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.

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.

Optimization of Control Gains in Numerical Control

2016 ◽  
Vol 1136 ◽  
pp. 651-654
Author(s):  
Hideki Aoyama ◽  
Duo Zhang
Keyword(s):  
Feed Rate ◽  
Machine Tools ◽  
Cutting Tool ◽  
Numerical Control ◽  
Machining Processes ◽  
Nc Program ◽  
Acceleration And Deceleration

It is frequently the case that the feed rate indicated in a numerical control (NC) program does not obtain in actual machining processes and the cutting tool does not path the points indicated in the NC. A reason underlying such problems is that control gains are not optimized, which causes issues with acceleration and deceleration in the control of machine tools. To address these problems, in this paper, we propose a method for the optimization of control gains using the MATLAB and Simulink software by considering the weight of the workpiece, the controlling distance, and the controlling speed. Simulations confirmed the effectiveness of our proposed optimization.

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.

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 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.

Synchronous Adjustment of Milling Tool Path Based on the Relative Deviation

2011 ◽  
Vol 133 (5) ◽  
Author(s):  
Xiao-Jin Wan ◽  
Cai-Hua Xiong ◽  
Lin Hua
Keyword(s):  
Tool Path ◽  
Cutting Tool ◽  
Cnc Machining ◽  
Numerical Control ◽  
Machining Process ◽  
Machining Accuracy ◽  
Source File ◽  
Modern Computer ◽  
Adjustment Strategy ◽  
Machining System

In machining process, machining accuracy of part mainly depends on the position and orientation of the cutting tool with respect to the workpiece which is influenced by errors of machine tools and cutter-workpiece-fixture system. A systematic modeling method is presented to integrate the two types of error sources into the deviation of the cutting tool relative to the workpiece which determines the accuracy of the machining system. For the purpose of minimizing the machining error, an adjustment strategy of tool path is proposed on the basis of the generation principle of the cutter location source file (CLSF) in modern computer aided manufacturing (CAM) system by means of the prediction deviation, namely, the deviation of the cutting tool relative to the workpiece in computer numerical control (CNC) machining operation. The resulting errors are introduced as adjustment values to adjust the nominal tool path points from cutter location source file from commercial CAM system prior to machining. Finally, this paper demonstrates the effectiveness of the prediction model and the adjustment technique by two study cases.

A Method for Using a Virtual Machining Simulation to Consider Both Equivalent CO2Emissions and Machining Costs in Determining Cutting Conditions

2015 ◽  
Vol 9 (2) ◽  
pp. 115-121 ◽  
Author(s):  
Hirohisa Narita ◽  
Keyword(s):  
Evaluation System ◽  
Cutting Tool ◽  
Cutting Speed ◽  
Cutting Conditions ◽  
Machining Process ◽  
Machining Simulation ◽  
End Mill ◽  
Virtual Machining ◽  
Mill Operation ◽  
Nc Program

An evaluation system for calculating equivalent CO2emissions and machining costs is developed using an activity-based model. The system can evaluate a machining process from an NC program, workpiece information, and cutting tool information, and it can then calculate accurate equivalent CO2emissions and the machining cost. The cutting speed of an end mill operation is evaluated in terms of the equivalent CO2emission and the machining cost. Based on the results, optimal cutting conditions are determined to minimize the equivalent CO2emissions and the machining cost to the extent possible.

Investigation on Chip Formation during Machining Using Finite Element Modeling

2012 ◽  
Vol 505 ◽  
pp. 31-36 ◽  
Author(s):  
Moaz H. Ali ◽  
Basim A. Khidhir ◽  
Bashir Mohamed ◽  
A.A. Oshkour
Keyword(s):  
Finite Element ◽  
Tool Wear ◽  
Finite Element Modeling ◽  
Chip Formation ◽  
Cutting Tool ◽  
Chip Morphology ◽  
Machining Process ◽  
Element Modeling ◽  
Segmented Chip ◽  
Cutting Speeds

Titanium alloys are desirable materials for aerospace industry because of their excellent combination of high specific strength, lightweight, fracture resistant characteristics, and general corrosion resistance. Therefore, the chip morphology is very important in the study of machinability of metals as well as the study of cutting tool wear. The chips are generally classified into four groups: continuous chips, chips with built-up-edges (BUE), discontinuous chips and serrated chips. . The chip morphology and segmentation play a predominant role in determining machinability and tool wear during the machining process. The mechanics of segmented chip formation during orthogonal cutting of titanium alloy Ti–6Al–4V are studied in detail with the aid of high-speed imaging of the chip formation zone. The finite element model of chip formation of Ti–6Al–4V is suggested as a discontinuous type chip at lower cutting speeds developing into a continuous, but segmented, chip at higher cutting speeds. The prediction by using finite-element modeling method and simulation process in machining while create chips formation can contribute in reducing the cost of manufacturing in terms of prolongs the cutting tool life and machining time saving.

scholarly journals System for Tool-Wear Condition Monitoring in CNC Machines under Variations of Cutting Parameter Based on Fusion Stray Flux-Current Processing

Sensors ◽  
2021 ◽  
Vol 21 (24) ◽  
pp. 8431
Author(s):  
Arturo Yosimar Jaen-Cuellar ◽  
Roque Alfredo Osornio-Ríos ◽  
Miguel Trejo-Hernández ◽  
Israel Zamudio-Ramírez ◽  
Geovanni Díaz-Saldaña ◽  
...  
Keyword(s):  
Tool Wear ◽  
Condition Monitoring ◽  
Feed Rate ◽  
Cutting Tool ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Economic Benefits ◽  
Numerical Control ◽  
Cnc Machines ◽  
Cutting Tool Wear

The computer numerical control (CNC) machine has recently taken a fundamental role in the manufacturing industry, which is essential for the economic development of many countries. Current high quality production standards, along with the requirement for maximum economic benefits, demand the use of tool condition monitoring (TCM) systems able to monitor and diagnose cutting tool wear. Current TCM methodologies mainly rely on vibration signals, cutting force signals, and acoustic emission (AE) signals, which have the common drawback of requiring the installation of sensors near the working area, a factor that limits their application in practical terms. Moreover, as machining processes require the optimal tuning of cutting parameters, novel methodologies must be able to perform the diagnosis under a variety of cutting parameters. This paper proposes a novel non-invasive method capable of automatically diagnosing cutting tool wear in CNC machines under the variation of cutting speed and feed rate cutting parameters. The proposal relies on the sensor information fusion of spindle-motor stray flux and current signals by means of statistical and non-statistical time-domain parameters, which are then reduced by means of a linear discriminant analysis (LDA); a feed-forward neural network is then used to automatically classify the level of wear on the cutting tool. The proposal is validated with a Fanuc Oi mate Computer Numeric Control (CNC) turning machine for three different cutting tool wear levels and different cutting speed and feed rate values.

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