Force-torque based on-line tool wear estimation system for CNC milling of Inconel 718 using neural networks

KAYA B., OYSU C., ERTUNÇ H. M.

ADVANCES IN ENGINEERING SOFTWARE, cilt.42, sa.3, ss.76-84, 2011 (SCI-Expanded) identifier identifier

  • Yayın Türü: Makale / Tam Makale
  • Cilt numarası: 42 Sayı: 3
  • Basım Tarihi: 2011
  • Doi Numarası: 10.1016/j.advengsoft.2010.12.002
  • Dergi Adı: ADVANCES IN ENGINEERING SOFTWARE
  • Derginin Tarandığı İndeksler: Science Citation Index Expanded (SCI-EXPANDED), Scopus
  • Sayfa Sayıları: ss.76-84
  • Anahtar Kelimeler: On-line monitoring, Cutting forces, Torque, Wear, Milling, Neural networks, MONITORING-SYSTEM, CUTTING SPEED, FLANK WEAR
  • Kocaeli Üniversitesi Adresli: Evet

Özet

In a modern machining system, tool condition monitoring systems are needed to get higher quality production and to prevent the downtime of machine tools due to catastrophic tool failures. Also, in precision machining processes surface quality of the manufactured part can be related to the conditions of the cutting tools. This increases industrial interest for in-process tool condition monitoring (TCM) systems. TCM supported modern unmanned manufacturing process is an integrated system composed of sensors, signal processing interface and intelligent decision making strategies. This study includes key considerations for development of an online TCM system for milling of Inconel 718 superalloy. An effective and efficient strategy based on artificial neural networks (ANN) is presented to estimate tool flank wear. ANN based decision making model was trained by using real time acquired three axis (F(x), F(y), F(z)) cutting force and torque (M,) signals and also with cutting conditions and time. The presented ANN model demonstrated a very good statistical performance with a high correlation and extremely low error ratio between the actual and predicted values of flank wear. (C) 2010 Elsevier Ltd. All rights reserved.