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Research Papers

Tool Wear Monitoring of Wiper Inserts in Multi-Insert Face Milling Using Three-Dimensional Surface Form Indicators

[+] Author and Article Information
Meng Wang

State Key Laboratory of Mechanical System
and Vibration,
Department of Industrial Engineering
and Logistics Management,
School of Mechanical Engineering,
Shanghai Jiao Tong University,
800 Dongchuan Road,
Shanghai 200240, China
e-mail: mwang@sjtu.edu.cn

Te Ken

State Key Laboratory of Mechanical System
and Vibration,
Department of Industrial Engineering
and Logistics Management,
School of Mechanical Engineering,
Shanghai Jiao Tong University,
800 Dongchuan Road,
Shanghai 200240, China
e-mail: kente@sjtu.edu.cn

Shichang Du

State Key Laboratory of Mechanical System
and Vibration,
Department of Industrial Engineering
and Logistics Management,
School of Mechanical Engineering,
Shanghai Jiao Tong University,
800 Dongchuan Road,
Shanghai 200240, China
e-mail: lovbin@sjtu.edu.cn

Lifeng Xi

State Key Laboratory of Mechanical System
and Vibration,
Department of Industrial Engineering
and Logistics Management,
School of Mechanical Engineering,
Shanghai Jiao Tong University,
800 Dongchuan Road,
Shanghai 200240, China
e-mail: lfxi@sjtu.edu.cn

1Corresponding author.

Contributed by the Manufacturing Engineering Division of ASME for publication in the JOURNAL OF MANUFACTURING SCIENCE AND ENGINEERING. Manuscript received May 11, 2014; final manuscript received October 17, 2014; published online February 18, 2015. Assoc. Editor: Robert Gao.

J. Manuf. Sci. Eng 137(3), 031006 (Jun 01, 2015) (8 pages) Paper No: MANU-14-1279; doi: 10.1115/1.4028924 History: Received May 11, 2014; Revised October 17, 2014; Online February 18, 2015

The wear of wiper inserts directly affects the finishing surface quality in multi-insert face milling. This research aims at monitoring the wear of wiper inserts, using 3D surface form as tool wear indicators. 3D surface height map of the face-milled surface is measured by a high definition metrology (HDM) instrument and converted into height-encoded and toolmark-straightened gray images. 3D surface form indicators, including entropy and contrast, are extracted from the converted images with a modified gray level co-occurrence matrix (GLCM) method. Meanwhile, the wear of wiper inserts is measured using a tool presetter and measuring machine without dismounting wiper inserts from the cutter. Experimental results indicate that entropy shows a strong correlation with average axial wear of the wiper edges and contrast reflects the evolution of axial offset between wiper inserts.

FIGURES IN THIS ARTICLE
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Copyright © 2015 by ASME
Topics: Wear , Milling , Cutting
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Figures

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Fig. 1

3D surface height map measured by HDM

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Fig. 2

The face milling cutter with 15 cutting inserts and 3 wiper inserts

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Fig. 3

Wear of wiper inserts

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Fig. 4

Axial height of wiper edges versus number of blocks machined: (a) measured axial height and (b) compensated axial height

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Fig. 5

Average axial lowering of the three wiper inserts

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Fig. 6

Face milling toolmark straightening

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Fig. 7

Height-encoded gray image converted from HDM data: (a) original toolmark and (b) straightened toolmark

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Fig. 8

(a) entropy versus number of blocks machined and (b) contrast versus number of blocks machined

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Fig. 9

(a) Flatness versus number of blocks machined and (b) roughness and waviness versus number of blocks machined

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