MONITORING THE FLANK WEAR USING PIEZOELECTRIC OF ROTATING TOOL OF MAIN CUTTING FORCE IN END MILLING

Authors

  • N.H.M. Tahir Department of Mechanical and Materials Engineering, Faculty of Engineering and Build Environment, Universiti Kebangsaan Malaysia, 43600 Bangi, Selangor
  • R. Muhammad Department of Mechanical Engineering, Faculty of Engineering, Syiah Kuala University (UNSYIAH), 23111 Darussalam, Banda Aceh, Indonesia
  • J. A. Ghani Department of Mechanical and Materials Engineering, Faculty of Engineering and Build Environment, Universiti Kebangsaan Malaysia, 43600 Bangi, Selangor
  • M. Z. Nuawi Department of Mechanical and Materials Engineering, Faculty of Engineering and Build Environment, Universiti Kebangsaan Malaysia, 43600 Bangi, Selangor
  • C. H. C. Haron Department of Mechanical and Materials Engineering, Faculty of Engineering and Build Environment, Universiti Kebangsaan Malaysia, 43600 Bangi, Selangor

DOI:

https://doi.org/10.11113/jt.v78.9187

Keywords:

Rotating dynamometer, piezoelectric, cutting force signals, milling process

Abstract

Tool condition monitoring (TCM) system in the industry are mainly used to detect tool wear, breakage and chatter on the tool. Tool wear of AISI P20 under various cutting conditions have been investigated in end milling using cutting force signals due flank wear progression. This study is focused on the piezoelectric sensor system which is integrated on rotating cutting tool for tool wear monitoring system in milling process. The signal captured by piezoelectric sensors are analyzed in time and frequency domain. The signal amplitudes of main cutting force, Fc in time domain are increased, while the peak of the amplitude in frequency domain is decreased as the flank wear and cutting speed increases. By using 3D I-kazTM statistical analysis method, the relationship and correlation between I-kaz coefficients, Z∞  values with resultant flank wear width data, VB are proved. The results show that 3D I-kazTM statistical analysis method can be effectively used to monitor tool wear progression using a wireless telemetry system during milling operations.

References

Yu, G. 2002. Tool Wear Monitoring in Turning Operations using Ultrasonic Wave and Artificial Neural Network, Milwaukee: The University of Wisconsin.

Singh, N. 1996. System Approach to Computer- Integrated Design and Manufacturing. New York : John Willey & sons.

Kassim AA, Mannan MA, Mian Z. 2007. Texture analysis methods for tool condition monitoring. Image Vision Computer. 25:1080–1090.

Choudhury, S.K. and S. Rath. 2000. In-Process Tool Wear Estimation In Milling Using Cutting Force Model. Journal Material Process Technology. 99: 113-119.

Oraby S. E., Hayhurst D. R. 1990. High-Capacity Compact Three-Component Cutting Force Dynamometer. International Journal of Machine Tools and Manufacture. 30 (4): 549–559.

Kaya, B., Oysu, C., Ertunc, H. M. 2011. Force-Torque Based On-Line Tool Wear Estimation System For CNC Milling Of Inconel 718 Using Neural Networks. Advances in Engineering Software. 42 (3): 76-84.

Kistler, 2012. Brochure of Cutting Force Measurement. Retrieved from: http://www.kistler.com/CH_en-ch/ 46_ Product Finder_ Manufacturing 3000.-.17/ Product- Finder- Manufacturing.html. Also Retrieved from: . (Assessed on: July 9, 2014).

Kuljanic E., M. Sortino. 2005. Tool Wear Estimation Method – TWEM Using Cutting Forces In Face Milling. International Journal of Machine Tools and Manufacture. 45: 23–34.

Karabay, S. 2007. Design Criteria For Electro-Mechanical Transducers And Arrangement For Measurement Of Strains Due To Metal Cutting Forces Acting On Dynamometers. Materials and Design. 28 (2): 496-506.

Totis, G., G. Wirtz, M. Sortino, D. Veselovac, E. Kuljanic and F. Klocke. 2010. Development of a dynamometer for measuring individual cutting edge forces in face milling. Mechanical System Signal Process. 24: 1844-1857.

R. Muhammad, J. A. Ghani, M. Z. Nuawi, C. H. C. Hassan. 2014. A Wireless System and Embedded Sensors on Spindle Rotating Tool for Condition Monitoring. Advanced Science Letters. 20 (10): 1829-1832.

M. Z. Nuawi, M. J. M. Nor, N. Jamaludin, S. Abdullah, F. Lamin, C. K. E. Nizwan. 2008. Development Of Integrated Kurtosis-Based Algorithm For Z-Filter Technique. Journal of Applied Sciences. 8(8): 1541-1547.

Liang S. Y, Perry S. A. 1994. In-Process Compensation For Milling Cutter Run Out Via Chip Load Manipulation. Journal Engineering Industry. 116(2):153-160

Bayoumi A. E, Yu ¨cesan G, Kendall L. A. 1994. An analytic mechanistic cutting force model for milling operations: a theory and methodology. Journal Engineering Industry. 116(3): 324-330

Downloads

Published

2016-06-23

Issue

Vol. 78 No. 6-10: Advances in Research on Automotive Technology Vol. 2

Section

Science and Engineering

License

Copyright of articles that appear in Jurnal Teknologi belongs exclusively to Penerbit Universiti Teknologi Malaysia (Penerbit UTM Press). This copyright covers the rights to reproduce the article, including reprints, electronic reproductions, or any other reproductions of similar nature.

How to Cite

MONITORING THE FLANK WEAR USING PIEZOELECTRIC OF ROTATING TOOL OF MAIN CUTTING FORCE IN END MILLING. (2016). Jurnal Teknologi (Sciences & Engineering), 78(6-10). https://doi.org/10.11113/jt.v78.9187