Monitoring Method of Process Temperature and Vibration of Rotating Machining Tool with a Wireless Communication Holder System

2016 ◽  
Vol 874 ◽  
pp. 519-524 ◽  
Author(s):  
Ryo Matsuda ◽  
Masatoshi Shindou ◽  
Tatsuya Furuki ◽  
Toshiki Hirogaki ◽  
Eiichi Aoyama
Keyword(s):  
Wireless Communication ◽  
Infrared Thermography ◽  
Process Monitoring ◽  
End Milling ◽  
Process Temperature ◽  
Chatter Vibration ◽  
End Mill ◽  
Monitoring Method ◽  
Mems Accelerometer ◽  
Boring Tool

We developed a wireless communication holder system to monitor the process temperature and vibration of a rotating machining tool. This report presents an estimation of the process temperature in end-milling and the chatter vibration when boring with it. The thermocouple is set in the end-mill tool to measure the process temperature, and the MEMS accelerometer is set in the boring tool to measure the chatter vibration. We also present an investigation of the end-mill temperature observed using infrared thermography and the vibration of the spindle using a traditional accelerometer. The proposed holder system was found to be effective to estimate the process monitoring of the rotating machining tools.

Investigation of End-Milling Process Based on Monitoring Method with Wireless Telegraphic Multifunctional Tool Holder and Infrared Thermography

2016 ◽  
Vol 1136 ◽  
pp. 606-611
Author(s):  
Masatoshi Shindou ◽  
Ryo Matsuda ◽  
Tatsuya Furuki ◽  
Toshiki Hirogaki ◽  
Eiichi Aoyama
Keyword(s):  
Infrared Thermography ◽  
High Speed ◽  
End Milling ◽  
Temperature Monitoring ◽  
Machining Process ◽  
Internal Temperature ◽  
End Mill ◽  
Tool Temperature ◽  
Monitoring Method ◽  
Tool Holder

Infrared thermographic technology has attracted the attention of various industrial fields. We therefore focus on it as a novel tool temperature monitoring method to improve the end-milling conditions of difficult-to-cut materials. However, it is difficult to measure tool temperature under coolant conditions because coolant prevents the monitoring of end-mill tool surfaces. Thus, we developed a novel temperature monitoring method by applying a pore electric discharge machining process to place a thermocouple sensor in the end-mill tool and by using a wireless telegraphic multifunctional tool holder to directly measure the internal temperature of the end-mill tool under rotation. We evaluated internal temperature distribution under various end-milling conditions on the basis of multipoint simultaneous measurements and discussed the influence of forced convection heat transfer on the internal temperature of the tool under various rotating conditions. In addition, we used a finite element method to analyze unsteady heat conduction on the basis of temperature measurement by high-speed video infrared thermography and compared the results with those of the wireless telegraphic multifunctional tool holder to demonstrate its validity and usefulness.

An Experimental Study on Suppression of Chatter Vibration with Different Helix Angles End-Mill

2009 ◽  
Vol 407-408 ◽  
pp. 37-40 ◽  
Author(s):  
Heisaburo Nakagawa ◽  
Keiji Ogawa ◽  
Satoshi Demachi ◽  
Hideyasu Hasegawa
Keyword(s):  
Stainless Steels ◽  
Vibration Mode ◽  
End Milling ◽  
Cutting Speed ◽  
Austenitic Stainless Steels ◽  
Helix Angle ◽  
Chatter Vibration ◽  
End Mill ◽  
Monitoring Method ◽  
Cutting Speeds

In this study we attempted to suppress chatter vibration in end-milling of austenitic stainless steels with an end-mill having different helix angles. We showed there were two types of chatter vibration in end-milling with a conventional end-mill with regular helix angle. The two types of chatter vibration depend on the cutting speed. We detected these two types of chatter vibration by the developed monitoring method using laser Doppler vibrometers. We classified the two types of chatter vibration according to chatter generating tendency, frequency and vibration mode. We showed that chatter vibration generated at lower cutting speeds was regenerative chatter vibration. On the other hand, chatter vibration generated at higher cutting speeds was another type. We showed that a end-mill with different helix angles could prevent generative chatter vibration at lower cutting speeds and was also effective in suppressing chatter vibration at higher cutting speeds.

Novel State Estimation Method of Surface Chatter Pattern via Image Processing After End Milling

2019 ◽  
Author(s):  
Nobutoshi Ozaki ◽  
Shota Matsui ◽  
Toshiki Hirogaki ◽  
Eiichi Aoyama
Keyword(s):  
End Milling ◽  
Estimation Method ◽  
Digital Camera ◽  
Image Data ◽  
Displacement Sensor ◽  
Chatter Vibration ◽  
End Mill ◽  
Tool Edge ◽  
Acceleration Sensors ◽  
Processing Site

Abstract We studied a new analytical method for determining self-excited chatter vibration at an end mill processing site. When chatter vibration occurs, cutting marks with periodic features called “chatter marks” are generated on the processed surface. We focused on the relationship between the vibration generated during cutting and the roughness of the processed surface. We developed a method to analyze such vibrations, based on the roughness of the finished surface. Instead of using a roughness meter and laser-measuring instrument, which are often used for measuring the contours of a processed surface, we presumed the roughness of the processed surface from image data obtained using a digital camera. As a comparative experiment to verify the proposed method, side cutting with an end mill was performed. Chatter vibrations occurring during the cutting were measured using a displacement sensor and microphone, and compared with the vibration of the tool edge as determined from the processed surface. The chatter frequency read from the processed surface was close to that obtained from the displacement sensor and microphone. Thus, the proposed method can be used to analyze the information of chatter vibration inexpensively and easily. It can serve as a substitute for displacement and acceleration sensors.

Monitoring of End-Mill Temperature with Infrared Thermography and Wireless Tool Holder System

2014 ◽  
Vol 1017 ◽  
pp. 624-629 ◽  
Author(s):  
Masatoshi Shindou ◽  
Ryo Matsuda ◽  
Tatsuya Furuki ◽  
Toshiki Hirogaki ◽  
Eiichi Aoyama
Keyword(s):  
End Milling ◽  
Small Diameter ◽  
Sampling Time ◽  
End Mill ◽  
Monitoring Tool ◽  
Tool Temperature ◽  
Wireless System ◽  
Response Measurement ◽  
Tool Holder ◽  
Novel Method

Nowadays, infrared thermographic technology has been attracting attention in various industrial fields. We therefore focus on it as a novel method for monitoring tool temperature to improve end-milling conditions for difficult-to-cut materials. However, a problem has emerged; it is difficult to measure the tool temperature when there is a coolant because the coolant prevents monitoring of the surface of the end-mill tool. Thus, we developed a wireless tool holder system equipped with a thermocouple in the end mill to monitor the tool temperature under coolant conditions. In this report, we compared the temperature measured by infrared thermographic imagery with that measured by a wireless tool holder system when end milling the stainless steel under dry coolant conditions. The thermocouple, which has a small diameter of 0.12 mm, was used to ensure high response measurement in the proposed wireless tool holder. We obtained the tool temperatures by infrared thermographic imagery and by wireless tool holder equipped with a thermocouple at a sampling time of 1/30 of a second. We confirmed that the temperature measured by the wireless tool holder agrees with that measured by infrared thermographic imagery. As a result, we demonstrated that the developed method with a wireless system is effective to estimate the tool temperature in end-milling processes and makes it feasible to measure it under coolant conditions.

Surface Roughness Analysis for Radius End Mill in Cross Feed Direction Both Contour and Scanning Line Machinings

2020 ◽  
Author(s):  
Hirohisa Narita
Keyword(s):  
Surface Roughness ◽  
Inclination Angle ◽  
End Milling ◽  
Contour Line ◽  
End Mill ◽  
Good Surface ◽  
Corner Radius ◽  
Feed Direction ◽  
Scanning Line ◽  
Influence Degree

Abstract An optimum experimental condition, which realize good surface roughness in cross direction both contour and scanning lines, for radius end mill against some inclined surfaces is obtained and some features is these cutting processes is discussed in this paper. The optimum experimental condition, which consists of cutting type (or feed direction), spindle speed, feed rate, depth of immersion, inclination angle, corner radius of end mill and cross feed, is obtained and the influence degree of these parameters is calculated by using Taguchi method. The experiment is carried out based on L18 orthogonal array. Based on the influence degree and geometric contact status due to unique shape of radius end mill, some feature of radius end milling is introduced. As a result of the contour line machining, a scallop height is very influenced by the inclination angle and the corner radius, and surface machined by bottom edge must not be remained. Regarding the scanning line machining, “go-up” is good for the feed direction. Big corner radius is also suitable because side edge does not contact to workpiece. In other words, the cutting force in radial direction becomes small. Furthermore, the surface roughness of the scanning line machining is smaller than the one of the contour line machining.

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