Tool breakage detection in CNC high-speed milling based in feed-motor current signals

Sevilla-Camacho, P. Y.; Herrera-Ruíz, Gilberto; Robles-Ocampo, J.B.; Jáuregui-Correa, Juan Carlos

doi:10.1007/s00170-010-2907-9

Cited by 48 publications

(22 citation statements)

References 27 publications

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“…The method based on motor current is considered one of the least disruptive and economical methods to estimate feed force and tool state. Li [14] and Sevilla-Camacho et al [15] presented the approaches to detect the tool wear rate with current signal. It was carried by measuring both feed and motor current and then accomplished by using a regression analysis to classify the different tool states.…”

Section: The Backgroundmentioning

confidence: 99%

“…One of the prominent and most widely studied aspects is the detection of tool conditions such as tool wear [8,10,48] and tool breakage [14,15], which are the main problems during machining under normal conditions. Studies on machining condition monitoring have also been carried from a system point of view, such as chatter [49], vibration [50], and control [3,17].…”

Section: Applicationsmentioning

confidence: 99%

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Compressive sensing and sparse decomposition in precision machining process monitoring: From theory to applications

Zhu

Lin

et al. 2015

Mechatronics

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Section: The Backgroundmentioning

confidence: 99%

Section: Applicationsmentioning

confidence: 99%

Compressive sensing and sparse decomposition in precision machining process monitoring: From theory to applications

Zhu

Lin

et al. 2015

Mechatronics

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“…Severe breakage of tooth likely occurs in the portion adjoining the bottom of mills; it is somewhat like tip breakage shown by Sevilla-Camacho, Herrera-Ruiz, Robles-Ocampo, et al [7]. The simplified model of breakage section is shown in Fig.…”

Section: Geometry Features Of Breakage Sections On Broken Tooth Of Enmentioning

confidence: 99%

“…From the implications of Lin [4], Cui, Zhao, and Tian [5], and Xu, Huang, and Ai [3], the chipping was that only part of tool edge being lost, the flaking was tool material on rake face or flank face adjoining tool edge falling offer, and the cracking was that induced by fatigue in interrupted cutting. Bai, Li, Liang, et al [6] and Sevilla-Camacho, Herrera-Ruiz, RoblesOcampo, et al [7] got the photos of tip breakage for end mills. Zhou, Andersson, Stahl [1] thought modern cutter should be easy to induce brittle fracture for its lower tensile strength.…”

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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“…However, few monitoring systems have been developed and reported to detect the tool condition in HSM. These systems are based on the measurement of physical variables related to the cutting tool conditions, such as cutting force [1,2], feed and spindle motor currents [3,4], and vibration [5,6]. Nevertheless, some of these reported systems have limitations for their industrial application, e.g., high costs, difficult installation on the machine tool, or operation with limited characteristics.…”

Section: Introductionmentioning

confidence: 98%

FPGA-based reconfigurable system for tool condition monitoring in high-speed machining process

et al. 2015

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Tool breakage detection in CNC high-speed milling based in feed-motor current signals

Cited by 48 publications

References 27 publications

Compressive sensing and sparse decomposition in precision machining process monitoring: From theory to applications

Compressive sensing and sparse decomposition in precision machining process monitoring: From theory to applications

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

FPGA-based reconfigurable system for tool condition monitoring in high-speed machining process

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