Development Of Milling Cutter Runout And Wear On-line Monitoring System

Because of versatility and high material removal rate, End Milling is widely appliedto various fields, the real-time and effective cutter status monitoring is the key factor toimprove the quality of the workpieces, achieve mechanical processing automation,improve productivity and products competitiveness. In this paper, the end milling forcesignals are as the research object, cutter runout and wear condition monitoring parametersare determined by the characteristics of force signal, and the design and development ofmilling cutter runout and wear condition monitoring system is accomplished, which hasvery important practical significance to the timely discovery of abnormal state in theprocess of machining.Research work carried out in this paper as follows:First, based on the integrated factors of cutting tools, material of workpieces, millingparameters, milling force acquisition system and the influence of the sensor on signalcharacteristics, making out several different sets of milling parameters; Experiments wascarried out to collect milling force data by utilizing milling force signal acquisition systemunder several different conditions. And measuring the value of static cutter runout at astandstill.Then, filtering the collected force signal and making time domain and frequencydomain analysis, discovering characteristics of the force signals. Comparing the value ofmilling force, runout, cutters wear to the sensitivity of different milling parameters invarious experiments, and acquiring the feature quantity which has lower sensitivity to themilling parameters but higher sensitivity to runout and cutter wear. on this basis. On thebasis of this, extracting characteristic parameters(namely average milling force peak value)which can effectively demarcate cutter runout and wear.Again, Matlab software is used to package the logical calculation of the entiremonitoring process as a COM components, and embeding the COM components inVC++6.0software, so a milling cutter condition monitoring system is completed.Finally, milling tests to verify the effectiveness and reliability of the monitoringsystem.The results showed that: the research based on milling force signal applied in milling cutter runout and wear state monitoring system is easy to operate, which is less affected bythe work condition and higher sensitive to the tools state. It consummates the theory ofcutter condition monitoring and practical applications，improves the safety and efficiencyof the machining and has a certain guiding significance on the the cutter runout and wearstate recognition in practical production.