Although a wide variety of tool failure sensing techniques have been developed over the years, few of them have been used in industries successfully. This paper provides a review of the numerous techniques and methods of monitoring tool wear particularly in turning operations. By and large, these techniques appear to be “single-minded” in that they are capable of detecting and diagnosing tool wear and failure relating to particular classes of faults. A universal approach which can detect the very many failure modes in tool condition monitoring has still not been devised.

Tool wear and failure monitoring techniques for turning—A review

Flank wear is the most commonly observed and unavoidable phenomenon in metal cutting which is also a major source of economic loss resulting due to material loss and machine down time. A wide variety of monitoring techniques have been developed for the online detection of flank wear. In order to provide a broad view of flank wear monitoring techniques and their implementation in tool condition monitoring system (TCMS), this paper reviews three key features of a TCMS, namely (1) signal acquisition, (2) signal processing and feature extraction, and (3) artificial intelligence techniques for decision making.

A review of flank wear prediction methods for tool condition monitoring in a turning process

A reconfigurable manufacturing system (RMS) is designed for rapid adjustment of production capacity and functionality in response to new market conditions and new process technology. It has several distinct characteristics including modularity, integrability, customisation, convertibility and diagnosability. There are a number of key interrelated technologies that should be developed and implemented to achieve these characteristics. This paper examines and identifies these technologies. After a brief description of the RMSs and their goals, aspects of reconfiguration (reconfigurable system, software, controller, machine, and process) are explained; this provides one with a better understanding of the enabling technologies of RMSs. Some of the issues related to the technology requirements of RMSs at the system and machine design levels, and ramp -up time reduction are then explained. The paper concludes with descriptions of some of the future research directions for RMSs.

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Reconfigurable manufacturing systems and their enabling technologies

http://maps.pme.nthu.edu.tw/backup/%E7%B6%B2%E9%A0%81%E5%8D%80/paper/PUBLICATION-TEXT/099-1.pdf

Effect of tool wear on delamination in drilling composite materials

An analysis of the chatter behavior for a slender cutting tool in turning in the presence of wear flat on the tool flank is presented in this research. The mechanism of a self-excited vibration development process with tool wear effect is studied. The components contributing to the forcing function in the turning vibration dynamics are analyzed in the context of cutting force and contact force. A comparison of the chatter stability for a fresh cutting tool and a worn cutting tool is provided. Stability plots are presented to relate width of cut to cutting velocity in the determination of chatter stability. Machining experiments at various conditions were conducted to identify the characteristic parameters involved in the vibration system and to identify the analytical stability limits. The theoretical result of chatter stability agrees qualitatively with the experimental result concerning the development of chatter stability model with tool wear effect.

Chatter stability of a slender cutting tool in turning with tool wear effect

Tool Wear Monitoring Through the Dynamics of Stable Turning

<italic>Gaṇitagannaḍ: Mirror of Mathematics, An Astronomy Text of 1604 CE in Kannada by Śankaranārāyana Joisaru of Śṛngeri</italic>, translated and with a mathematical analysis by B.S. Shylaja and Seetharama Javagal.

S. B. Rao

Papers

Tool Wear Monitoring Through the Dynamics of Stable Turning

<italic>Gaṇitagannaḍ: Mirror of Mathematics, An Astronomy Text of 1604 CE in Kannada by Śankaranārāyana Joisaru of Śṛngeri</italic>, translated and with a mathematical analysis by B.S. Shylaja and Seetharama Javagal.

Importance of bhāskara’s karaṇakutūhala as an algorithmic handbook