Preliminary Study on Machining Condition Monitoring System Using 3-Channel Force Sensor Analyzed by I-kaz Multilevel Method

Karim, Z.; Nuawi, Mohd. Zaki; Ghani, Jaharah A; Said, A.Y.M.

doi:10.18517/ijaseit.6.4.896

Cited by 4 publications

(5 citation statements)

References 10 publications

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“…The I-kaz multilevel SF for each signal from each machining run has its own values depending on the amplitude of the vibration with respect to the flank wear size. [19]. I-kaz multilevel coefficients ( 7 Z ∞ ) were calculated from the vibration signals in time domain and then correlated to the flank wear status.…”

Section: Sf Correlation With Wearmentioning

confidence: 99%

Vibration–Based online Tool Wear Monitoring Using Piezo Film Sensor Analyzed by I-kaz Multilevel Signal Feature

Karim

Hussin

Yasir

et al. 2019

IJEAT

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Abstract: Wear in cutting tool is a normal phenomenon in machining process. Problems such as dimensional precision, surface finish quality and defect cost is due to the wear. The wear also can cause unexpected stop time and lower down the manufacturing productivity. Therefore, a system to monitor the progression of the tool wear is needed to predict the wear status and stop machining operation once the wear reach the allowed limit. In this study, Vibration signal and wear measurement were recorded for each run in the experiment. The experiment were stopped once the wear reach approximately 0.3mm. I-kaz multilevel signal features were extracted from the vibration signal recorded and then correlated with the flank wear status. There is a solid or substantial correlation between the cutting tool wear condition and I-kaz multilevel coefficient value, with average of 0.87 for I-kaz x coefficient (tangential direction) and 0.910 for I-kaz z coefficient (feed direction). This affirm that I-kaz multilevel signal feature can be assigned as the input criterion for the tool condition monitoring system that can estimate the current status of the flank wear on the cutting tools which can prevent defect in the machining process. the monitoring system was designed by utilizing 2 units of piezoelectric film sensors which are capable of detecting and analyzing signals related to tool holder vibration during the machining process in both feed and tangential axes. The sensors were stacked on x axis and z axis surfaces of the tool holder and signals were channeled to a charge amplifier and then to the digital data acquisition equipment which then display the vibration signal in time domain on the computer screen. A total of 8 experiments were carried out using CNC turning machine.

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Section: Sf Correlation With Wearmentioning

confidence: 99%

Vibration–Based online Tool Wear Monitoring Using Piezo Film Sensor Analyzed by I-kaz Multilevel Signal Feature

Karim

Hussin

Yasir

et al. 2019

IJEAT

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“…"True value" of direct measurements expressed as a value -the average of the measurement results. = ∑ (1) Where : ̅ = average value ∑ = the total number of measurements n = number of measurements Uncertainty in the value of repeated measurements expressed as standard deviation, which can be calculated by the formula [25]:…”

Section: Observation Of Changes In Acoustic Emission Signal and VImentioning

confidence: 99%

“…Each condition monitoring techniques require special features for decisionmaking algorithms such as neural networks, artificially intelligent, statistical analysis, finite element analysis and others. The data analyzed by various methods, one of which is a method of multilevel I-Kaz [1] to monitor the progression of flank wear during the turning process. A 3channel Kistler force sensor was assembled to measure the force on the cutting tools.…”

Section: Introductionmentioning

confidence: 99%

Observation of Changes in Acoustic Emission and Vibration Signals to Transverse Crack on Rotating Shaft: An Experiment Investigation

Thenu

Ariana

Zubaydi

et al. 2017

International Journal on Advanced Science, Engineering and Information Technology

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This paper focuses on the observation of changes in acoustic emission and vibration signal to transverse crack on rotating shaft. The fundamental difference to other studies is the use of a microphone as acoustic emission sensor placed no direct contact with the part examined. The result of measurements of the acoustic emission signal compared with the vibration signal indicates that the acoustic emission signal apparently was seen and displays the number of maximum spectral peak fewer and amplitude values more consistent. Increasing the shaft speed and the depth of crack increases the magnitude of amplitude.

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“…According to this study Optimum surface roughness can be achieved by selecting relatively higher values of speed (>65.37m/min), higher values of depth of cut (>0.75mm), and relatively lower values of feed rate (<0.10mm/rev).Ghani, J. A. et al [3], studied the online tool wear using low cost technique and user friendly GUI. For this, they use low cost sensor.…”

Section: Introductionmentioning

confidence: 99%

Optimization of Resultant Cutting Force in CNC Turning Process for Hard (62-64 HRC) AISI M2

Pawar¹

2017

IJRASET

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I. INTRODUCTIONThe CNC turning process is common machining process. It is found in near about in all manufacturing industries. After vibration response parameter optimization in CNC turning next important parameter is cutting force. This factor is also equally responsible for tool wear and tool life. Especially in the hard turning the study of cutting for forces is very important to get the minimum surface roughness. Li, B. et al. [1], presented a analytical study based on the unequal shear zone model to study machining predictive theory. The cutting force can be predicted only by the work-piece material properties and cutting condition. In shear zone, the material constitutive relationship is described by Johnson-Cook model, and the material characteristics such as strain rate sensitivity, strain hardening, and thermal softening are considered. They assumed the chip formation within the primary shear zone and governing flow equation is established by the introducing a piecewise power law distribution assumption of the shear strain rate. They calculated cutting force for different cutting condition in computing the flow stress, the strain, strain rate, and temperature effects are taken into consideration. Jadhav J. S. and Jadhav B. R. [2], studied effect of cutting parameters on cutting force (Fc) & feed force in turning Process. They conducted experiment on precision centre LATHE machine and influence of cutting parameter has been studied with use of analysis of variance technique (ANOVA) which is based on adjustable approach. They considered three level of cutting parameter. The result shows that feed rate has significant effect on cutting force surface roughness. They show that cutting speed not having much more influence on the cutting force and surface roughness. According to this study Optimum surface roughness can be achieved by selecting relatively higher values of speed (>65.37m/min), higher values of depth of cut (>0.75mm), and relatively lower values of feed rate (<0.10mm/rev). Ghani, J. A. et al. [3], studied the online tool wear using low cost technique and user friendly GUI. For this, they use low cost sensor. Due to that the system is able to detect and analyze signals relating to the deflection of the tool holder from the cutting force, and the corresponding estimation of wear is displayed on the computer screen. In experimental process they used two-channel strain gauge at tool holder to measure deflections in both tangential direction and feed direction. MATLAB software is used as the platform software to develop a user-friendly graphical user interface (GUI) for online monitoring purposes. Cus, F. and Zuperl, U. et al. [4], developed a real time monitoring system that can detect tool breakage in real time by using a combination of neural decision system and ANFIS tool wear estimator. They used ANFIS method to extract the features of tool states from cutting force signals. Force signals contain the most useful information for determining the tool condition. The ANFIS method uses the relationshi...

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Preliminary Study on Machining Condition Monitoring System Using 3-Channel Force Sensor Analyzed by I-kaz Multilevel Method

Cited by 4 publications

References 10 publications

Vibration–Based online Tool Wear Monitoring Using Piezo Film Sensor Analyzed by I-kaz Multilevel Signal Feature

Vibration–Based online Tool Wear Monitoring Using Piezo Film Sensor Analyzed by I-kaz Multilevel Signal Feature

Observation of Changes in Acoustic Emission and Vibration Signals to Transverse Crack on Rotating Shaft: An Experiment Investigation

Optimization of Resultant Cutting Force in CNC Turning Process for Hard (62-64 HRC) AISI M2

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