Tool life monitoring in end milling of AISI H13 hot work die steel using a low‑cost vibration sensor connected to a wireless system.
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Date
2022
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Abstract
Machining of complex components with high added value requires the development and implementation of technologies for
monitoring the processes outputs and to ensure the performance and reliability of the manufactured part. Cutting tool wear is
one of the most relevant variables in machining due to its efect on both the machining cost and quality of the manufactured
component. Although tool wear has been extensively investigated for more than a century, the advent of Industry 4.0 has
required more accurate and reliable monitoring systems. This work investigates the feasibility of using a low-cost vibration
sensor, based on a micro-electromechanical system (MEMS), connected to a wireless data transmission system attached to a
rotary tool (milling cutter) for tool wear monitoring when milling annealed AISI H13 hot work die with coated tungsten carbide inserts. A microcontroller with an integrated internet connection connected to a local server through the Wi-Fi network
was employed. In order to validate the proposed system, tests were performed comparing its behavior with a conventional
piezoelectric sensor in terms of sensitivity to changes in the cutting conditions and tool wear evolution. The results indicated
that the proposed system responds satisfactorily to changes in the cutting conditions, with approximately a four-fold increase
in the acceleration amplitude when either cutting speed or axial depth of cut were doubled. Although neither the MEMS nor
the piezoelectric accelerometer was capable to detect tool wear evolution (considering a tool life criterion VBB=0.3 mm),
the RMS value of the signal generated by the vibration sensor based on MEMS is approximately four times higher than that
provided by the piezoelectric accelerometer, thus indicating a better representation of the vibration phenomenon resulting
from fxing the MEMS on the tool (in contrast to the piezoelectric accelerometer attached to the workpiece).
Description
Keywords
Monitoring, Milling, Wear, Vibration
Citation
VIANELLO, P. I. A. et al. Tool life monitoring in end milling of AISI H13 hot work die steel using a low‑cost vibration sensor connected to a wireless system. Experimental Techniques, nov. 2022. Disponível em: <https://link.springer.com/article/10.1007/s40799-022-00619-9>. Acesso em: 03 maio 2023.