Tool wear monitoring of high-speed broaching process with carbide tools to reduce production errors

Real-time monitoring in CNC machine tools is focused on the early detection of tool wear, and in this way to assess part piece quality. The machining process known as broaching is critical for firtree slots (dovetails) production in turbomachinery components, such as turbine disks. Tight tolerances...

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Autores: Del Olmo Sanz, Ander, López de Lacalle Marcaide, Luis Norberto, Martínez de Pissón Caruncho, Gonzalo, Pérez-Salinas, Cristian Fabian, Ealo Muñoz, Jon Ander, Sastoque Pinilla, Edwar Leonardo, Fernandes Rodrigues, María Helena
Tipo de documento: artigo
Data de publicação:2022
País:España
Recursos:Universidad del País Vasco
Repositório:Addi. Archivo Digital para la Docencia y la Investigación
OAI Identifier:oai:addi.ehu.eus:10810/68228
Acesso em linha:http://hdl.handle.net/10810/68228
Access Level:Acceso aberto
Palavra-chave:broaching
carbide tool
tool wear
monitoring
accelerometer
natural frequency
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spelling Tool wear monitoring of high-speed broaching process with carbide tools to reduce production errorsDel Olmo Sanz, AnderLópez de Lacalle Marcaide, Luis NorbertoMartínez de Pissón Caruncho, GonzaloPérez-Salinas, Cristian FabianEalo Muñoz, Jon AnderSastoque Pinilla, Edwar LeonardoFernandes Rodrigues, María Helenabroachingcarbide tooltool wearmonitoringaccelerometernatural frequencyReal-time monitoring in CNC machine tools is focused on the early detection of tool wear, and in this way to assess part piece quality. The machining process known as broaching is critical for firtree slots (dovetails) production in turbomachinery components, such as turbine disks. Tight tolerances on one hand, even less than 5 µm in firtree-slots pressure faces, and high productivity on the other, are the two main requirements. Besides, broaching tools are very expensive and the cutting edges wear must be estimated during the process; in fact, tool wear in difficult-to-cut materials machining may cause a waste not only in terms of the tool but also of the very expensive workpieces. Broaching usually is one of the last operations in the process chain, so components start the operation with a very high-added value. Hence, only one bad slot implies an unrecoverable piece and therefore a huge waste of time and money. In this paper, a monitoring method for efficient broaching is proposed by combining real-time monitoring and off-line tool wear inspection. Firstly, the cutting tool characteristics are defined, and those affected by tool degradation. Secondly, some broaching cycles were carried out while measuring a) process accelerations through two accelerometers, b) cutting force by load cells, and c) motor drive consumption. They were simultaneously recorded. Furthermore, the sensitivity between tool wear and broaching process natural frequencies is established. Finally, a series of experimental tests were executed for verification, showing the useful approach for daily life production. The paper focuses on signals and their sensitivity to significant process variations.This research was funded by Basque government group IT IT1337-19 and the Ministry of Mineco Grant PID2019-109340RB-I00 funded by MCIN/AEI/ 10.13039/501100011033, and by the European commission by H2020 project n. 958357, and it is an initiative of the Factories-of-the-Future (FoF) Public Private Partnership, project InterQ Interlinked Process, Product and Data Quality framework for Zero-Defects Manufacturing. Experiments were performed by help of project (QUOLINK TED2021-130044B-I00) Ministerio de Ciencia e Innovación 2021. Thanks are also given to the Basque Country government in Elkartek OPTICED, in all aspects related to integration of edge-computing devices. Thanks are also given to special Unit AIMS, funded by the University of the Basque Country, Ideko, IMH and BCAM.ElsevierEuropean Commission202420242022info:eu-repo/semantics/articleapplication/pdfhttp://hdl.handle.net/10810/68228reponame:Addi. Archivo Digital para la Docencia y la Investigacióninstname:Universidad del País VascoInglésinfo:eu-repo/grantAgreement/MICINN/PID2019-109340RB-I00/info:eu-repo/grantAgreement/EC/H2020/958357info:eu-repo/grantAgreement/MICINN/TED2021-130044B-I00/https://www.sciencedirect.com/science/article/pii/S0888327022001819info:eu-repo/semantics/openAccesshttp://creativecommons.org/licenses/by-nc-nd/3.0/es/© 2022 The Author(s). Published by Elsevier Ltd. This is an open access article under the CC BY-NC-ND license (http://creativecommons.org/licenses/by-nc-nd/4.0/).Atribución-NoComercial-SinDerivadas 3.0 Españaoai:addi.ehu.eus:10810/682282026-06-18T09:23:17Z
dc.title.none.fl_str_mv Tool wear monitoring of high-speed broaching process with carbide tools to reduce production errors
title Tool wear monitoring of high-speed broaching process with carbide tools to reduce production errors
spellingShingle Tool wear monitoring of high-speed broaching process with carbide tools to reduce production errors
Del Olmo Sanz, Ander
broaching
carbide tool
tool wear
monitoring
accelerometer
natural frequency
title_short Tool wear monitoring of high-speed broaching process with carbide tools to reduce production errors
title_full Tool wear monitoring of high-speed broaching process with carbide tools to reduce production errors
title_fullStr Tool wear monitoring of high-speed broaching process with carbide tools to reduce production errors
title_full_unstemmed Tool wear monitoring of high-speed broaching process with carbide tools to reduce production errors
title_sort Tool wear monitoring of high-speed broaching process with carbide tools to reduce production errors
dc.creator.none.fl_str_mv Del Olmo Sanz, Ander
López de Lacalle Marcaide, Luis Norberto
Martínez de Pissón Caruncho, Gonzalo
Pérez-Salinas, Cristian Fabian
Ealo Muñoz, Jon Ander
Sastoque Pinilla, Edwar Leonardo
Fernandes Rodrigues, María Helena
author Del Olmo Sanz, Ander
author_facet Del Olmo Sanz, Ander
López de Lacalle Marcaide, Luis Norberto
Martínez de Pissón Caruncho, Gonzalo
Pérez-Salinas, Cristian Fabian
Ealo Muñoz, Jon Ander
Sastoque Pinilla, Edwar Leonardo
Fernandes Rodrigues, María Helena
author_role author
author2 López de Lacalle Marcaide, Luis Norberto
Martínez de Pissón Caruncho, Gonzalo
Pérez-Salinas, Cristian Fabian
Ealo Muñoz, Jon Ander
Sastoque Pinilla, Edwar Leonardo
Fernandes Rodrigues, María Helena
author2_role author
author
author
author
author
author
dc.contributor.none.fl_str_mv European Commission
dc.subject.none.fl_str_mv broaching
carbide tool
tool wear
monitoring
accelerometer
natural frequency
topic broaching
carbide tool
tool wear
monitoring
accelerometer
natural frequency
description Real-time monitoring in CNC machine tools is focused on the early detection of tool wear, and in this way to assess part piece quality. The machining process known as broaching is critical for firtree slots (dovetails) production in turbomachinery components, such as turbine disks. Tight tolerances on one hand, even less than 5 µm in firtree-slots pressure faces, and high productivity on the other, are the two main requirements. Besides, broaching tools are very expensive and the cutting edges wear must be estimated during the process; in fact, tool wear in difficult-to-cut materials machining may cause a waste not only in terms of the tool but also of the very expensive workpieces. Broaching usually is one of the last operations in the process chain, so components start the operation with a very high-added value. Hence, only one bad slot implies an unrecoverable piece and therefore a huge waste of time and money. In this paper, a monitoring method for efficient broaching is proposed by combining real-time monitoring and off-line tool wear inspection. Firstly, the cutting tool characteristics are defined, and those affected by tool degradation. Secondly, some broaching cycles were carried out while measuring a) process accelerations through two accelerometers, b) cutting force by load cells, and c) motor drive consumption. They were simultaneously recorded. Furthermore, the sensitivity between tool wear and broaching process natural frequencies is established. Finally, a series of experimental tests were executed for verification, showing the useful approach for daily life production. The paper focuses on signals and their sensitivity to significant process variations.
publishDate 2022
dc.date.none.fl_str_mv 2022
2024
2024
dc.type.none.fl_str_mv info:eu-repo/semantics/article
format article
dc.identifier.none.fl_str_mv http://hdl.handle.net/10810/68228
url http://hdl.handle.net/10810/68228
dc.language.none.fl_str_mv Inglés
language_invalid_str_mv Inglés
dc.relation.none.fl_str_mv info:eu-repo/grantAgreement/MICINN/PID2019-109340RB-I00/
info:eu-repo/grantAgreement/EC/H2020/958357
info:eu-repo/grantAgreement/MICINN/TED2021-130044B-I00/
https://www.sciencedirect.com/science/article/pii/S0888327022001819
dc.rights.none.fl_str_mv info:eu-repo/semantics/openAccess
http://creativecommons.org/licenses/by-nc-nd/3.0/es/
Atribución-NoComercial-SinDerivadas 3.0 España
eu_rights_str_mv openAccess
rights_invalid_str_mv http://creativecommons.org/licenses/by-nc-nd/3.0/es/
Atribución-NoComercial-SinDerivadas 3.0 España
dc.format.none.fl_str_mv application/pdf
dc.publisher.none.fl_str_mv Elsevier
publisher.none.fl_str_mv Elsevier
dc.source.none.fl_str_mv reponame:Addi. Archivo Digital para la Docencia y la Investigación
instname:Universidad del País Vasco
instname_str Universidad del País Vasco
reponame_str Addi. Archivo Digital para la Docencia y la Investigación
collection Addi. Archivo Digital para la Docencia y la Investigación
repository.name.fl_str_mv
repository.mail.fl_str_mv
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score 15,198674

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