Tools 4.0 – Intelligence starts on the cutting edge

Abstract

Predominantly milling tools with indexable inserts, so-called inserted-tooth cutters, are used to produce plane metal surfaces. The remarkable features of efficient milling tools are that great production qualities can be attained at large material removal rates and that they are very reliable in use. Hence, it is important for the user that the cutting process is performed at the greatest possible material removal rate with the best possible surface quality. An important cost factor here is the tool life, i.e. the service life of the tool until the cutting edge has to be replaced.Today under Industry 4.0, production is combined with cutting-edge information and communication technology. The goal of a joint project initiated by industry is to increase reliability and save costs by a continuous predictive analysis of the milling process. In this project, the relevant information of the cutting process were permanently established directly in the milling tool during cutting, then processed with intelligent algorithms and displayed to the operator. The physical parameters here are the cutting force directly on the cutting edge, the rotational speed of the tool, the hardness of the machining as well as the temperature close to the cutting edge. An integrated accelerometer is used to determine the rotational speed and also serves as an on/off switching function of the electronics.The measuring data already prefiltered are received by an intelligent tool changer for indexable inserts, which is located right in the middle of several machines. This tool changer functions as charging station and tool for indicating worn indexable inserts. Moreover, it serves as a base for up to five milling tools and as a transmitting terminal for transferring process data to various terminals. Critical system states and necessary changes of indexable inserts can be displayed on terminals, such as computers, smartphones, tablets or smartwatches.This paper presents a functional information chain with the main focus on the design of an intelligent and sensitive tool.