Investigation of Tool Failure Modes and Machining Disturbances Using Monitoring Signals

Abstract

The ACCENT Project (FP7-AAT-2007-RTD-1) will allow the European Aero Engine manufacturers to improve their competitiveness by applying adaptive control techniques to the manufacturing of their components. For the critical rotating parts of aircraft engines, the surface integrity generated after machining is a key factor on the life cycle. In this context, one particular attention has to be carried out on tool condition. The aim of this paper is to define a monitoring approach able to detect the tool condition and machining disturbances. The main failure modes characterizing this particular Nickel base drilling and the apparition of embedded chips over the machined surface were identified. By experimental techniques, cartography of failure modes was performed. The results show that flank wear and notch are the main failure modes limiting the tool life. For some cutting conditions, the tool failure occurs after the first hole due to the important cutting forces. Some interesting combinations are made between the spindle current/accelerometers/ thrust force and flank wear, tool breakage and notch. Before these correlations, a detailed signal analysis was performed, considering different disturbing phenomena, such as chips evacuation problem. Finally, a “synopsis” for process monitoring is proposed, considering the analyzed phenomena.