tool monitoring

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Tool Monitoring Advanced CNC project; S. Sajjad Ahmadpoor

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Page 1: Tool monitoring

Tool Monitoring

Advanced CNC project;S. Sajjad Ahmadpoor

Page 2: Tool monitoring

Tool wear describes the gradual failure of cutting tools due to regular operation. It is a term often associated with tipped tools, tool bits, or drill bits that are used with machine tools. crater wear in which contact with chips erodes the rake face.

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Tool Monitoring Methods

Didect: In the direct method the tool directly measuredAnd to directly monitor and so wear directly measuredWhich are divided into some methods…

Indirect: the indirect method of measuring parameters, some parameters that connected with wear rate such as temperature, cutting forces, vibration and ultrasonic waves are measured. in this case, some factors are depend on machining process such as temperature, strain, acoustics, vibrations and cutting forces. and some other factors back to the motors. the wear is monitored with their changes.

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Probing systems for CNC machine tools:

Inspection probes for machining centersare typically located in a tool carousel andare interchanged like conventional tools.On lathes, the probe is typically a semi-permanent feature of a rotating turret.In both case, signaling between probeand CNC generally has to be remote.

For tool setting applications, typically theprobe is mounted in a fixed location, therebyallowing direct communication between probe and CNC.

probes use four main types oftransmission systems:

Optical

Radio

Inductive

Direct or ‘hard-wired’

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Optical transmission systems:An optical transmission system uses infra-red technology for communicating between the probe and the CNC controller.

· Optical machine module (OMM)· Machine interface unit (MI12)· Optical machine interface (OMI)· Optical machine interface (OMI-2/OMI-2C)

OMM OMI

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Radio transmission systems:A radio transmission system provideslong range (up to 15 m path length) of communication between the probe and the machine’s controller. The system hops between channels, within the designated frequency band. The use of unique identifiersallow multiple radio systems to operate in close proximity.

· Machine interface (RMI)

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Inductive transmission systems :Inductive transmission works by passingpower and probe signals across a smallair gap between two induction modules.Typically, a probe fitted with an inductivetransmission system comprises the following:

· Probe and inductive probe module (IMP)· Machine module (IMM) · Machine interface unit (MI5)

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Hard-wired transmission systems :

A hard-wired probe system has the simplest form of transmission system and typically, comprises the following elements:

· Signal cable

· Machine interface unit (MI8)

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Applications: • CNC machining centre and

milling machine inspection

• CNC machining centre tool setting and breakage detection

• CNC lathe and grinder inspection

• CNC lathe tool setting

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Lathe Tool presetting:

• the quicksetter automatically sets the values of the work coordinate and the tool offset registers

• quicksetters can also measure the size of tools before cutting starts

• check for tool wear, damage or breakage during the machining operation

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Lathe Tool presetting:

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Touch Probes for Tool Measurement:

Together with the measuring cycles of theCNC control, the tool touch probes enableto measure tools automaticallywhile they are in the machine spindle.The control saves the values measured fortool length and radius in the central toolfile. By inspecting the tool during machiningyou can quickly and directly measurewear or breakage to prevent scrap or rework.If the measured deviations lie outsidethe tolerances, or if the monitored lifeof the tool is exceeded, the control can lockthe tool or automatically insert a replacementtool.

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Measuring tool length and radiuswith stationary or rotating spindle

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Laser Systems for Tool Measurement:

Tool monitoring with a laser system is a very flexible solution. The contact-free optical measurement enables you to check even the smallest tools rapidly, reliably and without collision. Even the most sensitive tools are completely secure from damage.

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