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1.
Intelligent cutting tool condition monitoring in milling
Uroš Župerl, Franc Čuš, Jože Balič, 2011, original scientific article

Abstract: Purpose: of this paper is to present a tool condition monitoring (TCM) system that can detect tool breakage in real time by using a combination of neural decision system, ANFIS tool wear estimator and machining error compensation module. Design/methodology/approach: The principal presumption was that the force signals contain the most useful information for determining the tool condition. Therefore, ANFIS method is used to extract the features of tool states from cutting force signals. The trained ANFIS model of tool wear is then merged with a neural network for identifying tool wear condition (fresh, worn). Findings: The overall machining error is predicted with very high accuracy by using the deflection module and a large percentage of it is eliminated through the proposed error compensation process. Research limitations/implications: This study also briefly presents a compensation method in milling in order to take into account tool deflection during cutting condition optimization or tool-path generation. The results indicate that surface errors due to tool deflections can be reduced by 65-78%. Practical implications: The fundamental limitation of research was to develop a single-sensor monitoring system, reliable as commercially available system, but much cheaper than multi-sensor approach. Originality/value: A neural network is used in TCM as a decision making system to discriminate different malfunction states from measured signals.
Keywords: tool condition monitoring, TCM, wear, tool deflection, ANFIS, neural network, end-milling
Published: 01.06.2012; Views: 875; Downloads: 20
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2.
A model of tool wear monitoring system for turning
Aco Antić, Goran Šimunović, Tomislav Šarić, Mijodrag Milošević, Mirko Ficko, 2013, original scientific article

Abstract: Acquiring high-quality and timely information on the tool wear condition in real time, presents a necessary prerequisite for identification of tool wear degree, which significantly improves the stability and quality of the machining process. Defined in this paper is a model of tool wear monitoring system with special emphasis on the module for acquisition and processing of vibration acceleration signal by applying discrete wavelet transformations (DWT) in signal decomposition. The paper presents a model of the developed fuzzy system for tool wear classification. The system comprises three modules: module for data acquisition and processing, module for tool wear classification, and module for decision-making. The selected method for feature extraction is presented within the module for data classification and processing. The selected model for the fuzzy classifier and classification in experimental laboratory conditions is shown within data classification and clustering. The proposed model has been tested in longitudinal and transversal machining operations.
Keywords: artificial intelligence, tool wear monitoring, feature extraction
Published: 10.07.2015; Views: 322; Downloads: 48
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3.
Real-time cutting tool condition monitoring in milling
Franc Čuš, Uroš Župerl, 2011, original scientific article

Abstract: Reliable tool wear monitoring system is one of the important aspects for achieving a self-adjusting manufacturing system. The original contribution of the research is the developed monitoring system that can detect tool breakage in real time by using a combination of neural decision system and ANFIS tool wear estimator. The principal presumption was that force signals contain the most useful information for determining the tool condition. Therefore, the ANFIS method is used to extract the features of tool states from cutting force signals. ANFIS method seeks to provide a linguistic model for the estimation of tool wear from the knowledge embedded in the artificial neural network. The ANFIS method uses the relationship between flank wear and the resultant cutting force to estimate tool wear. A series of experiments were conducted to determine the relationship between flank wear and cutting force as well as cutting parameters. Speed, feed, depth of cutting, time and cuttingforces were used as input parameters and flank wear width and tool state were output parameters. The forces were measured using a piezoelectric dynamometer and data acquisition system. Simultaneously flank wear at the cutting edge was monitored by using a tool maker's microscope. The experimental force and wear data were utilized to train the developed simulation environment based on ANFIS modelling. The artificial neural network, was also used to discriminate different malfunction states from measured signals. By developed tool monitoring system (TCM) the machining process can be on-line monitored and stopped for tool change based on a pre-set tool-wear limit. The fundamental limitation of research was to develop a single sensor monitoring system, reliable as commercially available system, but 80% cheaper than multisensor approach.
Keywords: end-milling, tool condition monitoring, wear estimation, ANFIS
Published: 10.07.2015; Views: 876; Downloads: 71
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