Intelligent Tool Condition Monitoring System Based on Rough Sets and Mathematical Morphology

2007 ◽  
Vol 10-12 ◽  
pp. 722-726 ◽  
Author(s):  
Li Zhang ◽  
Shi Ming Ji ◽  
Yi Xie ◽  
Qiao Ling Yuan ◽  
Yin Dong Zhang ◽  
...  
Keyword(s):  
Tool Wear ◽  
Mathematical Morphology ◽  
Condition Monitoring ◽  
Rough Sets ◽  
Cutting Tool ◽  
Cutting Tools ◽  
Tool Condition Monitoring ◽  
Online Tool ◽  
Tool Condition ◽  
Condition Monitoring System

The image of cutting tools provides reliable information regarding the extent of tool wear. In this paper, we propose the theory of image processing based on rough sets and mathematical morphology to analyzing the flank faces which are chosen as our monitoring object. First, through plotting the appropriate subset, the rough sets filter is used to enhancement the image of tool wear. Then, the mathematical morphology theory is applied to process the translated binary image. Finally, tool condition monitoring is realized by measuring the area of tool wear. This paper gives the corresponding monitoring principal and proposes a new algorithm to process the cutting tool image. The algorithm is also flexible and fast enough to be implemented in real time for online tool wear or tool condition monitoring.

TOOL CONDITION MONITORING SYSTEM IN SERIAL PRODUCTION CONDITIONS

2020 ◽  
Vol 4 (2) ◽  
pp. 161-168
Author(s):  
V.I. GOLOVIN ◽  
S.Yu. RADCHENKO
Keyword(s):  
Monitoring System ◽  
Condition Monitoring ◽  
Cutting Tool ◽  
Tool Condition Monitoring ◽  
Serial Production ◽  
Tool Condition ◽  
Decision Making System ◽  
Software And Hardware ◽  
Condition Monitoring System ◽  
The Cost

One of the most important tasks of serial and mass production is to maintain the continuity of the technological process in order to reduce equipment downtime and, as a result, the cost of production. One of the systems is the tool condition monitoring system. However, the solutions used today are complex software and hardware systems that are not available for most medium and small productions. The article proposes a system based on a comparative analysis of the applied tool with reference instances. The results of the analysis are sent to the decision-making system, which determines the feasibility of further use of the cutting tool for subsequent machining. An example of an experimental study of milling processing is given. The results obtained show the possibility and rationality of using this model to predict the state of the instrument.

Experimental Investigation to Predict Tool Wear and Vibration Displacement in Turning – A Base for Tool Condition Monitoring

2016 ◽  
Vol 16 (2) ◽  
pp. 103-114
Author(s):  
M. Prakash Babu ◽  
Balla Srinivasa Prasad
Keyword(s):  
Mathematical Model ◽  
Tool Wear ◽  
Condition Monitoring ◽  
Cutting Forces ◽  
Cutting Tool ◽  
Tool Condition Monitoring ◽  
Depth Of Cut ◽  
Vibration Displacement ◽  
Tool Condition ◽  
Tool Vibrations

AbstractIn the present work investigation primarily focuses on identifying the presence of cutting tool vibrations during face turning process. For this purpose an online non-contact vibration transducer i. e. laser Doppler Vibrometer is used as part of a novel approach. The revisions in the values of cutting forces, vibrations and acoustic optic emission signals with cutting tool wear are recorded and analyzed. This paper presents a mathematical model in an attempt to understand tool lifeunder vibratory cutting conditions. Tool wear and cutting force data are collected in the dry machiningof AISI 1040 steel at different vibrationinduced test conditions. Identifying the correlation among tool wear, cutting forces and displacement due to vibration is a critical task in the present study. These results are used to predict the evolution of displacement and tool wear in the experiment. Specifically, the research tasks include: to provide an appropriate experimental data to prove the mathematical model of tool wear based on the influence of cutting tool vibrations in turning.The modeling is focused on demonstrating the scientific relationship between the process variables such as vibration displacement, vibration amplitude, feedrate, depth of cut and spindle speed while getting into account machine dynamics effect and the effects such as surface roughness and tool wear generated in the operation. Present work also concentrates on the improvement in machinability during vibration assisted turning with different cutting tools. The effect of work piece displacement due to vibration on the tool wear is critically analyzed. Finally, tool wear is established on the basis of the maximum displacement that can be tolerated in a process for an effective tool condition monitoring system.

Tool condition monitoring system based on support vector machine and differential evolution optimization

2016 ◽  
Vol 231 (5) ◽  
pp. 805-813 ◽  
Author(s):  
Guo F Wang ◽  
Qing L Xie ◽  
Yan C Zhang
Keyword(s):  
Support Vector Machine ◽  
Tool Wear ◽  
Differential Evolution ◽  
Condition Monitoring ◽  
Support Vector Machine Classifier ◽  
Tool Condition Monitoring ◽  
Support Vector ◽  
Grid Search ◽  
Tool Condition ◽  
Condition Monitoring System

A tool condition monitoring system based on support vector machine and differential evolution is proposed in this article. In this system, support vector machine is used to realize the mapping between the extracted features and the tool wear states. At the same time, two important parameters of the support vector machine which are called penalty parameter C and kernel parameter [Formula: see text] are optimized simultaneously based on differential evolution algorithm. In order to verify the effectiveness of the proposed system, a multi-tooth milling experiment of titanium alloy was carried out. Cutting force signals related to different tool wear states were collected, and several time domain and frequency domain features were extracted to depict the dynamic characteristics of the milling process. Based on the extracted features, the differential evolution-support vector machine classifier is constructed to realize the tool wear classification. Moreover, to make a comparison, empirical selection method and four kinds of grid search algorithms are also used to select the support vector machine parameters. At the same time, cross validation is utilized to improve the robustness of the classifier evaluation. The results of analysis and comparisons show that the classification accuracy of differential evolution-support vector machine is higher than empirical selection-support vector machine. Moreover, the time consumption of differential evolution-support vector machine classifier is 5 to 12 times less than that of grid search-support vector machine.

scholarly journals An Improved Deep Learning Model for Online Tool Condition Monitoring Using Output Power Signals

2020 ◽  
Vol 2020 ◽  
pp. 1-12
Author(s):  
Lang Dai ◽  
Tianyu Liu ◽  
Zhongyong Liu ◽  
Lisa Jackson ◽  
Paul Goodall ◽  
...  
Keyword(s):  
Tool Wear ◽  
Output Power ◽  
Condition Monitoring ◽  
Test Data ◽  
Cutting Tool ◽  
Short Term Memory ◽  
Cutting Tools ◽  
Intelligent Manufacturing ◽  
Accurate Identification ◽  
Tool Condition

Something like normal functionality of tools in a manufacturing process is typically designed to ensure reliability, where fast and accurate identification of tool abnormal operation plays a vital role in intelligent manufacturing. In this study, a novel method is proposed to assess the cutting tool condition, which consists of a convolutional neural network with wider first-layer kernels (W-CONV), and long short-term memory (LSTM). The analysis benefits from the use of output power signals from the cutting tool, since they can be obtained easily and efficiently, enabling the proposed method to be applicable in practical operation for online condition monitoring. Moreover, effectiveness of the proposed method is investigated, using test data from cutting tools at various tool wear conditions. Results demonstrate that with the proposed method, tool wear condition can be identified accurately and efficiently. Furthermore, with test data collected at cutting tools with different sizes, the robustness of the proposed method can be further clarified.

Local Region Mahalanobis Distance Feature and Its Application in Monitoring Wearing and Breakage States of Cutting Tools

2004 ◽  
Vol 471-472 ◽  
pp. 418-421
Author(s):  
Shi Ming Ji ◽  
Li Zhang ◽  
Y.H. Wan ◽  
X. Zhang ◽  
Ju Long Yuan ◽  
...  
Keyword(s):  
Condition Monitoring ◽  
Mahalanobis Distance ◽  
Cutting Tool ◽  
Cutting Tools ◽  
Tool Condition Monitoring ◽  
Local Region ◽  
Structure Form ◽  
Tool Condition ◽  
On Line ◽  
New Research

The Mahalanobis distance feature proposed by P.C .Mahalanobis, an indian statistician. In this paper, we propose a new concept, Local Region Mahalanobis Distance feature –LRMD feature, we shall discuss the structure form, the obtaining methods of LRMD feature from an image and the relations between the LRMD feature and wearing and breakage states of cutting tools. The new research results indicate that the method of automatic on-line cutting tool condition monitoring based on LRMD feature can has better inspect result than the method of Mahalanobis Distance feature.

Tool Wear Monitoring Using Microphone Signals and Recurrence Quantification Analysis when Drilling Composites

2013 ◽  
Vol 711 ◽  
pp. 239-244 ◽  
Author(s):  
Eshetu D. Eneyew ◽  
M. Ramulu
Keyword(s):  
Condition Monitoring ◽  
Cutting Tool ◽  
Flank Wear ◽  
Recurrence Quantification Analysis ◽  
Tool Condition Monitoring ◽  
Monitoring Method ◽  
Online Tool ◽  
Tool Condition ◽  
Quantification Analysis

The quality of the hole produced during the drilling of composite materials is one of the controlling factors for the resulting joint strength and integrity of the structural component. Quality of the hole depends on the condition of the cutting tool. Continuous cutting tool condition monitoring method is vital to accomplish the desired hole quality. To address this concern, an online tool condition monitoring technique using a simple audio microphone as a sensor is developed and Recurrence Quantification Analysis (RQA) methodology was used as a signal analysis tool to predict the tool condition in terms of flank wear. A series of experimental drilling operation was carried out on uni-directional carbon fiber reinforced plastic (CFRP) composite. It was found that the amplitude of the microphone signal decreases with the increase of the tool flank wear. In addition, from the selected eight RQA output variables, six of them show an increasing trend with the increase of the measured flank wear, whereas, two of them show a decreasing trend with the increase of tool wear. The same trend has been observed in both set of experiments. These results demonstrate that, this novel approach is an effective and economical online tool condition monitoring method.

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