Real-time failure forecasting for flat, ball-nose, roughing, and tapered endmills using an accelerometer

Christopher A. Suprock, John Timothy Roth, Larry M. Downey

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

7 Citations (Scopus)

Abstract

In this paper, flat, ball-nose, roughing, and tapered endmilling tools are investigated for their respective wear trends. These curves are contrasted with the trend exhibited by traditional flat endmills. To isolate the wear behavior of the various tool geometries, an autoregressive based monitoring algorithm is used to track the tool's condition using a tri-axial accelerometer. An accelerometer is used due to its low cost and since it does not limit the machining envelope. To demonstrate repeatability, eight life tests were conducted (two life tests for each type of endmill). The technique discussed herein successfully identifies impending fracture or meltdown due to wear in all cases, providing sufficient time to remove the tools before failure is realized. Furthermore, the algorithm produces similar trends capable of forecasting failure, regardless of tool geometry, in all cases, without requiring algorithm modifications or prior information regarding the cutting conditions.

Original languageEnglish (US)
Title of host publicationTransactions of the North American Manufacturing Research Institution of SME 2007 - Papers Presented at NAMRC 35
Pages185-192
Number of pages8
Volume35
StatePublished - 2007
Event35th North American Manufacturing Research Conference, NAMRC 35 - Ann Arbor, MI, United States
Duration: May 22 2007May 25 2007

Other

Other35th North American Manufacturing Research Conference, NAMRC 35
CountryUnited States
CityAnn Arbor, MI
Period5/22/075/25/07

Fingerprint

Accelerometers
Wear of materials
Geometry
Machining
Monitoring
Costs

All Science Journal Classification (ASJC) codes

  • Engineering(all)

Cite this

Suprock, C. A., Roth, J. T., & Downey, L. M. (2007). Real-time failure forecasting for flat, ball-nose, roughing, and tapered endmills using an accelerometer. In Transactions of the North American Manufacturing Research Institution of SME 2007 - Papers Presented at NAMRC 35 (Vol. 35, pp. 185-192)
Suprock, Christopher A. ; Roth, John Timothy ; Downey, Larry M. / Real-time failure forecasting for flat, ball-nose, roughing, and tapered endmills using an accelerometer. Transactions of the North American Manufacturing Research Institution of SME 2007 - Papers Presented at NAMRC 35. Vol. 35 2007. pp. 185-192
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Suprock, CA, Roth, JT & Downey, LM 2007, Real-time failure forecasting for flat, ball-nose, roughing, and tapered endmills using an accelerometer. in Transactions of the North American Manufacturing Research Institution of SME 2007 - Papers Presented at NAMRC 35. vol. 35, pp. 185-192, 35th North American Manufacturing Research Conference, NAMRC 35, Ann Arbor, MI, United States, 5/22/07.

Real-time failure forecasting for flat, ball-nose, roughing, and tapered endmills using an accelerometer. / Suprock, Christopher A.; Roth, John Timothy; Downey, Larry M.

Transactions of the North American Manufacturing Research Institution of SME 2007 - Papers Presented at NAMRC 35. Vol. 35 2007. p. 185-192.

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

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Suprock CA, Roth JT, Downey LM. Real-time failure forecasting for flat, ball-nose, roughing, and tapered endmills using an accelerometer. In Transactions of the North American Manufacturing Research Institution of SME 2007 - Papers Presented at NAMRC 35. Vol. 35. 2007. p. 185-192