Tool pre-failure monitoring in intermittent cutting operations

DOIResolve DOI: http://doi.org/10.1115/IMECE2016-65748
AuthorSearch for: ; Search for: ; Search for: ; Search for: ; Search for:
TypeArticle
Proceedings titleASME 2016 International Mechanical Engineering Congress and Exposition, volume 2: Advanced Manufacturing
ConferenceASME 2016 International Mechanical Engineering Congress and Exposition, November 11, 2016, Phoenix, Arizona, USA
ISBN978-0-7918-5052-7
PagesV002T02A049
AbstractTool failure remains one of the most challenging phenomena in machining that affects the productivity and product quality, and hence the cost. In high feed rough milling operations of hard-to-cut materials, chipping and breakage have been observed as the dominant failure modes of the end mill cutters. Most of the work in the open literature is focusing on either detecting the complete tool breakage after it takes place or detecting the progressive tool wear. Detecting the abrupt/sudden tool failure due to tool chipping before it takes place, which is essential to avoid any damage to the machined part, has not been addressed. Therefore, the main objective of this research work is to investigate the ability of using the process monitoring signals in order to detect the tool pre-failure and failure by chipping/breakage in intermittent cutting operations. A method was devised to induce impact load on the cutting tool tip to study the features of signals collected by various sensors due to unstable crack propagation and chipping, while ensuring minimal tool wear effect. The acoustic emission (AE) signal features were able to successfully capture tool pre-failure, while other signals could detect the failure occurrence only.
Publication date
PublisherASME
LanguageEnglish
AffiliationAerospace; National Research Council Canada
Peer reviewedYes
NPARC number23001464
Export citationExport as RIS
Report a correctionReport a correction
Record identifier0ae416e3-7f7a-41b1-b9f1-8f4d9a8fef75
Record created2017-02-14
Record modified2017-02-14
Bookmark and share
  • Share this page with Facebook (Opens in a new window)
  • Share this page with Twitter (Opens in a new window)
  • Share this page with Google+ (Opens in a new window)
  • Share this page with Delicious (Opens in a new window)