• 한국정밀공학회지
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• 제15권11호
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• pp.32-38
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• 1998

For the purpose of monitoring the abnormal state in proportion to cutting in automatic production process, the 3 kinds of specimens different from mechanical properties by austempering through temperature variation were manufactured, and the effects of tool wear on thrust and AE RMS was analyzed with sequential drilling in in-process. When the ADI specimens were drilled, the relationship of thrust and AE RMS with flank wear was studied through experiments, and it is confirmed that the reliable wear state is able to be monitored by using these signals. It was shown that thrust and AE RMS increased slowly till flank wear reached to V$_{B}$ = 0.25mm, and they increased steeply over the value. The effective tool exchange time was able to be pre-estimated by using this fact. It was validated that the tool breakage was able to be detected on the real time by monitoring in in-process.s.

• 한국공작기계학회:학술대회논문집
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• 한국공작기계학회 2002년도 춘계학술대회 논문집
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• pp.245-250
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• 2002

A successful on-line monitoring system for conventional machining operations has the potential to reduce cost, guarantee consistency of product quality, improve productivity and provide a safer environment for the operator. In fee-shape machining, typical signs of tool problems such as vibration, noise, chip flow characteristics and visual signs are almost unnoticeable without the use of special equipment. These characteristics increase the importance of automatic monitoring in fine-shape machining; however, sensing and interpretation of signals are more complex. In addition, the shafts of the micro-tools break before the typical extensive cutting edge of the tool gets damaged. In this study, the existence of a relationship between the characteristics of the cutting force and tool usage was investigated, and tool breakage detection algorithm was developed and the fellowing results are obtained. In data analysis, didn't use a relative error compare which mainly used in established experiment and investigated tool breakage detection algorithm in time domain which can detect AE and cutting force signals more effective and accurate.

• 한국정밀공학회지
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• 제13권6호
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• pp.168-176
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• 1996

A diagnosis system which can monitor tool breakage and chipping in real time was developed using a DSP(Digital Signal Processor) board in face milling operation. AR modelling and band energy method were used to extract the feature of tool states from cutting force signals. Artificial neural network embedded on DSP board discriminates different patterns from features got after signal processing. The features extracted from AR modelling are more accurate for the malfunction of a process than those from band energy method, even though the computing speed of the former is slow. From the processed features, we can construct the real time diagnosis system which monitors malfunction by using a DSP board having a parallel processing capability.

• 한국정밀공학회지
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• 제12권3호
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• pp.130-143
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• 1995

This paper presents a new methodology for on-line tool breadage detection by sensor fusion of an acoustic emission (AE) sensor and a built-in force sensor. A built-in piezoelectric force sensor, instead of a tool dynamometer, was used to measure the cutting force without altering the machine tool dynamics. The sensor was inserted in the tool turret housing of an NC lathe. FEM analysis was carried out to locate the most sensitive position for the sensor. A burst of AE signal was used as a triggering signal to inspect the cutting force. A sighificant drop of cutting force was utilized to detect tool breakage. The algorithm was implemented on a DSP board for in-process tool breakage detection. Experiental works showed an excellent monitoring capability of the proposed tool breakage detection system.

• 한국정밀공학회지
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• 제32권7호
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• pp.611-617
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• 2015

In the development of a vibration-based condition monitoring system in gearbox, one of the most important research topics is a quantitative analysis and test of the effect of gear damage on vibration of gearbox. This paper presents the evaluation result of vibration condition indicator according to the gear tooth damage through the vibration test of gearbox. The dynamic load test was performed with high speed railway (KTX)'s gearbox. The vibration of gearbox was measured according to a rotational speed change with the common gear fault modes, such as pitting and tooth breakage. The characteristics and the possibility of applying of vibration condition indicator on condition monitoring system were analyzed. As a result, the value of most condition indicator is gradually increased with the severity of gear faults. The NA6 indicator shows a low variation with the rotational speed change and high sensitivity in accordance with the gear fault.

• 한국공작기계학회:학술대회논문집
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• 한국공작기계학회 2001년도 추계학술대회(한국공작기계학회)
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• pp.14-18
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• 2001

Rise in cutting force causes tool damage and worsens product quality resulting in machining accuracy deterioration. Especially, fragile material cutting brings about breakage of material and worsens product surface quality. In this study, we trace the locus of cutting force and examine the machined surface corresponding to the cutting force loci. and build up a monitoring system for deciding normal operation or not of cutting process.

• 제어로봇시스템학회:학술대회논문집
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• 제어로봇시스템학회 2002년도 ICCAS
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• pp.95.5-95
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• 2002

Tool condition monitoring is recognized important in CNC machining processes since the excessive wear or breakage of tool has to be noticed immediately in an automated manufacturing system to keep the quality and productivity. In this research, as an economic way of detecting the status of tool change, the wavelet transform has been applied to the measurement of spindle motor current. The energy of a specific level shows the difference between a normal tool and worn one. By setting a limit on the change of energy, it is possible to notify the time to inspect the tool.

• 한국공작기계학회:학술대회논문집
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• 한국공작기계학회 1999년도 추계학술대회 논문집 - 한국공작기계학회
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• pp.204-209
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• 1999

The dressing time monitoring in cylindrical grinding is very important with respect to machining efficiency. Therefore, the purpose of this paper is to determine the wheel life by monitoring behavior of grinding power for Wa, 19A and GC. For this purpose, we investigated indirectly the attritious wear of grain edge, the loading of grinding wheel and the breakage of grain through the grinding power and the surface roughness under various grinding conditions. From obtained the results, the relationship between the wheel life and the average sectional chip area is examined to guide for the determination of dressing time.

• 한국기계가공학회지
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• 제3권3호
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• pp.24-31
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• 2004

A successful on-line monitoring system for conventional machining operations has the potential to reduce cost, guarantee consistency of product quality, improve productivity and provide a safer environment for the operator. In fine-shape machining, typical signs of tool problems such as vibration, noise, chip flow characteristics and visual signs are almost unnoticeable without the use of special equipment. These characteristics increase the importance of automatic monitoring in fine-shape machining, however, sensing and interpretation of signals ar more complex. In addition, the shafts of the mini-tools break before the typical extensive cutting edge of the tool gets damaged. In this study, the existence of a relationship between the characteristics of the cutting force and tool usage was investigated, and tool breakage detection algorithm by LabVIEW was developed and the following results are obtained. It was possible to use a relative error compare which mainly used in established experiment and investigated tool breakage detection algorithm in time domain which can detect AE and cutting force signals more effective and accurate.

• Journal of Mechanical Science and Technology
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• 제18권7호
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• pp.1055-1061
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• 2004

In this research, a vision system for detecting breakages of small-diameter taps, which are rarely detected by the indirect in-process monitoring methods such as acoustic emission, cutting torque and motor current, was developed. Two HMI (Human Machine Interface) programs to embed the developed vision system into a Siemens open architecture controller, 840D, were developed. They are placed in sub-windows of the main window of the 840D and can be activated or deactivated either by a softkey on the operating panel or the M code in the NC part program. In the event that any type of tool breakage is detected, the HMI program issues a command for an automatic tool change or sends an alarm signal to the NC kernel. An evaluation test in a high-speed tapping machine showed that the developed vision system was successful in detecting breakages of small-diameter taps up to M1.