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TECHNICAL PAPERS

Development of a Cutting Direction and Sensor Orientation Independent Monitoring Technique for End-Milling

[+] Author and Article Information
John T. Roth

Arkansas State University, State University, AR 72467

Sudhakar M. Pandit

Michigan Technological University, Houghton, MI 49931

J. Manuf. Sci. Eng 122(4), 671-677 (Feb 01, 1999) (7 pages) doi:10.1115/1.1286169 History: Received February 01, 1999
Copyright © 2000 by ASME
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References

Pandit,  S. M., and Kashou,  S., 1982, “A Data Dependent Systems Strategy of On-line Tool Wear Sensing,” ASME J. Eng. Ind., 104, pp. 217–223.
Tansel,  I. N., and McLaughlin,  C., 1993, “Detection of Tool Breakage in Milling Operations—I. The Time Series Analysis Approach,” Int. J. Mach. Tools Manuf., 33, No. 4, pp. 531–544.
Ruiz, G. H., Mori, K., and Kasashima, N., 1995, “Detection of Tool Failure in Milling Process Using Wavelet Transform,” First World Congress on Int. Manuf. Proc. and Sys., 1, San Juan, Puerto Rico, pp. 271–281.
O’Brien,  D. J., Sutherland,  J. W., and Kapoor,  S. G., 1990, “A Force-Based Approach to On-Line Flute Breakage Detection in a Peripheral End Milling Process,” Autom. Manuf. Proc., ASME Bound Volume—DSC22, 47–58.
Liu, T., and Lee, C., 1998, “On-Line Evaluation of Drill Conditions for Operational Safety and Product Quality,” MED-Vol. 8, Proceedings of the ASME, pp. 877–884.
Kim,  S., and Klamecki,  B. E., 1997, “Milling Cutter Wear Monitoring Using Spindle Shaft Vibration,” ASME J. Manuf. Sci. Eng., 119, pp. 118–119.
Roth,  J. T., and Pandit,  S. M., 1998, “Monitoring End-Mill Wear and Predicting Tool Failure using Accelerometers,” J. Manuf. Sci. Eng., MED8, pp. 867–875. Also in ASME J. Manuf. Sci. Eng. 121, August 1999.
Lin,  S. C., and Lin,  R. J., 1996, “Tool wear monitoring in face milling using force signals,” Wear, 198, pp. 136–142.
Wilcox,  S. J., and Reuben,  R. L., 1994, “The detection of short time-scale tool degradation events during face milling operations using cutting force and acoustic emission,” J. Eng. Manuf., 208, pp. 205–215.
Altintas,  Y., and Yellowley,  I., 1989, “In-Process Detection of Tool Failure in Milling Using Cutting Force Models,” ASME J. Eng. Ind., 111, pp. 149–157.
Diei,  E. N., and Dornfeld,  D. A., 1987, “Acoustic Emission Sensing of Tool Wear in Face Milling,” ASME J. Eng. Ind., 109, pp. 234–240.
Sutherland,  J. W., O’Brien,  D. J., and Wagner,  M. S., 1989, “An Algorithm for the Detection of Flute Breakage in a Peripheral End Milling Process,” Trans. NAMRI/SME, 17, pp. 144–151.
Altintas,  Y., Yellowley,  I., and Tlusty,  J., 1988, “The Detection of Tool Breakage in Milling Operations,” ASME J. Eng. Ind., 110, pp. 271–277.
Yao,  Y., and Fang,  X., 1992, “Modeling of Multivariate Time Series for Tool Wear Estimation in Finish-Turning,” Int. J. Mach. Tools Manuf., 32, No. 4, pp. 495–508.
Pandit, S. M., 1991, Modal and Spectrum Analysis: Data Dependent Systems in State Space, Wiley, New York.
Pandit, S. M., and Wu, S. M., 1993, Time Series and Systems Analysis with Applications, Wiley, 1983, reprint by Krieger.
Roth, J. T., 1998, Monitoring End-Mill Wear and Predicting Tool Failure using Accelerometers, Ph.D. Thesis, Michigan Technological University.
Roth,  J. T., and Pandit,  S. M., 1999, “Early Prediction of Impending End-Milling Tool Failure Using Acceleration Signals,” Tech. Pap. NAMRI/SME, 27, pp. 63–68.
Wylie, C. R., and Barrett, L. C., 1982, Advanced Engineering Mathematics, 5th ed., McGraw-Hill, Inc., New York.
Lancaster, P., and Tismenetsky, M., 1985, The Theory of Matrices Second Edition with Applications, 2nd ed., Academic Press, San Diego.

Figures

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Univariate models to the life test results
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Modal energy trend using the sum of the modal energy matrix elements
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Modal energy trend using the maximum eigenvalue of the modal energy matrix
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Example modal energy trend: feed direction
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Example modal energy trend: cross-feed direction
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Y-axis modal energy trend including turning
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X-axis modal energy trend including turning

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