Abstract
Indirect Tool Condition Monitoring (TCM) methods have shown significant potential to automatically detect worn tools without intervention in the machining process. This paper presents the development of a non-intrusive and online TCM system for large diameter indexable insert drills. The TCM system developed used two cutting force-related signals of a horizontal boring machine, namely the spindle motor current and the axial feed motor current, and features extracted from these signals were taken as the inputs to a series of models to predict the tool wear state and the hole diameter. A tool replacement strategy based on applying limits to the predicted hole diameter was also developed. Adjusting these limits allows the strategy to be tuned for either hole accuracy or tool life depending on the requirements of a specific application. Experiments of drilling of 39.0-mm-diameter holes in 2205 Duplex stainless steel in an industrial field were designed and performed with the results to illustrate the effectiveness of developed TCM and strategies. Specifically, the TCM system ensured that none of over tolerance holes would have been drilled, which is critically important since any over-tolerance hole can result in the failure of an entire finished product of tubesheet; the replacement strategy for tool life resulted in a 44 % increase in tool life and a non-trivial reduction in machine down time due to fewer tool changes while holding a hole diameter tolerance of ±0.1 mm.
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X. B. Chen is an ASME Member
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Griffin, R., Cao, Y., Peng, J.Y. et al. Tool wear monitoring and replacement for tubesheet drilling. Int J Adv Manuf Technol 86, 2011–2020 (2016). https://doi.org/10.1007/s00170-015-8325-2
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DOI: https://doi.org/10.1007/s00170-015-8325-2