Development of On-Line Drill Wear Monitoring System in Machining of AISI 1018 Steel Using Virtual Instrumentation


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Abstract


This paper describes the development of on-line wear state monitoring system in drilling process on Vertical Machining Centre (VMC). In this work, standard data acquisition software LabVIEW (Laboratory Virtual Instrumentation Engineering Workbench) in the application of Virtual Instrumentation (VI) has been applied to predict the drill wear states of High Speed Steel (HSS) drill bit for drilling on a AISI 1018 Steel  work piece.  Drill wear state prediction allows the determination of the hole quality as well as tool replacement at proper time, during machining. Drilling experiments have been carried out over a wide range of varying cutting conditions (cutting speed, drill diameter, feed-rate) and the effects of drill wear on the spindle motor cutting current signals have been investigated. The effective drill wear model has been established to predict the drill wear states based on the relationship between the spindle motor cutting current signals and the various cutting parameters, using LabVIEW. The established on-line drill wear process monitoring system has been used for the continuous monitoring of the cutting tool status, and to exhibit the drill wear states as a percentage of the maximum permissible wear. Meanwhile, it facilitates defective tool replacement at the proper time in an automated manufacturing environment, and found to be in very good agreement to the experimentally determined drill wear values.
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Keywords


Cutting Current Signals; Drill Wear Monitoring; AISI 1018 Steel; LabVIEW; VMC

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