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In-Process Tool Wear Detection Using Internal Encoder Signals for Unmanned Robust Machining
Högskolan Väst, Institutionen för ingenjörsvetenskap, Avdelningen för avverkande och additativa tillverkningsprocesser (AAT). (PTW)ORCID-id: 0000-0002-3436-3163
GKN Aerospace Engine Systems AB, Dept. 9634 – TL-3, SE-46181 Trollhättan, Sweden.
Högskolan Väst, Institutionen för ingenjörsvetenskap, Avdelningen för avverkande och additativa tillverkningsprocesser (AAT). (PTW)ORCID-id: 0000-0003-0976-9820
Högskolan Väst, Institutionen för ingenjörsvetenskap, Avdelningen för avverkande och additativa tillverkningsprocesser (AAT). North Carolina State University, Dept. of Mechanical and Aerospace Engineering, Raleigh, USA. (PTW)
2016 (engelsk)Inngår i: High Speed Machining, Vol. 2, nr 1, s. 37-50Artikkel i tidsskrift (Fagfellevurdert) Published
Abstract [en]

Automated Tool Condition Monitoring (TCM) often relies on additional sensors sensitive to tool wear to achieve robust machining processes. The need of additional sensors could impede the implementation of tool monitoring systems in industry due to the cost and retrofitting difficulties. This paper has investigated the use of existing position encoder signals to monitor a special face turning process with constant feed per revolution and machining speed. A signal processing method by converting encoder signals into a complex-valued form and a new vibration signature extraction method based on phase function were developed to analyze the encoder signals in the frequency domain. The cumulative spectrum indicated that the spectral energy would shift from the lower to the higher frequency band with increasing cutting load. The embedded vibration signatures extracted from the encoder signals provided real-time detectability of the machining condition with distinguishable spectral modes. The embedded vibration signatures extracted from the encoder signals provided additional detectability of the machining condition with distinguishable spectral modes. In particular, tool chipping manifested itself as significant amplitude changes at a specific frequency band 20-30 Hz in the extracted vibration signatures. A new monitoring metric based on the XY-plane modulations combined with statistical process control charts was proposed and shown to be a robust tool wear and tool wear rate indicator. The results show that when tool chipping occurred, it could be detected in real-time when this this tool wear rate value jumped in combination with breach of the control limits. This confirms that internal encoder signals, together with the proposed metric, could be a robust in-process tool wear monitor.

sted, utgiver, år, opplag, sider
De Gruyter Open, 2016. Vol. 2, nr 1, s. 37-50
Emneord [en]
Face turning, TCM, tool wear, encoder signals, SPC, EWMA
HSV kategori
Forskningsprogram
TEKNIK, Produktions- och materialteknik; Produktionsteknik
Identifikatorer
URN: urn:nbn:se:hv:diva-10071DOI: 10.1515/hsm-2016-0004OAI: oai:DiVA.org:hv-10071DiVA, id: diva2:1040357
Tilgjengelig fra: 2016-10-27 Laget: 2016-10-27 Sist oppdatert: 2019-11-18bibliografisk kontrollert

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[HSM 2016] In-Process Tool Wear Detection Using Internal Encoder Signals for U R M(3614 kB)197 nedlastinger
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