Abstract
The tapping process is one of the most widespread manufacturing processes for internal threads, usually carried out at the end of the value chain. Any non-compliance with required quality standards or even the destruction of the thread due to process uncertainty in the tapping process is therefore subjected to high rework costs. Possible process uncertainties in the tapping process can be triggered by synchronization errors between feed rate and spindle speed, axis offset, faulty core holes and wear of the tapping tool. In order to detect process uncertainties during tapping and thus provide a basis for initiating countermeasures, a sensor-integrated tap holder was developed. This paper presents the realized concept of a rotating telemetry unit for signal processing, data acquisition and wireless data transmitting via WiFi standard on basis of low-cost embedded systems. Furthermore, two unique sensor concepts for measuring close-to-tool vibrations and the axial length compensation of the tapping tool are shown. Based on the sensor data in combination with feature engineering methods, process uncertainty during tapping are detected.
Highlights
The manufacturing of internal threads by tapping process is common and widely used [6]
This paper presents a sensor-integrated tap holder consisting of a developed telemetry unit that rotates with the tap holder and two sensor concepts for process uncertainty detection during tapping
Only three types of uncertainty were deliberately and randomly induced. Those were: (a) synchronization errors caused by using a pitch of 1.30 mm instead of 1.25 mm for the tapping cycle within the machine program, (b) faulty core hole diameter by using 6.6 mm and 7.0 mm instead of 6.8 mm and (c) axis offset in single axis direction of 0.3 mm
Summary
The manufacturing of internal threads by tapping process is common and widely used [6]. Since the tapping process is usually carried out at the end of the value chain, any non-compliance with required thread quality or destruction of the thread due to process uncertainty is subjected with high rework costs.
Talk to us
Join us for a 30 min session where you can share your feedback and ask us any queries you have
More From: The International Journal of Advanced Manufacturing Technology
Disclaimer: All third-party content on this website/platform is and will remain the property of their respective owners and is provided on "as is" basis without any warranties, express or implied. Use of third-party content does not indicate any affiliation, sponsorship with or endorsement by them. Any references to third-party content is to identify the corresponding services and shall be considered fair use under The CopyrightLaw.