Sensor-Assisted Machining

This chapter provides comprehensive knowledge regarding the application of various sensors and monitoring techniques to machining processes, cutting tools and machine tools. A number of monitoring methods used in manufacturing and relevant sensors are characterized. In particular, three most frequently used sensors, i.e., force, acceleration and acoustic emission, are presented and their characteristics and advantages are highlighted. The architectures of multiple-sensor tool-monitoring systems for detection of tool wear and breakage and collision for machine tools, including details of sensor fusion, signal processing and decision-making, are presented. Moreover, the concepts of sensor-based intelligent manufacturing system and adaptive control systems are involved. The principles and practical applications of touch probing for the workpiece and tool setting probing, and typical designs of touch probes are provided. Machine vision systems, machine vision sensors and using their in-line inspection of part quality are outline. Smart and intelligent (mechatronic) cutting tools which can monitor the machining process and communicate with the CNC system are described. Some developing trends in sensor-assisted manufacturing are discussed.

[1]  Bert P. Erdel.  high-speed Machining , 2003 .

[2]  Jan Kosmol,et al.  Selected examples of cutting process monitoring and diagnostics , 2001 .

[3]  George Chryssolouris,et al.  Sensor Synthesis for Control of Manufacturing Processes , 1992 .

[4]  Jan-Eric Ståhl,et al.  Identification of cutting errors in precision hard turning process , 2004 .

[5]  J. Tlusty,et al.  A Critical Review of Sensors for Unmanned Machining , 1983 .

[6]  A David Dornfeld.  In Process Recognition of Cutting States , 1994 .

[7]  Fritz Klocke,et al.  Development of a tool wear-monitoring system for hard turning , 2003 .

[8]  Hidenori Shinno,et al.  In-Process Monitoring Method for Machining Environment Based on Simultaneous Multiphenomena Sensing , 1997 .

[9]  M. F. DeVries,et al.  Neural Network Sensor Fusion for Tool Condition Monitoring , 1990 .

[10]  Erkki Jantunen,et al.  A summary of methods applied to tool condition monitoring in drilling , 2002 .

[11]  Krzysztof Jemielniak,et al.  Advanced monitoring of machining operations , 2010 .

[12]  Gerry Byrne,et al.  Towards the improvement of tool condition monitoring systems in the manufacturing environment , 2001 .

[13]  A. Weckenmann,et al.  Probing Systems in Dimensional Metrology , 2004 .

[14]  Roberto Teti,et al.  Intelligent Computing Methods for Manufacturing Systems , 1997 .

[15]  Paul K. Wright,et al.  Drill wear sensing and failure prediction for untended machining , 1988 .

[16]  H.J.J. Kals,et al.  Developments and Trends in Monitoring and Control of Machining Processes , 1988 .

[17]  Mamoru Mitsuishi,et al.  Actual Conceptual Design Process for an Intelligent Machining Center , 1995 .

[18]  Berend Denkena,et al.  Mechatronic Systems for Machine Tools , 2007 .

[19]  Ramon Bakerjian,et al.  Tool and Manufacturing Engineers Handbook , 1989 .

[20]  Yoram Koren,et al.  Design of a Precision, Agile Line Boring Station , 1999 .