Design of an instrumented smart cutting tool and its implementation and application perspectives

This paper presents an innovative design of a smart cutting tool, using two surface acoustic wave (SAW) strain sensors mounted onto the top and the side surface of the tool shank respectively, and its implementation and application perspectives. This surface acoustic wave-based smart cutting tool is capable of measuring the cutting force and the feed force in a real machining environment, after a calibration process under known cutting conditions. A hybrid dissimilar workpiece is then machined using the SAW-based smart cutting tool. The hybrid dissimilar material is made of two different materials, NiCu alloy (Monel) and steel, welded together to form a single bar; this can be used to simulate an abrupt change in material properties. The property transition zone is successfully detected by the tool; the sensor feedback can then be used to initiate a change in the machining parameters to compensate for the altered material properties.The UK Technology Strategy Board (TSB) for supporting this research (SEEM Project, contract No. BD266E

A multi-sensor based online tool condition monitoring system for milling process

Tool condition monitoring has been considered as one of the key enabling technologies for manufacturing optimization. Due to the high cost and limited system openness, the relevant developed systems have not been widely adopted by industries, especially Small and Medium-sized Enterprises. In this research, a cost-effective, wireless communication enabled, multi-sensor based tool condition monitoring system has been developed. Various sensor data, such as vibration, cutting force and power data, as well as actual machining parameters, have been collected to support efficient tool condition monitoring and life estimation. The effectiveness of the developed system has been validated via machining cases. The system can be extended to wide manufacturing applications

A comparative study of using spindle motor power and eddy current for the detection of tool conditions in milling processes

This paper investigates the use of the power of the driving motor of a CNC spindle in comparison to two perpendicular eddy current sensors for the detection of tool wear in milling processes. Monitoring the power through the current profile is a low cost system which has been utilised in this study as an attempt to detect the fluctuation in the motor load as a result of the conditions of the cutting tool. Eddy current sensors are dedicated sensors that are installed on the spindle to measure the vibration of the rotating spindle in two axes. Experimental work has been conducted using fresh and worn tools to investigate the effect of tool conditions on the two sensory systems. Time domain features are utilised to compare between the two sensors in relation to this application. The results indicate that Eddy current sensors are found to be more successful and sensitive, in general, than the power of the motor in detecting the changes of the cutting tools during the machining operation. However, the kurtosis value of the power of the spindle has been found to be successful in predicting the tool conditions with high sensitivity

Design of a smart turning tool with application to in-process cutting force measurement in ultraprecision and micro cutting

In modern micromachining, there is a need to measure and monitor certain machining process parameters in process so as to detect tool wear in real time, to optimize the process parameters setup, and to render the machining process some level of smartness and intelligence. This paper presents the innovative design of a smart turning tool using two pieces of piezoelectric films to measure cutting and feed force in real time. The tool was tested on its performance through the calibration and cutting trials against the commercial dynamometer. The results show the smart turning tool has achieved the performance as designed

Design and analysis of a piezoelectric film embedded smart cutting tool

This is the author's accepted manuscript. The final published article is available from the link below. Copyright @ 2012 Institution of Mechanical Engineers.The condition of a cutting tool is an important factor for manufacturing processes. Tool wear has a strong influence on the cutting forces, resulting in poor surface roughness and dimensional accuracy of the workpiece. Therefore, the use of a dynamometer to measure cutting forces is a well-known approach, but it has several limitations such as high cost, poor performance in harsh industrial machining environments and possible interference with cutting dynamics. This article presents a novel smart cutting tool using a separate single-layer piezoelectric film as the sensing unit to detect the orthogonal cutting force. Simulations were performed to validate the feasibility of the proposed design, and the model was also able to detect better force measurement sensitivity. Furthermore, cutting trials were carried out to validate cutting tool performance experimentally

Rapid design of tool-wear condition monitoring systems for turning processes using novelty detection

Condition monitoring systems of manufacturing processes have been recognised in recent years as one of the key technologies that provide the competitive advantage in many manufacturing environments. It is capable of providing an essential means to reduce cost, increase productivity, improve quality and prevent damage to the machine or workpiece. Turning operations are considered one of the most common manufacturing processes in industry. It is used to manufacture different round objects such as shafts, spindles and pins. Despite recent development and intensive engineering research, the development of tool wear monitoring systems in turning is still ongoing challenge. In this paper, force signals are used for monitoring tool-wear in a feature fusion model. A novel approach for the design of condition monitoring systems for turning operations using novelty detection algorithm is presented. The results found prove that the developed system can be used for rapid design of condition monitoring systems for turning operations to predict tool-wear

Design methodology for smart actuator services for machine tool and machining control and monitoring

This paper presents a methodology to design the services of smart actuators for machine tools. The smart actuators aim at replacing the traditional drives (spindles and feed-drives) and enable to add data processing abilities to implement monitoring and control tasks. Their data processing abilities are also exploited in order to create a new decision level at the machine level. The aim of this decision level is to react to disturbances that the monitoring tasks detect. The cooperation between the computational objects (the smart spindle, the smart feed-drives and the CNC unit) enables to carry out functions for accommodating or adapting to the disturbances. This leads to the extension of the notion of smart actuator with the notion of agent. In order to implement the services of the smart drives, a general design is presented describing the services as well as the behavior of the smart drive according to the object oriented approach. Requirements about the CNC unit are detailed. Eventually, an implementation of the smart drive services that involves a virtual lathe and a virtual turning operation is described. This description is part of the design methodology. Experimental results obtained thanks to the virtual machine are then presented

Design of a five-axis ultra-precision micro-milling machine—UltraMill. Part 2: Integrated dynamic modelling, design optimisation and analysis

Using computer models to predict the dynamic performance of ultra-precision machine tools can help manufacturers to substantially reduce the lead time and cost of developing new machines. However, the use of electronic drives on such machines is becoming widespread, the machine dynamic performance depending not only on the mechanical structure and components but also on the control system and electronic drives. Bench-top ultra-precision machine tools are highly desirable for the micro-manufacturing of high-accuracy micro-mechanical components. However, the development is still at the nascent stage and hence lacks standardised guidelines. Part 2 of this two-part paper proposes an integrated approach, which permits analysis and optimisation of the entire machine dynamic performance at the early design stage. Based on the proposed approach, the modelling and simulation process of a novel five-axis bench-top ultra-precision micro-milling machine tool—UltraMill—is presented. The modelling and simulation cover the dynamics of the machine structure, the moving components, the control system and the machining process and are used to predict the entire machine performance of two typical configurations