Abstract

To fully automate production processes, a monitoring system is required to detect abnormal phenomena that may occur during a cutting process, such as tool wear, chipping and fracture, excessive chatter, and built-up edge formation. In this study, a system is developed to detect drill breakage in real-time and in-process conditions during drilling. Through a number of preliminary experiments, it was confirmed that the thrust forces could be effectively used to detect drill breakage, and an algorithm for detecting breakage was thus established through signal processing of these thrust forces. The detection algorithm was implemented using LabVIEW on a PC. It is thus confirmed that drill breakages can be detected in-process and in real-time by applying the developed drill breakage detection system to actual NC drilling operations.

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