Assessment of Tool Wear Based on Surface Texture Parameters

2009 ◽  
Author(s):  
Yi Liao ◽  
David A. Stephenson ◽  
Jun Ni
Keyword(s):  
Tool Wear ◽  
Surface Texture ◽  
Surface Measurement ◽  
Warning Sign ◽  
Surface Waviness ◽  
High Definition ◽  
Statistical Process ◽  
Texture Parameters ◽  
Machined Parts ◽  
On Line

This research presents a new way to determine the condition of a cutting tool based on high definition surface texture parameters. Recently, a laser holographic interferometer has been developed to rapidly measure the whole workpiece surface (e.g. 300mm×300mm) and generate a 3D surface height map with micron level accuracy. This technique enables on-line surface measurement for machined parts. By measuring the surface texture of workpieces, the interaction between the tool’s cutting edges and the surface can be extracted as a spatial signature. It can then be used as a warning sign for tool change because the workpiece produced by a heavily worn tool exhibits more irregularities than those produced by a normal tool. Three surface texture parameters: image intensity histogram, surface peak-to-valley height and surface waviness are employed to detect the onset of severe tool wear. Furthermore, surface waviness can also be used to classify the different phases of tool wear. In this work, nine surface samples under different tool wear phases are created and analyzed using surface texture parameters combined with Statistical Process Control (SPC) charts to assess tool conditions. The results verify that these surface texture parameters can be used for on-line tool wear monitoring.

A Multifeature Approach to Tool Wear Estimation Using 3D Workpiece Surface Texture Parameters

2010 ◽  
Vol 132 (6) ◽  
Author(s):  
Yi Liao ◽  
David A. Stephenson ◽  
Jun Ni
Keyword(s):  
Tool Wear ◽  
Surface Texture ◽  
Polycrystalline Diamond ◽  
Texture Features ◽  
Surface Measurement ◽  
Warning Sign ◽  
Workpiece Surface ◽  
3D Surface ◽  
Texture Parameters ◽  
3D Surface Texture

This work presents a new way to determine the condition of a cutting tool based on 3D texture parameters of workpiece surface. Recently, a laser holographic interferometer has been developed to rapidly measure a large workpiece surface and generate a 3D surface height map with micron level accuracy. This technique enables online surface measurement for machined workpieces. By measuring and analyzing workpiece surface texture, the interaction between the tool’s cutting edges and the workpiece surface can be extracted as a spatial signature. It can then be used as a warning sign for tool change because the workpiece produced by a heavily worn tool exhibits more irregularities in its surface texture than that produced by a normal tool. Multiple texture parameters such as image intensity histogram distribution parameter, 3D peak-to-valley height, and 3D surface waviness parameter are employed to indicate the onset of severe tool wear. In this work, aluminum (Al308) and compacted graphite iron parts were machined by a polycrystalline diamond insert and a multiphase coated tungsten carbide insert, respectively. After that, multiple 3D surface texture features of workpieces samples under different phases of tool wear were analyzed in order to assess tool wear conditions. The experimental results verify that these surface texture features can be used as good indicators for online tool wear monitoring.

Profile Characterization of Manufactured Surfaces Using Random Function Excursion Technique—Part 1: Theory

1975 ◽  
Vol 97 (1) ◽  
pp. 190-195 ◽  
Author(s):  
T. S. Sankar ◽  
M. O. M. Osman
Keyword(s):  
Surface Texture ◽  
Low Cost ◽  
Measuring Device ◽  
Rolling Circle ◽  
Measuring Devices ◽  
Texture Parameters ◽  
Probability Densities ◽  
On Line ◽  
Excursion Probability

This paper discusses a new approach for describing accurately the typology of manufactured surfaces. The method employs the theory of stochastic excursions to characterize the surface texture in the amplitude and lengthwise directions. The mathematical principle behind the approach is briefly explained, and it is shown that an accurate description of the roughness can be obtained from the knowledge of the intercept probabilities of the crest and valley excursions of the surface texture about any given level, say the CLA value, specified with respect to the mean line. Based on the preceding excursion probability densities, new surface texture parameters are proposed. These parameters may be computed directly from the surface roughness data obtained from commercially available measuring devices. On the basis of this investigation, it is feasible to develop a low-cost measuring device for “on-line” surface evaluation in production. It is also shown that the sampling length provides a geometrically well-defined filter characteristic similar to that of the rolling circle radius in the E-system.

scholarly journals Characterization of the surface of formworks – Influence of the surface energy and surface texture parameters on the demolding forces

2021 ◽  
Vol 272 ◽  
pp. 121947
Author(s):  
Calypso Chadfeau ◽  
Safiullah Omary ◽  
Essia Belhaj ◽  
Christophe Fond ◽  
Françoise Feugeas
Keyword(s):  
Surface Energy ◽  
Surface Texture ◽  
Texture Parameters

scholarly journals Oversizing Thread Diagnosis in Tapping Operation

Metals ◽  
2021 ◽  
Vol 11 (4) ◽  
pp. 537
Author(s):  
Alain Gil Del Val ◽  
Fernando Veiga ◽  
Mariluz Penalva ◽  
Miguel Arizmendi
Keyword(s):  
Control Chart ◽  
Manufacturing Systems ◽  
Spindle Motor ◽  
Multivariate Statistical ◽  
Statistical Process ◽  
Knowing That ◽  
On Line ◽  
High Level ◽  
Screw Threads ◽  
Multivariate Control

Automotive, railway and aerospace sectors require a high level of quality on the thread profiles in their manufacturing systems knowing that the tapping process is a complex manufacturing process and the last operation in a manufacturing cell. Therefore, a multivariate statistical process control chart, for each tap, is presented based on the principal components of the torque signal directly measured from spindle motor drive to diagnosis the thread profile quality. This on-line multivariate control chart has implemented an alarm to avoid defected screw threads (oversized). Therefore, it could work automatically without any operator intervention assessing the thread quality and the safety is guaranteed during the tapping process.

scholarly journals Analysis of High-Friction Surface Texture with Respect to Friction and Wear

Coatings ◽  
2021 ◽  
Vol 11 (7) ◽  
pp. 758
Author(s):  
Cibi Pranav ◽  
Minh-Tan Do ◽  
Yi-Chang Tsai
Keyword(s):  
Friction Coefficient ◽  
Surface Texture ◽  
Safety Concern ◽  
Future Research ◽  
Scanning System ◽  
Novel Approach ◽  
Texture Parameters ◽  
Aggregate Loss ◽  
Friction Surfaces ◽  
The Impact

High Friction Surfaces (HFS) are applied to increase friction capacity on critical roadway sections, such as horizontal curves. HFS friction deterioration on these sections is a safety concern. This study deals with characterization of the aggregate loss, one of the main failure mechanisms of HFS, using texture parameters to study its relationship with friction. Tests are conducted on selected HFS spots with different aggregate loss severity levels at the National Center for Asphalt Technology (NCAT) Test Track. Friction tests are performed using a Dynamic Friction Tester (DFT). The surface texture is measured by means of a high-resolution 3D pavement scanning system (0.025 mm vertical resolution). Texture data are processed and analyzed by means of the MountainsMap software. The correlations between the DFT friction coefficient and the texture parameters confirm the impact of change in aggregates’ characteristics (including height, shape, and material volume) on friction. A novel approach to detect the HFS friction coefficient transition based on aggregate loss, inspired by previous works on the tribology of coatings, is proposed. Using the proposed approach, preliminary outcomes show it is possible to observe the rapid friction coefficient transition, similar to observations at NCAT. Perspectives for future research are presented and discussed.

A Framework for Big Data Driven On-Line Monitoring of Tool Wear

2021 ◽  
Author(s):  
Yong Gui ◽  
Sheng Leng ◽  
Zhiqiang Dai ◽  
Jiyuan Wu
Keyword(s):  
Big Data ◽  
Tool Wear ◽  
Data Driven ◽  
On Line

Numerical and experimental study on the effect of surface texture with roughness orientation considered under a mixed lubrication state

2021 ◽  
Vol ahead-of-print (ahead-of-print) ◽  
Author(s):  
Junru Wang ◽  
Quandai Wang ◽  
Yueyan Li ◽  
Meiling Guo ◽  
Pengyang Li ◽  
...  
Keyword(s):  
Surface Texture ◽  
Surface Texturing ◽  
Mixed Lubrication ◽  
Laser Surface ◽  
Geometric Parameters ◽  
Laser Surface Texturing ◽  
Textured Surface ◽  
Asperity Contact ◽  
Content Type ◽  
Texture Parameters

Purpose The purpose of this paper is to investigate the effects of surface texture with roughness orientation considered on tribological properties under a mixed lubrication state numerically and experimentally. Design/methodology/approach Based on the average Reynolds equation and asperity contact model, the impacts of surface texture parameters and roughness orientation on lubrication properties have been calculated using finite difference method. Tin–bronze samples with various prescribed surface texture geometric parameters and roughness orientation were fabricated by laser surface texturing technique, and the tribology performance of the textured surface was studied experimentally. Findings The effects of surface geometric parameters and roughness orientation parameters have been discerned. The experimental observations are in good agreement with the numerical prediction, which suggests that the numerical scheme adopted in this work is suitable in capturing the surface texture and roughness effect under mixed lubrication state. Originality/value By meticulously controlling the surface roughness and surface texture geometric characteristics based on the laser surface texturing process, samples with prescribed surface texture parameters and roughness orientation consistent with that in theoretical studies were fabricated and the theoretical model and results were verified experimentally.

On-line tool wear sensing and compensation in turning

1995 ◽  
Vol 49 (3-4) ◽  
pp. 247-254 ◽  
Author(s):  
S.K. Choudhury ◽  
S. Ramesh
Keyword(s):  
Tool Wear ◽  
On Line

Estimation of Service Life of Mechanical Engineering Components

2019 ◽  
Vol 799 ◽  
pp. 71-76
Author(s):  
Oskars Linins ◽  
Ernests Jansons ◽  
Armands Leitans ◽  
Irina Boiko ◽  
Janis Lungevics
Keyword(s):  
Service Life ◽  
Service Time ◽  
Surface Texture ◽  
Mechanical Engineering ◽  
Friction Pair ◽  
Theory Of Elasticity ◽  
New Approach ◽  
Material Fatigue ◽  
Texture Parameters ◽  
3D Surface Texture

The paper is aimed to the methodology for estimation of service life of mechanical engineering components in the case of elastic-plastic contact of surfaces. Well-known calculation methods depending on physics, theory of probability, the analysis of friction pair’ shape and fit include a number of parameters that are difficult or even impossible to be technologically controlled in the manufacturing of mechanical engineering components. The new approach for wear rate estimation using surface texture parameters as well as physical-mechanical properties and geometric parameters of components is proposed. The theoretical part of the calculations is based on the 3D surface texture principles, the basics of material fatigue theory, the theory of elasticity and the contact mechanics of surfaces. It is possible to calculate the service time of the machine, but the process of running-in of the components is relatively short (less than 5%), therefore, the service time is mainly determined by a normal operating period, which also was used to evaluate this period. The calculated input parameters are technologically and metrologically available and new method for calculating the service time can be used in the design process of the equipment. The results of approbation of the method for estimation service time of mechanical engineering, which prove the applicability of mentioned method, are offered as well.

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