A microcontroller-based end milling cutter monitoring and management system

Prickett, Paul William; Siddiqui, Raees A.; Grosvenor, Roger Ivor

doi:10.1007/s00170-010-3135-z

Cited by 8 publications

(6 citation statements)

References 31 publications

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“…Use of electrical power [7] is rather versatile in this arrangement because a measuring instrument can be placed far away from a tool and workpiece. The power consumption method is suitable for detecting tool degradation in terms of flank wear [8] as well as breakage [9]. However, as the sensitivity changes as a result of the rated power of each machine tool, it is difficult to set a proper threshold for prognosis, especially in small batch production.…”

Section: Introductionmentioning

confidence: 99%

Tool condition monitoring for form milling of large parts by combining spindle motor current and acoustic emission signals

Uekita

Takaya

2016

Int J Adv Manuf Technol

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To ensure overall quality of a precision large-scale component, a tool condition monitoring (TCM) technique for multi-step form milling is presented. The form milling of fir tree slots for a steam turbine rotor is an appropriate example that requires a fine surface finish and high dimensional accuracy. Therefore, we propose a novel TCM system based on a multi-sensor fusion strategy which utilises the combination of spindle motor current and acoustic emission (AE) as well as adaptive thresholding for multiple manufacturing steps (roughing, semi-finishing and finishing). To investigate the tool deterioration process, tool longevity tests using a test piece are carried out for each step. With the aid of qualitative inspection, it is found that AE signals provide comprehensive tool state information regarding tool flank wear, crack propagation and severe adhesive wear. In addition, by intentionally adding a bundle of chips to the surface, bursts of AE of large amplitudes occur in finishing, which provides the possibility of discovering anomalous events related to surface quality. By careful consideration of such characteristics, provisional alert levels are determined using a two-dimensional diagram with respect to both sensors. The strategy is verified throughout the actual manufacturing processes of the rotors. The proposed TCM system shows not only an excellent ability to prevent catastrophic tool failure and surface irregularities in form milling but also acceptable expendability for various groove specifications.

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Section: Introductionmentioning

confidence: 99%

Tool condition monitoring for form milling of large parts by combining spindle motor current and acoustic emission signals

Uekita

Takaya

2016

Int J Adv Manuf Technol

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“…Connection among microcontrollers described in this paper is not limited for two microcontroller, but can be used for communication with many microcontrollers at the same time in parallel, tree, or series connections. An example of each connection type used can be seen in Figures 5,6,and 7. Specifically in tree connection, an additional confirmation step is required for sending data to a specific microcontroller. This step to ensure that the data transmitted to the microcontroller target is correct.…”

Section: Method/materialsmentioning

confidence: 99%

“…Data communication via UART / YS-C20K will be troublesome if the communication is done among many microcontrollers simultaneously. Research that applied communication via the CAN bus have been done by Prickett [7] and Kutlu [8], however, communication using this medium requires an additional interface. Moreover, it is difficult to be implemented on an 8-bit microcontroller with the minimum system which does not provide an embedded CAN controller i.e.…”

Section: Introductionmentioning

confidence: 99%

Algorithm of 32-bit Data Transmission Among Microcontrollers Through an 8-bit Port

Mirdanies

Saputra

Rijanto

2015

J. Mechatron. Electr. Power Veh. Technol.

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This paper proposes an algorithm for 32-bit data transmission among microcontrollers through one 8-bit port. This method was motivated by a need to overcome limitations of microcontroller I/O as well as to fulfill the requirement of data transmission which is more than 10 bits. In this paper, the use of an 8-bit port has been optimized for 32-bit data transmission using unsigned long integer, long integer, and float types. Thirty-two bit data is extracted into binary number, then sent through a series of 8-bit ports by transmitter microcontroller. At receiver microcontroller, the binary data received through 8-bit port is reconverted into 32 bits with the same data type. The algorithm has been implemented and tested using C language in ATMega32A microcontroller. Experiments have been done using two microcontrollers as well as four microcontrollers in the parallel, tree, and series connections. Based on the experiments, it is known that the data transmitted can be accurately received without data loss. Maximum transmission times among two microcontrollers for unsigned long integer, long integer, and float are 630 µs, 1,880 µs, and 7,830 µs, respectively. Maximum transmission times using four microcontrollers in parallel connection are the same as those using two microcontrollers, while in series connection are 1,930 µs for unsigned long integer, 5,640 µs for long integer, and 23,540 µs for float. The maximum transmission times of tree connection is close to those of the parallel connection. These results prove that the algorithm works well.

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“…Cho, Asfour, Onar, et al [8] thought there would be two kinds of mill breakage as shank breakage and flute breakage; in flute breakage, with only partial edge loss, if a tooth was broken, its peak cutting force would rise, which then might led to further fracture of edge; however, in shank breakage, the cutting force of broken tooth would decline to zero. Prickett, Siddiqui, and Grosvenor [9] present that the signal of spindle load would be stronger after cutter is broken. Baek, Ko, and Kim [10] thought that the broken insert whose breakage was induced by transient impact force should still engage cutting, and its cutting force should rise; they thought this should be the main mode of insert fracture.…”

Section: Introductionmentioning

confidence: 98%

“…Research studies on breakage monitoring of mills usually took cutting-force-related signals [8][9][10][11][12][13][14][15][16][17][18][19][20][21][22], where it was needed to assume the variation direction of these signals beforehand.…”

Section: Introductionmentioning

confidence: 99%

Geometry features of breakage section and variation of cutting force for end mills after brittle breakage

Liu

et al. 2015

Int J Adv Manuf Technol

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Some broken end mills with many brittle breakage sections were collected, and the geometry features of these sections were summed up. As for minor breakage, the breakage sections were narrow planes parallel to the tool edge, and the depths of breakage were shallow. As for severe breakage, it likely occurred near the edge tip; its breakage sections were approximate planes perpendicular to the bottom of tool and tilted approximately 35°to the bottom edge; moreover, the broken degree of section side near the rake face was heavier, while that near the flank face was slighter. By taking these geometry features into account, mathematical instantaneous expressions of cutting force for broken end mills were amended correspondingly. Then, with these expressions, it could be analyzed that, on one hand, the amount of material removed by broken edge segment declined and, on the other hand, its coefficient of cutting force rose; therefore, the instantaneous cutting force might be in reverse relation with broken degree, and in positive relation with feed, and also the removed material by the tooth following the broken one would rise. These results indicate that, if a tooth is brittle broken, there exist two kinds of possibility as rise and decline for its cutting force-the cutting force of slightly broken tooth would rise, while that of heavily broken tooth would decline, the cutting force of tooth following the broken one would always rise, and that of other teeth would remain the same. Using artificial tooth breakage, cutting tests of broken end mills were taken; the test results agreed with above conclusions. Conclusions of this study may be used in modifying indices of monitoring brittle breakage for end mills.

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A microcontroller-based end milling cutter monitoring and management system

Cited by 8 publications

References 31 publications

Tool condition monitoring for form milling of large parts by combining spindle motor current and acoustic emission signals

Tool condition monitoring for form milling of large parts by combining spindle motor current and acoustic emission signals

Algorithm of 32-bit Data Transmission Among Microcontrollers Through an 8-bit Port

Geometry features of breakage section and variation of cutting force for end mills after brittle breakage

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