Development of an on-line tool-life monitoring system using acoustic emission signals in gear shaping

Sensing techniques for monitoring machining processes have been one of the focuses of research on process automation. This paper presents the development of on-line tool-life monitoring system for gear shaping that uses acoustic emission (AE). Characteristics of the AE signals are related to the cut...

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Bibliographic Details
Published in:International journal of machine tools & manufacture 1999-11, Vol.39 (11), p.1761-1777
Main Authors: Kim, Jeong-Suk, Kang, Myeong-Chang, Ryu, Byung-Jin, Young-Kwon Ji
Format: Article
Language:English
Subjects:
Acoustic emission
Acoustic emissions
Electric potential
Metal cutting
Monitoring
Monitoring system
Pinion cutter
Signal processing
Signal processing technique
Wear of materials
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Summary:Sensing techniques for monitoring machining processes have been one of the focuses of research on process automation. This paper presents the development of on-line tool-life monitoring system for gear shaping that uses acoustic emission (AE). Characteristics of the AE signals are related to the cutting condition, tool material and tool geometry in the cutting of metals. The relationship between AE signal and tool wear was investigated experimentally. Experiments were carried out on the gear shaping of SCM 420 material with a pinion cutter having 44 teeth. Root-mean-square (RMS) AE voltages increase regularly according to tool wear. It is suggested that the maximum value of RMS AE voltage is an effective parameter to monitor tool life. In this study, not only the acquisition method of AE signals for rotating objects but also the signal-processing technique were developed in order to realize the in-process monitoring system for gear shaping. The on-line tool-life monitoring system developed has been successfully applied to gear machining processes.
ISSN:0890-6955
1879-2170
DOI:10.1016/S0890-6955(99)00030-9