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 Scopus citations

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
Publication statusPublished - Aug 22 2007
Event35th North American Manufacturing Research Conference, NAMRC 35 - Ann Arbor, MI, United States
Duration: May 22 2007May 25 2007

Publication series

NameTransactions of the North American Manufacturing Research Institution of SME
Volume35
ISSN (Print)1047-3025

Other

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

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All Science Journal Classification (ASJC) codes

  • Mechanical Engineering
  • Industrial and Manufacturing Engineering

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 (pp. 185-192). (Transactions of the North American Manufacturing Research Institution of SME; Vol. 35).