaya PADHY ◽  
Pariniti SINGH
Keyword(s):  
Optimization Technique ◽  
Minimum Quantity Lubrication ◽  
Chip Morphology ◽  
Machining Process ◽  
Cutting Fluid ◽  
Inconel 625 ◽  
Machining Parameters ◽  
Machining Performance ◽  
Tribological Behaviour ◽  
Machined Surface

Minimum quantity lubrication (MQL) is currently a widely used lubricating technique during machining, in which minimum amount of lubricant in the form of mist is delivered to the machining interface, thus helps to reduce the negative effects caused to the environment and human health. Further, to enhance the productivity of machining process specifically for hard-to-cut materials, nano cutting fluid (suitably mixed nano materials with conventional cutting fluid) is used as an alternative method to conventional lubrication (wet) in MQL. In this study, h-BN nano cutting fluid was formulated with 0.1% vol. concentration of h-BN in conventional cutting fluid (Servo- ‘S’) for NCF-MQL technique and its tribological behaviors on machining(turning) performance of Inconel 625 were studied and compared with other lubricating conditions (dry, wet, MQL conventional). The tribological effects were analyzed in terms of tool wear analysis, chip morphology along with statistical analysis for machined surface and evolved cutting forces during machining. The optimal input machining parameters for experiments were defined by the use of Taguchi and Grey relational based multi response optimization technique. Finally, the tribological study shows that the use of h-BN NCF-MQL is a viable and sustainable option for improving machining performance of hard- to- cut material like Inconel 625.

scholarly journals Comparison contact and thermal imaging methods measure the temperatures of the turning blades during cutting

Mechanik ◽  
2017 ◽  
Vol 90 (3) ◽  
pp. 214-216
Author(s):  
Karol Grochalski ◽  
Piotr Jabłoński
Keyword(s):  
Tool Wear ◽  
Thermal Imaging ◽  
Cutting Tool ◽  
Processing Parameters ◽  
Machining Process ◽  
Influence Of Temperature ◽  
Imaging Methods ◽  
Advantages And Disadvantages ◽  
Influence Of Temperature On ◽  
Materials Used

The paper presents a method of measuring the temperature during cutting and its impact on the machining process. The influence of temperature on the intensity of the cutting tool wear cutting and durability. Shows the measuring position, the materials used and the cutting tool. We present the results of the processing parameters, during which the measurements are made. This paper presents methods for measuring the temperature of the blade using a thermocouple and methods of radiation. It lists the advantages and disadvantages of each method.

Research and Application on High Efficiency Reversible Cutting Technique

2004 ◽  
Vol 471-472 ◽  
pp. 825-829
Author(s):  
Wen Ge Wu ◽  
Si Qin Pang ◽  
Qi Xun Yu
Keyword(s):  
High Efficiency ◽  
Cutting Tool ◽  
Handling Time ◽  
Cutting Parameters ◽  
Machining Process ◽  
Processing Route ◽  
Rough Machining ◽  
Machined Surface ◽  
Primary Motion ◽  
The Way

Reversible cutting method is a research thesis proposed to shorten processing route, decrease tool number and handling time, increase machining efficiency. There are three movement ways, i.e. reversible feed motion, reversible primary motion and reversible composite motion. Primary motion is done by workpiece, conventional or reversible feed motion is done by cutting tool in the way of reversible feed motion, e.g. turning. Cutting velocity is passed to cutting tool, clockwise or anti-clockwise cutting movement is done by cutting tool in the way of reversible primary motion, e.g. milling, shaping, drilling (spade drill), reaming. Primary and feed motions are all reversible in composite motion, e.g. turn-milling. Chip deformation and machined surface with reversible finishing is discussed. A mechanical analysis is carried out to the workpiece deformation of slender shaft turning in normal direction and reversible direction. The result has been verified by experiments. Experimental data for the range of cutting parameters tested showed that the reversible fine machining produce the compressive residual stresses at the surface, which are critical in the performance of the machined components. Experimental research indicted that the results of micro-hardness of reversible fine machining technique are smaller than that of general fine machining show that decreased plastic deformation of the surface layer and work-hardening. It can be adopted such planning which rough machining during advance stroke and fine machining during return stroke in machining process.

Tool Wear Analysis of MTConnect Production Data

2021 ◽  
Author(s):  
David Stock ◽  
Aditi Mukhopadhyay ◽  
Rob Potter ◽  
Andy Henderson
Keyword(s):  
Tool Wear ◽  
Cutting Tool ◽  
Numerical Control ◽  
Machining Process ◽  
Total Load ◽  
Wear Rates ◽  
Wear Analysis ◽  
Nc Program ◽  
Small Set ◽  
Key Steps

Abstract This paper presents the analysis of data collected using the MTConnect protocol from a lathe with a Computer Numerical Control (CNC). The purpose of the analysis is to determine an estimated cutting tool life and generate a model for calculating a real-time proxy of cutting tool wear. Various streams were used like spindle load, NC program blocks, the mode, execution etc. The novelty of this approach is that no information about the machining process, beyond the data provided by the machine, was necessary to determine the tool’s expected life. This method relies on the facts that a) it is generally accepted cutting loads increase with tool wear and b) that many CNC machines rely on a small set of regularly run CNC programs. These facts are leveraged to extract the total load for each run of each program on the machine, creating a dataset which is a good indicator of tool wear and replacement. The presented methodology has four key steps: extracting cycle metadata from the machine execution data; computing the integrated spindle loads for every cycle; normalizing the integrated spindle loads between different programs; extracting tool wear rates and changes from the resulting dataset. It is shown that the method can successfully extract the signature of tool wear under a common set of circumstances which are discussed in detail.

Performance of Low Cost 3D Printed Minimum Quantity Lubrication Applicator Using Palm Oil in Milling Steel

2020 ◽  
Vol 997 ◽  
pp. 85-92
Author(s):  
Abang Mohammad Nizam Abang Kamaruddin ◽  
Abdullah Yassin ◽  
Shahrol Mohamaddan ◽  
Syaiful Anwar Rajaie ◽  
Muhammad Isyraf Mazlan ◽  
...  
Keyword(s):  
Tool Wear ◽  
Cutting Forces ◽  
Cutting Tool ◽  
Low Cost ◽  
Minimum Quantity Lubrication ◽  
Machining Process ◽  
Cutting Condition ◽  
Dry Cutting ◽  
Minimum Quantity ◽  
Tool Performance

One of the most significant factors in machining process or metal cutting is the cutting tool performance. The rapid wear rate of cutting tools and cutting forces expend due to high cutting temperature is a critical problem to be solved in high-speed machining process, milling. Near-dry machining such as minimum quantity lubrication (MQL) is regarded as one of the solutions to solve this problem. However, the function of MQL in milling process is still uncertain so far which prevents MQL from widely being utilized in this specific machining process. In this paper, the mechanism of cutting tool performance such as tool wear and cutting forces in MQL assisted milling is investigated more comprehensively and the results are compared in three different cutting conditions which is dry cutting, wet cutting (flooding) and MQL. The MQL applicator is constructed from a household grade low-cost 3D printing technique. The chips surface of chips formation in each cutting condition is also observed using Scanning Electron Microscopy (SEM) machine. It is found out that wet cutting (flooding) is the best cutting performance compare to MQL and dry cutting. However, it can also be said that wet cutting and MQL produced almost the same value of tool wear and cutting forces as there is negligible differences in average tool wear and cutting forces between them based on the experiment conducted.

scholarly journals Findings of performance evaluation of EDM for different materials of electrodes and work pieces- a review

2018 ◽  
Vol 7 (4.5) ◽  
pp. 542
Author(s):  
Harshalkumar R. Mundane ◽  
Dr. A. V. Kale ◽  
Dr. J. P. Giri
Keyword(s):  
Surface Roughness ◽  
Tool Wear ◽  
Performance Measure ◽  
Machining Process ◽  
Machining Parameters ◽  
Spark Erosion ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Off Time ◽  
Time Pulse

EDM (Spark erosion) is non-conventional machining process which uses as removing unwanted material by electrical spark erosion. EDM Machining parameters affecting to the performance and the industries goal is to produce high quality of product with less time consuming and cost. To achieve these goals, optimizing the machining parameters such as pulse on time, pulse off time, cutting speed, depth of cut, duty cycle, arc gap, voltage etc. The performance measure of EDM is calculated on the basis of Material Remove Rate(MRR), Tool Wear Rate(TWR), and Surface Roughness(SR).The main objective of present work is to investigate of the influence of input EDM (Electro Discharge Machining) parameters on machining characteristics like surface roughness and the effects of various EDM process parameters such as pulse on time, pulse off time, servo voltage, peak current, dielectric flow rate, on different process response parameters such as material removal rate (MRR), surface roughness (Ra), Kerf (width of Cut), tool wear ratio(TWR)and surface integrity factors. In this paper few selected research paper related to Die-sinker EDM with effect of MRR, TWR, surface roughness (SR) and work piece material have been discussed.   

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