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TECHNICAL PAPERS

A New Method for Real-Time Tool Condition Monitoring in Transfer Machining Stations

[+] Author and Article Information
Ya Wu, Philippe Escande, R. Du

Dept. of Industrial Engineering, University of Miami, Miami, FL 33124

J. Manuf. Sci. Eng 123(2), 339-347 (Feb 01, 2000) (9 pages) doi:10.1115/1.1334859 History: Received November 01, 1997; Revised February 01, 2000
Copyright © 2001 by ASME
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References

Cook,  N. H., 1980, “Tool Wear Sensors,” Wear, 62, pp. 49–57.
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Byrne,  G., , 1995, “Tool Condition Monitoring (TCM)-The Status of Research and Industrial Applications,” CIRP Ann., 44/2, pp. 541–576.
Fan,  Y. Y., and Du,  R., 1996, “A Laser Diffraction Method for Rotating Tool Condition Monitoring,” ASME J. Eng. Ind., 118, No. 4, pp. 664–667.
Du, R., Zhang, B., Hungerford, W., and Pryor, T., 1993, “Tool Condition Monitoring and Compensation in Finish Turning Using Optical Sensor,” 1993 ASME WAM, Symposium of Mechatronics, DSC-Vol. 50/PED-Vol. 63, pp. 245–253.
Liu,  T. I., and Wu,  S. M., 1990, “On-line Detection of Drill Wear,” ASME J. Eng. Ind., 112, pp. 299–302.
Barker,  R. W., Klutke,  G., and Hinich,  M. J., 1993, “Monitoring Rotating Tool Wear Using Higher-Order Spectral Features,” ASME J. Eng. Ind. 115, No. 1, pp. 23–29.
Du,  R., Elbestawi,  M. A., and Li,  S., 1992, “Tool Condition Monitoring in Turning Using Fuzzy Set Theory,” Int. J. Mach. Tools Manuf., 32, No. 6, pp. 781–796.
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Constantinides,  N., and Bennett,  S., 1987 “An Investigation of Methods for the On-line Estimation of Tool Wear,” Int. J. Mach. Tools Manuf., 27, No. 2, pp. 225–237.
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Daubechies,  I., 1990, “The Wavelet Transform, Time-Frequency Localization and Signal Analysis,” IEEE Trans. Inf. Theory, 36, No. 9, pp. 961–1005.
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Tansel,  I. N., and McLauglin,  C., 1993, “Monitoring Drill Conditions with Wavelet Based Encoding and Neural Networks,” Int. J. Mach. Tools Manuf.,33, No. 4, pp. 559–575.
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Figures

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A typical power signal from a transfer drilling station
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(a) The filtered signal of the signal shown in Fig. 1—using Chebyshev type I filter with a cut-off frequency of 20 Hz; (b) the filtered signal of the signal shown in Fig. 1—using Chebyshev type I filter with a cut-off frequency between 12–30 Hz
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Illustration of the structural modeling of a signal
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The residual series and its FFT spectrum after the structural modeling of the signal shown in Fig. 1
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The wavelet packet transform of the signal shown in Fig. 1
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The feature packets of the signal shown in Fig. 1
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The reconstructed signal using feature packets and the errors corresponding to the signal shown in Fig. 1
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Illustration of the threshold crossing of a random signal and the corresponding binary time series
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An example of threshold band
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The schematic of the experiment setup for monitoring of the transfer drilling station
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Illustration of the three stages of tool wear and the sampling scheme in the experiment
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An example of new tool data against the alarm threshold bands
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An example of worn tool data against the alarm threshold bands

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