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Assessing uneven milling cutting tool wear using component measurement

Ahmed, Zinah, Prickett, Paul ORCID: and Grosvenor, Roger ORCID: 2017. Assessing uneven milling cutting tool wear using component measurement. Presented at: COMADEM 2017: 30th International Congress & Exhibition on Condition Monitoring and Diagnostic Engineering Management, Preston and Grange-Over-Sands, UK, 10-13 July 2017. 30th International Conference on Condition Monitoring and Diagnostic Engineering Management. pp. 262-269.

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Tool wear is a complex phenomenon inherent in any cutting process. Cutting tool wear monitoring is therefore deployed in CNC milling to support machining operations in order to plan tool changes and avoid economic losses. The application of tool life management strategies can lead to premature removal of healthy tool or the continued use of a dangerously worn tool. This has led to the investigation of more appropriate strategies. Depending upon the nature of the sensor technology deployed tool wear monitoring methods are categorized as being either direct or indirect. The benefits and challenges to machine tool users of both approaches are subject to a body of ongoing research. In this study, a series of milling machining tests were performed in order to allow the confirmation of the presence of uneven tool flank wear. This was enabled by the indirect assessment of the tool condition by utilising a Coordinate Measurement Machine (CMM) to accurately measure the workpieces. Using a defined machining process with set cutting parameters each workpiece was machined to produce eight off 40 mm cylindrical holes; in this manner using four workpieces a series of 32 holes were machined. Each cylinder was machined using four separate cuts, at increasing depths, producing four identifiable sections. Each section was measured and the form of the geometry produced was established. After assessing the diameters of all the sections for each cylinder, the presence of uneven flank wear was confirmed and the levels obtained. This is related directly to the differing amount of metal removed by the cutter during the established cutting cycle. The same processes was undertaken using three different sets of cutting parameters. The analysis showed the CMM to be a reliable basis for the measurement of uneven tool wear based upon the geometry of the component.

Item Type: Conference or Workshop Item (Paper)
Date Type: Publication
Status: Published
Schools: Engineering
Subjects: T Technology > TS Manufactures
Related URLs:
Date of First Compliant Deposit: 4 September 2017
Last Modified: 22 Oct 2022 13:35

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