Research And Application On Insert Breakage Monitoring And Prevention Technology Of Rotor Milling

The milling process of generator rotor wire embedding slot milling is very complex.It is difficult to achieve quantitative and standardized management of milling inserts.Badly damage may be caused by the problem of insert breakage and misuse,which will affect the quality of parts,even destroy machine tools,and cause significant economic losses.This paper deals with the problem of insert breakage.An insert information management system and Acoustic Emission monitoring system are developed for the actual processing.A unique two-dimensional code is marked by laser on each insert before processing.The cutting parameters,installation position,cutting part,material properties are recorded using management system during the process of slot milling.At the same time,badly insert breakage and other unusual phenomenon are monitored using Acoustic Emission real-time online monitoring system.The breakage of the insert is measured after machining.All these data is associated and structured recorded to analysis the key influencing factors.Material properties,total cutting number of insert,insert installation position and all possible factors of insert breakage are analyzed by Analysis of Variance(ANOVA).Targeted suggestions are put forward and proved by experiment to reduce the probability of insert badly breakage.An Acoustic Emission monitoring system is developed to acquire signal of insert badly breakage.Many time domain and frequency domain eigenvalues extracted to establish badly breakage recognition Support Vector Machine(SVM)model,which accuracy and robustness are optimized using grid search technique and Recursive Feature Elimination(RFE)algorithm.The Support Vector Machine model using 12 eigenvalues extracted from Acoustic Emission signals to recognize insert badly breakage.