Monitoring online cutting tool wear using low-cost technique and user-friendly GUI

Research output: Contribution to journalArticle

47 Citations (Scopus)

Abstract

Cutting tool wear is known to affect tool life, surface quality and production time. Because of this an online tool wear measurement and monitoring system has been developed, using a low-cost sensor. The system is able to detect and analyze signals relating to the deflection of the tool holder from the cutting force, and the corresponding estimation of wear is displayed on the computer screen. New statistical analysis is used to identify and characterise the changes in signals from the sensors. A two-channel strain gauge is mounted at the tool holder to measure the deflection in both tangential direction and feed direction. The signal is transmitted to the signal conditioning device, then to data acquisition, and finally to the computer system. MATLAB software is used as the platform software to develop a user-friendly graphical user interface (GUI) for online monitoring purposes. Results show that this developed online monitoring system, using the strain gauge signal, is an effective method of detecting the progression of flank wear width during machining. This is an efficient and low-cost method which can be used in the real machining industry to predict the level of wear in the cutting tool.

Original languageEnglish
Pages (from-to)2619-2624
Number of pages6
JournalWear
Volume271
Issue number9-10
DOIs
Publication statusPublished - 29 Jul 2011

Fingerprint

graphical user interface
Cutting tools
Graphical user interfaces
Wear of materials
Monitoring
Costs
Strain gages
strain gages
holders
Machining
machining
deflection
computer programs
Sensors
sensors
MATLAB
Surface properties
conditioning
Data acquisition
Statistical methods

Keywords

  • Flank wear
  • I-Kaz™ method
  • Low-cost monitoring
  • Strain gauge

ASJC Scopus subject areas

  • Condensed Matter Physics
  • Surfaces and Interfaces
  • Materials Chemistry
  • Surfaces, Coatings and Films
  • Mechanics of Materials

Cite this

Monitoring online cutting tool wear using low-cost technique and user-friendly GUI. / A Ghani, Jaharah; Rizal, M.; Nuawi, Mohd. Zaki; Ghazali, Mariyam Jameelah; Che Haron, Che Hassan.

In: Wear, Vol. 271, No. 9-10, 29.07.2011, p. 2619-2624.

Research output: Contribution to journalArticle

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