Development of an AE-Based Monitoring System
for Detecting Tool Tip Fracture and Wear in Machine Tools
[ Field Issue ]
Problem
Difficult to identify tool tip fracture and wear in real time without visual inspection during machining
Post-process confirmation (recognition after abnormal noise/vibration occurs) makes it difficult to take immediate action
Needs
Real-time detection of abnormal signs
of tool tip fracture and wear
of tool tip fracture and wear
Real-time monitoring system capable of detecting tool damage at an early stage
For the target equipment, it was confirmed that a real-time monitoring system is required to detect tool tip fracture and wear before they can be identified through post-process inspection. Tool tip fracture and wear can lead to excessive machining noise and vibration, making it possible to determine the need for early-stage monitoring.
[ Verification & Application ]
Continuous machining was performed using the same tool tip, and changes in the AE signal caused by tool wear were measured. A clear difference in AE signal levels was observed between the initial normal condition (green) and the wear/fracture progression stage (red).
The AE sensor enabled real-time monitoring of tool tip wear progression, confirming the feasibility of determining the appropriate tool replacement timing.
The AE sensor enabled real-time monitoring of tool tip wear progression, confirming the feasibility of determining the appropriate tool replacement timing.
Development of an AE-Based Monitoring System
for Detecting Tool Tip Fracture and Wear in Machine Tools
[ Field Issue ]
For the target equipment, it was confirmed that a real-time monitoring system is required to detect tool tip fracture and wear before they can be identified through post-process inspection.
Tool tip fracture and wear can lead to excessive machining noise and vibration, making it possible to determine the need for early-stage monitoring.
Problem
Need
Difficult to identify tool tip fracture and wear in real time without visual inspection during machining
Real-time detection of abnormal signs of tool tip fracture and wear
Post-process confirmation (recognition after abnormal noise/vibration occurs) makes it difficult to take immediate action
Real-time monitoring system capable of detecting tool damage at an early stage
[ Verification & Application ]
Continuous machining was performed using the same tool tip, and changes in the AE signal caused by tool wear were measured. A clear difference in AE signal levels was observed between the initial normal condition (green) and the wear/fracture progression stage (red).
The AE sensor enabled real-time monitoring of tool tip wear progression, confirming the feasibility of determining the appropriate tool replacement timing.
The AE sensor enabled real-time monitoring of tool tip wear progression, confirming the feasibility of determining the appropriate tool replacement timing.
