Cutting Tool Wearing Identification Through Predictive Maintenance and Its Impact on Surface Quality

Smart manufacturing has been in the media for a long time, but the reality shows that traditional mechanical manufacturing industries have not been able to implement data solutions aligned with Industry 4.0 standards. This work inquiries into the possibility of measuring cutting tool vibrations for CNC turning machines and presents the data analysis and a predictive model to identify tool wearing that can affects integrity surface quality of the manufactured component. These preliminary results are orientated towards implementing a predictive maintenance methodology in cutting tools.

Minimisation of Pose-Dependent Regenerative Vibrations for 5-Axis Milling Operations

The machining of free-formed surfaces, e.g., dies or moulds, is often affected by tool vibrations, which can affect the quality of the workpiece surface. Furthermore, in 5-axis milling, the dynamic properties of the system consisting of the tool, spindle and machine tool can vary depending on the tool pose. In this paper, a simulation-based methodology for optimising the tool orientation, i.e., tilt and lead angle of simultaneous 5-axis milling processes, is presented. For this purpose, a path finding algorithm was used to identify process configurations, that minimise tool vibrations based on pre-calculated simulation results, which were organised using graph theory. In addition, the acceleration behaviour of the feed drives, which limits the ability of adjusting the tool orientation with a high adaption frequency, as well as potential collisions of the tool, tool chuck and spindle with the workpiece were considered during the optimisation procedure.

Sensor-integrated tap holder for process uncertainty detection based on tool vibration and axial length compensation sensors

The tapping process is one of the most widespread manufacturing processes for internal threads, usually carried out at the end of the value chain. Any non-compliance with required quality standards or even the destruction of the thread due to process uncertainty in the tapping process is therefore subjected to high rework costs. Possible process uncertainties in the tapping process can be triggered by synchronization errors between feed rate and spindle speed, axis offset, faulty core holes and wear of the tapping tool. In order to detect process uncertainties during tapping and thus provide a basis for initiating countermeasures, a sensor-integrated tap holder was developed. This paper presents the realized concept of a rotating telemetry unit for signal processing, data acquisition and wireless data transmitting via WiFi standard on basis of low-cost embedded systems. Furthermore, two unique sensor concepts for measuring close-to-tool vibrations and the axial length compensation of the tapping tool are shown. Based on the sensor data in combination with feature engineering methods, process uncertainty during tapping are detected.

Monitoring of Vibrations in Free-Form Surface Processing Using Ball Nose End Mill Tools with Wireless Tool Holder Systems

Monitoring technologies have attracted attention in the factory automation fields that rely on the Internet of Things (IoT). However, it is difficult to monitor the process information from a round machining tool during rotating operations. Therefore, we developed a novel tool holder equipped with a wireless communication function to monitor tool vibrations. In the present study, we attempt to measure the tool holder vibrations during ball nose end milling processes using the servo driving information for different machine tools. We demonstrate that, using the developed tool holder with a wireless system, it is feasible to improve the machined free form surface by considering the servo driving information.

Minimizing tool vibrations when turning metals, as a method of energy-efficient cutting

Taking into account the interrelated vibration dynamics of cutting and the temperature in the cutting zone allows you to determine the most successful state or cutting mode in terms of energy costs. Purpose of the work: by forming a consistent model, determine the most convenient mechanism for the mode of operation of the cutting system, in which the further wear of the cutting wedge will be stabilized, the cutting force will also be stabilized, as well as the temperature in the cutting zone and the vibration of the tool. The paper examines: The process of metal processing by cutting on a lathe for the case of longitudinal turning of the product. Research methods: The research consists of a series of field experiments on real equipment using a modern measuring stand STD. 201-1, as well as using an experimental complex developed by us. Results and discussion. The results of processing experimental data, in particular, the results of measuring cutting forces, temperature and tool vibrations, are presented. The mechanism of stabilization of the processing process due to the relationship between temperature and vibrations during cutting and the formation of a quasi-stationary cutting mode is experimentally proved. It is assumed that due to the practical application of the results obtained in the work, it will be possible to increase the energy efficiency of metal processing by reducing the energy cost of vibration of the cutting wedge.

Drop impact estimate at cutting speed growth, force characteristics upon regenerative character of tool vibration

Revealed in numerous investigations a phenomenon connecting a cutting force drop at cutting speed growth effects considerably cutting dynamics. In the paper there is considered a dynamics of cutting taking into account the regenerative origin of tool vibrations with the estimate of cutting force changes impact upon vibrations. The results obtains may serve as a basis for a cutting mode choice in machine-tools of a lathe group.

Analysis of tool vibration and surface roughness with tool wear progression in hard turning: An experimental and statistical approach

The machined surface quality and dimensional accuracy obtained during hard turning is prominently gets affected due to tool wear and cutting tool vibrations. With this view, the results of tool wear progression on surface quality and acceleration amplitude is presented while machining AISI 52100 hard steel. Central Composite Rotatable Design (CCRD) is employed to develop experimental plan. The results reported that vibration signals sensed in a tangential direction (Vz) are most sensitive and found higher than the vibrations in the feed direction (Vx) and depth of cut direction (Vy). The acceleration signals in all three directions are observed to increase with the advancement of tool wear and good surface finish is observed as tool wear progresses up-to 0.136mm. The vibration amplitude is discovered high in the range 3 kHz – 10 kHz within selected cutting parameter range (cutting speed 60-180mm/min, feed 0.1-0.5mm/rev, depth of cut 0.1-0.5mm). The investigation is extended for the development of multiple regression models with regression coefficients value 0.9. These models found statically significant and give dependable estimates between a tool vibrations and cutting parameters.