A practical method to monitor tool wear in end milling using a changing cutting force model that requires no additional sensors
In end milling, proper tool life management is crucially important for achieving highly accurate machining, avoiding tool failure, and optimizing production costs. In recent years, a number of tool condition monitoring (TCM) methods aimed at improving tool life management have been proposed. However...
| Main Authors: | , , , |
|---|---|
| Format: | Article |
| Language: | English |
| Published: |
The Japan Society of Mechanical Engineers
2021-11-01
|
| Series: | Journal of Advanced Mechanical Design, Systems, and Manufacturing |
| Subjects: | |
| Online Access: | https://www.jstage.jst.go.jp/article/jamdsm/15/6/15_2021jamdsm0077/_pdf/-char/en |
| _version_ | 1818531944234745856 |
|---|---|
| author | Kazuki KANEKO Isamu NISHIDA Ryuta SATO Keiichi SHIRASE |
| author_facet | Kazuki KANEKO Isamu NISHIDA Ryuta SATO Keiichi SHIRASE |
| author_sort | Kazuki KANEKO |
| collection | DOAJ |
| description | In end milling, proper tool life management is crucially important for achieving highly accurate machining, avoiding tool failure, and optimizing production costs. In recent years, a number of tool condition monitoring (TCM) methods aimed at improving tool life management have been proposed. However, these methods have generally been impractical, and tool life still tends to be determined based on machining time or the quantity of the product produced. To address this shortcoming, a practical online TCM method is proposed. The proposed method is based on the idea that the frictional force acting on the flank face of a tool increases with increasing flank wear resulting from an increase in the contact surface area between the flank face and the machined surface. The implication is that tool wear can be indirectly monitored using the change in frictional force on the flank face, which can be determined by tracking the spindle motor torque obtained using a computerized numerical control (CNC) controller and a real time cutting force simulation. The influence of tool wear is not considered in the simulation model; rather, the frictional force is estimated from the difference between the average predicted cutting torque and the average monitored spindle motor torque. With the proposed method, no additional sensor is needed to monitor tool wear. Additionally, no parameter determination is necessary to perform the simulation because the parameters needed for the simulation are immediately determined at the beginning of the milling operation based on the monitored spindle motor torque. Thus, the TCM method proposed here offers a practical online alternative. |
| first_indexed | 2024-12-11T17:39:05Z |
| format | Article |
| id | doaj.art-0d798df6c851461ab2140d0ec4428e4b |
| institution | Directory Open Access Journal |
| issn | 1881-3054 |
| language | English |
| last_indexed | 2024-12-11T17:39:05Z |
| publishDate | 2021-11-01 |
| publisher | The Japan Society of Mechanical Engineers |
| record_format | Article |
| series | Journal of Advanced Mechanical Design, Systems, and Manufacturing |
| spelling | doaj.art-0d798df6c851461ab2140d0ec4428e4b2022-12-22T00:56:34ZengThe Japan Society of Mechanical EngineersJournal of Advanced Mechanical Design, Systems, and Manufacturing1881-30542021-11-01156JAMDSM0077JAMDSM007710.1299/jamdsm.2021jamdsm0077jamdsmA practical method to monitor tool wear in end milling using a changing cutting force model that requires no additional sensorsKazuki KANEKO0Isamu NISHIDA1Ryuta SATO2Keiichi SHIRASE3Graduate School of Science and Engineering, Ibaraki UniversityGraduate School of Engineering, Kobe UniversityGraduate School of Engineering, Kobe UniversityGraduate School of Engineering, Kobe UniversityIn end milling, proper tool life management is crucially important for achieving highly accurate machining, avoiding tool failure, and optimizing production costs. In recent years, a number of tool condition monitoring (TCM) methods aimed at improving tool life management have been proposed. However, these methods have generally been impractical, and tool life still tends to be determined based on machining time or the quantity of the product produced. To address this shortcoming, a practical online TCM method is proposed. The proposed method is based on the idea that the frictional force acting on the flank face of a tool increases with increasing flank wear resulting from an increase in the contact surface area between the flank face and the machined surface. The implication is that tool wear can be indirectly monitored using the change in frictional force on the flank face, which can be determined by tracking the spindle motor torque obtained using a computerized numerical control (CNC) controller and a real time cutting force simulation. The influence of tool wear is not considered in the simulation model; rather, the frictional force is estimated from the difference between the average predicted cutting torque and the average monitored spindle motor torque. With the proposed method, no additional sensor is needed to monitor tool wear. Additionally, no parameter determination is necessary to perform the simulation because the parameters needed for the simulation are immediately determined at the beginning of the milling operation based on the monitored spindle motor torque. Thus, the TCM method proposed here offers a practical online alternative.https://www.jstage.jst.go.jp/article/jamdsm/15/6/15_2021jamdsm0077/_pdf/-char/enend millingtool condition monitoringsensor-lessflank wearcutting torque simulation |
| spellingShingle | Kazuki KANEKO Isamu NISHIDA Ryuta SATO Keiichi SHIRASE A practical method to monitor tool wear in end milling using a changing cutting force model that requires no additional sensors Journal of Advanced Mechanical Design, Systems, and Manufacturing end milling tool condition monitoring sensor-less flank wear cutting torque simulation |
| title | A practical method to monitor tool wear in end milling using a changing cutting force model that requires no additional sensors |
| title_full | A practical method to monitor tool wear in end milling using a changing cutting force model that requires no additional sensors |
| title_fullStr | A practical method to monitor tool wear in end milling using a changing cutting force model that requires no additional sensors |
| title_full_unstemmed | A practical method to monitor tool wear in end milling using a changing cutting force model that requires no additional sensors |
| title_short | A practical method to monitor tool wear in end milling using a changing cutting force model that requires no additional sensors |
| title_sort | practical method to monitor tool wear in end milling using a changing cutting force model that requires no additional sensors |
| topic | end milling tool condition monitoring sensor-less flank wear cutting torque simulation |
| url | https://www.jstage.jst.go.jp/article/jamdsm/15/6/15_2021jamdsm0077/_pdf/-char/en |
| work_keys_str_mv | AT kazukikaneko apracticalmethodtomonitortoolwearinendmillingusingachangingcuttingforcemodelthatrequiresnoadditionalsensors AT isamunishida apracticalmethodtomonitortoolwearinendmillingusingachangingcuttingforcemodelthatrequiresnoadditionalsensors AT ryutasato apracticalmethodtomonitortoolwearinendmillingusingachangingcuttingforcemodelthatrequiresnoadditionalsensors AT keiichishirase apracticalmethodtomonitortoolwearinendmillingusingachangingcuttingforcemodelthatrequiresnoadditionalsensors AT kazukikaneko practicalmethodtomonitortoolwearinendmillingusingachangingcuttingforcemodelthatrequiresnoadditionalsensors AT isamunishida practicalmethodtomonitortoolwearinendmillingusingachangingcuttingforcemodelthatrequiresnoadditionalsensors AT ryutasato practicalmethodtomonitortoolwearinendmillingusingachangingcuttingforcemodelthatrequiresnoadditionalsensors AT keiichishirase practicalmethodtomonitortoolwearinendmillingusingachangingcuttingforcemodelthatrequiresnoadditionalsensors |