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DEVELOPMENT OF AN EXPERT SYSTEM FOR TOOL WEAR MONITORING IN MILLING, DRILLING AND BLANKING USING MULTI-SENSOR SYSTEMS, AND MACHINABILITY STUDIES USING ACOUSTIC EMISSION

Objective


This project developed the specifications for an expert system (TEMOS) which is designed to detect tool breakage and provide in-process monitoring of progressive tool wear, for milling and blanking operations. The system is capable of 'learning' machinability criteria derived from AE analysis to adapt tool life prediction.

Other achievements of this project are: the building and evaluation of three different interferometers; the design of a torque and thrust sensor, based on a strain gauge dynamometer integrated in the drill tool holder; design of an acoustic emission sensor based on the criteria of the NBS conical transducer and the PVDF displacement transducer; an identification system which offers a procedure to evaluate the process state for every combination of conditions; machinability criteria which are derived from statistical analysis of the acoustic emission.
ONE OF THE MAIN AIMS OF AN FMS IS TO PERMIT UNMANNED OPERATION FOR CONSIDERABLE PERIODS OF TIME. THIS REQUIRES SENSING SYSTEMS WHICH CAN MONITOR TOOL WEAR AND BREAKAGE TO ENSURE THAT TOOLS ARE CHANGED BEFORE THERE IS A DETERIORATION IN WORKPIECE QUALITY, OR A DANGER OF DAMAGE TO THE MACHINE ITSELF.THE MAJOR AIM OF THIS PROJECT IS TO DEVELOP THE SPECIFICATIONS OF AN EXPERT SYSTEM FOR TOOL WEAR MONITORING IN MILLING, DRILLING AND BLANKING OPERATIONS. THE EFFECT OF TOOL WEAR ON FORCE, TORQUE, POWER OR CURRENT AND ACOUSTIC EMISSION PARAMETERS IN MILLING AND DRILLING OPERATIONS WILL BE INVESTIGATED, AND A TOOL-LIFE PREDICTION MODEL IS TO BE DERIVED. NEW INVESTIGATIONS WILL RESULT IN THE IMPROVED CONTROL OF BLANKING OPERATIONS.
A MACHINABILITY TEST BASED ON ACOUSTIC EMISSION WILL BE DEFINED. NOVEL MULTI-PARAMETER SENSORS WHICH ARE SUITABLY COMPACT, ROBUST AND NON-INVASIVE FOR USE IN THE MONITORING OF MACHINING AND METALWORKING OPERATIONS IN THE INDUSTRIAL ENVIRONMENT WILL BE DEVELOPED. THEY WILL BE BASED ON FIBRE-OPTIC AND LASER TECHNIQUES AND WILL BE INCORPORATED INTO THE EXPERT SYSTEM.

Funding Scheme

CSC - Cost-sharing contracts

Coordinator

Centre Technique des Industries Mécaniques (CETIM)
Address
52 Avenue Félix Louat
60304 Senlis
France

Participants (7)

BRUNEL UNIVERSITY
CONSEJO SUPERIOR DE INVESTIGACIONES CIENTIFICAS
Spain
Address
Calle Serrano 117
Madrid
Centre Technique de l'Industrie du Décolletage
France
Address
750 Avenue De Colomby
74301 Cluses
Computer Technologies Company Ltd
Greece
Address

15342 Athens
FUNDACION TEKNIKER
Spain
Address
Avda. Otaola 20
Eibar
Heriot-Watt University
United Kingdom
Address
Riccarton, Lord Balerno Building
EH14 4AS Edinburgh
NICOLAS CORREA SA
Spain
Address

09007 Burgos