G. de Anda-Rodriguez, E. Castillo-Castañeda

1 Instituto Tecnológico de San Luis Potosí, México Av. Tecnológico s/n S. de G. S., San Luis Potosí, E-mail: memodeanda@yahoo.com.mx

2 Universidad Autónoma de Querétaro, México Centro Universitario, 76010 Querétaro México E-mail: ecast@uaq.mx

RESUMEN

Este documento presenta una técnica novedosa para el monitoreo en línea del desgaste de una herramienta de fresado. El desgaste es estimado directamente a partir de un sensor de proximidad de fibra óptica (SPFO) con características de alta resolución y alto ancho de banda. El SPFO proporciona una medida de la distancia entre su extremo y el perfil de la herramienta. La principal contribución de este trabajo es la aplicación del SPFO para monitorear en línea el desgaste de una herramienta de fresado. Puesto que la luz emitida por el SPFO proviene de un fotodiodo, esta no produce daño a los ojos, lo que la hace más segura que los sensores de desplazamiento de tipo láser. Esta técnica permite monitorear el desgaste de la herramienta en tiempo real, mientras la herramienta gira, con una precisión inferior a 1 micra. Se presentan resultados experimentales para una herramienta de fresado vertical de cuatro filos que gira a 300 rpm.

Palabras clave: Inspección óptica, detección de desgaste, monitoreo de herramientas, sensores de fibra óptica.

ABSTRACT

A novel technique for on-line wear monitoring of a milling tool is presented. The tool wear is estimated directly from a fiber optic proximity sensor (FOPS) with high resolution and high bandwidth characteristics. The FOPS provides a distance measurement between its probe and the tool profile. The main contribution of this work is the application of FOPS to sense on-line the wear of a milling tool. Since the light emitted by this sensor comes from a photodiode, it does not produce eye damage; this is safer than laser displacement sensors. This technique senses the tool wear in real time, while the tool is rotating, with an accuracy of less than 1 micron. Experimental results are also presented for a four-flank cutting tool rotating at 300 rpm.

Keywords: Optic inspection, wear detection, monitoring tools, fiber optic sensors.

AGRADECIMIENTOS

Los autores expresan su gratitud a la Universidad Autónoma de Querétaro, México, por brindar su apoyo para desarrollar este proyecto.

REFERENCIAS

[1] E. Castillo-Castañeda. “On line wear detection of milling tools using a Displacement Fiber Optic Sensor”. Journal of Applied Research and Technology. Vol. 1 Nº 2. July 2003.

[2] K. Jemielniak and O. Otman. “Catastrophic Tool Failure Detection Based on Acoustic Emission Signal Analysis”. Annals of CIRP. Vol. 47/1, pp. 31-34. 1998.

[3] W. Meyer, U. Neumann and H. Hörl. “Acoustic Emission Measurement for Quality Control and Process Monitoring in Cutting Operations”. Report of the Technical University of Chemnitz. Faculty of Mechanical Engineering and Material Processing. Germany. 1996.

[4] N. Kasashima, K. Mori and N. Taniguchi. “On line Failure Detection in Face Milling Using Discrete Wavelet Transform”. Annals of the CIRP. Vol. 44, pp. 483-487. 1995. 

[5] D. Barschdorff, L. Monostori, T. Kottenstede, G. Warnecke and M. Müller. “Cutting Tool Monitoring in Turning under Varying Cutting Conditions: An Artificial Neural Network Approach”. Proceedings of the Sixth International Conference on Industrial and Engineering Applications of Artificial Intelligence and Expert Systems, pp. 353-359. Edinburgh. Scotland. 1993.

[6] A. Novak. “On-Line Prediction of the Tool Life”, Annals of the CIRP. Vol. 45, pp. 93-96. 1996.

[7] Kurada and C. Bradley. “A review of machine vision sensors for tool condition monitoring”, Computers and Industry. Vol. 34 Nº 1, pp.55-72. 1997.

[8] D.C. Oguamanam, H. Raafat and S. M. Taboun. “A machine vision system for wear monitoring and breakage detection of single-point cutting tools”. Computers in Industrial Engineering. Vol. 26 Nº 3, pp. 245-251. 1994.

[9] E. Dimla and Snr. Dimla. “Sensor signals for tool-wear monitoring in metal cutting operations-a review of methods”. International Journal of Machine Tools & Manufacture”. Vol. 40, pp. 1073-1098. 2000.

[10] O. Ryabov, K. Mori, N. Kasashima, K. Uehara, “An In-process Direct Monitoring Method for Milling Tool Failures Using a Laser Sensor”. CIRP Annals. Vol. 45 Nº 1. 1996.