Research Papers

Endmill Condition Monitoring and Failure Forecasting Method for Curvilinear Cuts of Nonconstant Radii

[+] Author and Article Information
Christopher A. Suprock, John T. Roth

Mechanical Engineering, School of Engineering, Penn State Erie, The Behrend College, 5101 Jordan Road, Erie, PA 16563

Larry M. Downey

Mathematics, School of Science, Penn State Erie, The Behrend College, 5101 Jordan Road, Erie, PA 16563

J. Manuf. Sci. Eng 131(2), 021003 (Feb 24, 2009) (8 pages) doi:10.1115/1.3075895 History: Received February 25, 2008; Revised July 21, 2008; Published February 24, 2009

In this paper, an endmill condition monitoring technique is presented for curvilinear cutting. This algorithm operates without the need for prior knowledge of cutting conditions, tool type, cut curvature, cut direction, or directional rate of change. The goal of this method is an indirect measurement of the tool wear able to indicate when wear is accelerating without direct measurement of the tool. This technique is based on an autoregressive-type monitoring algorithm, which is used to track the tool’s condition using a tri-axial accelerometer. Accelerometer signals are monitored due to the sensor’s relatively low cost and since use of the sensor does not limit the machining envelope. To demonstrate repeatability, eight life tests were conducted. The technique discussed herein successfully delivers prognosis of impending fracture or meltdown due to wear in all cases, providing sufficient time to remove the tools before failure is realized. Furthermore, the algorithm produces similar trends capable of forecasting failure, regardless of tool type and cut geometry. Success is seen in all cases without requiring algorithm modifications or any prior information regarding the tool or cutting conditions.

Copyright © 2009 by American Society of Mechanical Engineers
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Figure 1

Known wear curve for endmill tools

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Figure 2

Spiral, linear, and rectangular cut path with corresponding sensor orientation

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Figure 3

Orientation of accelerometer with respect to spindle and workpiece

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Figure 4

Spiral life test 1.1 wear curve

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Figure 5

4340 steel spiral pocket geometry

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Figure 6

Linear life test 1.2 wear curve

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Figure 7

Rectangular life test 1.3 wear curve

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Figure 8

Spiral life test 2.1 wear curve

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Figure 9

Spiral life test 2.2 wear curve

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Figure 10

Catastrophic failure during high strain rate cutting

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Figure 11

Spiral life test 3.1 wear curve

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Figure 12

Spiral life test 3.2 wear curve

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Figure 13

Spiral life test 4.1 wear curve




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