Abstract
This work presents a non-invasive and low-cost alternative to traditional methods for measuring the performance of machining processes directly on existing machine tools. A prototype measuring system has been developed based on non-contact microphones, a custom designed signal conditioning board and signal processing techniques that take advantage of the underlying physics of the machining process. Experiments have been conducted to estimate the depth of cut during end-milling process by means of the measurement of the acoustic emission energy generated during operation. Moreover, the predicted values have been compared with well established methods based on cutting forces measured by dynamometers.
Highlights
The improvement of industrial processes demands new technologies that provide accurate information regarding the stationary or dynamic conditions of their operations
The prototype proposed in this work is a combination of hardware and software to measure the airborne acoustic emission during the end-milling process in order to estimate the depth of cut
The performance of the prototype measurement system was tested under different machining conditions during end-milling operations
Summary
The improvement of industrial processes demands new technologies that provide accurate information regarding the stationary or dynamic conditions of their operations. In the case of machining processes, the knowledge of operating conditions is required towards efficiency improvement and quality optimization. A wide range of methods have been developed to monitor milling processes, most of them are based on the measurement of the cutting forces present in the workpiece because it represents accurately most of common machining phenomena. Cutting force methods have the advantage of providing accurate results [1,2,3] and they are simple to implement, but they have the disadvantage of requiring high cost transducers and direct contact between the sensor and the workpiece. Other detecting methods rely on ultrasound emission and reception to measure the depth of cut in milling applications [4], solving the direct contact requirement. The contact between the cutting tool and the workpiece has been studied with their electrostatic contact to determine the engagement of each tooth [5,6]
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