State Space Modeling of Variation Propagation in Multistation Machining Processes Considering Machining-Induced Variations

2012 ◽  
Vol 134 (2) ◽  
Author(s):  
José V. Abellan-Nebot ◽  
Jian Liu ◽  
Fernando Romero Subirón ◽  
Jianjun Shi
Keyword(s):  
Tool Wear ◽  
Cutting Tool ◽  
Tolerance Allocation ◽  
Machining Processes ◽  
Process Diagnosis ◽  
Cutting Tool Wear ◽  
Differential Motion ◽  
Variation Propagation ◽  
Space Modeling ◽  
Stream Of Variation

In spite of the success of the stream of variation (SoV) approach to modeling variation propagation in multistation machining processes (MMPs), the absence of machining-induced variations could be an important factor that limits its application in accurate variation prediction. Such machining-induced variations are caused by geometric-thermal effects, cutting-tool wear, etc. In this paper, a generic framework for machining-induced variation representation based on differential motion vectors is presented. Based on this representation framework, machining-induced variations can be explicitly incorporated in the SoV model. An experimentation is designed and implemented to estimate the model coefficients related to spindle thermal-induced variations and cutting-tool wear-induced variations. The proposed model is compared with the conventional SoV model resulting in an average improvement on quality prediction of 67%. This result verifies the advantage of the proposed extended SoV model. The application of the new model can significantly extend the capability of SoV-model-based methodologies in solving more complex quality improvement problems for MMPs, such as process diagnosis and process tolerance allocation, etc.

Sensor Fusion Strategy in the Monitoring of Cutting Tool Wear

2006 ◽  
Vol 306-308 ◽  
pp. 727-732 ◽  
Author(s):  
Muslim Mahardika ◽  
Zahari Taha ◽  
Djoko Suharto ◽  
Kimiyuki Mitsui ◽  
Hideki Aoyama
Keyword(s):  
Tool Wear ◽  
Sensor Fusion ◽  
Cutting Tool ◽  
Fusion Technology ◽  
Machining Processes ◽  
Fusion Strategy ◽  
Cutting Tool Wear ◽  
Single Sensor ◽  
Paper Sensor

Cutting tool wear is a major problem in machining processes. It has a great effect on the quality of a workpiece. Thus, monitoring cutting tool wear is very important in order to maintain the workpiece quality as well to reduce production rate and production time. The use of a single sensor in a monitoring system may not be accurate to detect cutting tool wear. In this paper, sensor fusion technology is introduced for monitoring cutting tool wear.

scholarly journals Variation propagation modelling in multistage machining processes using dual quaternions

2020 ◽  
Vol 111 (9-10) ◽  
pp. 2987-2998
Author(s):  
Filmon Yacob ◽  
Daniel Semere
Keyword(s):  
Motion Vector ◽  
Manufacturing Processes ◽  
Machining Processes ◽  
Dual Quaternions ◽  
Multistage Manufacturing ◽  
Differential Motion ◽  
Variation Propagation ◽  
Stream Of Variation ◽  
Matrix Differential ◽  
Propagation Modelling

Abstract Variation propagation models play an important role in part quality prediction, variation source identification, and variation compensation in multistage manufacturing processes. These models often use homogenous transformation matrix, differential motion vector, and/or Jacobian matrix to represent and transform the part, tool and fixture coordinate systems and associated variations. However, the models end up with large matrices as the number features and functional element pairs increase. This work proposes a novel strategy for modelling of variation propagation in multistage machining processes using dual quaternions. The strategy includes representation of the fixture, part, and toolpath by dual quaternions, followed by projection locator points onto the features, which leads to a simplified model of a part-fixture assembly and machining. The proposed approach was validated against stream of variation models and experimental results reported in the literature. This paper aims to provide a new direction of research on variation propagation modelling of multistage manufacturing processes.

scholarly journals IN-LINE SPATIAL MONITORING OF CUTTING TOOL-WEAR

2017 ◽  
Vol 44 (1) ◽  
pp. 41
Author(s):  
Luka Čerče ◽  
Davorin Kramar ◽  
Janez Kopac
Keyword(s):  
Tool Wear ◽  
Cutting Tool ◽  
Cutting Tools ◽  
Machining Process ◽  
Strong Impact ◽  
Machining Processes ◽  
Cutting Tool Wear ◽  
Manual Inspection ◽  
Complete Automation

The tool-wear of cutting tools has a very strong impact on the product quality as well as efficiency of the machining processes. Despite the nowadays high automation level in machining industry, tool -wear diagnostic that is measured of the machine tool, still prevent complete automation of the entire machining process. Therefore, its in line characterization is crucial. Thus the paper presents developed innovative, robust and reliable direct measuring procedure for measuring spatial cutting tool-wear in-line, with the usage of laser profile sensor. The technique provides possibility for determination of 3D wear profiles, as advantage to currently used 2D subjective techniques (microscopes, etc.). The use of proposed measurement system removes the subjective manual inspection and minimizes the time used for wear easurement. In the manuscript the system is experimentally tested on a case s tudy, with further in-depth performed analyses of spatial cutting tool-wear.

A First Step towards a Tribological Approach to Investigate Cutting Tool Wear

2014 ◽  
Vol 611-612 ◽  
pp. 452-459 ◽  
Author(s):  
Giovenco Axel ◽  
Frédéric Valiorgue ◽  
Cédric Courbon ◽  
Joël Rech ◽  
Ugo Masciantonio
Keyword(s):  
Tool Wear ◽  
Cutting Tool ◽  
304L Stainless Steel ◽  
Fe Modelling ◽  
Wear Model ◽  
Cutting Tool Wear ◽  
The Will ◽  
Preliminary Study ◽  
The Impact ◽  
Macroscopic Parameters

The present work is motivated by the will to improve Finite Element (FE) Modelling of cutting tool wear. As a first step, the characterisation of wear mechanisms and identification of a wear model appear to be fundamental. The key idea of this work consists in using a dedicated tribometer, able to simulate relevant tribological conditions encountered in cutting (pressure, velocity). The tribometer can be used to estimate the evolution of wear versus time for various tribological conditions (pressure, velocity, temperature). Based on this design of experiments, it becomes possible to identify analytically a wear model. As a preliminary study this paper will be focused on the impact of sliding speed at the contact interface between 304L stainless steel and tungsten carbide (WC) coated with titanium nitride (TiN) pin. This experiment enables to observe a modification of wear phenomena between sliding speeds of 60 m/min and 180 m/min. Finally, the impact on macroscopic parameters has been observed.

Tool Wear Detection Using Time Series Analysis of Acoustic Emission

1989 ◽  
Vol 111 (3) ◽  
pp. 199-205 ◽  
Author(s):  
S. Y. Liang ◽  
D. A. Dornfeld
Keyword(s):  
Time Series ◽  
Acoustic Emission ◽  
Tool Wear ◽  
Time Series Analysis ◽  
Cutting Tool ◽  
Shear Zones ◽  
Parameter Vector ◽  
Model Parameter ◽  
Cutting Tool Wear ◽  
Series Analysis

This paper discusses the monitoring of cutting tool wear based on time series analysis of acoustic emission signals. In cutting operations, acoustic emission provides useful information concerning the tool wear condition because of the fundamental differences between its source mechanisms in the rubbing friction on the wear land and the dislocation action in the shear zones. In this study, a signal processing scheme is developed which uses an autoregressive time-series to model the acoustic emission generated during cutting. The modeling scheme is implemented with a stochastic gradient algorithm to update the model parameters adoptively and is thus a suitable candidate for in-process sensing applications. This technique encodes the acoustic emission signal features into a time varying model parameter vector. Experiments indicate that the parameter vector ignores the change of cutting parameters, but shows a strong sensitivity to the progress of cutting tool wear. This result suggests that tool wear detection can be achieved by monitoring the evolution of the model parameter vector during machining processes.

Cutting tool wear in the machining of hardened steels

Wear ◽  
2001 ◽  
Vol 247 (2) ◽  
pp. 152-160 ◽  
Author(s):  
J Barry ◽  
G Byrne
Keyword(s):  
Tool Wear ◽  
Cutting Tool ◽  
Hardened Steels ◽  
Cutting Tool Wear

scholarly journals Cutting Tool Wear Monitoring

2015 ◽  
Vol 15 (3) ◽  
pp. 380-384 ◽  
Author(s):  
Jan Madl ◽  
Michal Martinovsky
Keyword(s):  
Tool Wear ◽  
Cutting Tool ◽  
Tool Wear Monitoring ◽  
Cutting Tool Wear ◽  
Wear Monitoring

scholarly journals Milling Inconel 718 Workpiece With Cryogenically Treated And Untreated Cutting Tools

2021 ◽  
Author(s):  
Hüseyin Gürbüz ◽  
Şehmus Baday
Keyword(s):  
Surface Roughness ◽  
Tool Wear ◽  
Abrasive Wear ◽  
Inconel 718 ◽  
Cutting Tool ◽  
Cutting Tools ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Cutting Tool Wear ◽  
Feed Force

Abstract Although Inconel 718 is an important material for modern aircraft and aerospace, it is a kind material, which is known to have low machinability. Especially, while these types of materials are machined, high cutting temperatures, BUE on cutting tool, high cutting forces and work hardening occur. Therefore, in recent years, instead of producing new cutting tools that can withstand these difficult conditions, cryogenic process, which is a heat treatment method to increase the wear resistance and hardness of the cutting tool, has been applied. In this experimental study, feed force, surface roughness, vibration, cutting tool wear, hardness and abrasive wear values that occurred as a result of milling of Inconel 718 material by means of cryogenically treated and untreated cutting tools were investigated. Three different cutting speeds (35-45-55 m/min) and three different feed rates (0.02-0.03-0.04 mm/tooth) at constant depth of cut (0.2 mm) were used as cutting parameters in the experiments. As a result of the experiments, lower feed forces, surface roughness, vibration and cutting tool wear were obtained with cryogenically treated cutting tools. As the feed rate and cutting speed were increased, it was seen that surface roughness, vibration and feed force values increased. At the end of the experiments, it was established that there was a significant relation between vibration and surface roughness. However, there appeared an inverse proportion between abrasive wear and hardness values. While BUE did not occur during cryogenically treated cutting tools, it was observed that BUE occurred in cutting tools which were not cryogenically treated.

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