Condition monitoring with round ceramic inserts while face milling using acceleration data

Justin L. Milner, John Timothy Roth

Research output: Chapter in Book/Report/Conference proceedingConference contribution

1 Citation (Scopus)

Abstract

In order to automate machining operations, it is necessary to develop robust tool condition monitoring techniques. In this paper, a tool monitoring strategy for round whisker-reinforced ceramic end milling tools is presented based on the Fourier transform and statistical analysis of the vibrations of the tool during the machining operations. Using a low-cost tri-axial piezoelectric accelerometer, the presented algorithm demonstrates the ability to accurately monitor the condition of the tools as the wear increases during linear milling operations. One benefit of using accelerometer signals to monitor the cutting process is that the sensor does not limit the machines capabilities, as a workpiece mounted dynamometer does. To demonstrate capabilities of the technique for round coated and uncoated ceramic tooling, six tool wear life tests were conducted under various conditions. The indirect method discussed herein successfully tracks the tool's wear, even with the occurrence of minor chipping, and is shown to be sensitive enough to provide sufficient time to replace the insert prior to damage of the machine tool, cutter, and/or workpiece.

Original languageEnglish (US)
Title of host publicationASME 2010 International Manufacturing Science and Engineering Conference, MSEC 2010
Pages389-399
Number of pages11
Volume1
DOIs
StatePublished - 2010
EventASME 2010 International Manufacturing Science and Engineering Conference, MSEC 2010 - Erie, PA, United States
Duration: Oct 12 2010Oct 15 2010

Other

OtherASME 2010 International Manufacturing Science and Engineering Conference, MSEC 2010
CountryUnited States
CityErie, PA
Period10/12/1010/15/10

Fingerprint

Milling (machining)
Condition monitoring
Wear of materials
Accelerometers
Machining
Dynamometers
Machine tools
Statistical methods
Fourier transforms
Monitoring
Sensors
Costs

All Science Journal Classification (ASJC) codes

  • Industrial and Manufacturing Engineering

Cite this

Milner, J. L., & Roth, J. T. (2010). Condition monitoring with round ceramic inserts while face milling using acceleration data. In ASME 2010 International Manufacturing Science and Engineering Conference, MSEC 2010 (Vol. 1, pp. 389-399) https://doi.org/10.1115/MSEC2010-34188
Milner, Justin L. ; Roth, John Timothy. / Condition monitoring with round ceramic inserts while face milling using acceleration data. ASME 2010 International Manufacturing Science and Engineering Conference, MSEC 2010. Vol. 1 2010. pp. 389-399
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Milner, JL & Roth, JT 2010, Condition monitoring with round ceramic inserts while face milling using acceleration data. in ASME 2010 International Manufacturing Science and Engineering Conference, MSEC 2010. vol. 1, pp. 389-399, ASME 2010 International Manufacturing Science and Engineering Conference, MSEC 2010, Erie, PA, United States, 10/12/10. https://doi.org/10.1115/MSEC2010-34188

Condition monitoring with round ceramic inserts while face milling using acceleration data. / Milner, Justin L.; Roth, John Timothy.

ASME 2010 International Manufacturing Science and Engineering Conference, MSEC 2010. Vol. 1 2010. p. 389-399.

Research output: Chapter in Book/Report/Conference proceedingConference contribution

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Milner JL, Roth JT. Condition monitoring with round ceramic inserts while face milling using acceleration data. In ASME 2010 International Manufacturing Science and Engineering Conference, MSEC 2010. Vol. 1. 2010. p. 389-399 https://doi.org/10.1115/MSEC2010-34188