Development of machining condition monitoring system using piezoelectric sensor analyzed by I-kaz multilevel method

Z. Karim, Mohd. Zaki Nuawi, Jaharah A Ghani, E. A. Azrulhisham, S. Abdullah

Research output: Contribution to journalArticle

4 Citations (Scopus)

Abstract

Cutting tool wear is found to be the major cause affecting the finished product in term of surface finish quality, dimensional precision and the cost of the defect. This paper proposes the development of a reliable machine condition monitoring system by using a low-cost piezoelectric sensor to monitor the flank wear progression on the cutting tool. The wear of the cutting insert was measured and recorded using Mitutoyo microscope under different operational conditions in turning process. A single channel piezoelectric sensor was mounted at the tool holder to measure the deflection on the cutting tool in the tangential direction during the machining process. The signal was transmitted to the piezoelectric amplifier device, then to data acquisition and finally to the computer system. I-kaz Multilevel method was used to identify and characterize the changes in the signals from the sensor. Under different experimental set up, new tool wear models were successfully formulated. Good agreements between the predicted and measured tool flank wear land width show that the developed machine condition monitoring system can accurately predict tool flank wear. This monitoring system is an efficient and low-cost method for flank wear level prediction which can be used in the real machining industry.

Original languageEnglish
Pages (from-to)264-268
Number of pages5
JournalWorld Applied Sciences Journal
Volume21
Issue number2
DOIs
Publication statusPublished - 2013

Fingerprint

Condition monitoring
Machining
Wear of materials
Sensors
Cutting tools
Costs
Surface properties
Data acquisition
Microscopes
Computer systems
Defects
Monitoring
Industry

Keywords

  • Condition monitoring
  • Flank wear
  • I-kaz ™
  • I-kaz Multilevel
  • Signal processing

ASJC Scopus subject areas

  • General

Cite this

Development of machining condition monitoring system using piezoelectric sensor analyzed by I-kaz multilevel method. / Karim, Z.; Nuawi, Mohd. Zaki; A Ghani, Jaharah; Azrulhisham, E. A.; Abdullah, S.

In: World Applied Sciences Journal, Vol. 21, No. 2, 2013, p. 264-268.

Research output: Contribution to journalArticle

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