Sensor-less tool fracture detection applying disturbance observer theory

Research output: Chapter in Book/Report/Conference proceedingConference contribution

2 Citations (Scopus)

Abstract

Detection of a tool fracture is necessary to ensure cutting accuracy and to avoid a tool breakage because tool fracture is one of the significant prediction signals of the tool breakage. For monitoring the tool condition, generally additional sensors are used. However using these sensors causes high cost and increase of failure rate. In this paper, a novel sensor-less detection method of tool fracture in drilling process is proposed on the basis of a disturbance observer theory. It is applied to the x-y stage of the machine tool. The proposed method requires no external sensor because it uses only the servo information of the spindle control system. Since structures of normal drills with two floats are symmetrical with respect to a point, theoretically the cutting force in the x and y directions does not work. When the drill is fractured, its structure becomes asymmetry so that unbalanced forces would exert in the x and y directions at intervals of the spindle speed. Therefore, it is possible to detect a tool fracture by the frequency analysis of estimated disturbance force with a wavelet transform. The experimental results show that the proposed method is available for detection of the small tool fracture effectively.

Original languageEnglish
Title of host publicationKey Engineering Materials
Pages439-444
Number of pages6
Volume523-524
DOIs
Publication statusPublished - 2012
Event14th International Conference on Precision Engineering, ICPE 2012 - Hyogo, Japan
Duration: 2012 Nov 82012 Nov 10

Publication series

NameKey Engineering Materials
Volume523-524
ISSN (Print)10139826

Other

Other14th International Conference on Precision Engineering, ICPE 2012
CountryJapan
CityHyogo
Period12/11/812/11/10

Fingerprint

Sensors
Machine tools
Wavelet transforms
Drilling
Control systems
Monitoring
Costs
Direction compound

Keywords

  • Disturbance observer
  • Drill
  • Fracture
  • In-process monitoring
  • Wavelet transform

ASJC Scopus subject areas

  • Materials Science(all)
  • Mechanics of Materials
  • Mechanical Engineering

Cite this

Koike, R., Kakinuma, Y., & Aoyama, T. (2012). Sensor-less tool fracture detection applying disturbance observer theory. In Key Engineering Materials (Vol. 523-524, pp. 439-444). (Key Engineering Materials; Vol. 523-524). https://doi.org/10.4028/www.scientific.net/KEM.523-524.439

Sensor-less tool fracture detection applying disturbance observer theory. / Koike, Ryo; Kakinuma, Yasuhiro; Aoyama, Tojiro.

Key Engineering Materials. Vol. 523-524 2012. p. 439-444 (Key Engineering Materials; Vol. 523-524).

Research output: Chapter in Book/Report/Conference proceedingConference contribution

Koike, R, Kakinuma, Y & Aoyama, T 2012, Sensor-less tool fracture detection applying disturbance observer theory. in Key Engineering Materials. vol. 523-524, Key Engineering Materials, vol. 523-524, pp. 439-444, 14th International Conference on Precision Engineering, ICPE 2012, Hyogo, Japan, 12/11/8. https://doi.org/10.4028/www.scientific.net/KEM.523-524.439
Koike, Ryo ; Kakinuma, Yasuhiro ; Aoyama, Tojiro. / Sensor-less tool fracture detection applying disturbance observer theory. Key Engineering Materials. Vol. 523-524 2012. pp. 439-444 (Key Engineering Materials).
@inproceedings{9eac7c5eb3684bcba1a5796440a9d127,
title = "Sensor-less tool fracture detection applying disturbance observer theory",
abstract = "Detection of a tool fracture is necessary to ensure cutting accuracy and to avoid a tool breakage because tool fracture is one of the significant prediction signals of the tool breakage. For monitoring the tool condition, generally additional sensors are used. However using these sensors causes high cost and increase of failure rate. In this paper, a novel sensor-less detection method of tool fracture in drilling process is proposed on the basis of a disturbance observer theory. It is applied to the x-y stage of the machine tool. The proposed method requires no external sensor because it uses only the servo information of the spindle control system. Since structures of normal drills with two floats are symmetrical with respect to a point, theoretically the cutting force in the x and y directions does not work. When the drill is fractured, its structure becomes asymmetry so that unbalanced forces would exert in the x and y directions at intervals of the spindle speed. Therefore, it is possible to detect a tool fracture by the frequency analysis of estimated disturbance force with a wavelet transform. The experimental results show that the proposed method is available for detection of the small tool fracture effectively.",
keywords = "Disturbance observer, Drill, Fracture, In-process monitoring, Wavelet transform",
author = "Ryo Koike and Yasuhiro Kakinuma and Tojiro Aoyama",
year = "2012",
doi = "10.4028/www.scientific.net/KEM.523-524.439",
language = "English",
isbn = "9783037855096",
volume = "523-524",
series = "Key Engineering Materials",
pages = "439--444",
booktitle = "Key Engineering Materials",

}

TY - GEN

T1 - Sensor-less tool fracture detection applying disturbance observer theory

AU - Koike, Ryo

AU - Kakinuma, Yasuhiro

AU - Aoyama, Tojiro

PY - 2012

Y1 - 2012

N2 - Detection of a tool fracture is necessary to ensure cutting accuracy and to avoid a tool breakage because tool fracture is one of the significant prediction signals of the tool breakage. For monitoring the tool condition, generally additional sensors are used. However using these sensors causes high cost and increase of failure rate. In this paper, a novel sensor-less detection method of tool fracture in drilling process is proposed on the basis of a disturbance observer theory. It is applied to the x-y stage of the machine tool. The proposed method requires no external sensor because it uses only the servo information of the spindle control system. Since structures of normal drills with two floats are symmetrical with respect to a point, theoretically the cutting force in the x and y directions does not work. When the drill is fractured, its structure becomes asymmetry so that unbalanced forces would exert in the x and y directions at intervals of the spindle speed. Therefore, it is possible to detect a tool fracture by the frequency analysis of estimated disturbance force with a wavelet transform. The experimental results show that the proposed method is available for detection of the small tool fracture effectively.

AB - Detection of a tool fracture is necessary to ensure cutting accuracy and to avoid a tool breakage because tool fracture is one of the significant prediction signals of the tool breakage. For monitoring the tool condition, generally additional sensors are used. However using these sensors causes high cost and increase of failure rate. In this paper, a novel sensor-less detection method of tool fracture in drilling process is proposed on the basis of a disturbance observer theory. It is applied to the x-y stage of the machine tool. The proposed method requires no external sensor because it uses only the servo information of the spindle control system. Since structures of normal drills with two floats are symmetrical with respect to a point, theoretically the cutting force in the x and y directions does not work. When the drill is fractured, its structure becomes asymmetry so that unbalanced forces would exert in the x and y directions at intervals of the spindle speed. Therefore, it is possible to detect a tool fracture by the frequency analysis of estimated disturbance force with a wavelet transform. The experimental results show that the proposed method is available for detection of the small tool fracture effectively.

KW - Disturbance observer

KW - Drill

KW - Fracture

KW - In-process monitoring

KW - Wavelet transform

UR - http://www.scopus.com/inward/record.url?scp=84870612589&partnerID=8YFLogxK

UR - http://www.scopus.com/inward/citedby.url?scp=84870612589&partnerID=8YFLogxK

U2 - 10.4028/www.scientific.net/KEM.523-524.439

DO - 10.4028/www.scientific.net/KEM.523-524.439

M3 - Conference contribution

AN - SCOPUS:84870612589

SN - 9783037855096

VL - 523-524

T3 - Key Engineering Materials

SP - 439

EP - 444

BT - Key Engineering Materials

ER -