Research And Development Of Tool Condition Monitoring System In Milling Special Spiral Rod

During the process of milling special spiral rod, the most familiar trouble is tool wear and breakage, since they bring great damage to automation manufacture. So tool condition monitoring system becomes one of the most important parts of automation manufacture system. In the past years, scientists all over the world make great achievement on it through hard work, but there is not enough work on milling tool wear and breakage monitoring under condition of variable cutting parameters .It is necessary to look for a method used information amalgamation to ensure production qualityand improve the degree of automation in milling special spiral rod.To solve the problem mentioned above, the paper aim at building an online tool condition monitor system using new generation 16 bit Microcontroller 80C196KC of the Intel Corp .first, it can collect real time and display three channels signal of machine tool that reflect tool state: power, vibration and radius change of workpiece . And it also uses math model about tool wear and breakage to valuate the condition of milling to help the operator to take an action. It's main tasks as follows: 1) Based on the soft measure model of tool breakage, to evaluate the eigenvalue of tool breakage and compare with the given value, and make decision whether send message of tool breakage or not;2) Comparing radius change of workpiece with limitation real time , at the same time taking into account the result of tool wear model to decide whether send offset signal to machine tool or not.So this paper's emphasis are the design of hardware and software of tool condition monitor system. On the side of hardware design ,it builds a 16 bit hardware system with new generation Microcontroller 80C196KC,which includes circuit of memory development, circuit of coding and LCD & keyboard interface ,circuit of communication with machine and alarm. The core of soft design is to pick-up the signals' eigenvalue and calculate tool wear and breakage eigenvalue based on the soft measure model of tool breakage.To complete the paper, many advanced develop tool of hardware and software domestic and overseas are used, such as Protel99SE (32 bit EDA based on windows platform), Tasking C196 (C language complier of Tasking Corp for single chip computer) and ApBUILDER (one kind of soft disigned to initialize microcontroller system , Intel Corp).