Development of Insert Condition Classification System for CNC Lathes Using Power Spectral Density Distribution of Accelerometer Vibration Signals
Insert conditions significantly influence the product quality and manufacturing efficiency of lathe machining. This study used the power spectral density distribution of the vibration signals of a lathe machining accelerometer to design an insert condition classification system applicable to differe...
| Main Authors: | , |
|---|---|
| Format: | Article |
| Language: | English |
| Published: |
MDPI AG
2020-10-01
|
| Series: | Sensors |
| Subjects: | |
| Online Access: | https://www.mdpi.com/1424-8220/20/20/5907 |
| _version_ | 1797550479349121024 |
|---|---|
| author | Yi-Wen Huang Syh-Shiuh Yeh |
| author_facet | Yi-Wen Huang Syh-Shiuh Yeh |
| author_sort | Yi-Wen Huang |
| collection | DOAJ |
| description | Insert conditions significantly influence the product quality and manufacturing efficiency of lathe machining. This study used the power spectral density distribution of the vibration signals of a lathe machining accelerometer to design an insert condition classification system applicable to different machining conditions. For four common lathe machining insert conditions (i.e., built-up edge, flank wear, normal, and fracture), herein, the insert condition classification system was established with two stages—insert condition modeling and machining model fusion. In the insert condition modeling stage, the magnitude features of the segmented frequencies were captured according to the power spectral density distributions of the accelerometer vibration signals. Principal component analysis and backpropagation neural networks were used to develop insert condition models for different machining conditions. In the machining model fusion stage, a backpropagation neural network was employed to establish the weight function between the machining conditions and insert condition models. Subsequently, the insert conditions were classified based on the calculated weight values of all the insert condition models. Cutting tests were performed on a computer numerical control (CNC) lathe and utilized to validate the feasibility of the designed insert condition classification system. The results of the cutting tests showed that the designed system could perform insert condition classification under different machining conditions, with a classification rate exceeding 80%. Using a triaxial accelerometer, the designed insert condition classification system could perform identification and classification online for four common insert conditions under different machining conditions, ensuring that CNC lathes could further improve manufacturing quality and efficiency in practice. |
| first_indexed | 2024-03-10T15:29:52Z |
| format | Article |
| id | doaj.art-b84cc58ed6914b4684e90acd31c4223a |
| institution | Directory Open Access Journal |
| issn | 1424-8220 |
| language | English |
| last_indexed | 2024-03-10T15:29:52Z |
| publishDate | 2020-10-01 |
| publisher | MDPI AG |
| record_format | Article |
| series | Sensors |
| spelling | doaj.art-b84cc58ed6914b4684e90acd31c4223a2023-11-20T17:44:08ZengMDPI AGSensors1424-82202020-10-012020590710.3390/s20205907Development of Insert Condition Classification System for CNC Lathes Using Power Spectral Density Distribution of Accelerometer Vibration SignalsYi-Wen Huang0Syh-Shiuh Yeh1Institute of Mechatronic Engineering, National Taipei University of Technology, Taipei 10608, TaiwanDepartment of Mechanical Engineering, National Taipei University of Technology, Taipei 10608, TaiwanInsert conditions significantly influence the product quality and manufacturing efficiency of lathe machining. This study used the power spectral density distribution of the vibration signals of a lathe machining accelerometer to design an insert condition classification system applicable to different machining conditions. For four common lathe machining insert conditions (i.e., built-up edge, flank wear, normal, and fracture), herein, the insert condition classification system was established with two stages—insert condition modeling and machining model fusion. In the insert condition modeling stage, the magnitude features of the segmented frequencies were captured according to the power spectral density distributions of the accelerometer vibration signals. Principal component analysis and backpropagation neural networks were used to develop insert condition models for different machining conditions. In the machining model fusion stage, a backpropagation neural network was employed to establish the weight function between the machining conditions and insert condition models. Subsequently, the insert conditions were classified based on the calculated weight values of all the insert condition models. Cutting tests were performed on a computer numerical control (CNC) lathe and utilized to validate the feasibility of the designed insert condition classification system. The results of the cutting tests showed that the designed system could perform insert condition classification under different machining conditions, with a classification rate exceeding 80%. Using a triaxial accelerometer, the designed insert condition classification system could perform identification and classification online for four common insert conditions under different machining conditions, ensuring that CNC lathes could further improve manufacturing quality and efficiency in practice.https://www.mdpi.com/1424-8220/20/20/5907insert conditionsaccelerometerpower spectral densityCNC lathes |
| spellingShingle | Yi-Wen Huang Syh-Shiuh Yeh Development of Insert Condition Classification System for CNC Lathes Using Power Spectral Density Distribution of Accelerometer Vibration Signals Sensors insert conditions accelerometer power spectral density CNC lathes |
| title | Development of Insert Condition Classification System for CNC Lathes Using Power Spectral Density Distribution of Accelerometer Vibration Signals |
| title_full | Development of Insert Condition Classification System for CNC Lathes Using Power Spectral Density Distribution of Accelerometer Vibration Signals |
| title_fullStr | Development of Insert Condition Classification System for CNC Lathes Using Power Spectral Density Distribution of Accelerometer Vibration Signals |
| title_full_unstemmed | Development of Insert Condition Classification System for CNC Lathes Using Power Spectral Density Distribution of Accelerometer Vibration Signals |
| title_short | Development of Insert Condition Classification System for CNC Lathes Using Power Spectral Density Distribution of Accelerometer Vibration Signals |
| title_sort | development of insert condition classification system for cnc lathes using power spectral density distribution of accelerometer vibration signals |
| topic | insert conditions accelerometer power spectral density CNC lathes |
| url | https://www.mdpi.com/1424-8220/20/20/5907 |
| work_keys_str_mv | AT yiwenhuang developmentofinsertconditionclassificationsystemforcnclathesusingpowerspectraldensitydistributionofaccelerometervibrationsignals AT syhshiuhyeh developmentofinsertconditionclassificationsystemforcnclathesusingpowerspectraldensitydistributionofaccelerometervibrationsignals |