Tool-holder integrated printed piezoceramic sensors for process state classification and tool-wear progress evaluation in turning

Procedia CIRP, vol. 133, pp. 382–387

Abstract

Tool condition monitoring strategies in turning processes, using multiple sensor sources to measure dynamic quantities (e.g., force, acoustic emissions, acceleration), has gained significant attention in conjunction with machine learning methods. As a novel approach, the introduction of printed piezoceramic thick films in machine tools allows the customization of sensor shape and placement, optimized to fit the tool holder’s geometry and process boundary conditions. This work proposes integration concepts using two configurations of printed piezoceramic sensors. This includes the use of a finite element simulation to estimate the generated electric charge from sensors on three locations on the tool holder, induced by transient mechanical loading. The design is validated under controlled mechanical loading and tested across various cutting conditions and tool-wear states. Signal information content from each sensor location, relative to different machining conditions, is assessed through recursive feature elimination and validated using dimensionality reduction. Finally, tool-wear progress is evaluated using the selected features.

Authors 6

1. Miguel Panesso corresponding

   Fraunhofer Institute for Machine Tools and Forming Technology · Fraunhofer Institute for Machine Tools and Forming Technology Dresden

   Affiliation as printed

   Fraunhofer Institute for Machine Tools and Forming Technology, Nöthnitzer Str. 44, 01187 Dresden, Germany

2. Jan Berthold

   Fraunhofer Institute for Machine Tools and Forming Technology · Fraunhofer Institute for Machine Tools and Forming Technology Dresden

   Affiliation as printed

   Fraunhofer Institute for Machine Tools and Forming Technology, Nöthnitzer Str. 44, 01187 Dresden, Germany

3. Lucas Hamm

   Fraunhofer Institute for Machine Tools and Forming Technology · Fraunhofer Institute for Machine Tools and Forming Technology Dresden

   Affiliation as printed

   Fraunhofer Institute for Machine Tools and Forming Technology, Nöthnitzer Str. 44, 01187 Dresden, Germany

4. Zongshuo Li Aachen Manufacturing Technology Institute (MTI)

   RWTH Aachen University

   Affiliation as printed

   Manufacturing Technology Institute (MTI) of RWTH Aachen University, Campus-Boulevard 30, 52074 Aachen, Germany

5. Welf‐Guntram Drossel

   Fraunhofer Institute for Machine Tools and Forming Technology · Fraunhofer Institute for Machine Tools and Forming Technology Dresden

   Affiliation as printed

   Fraunhofer Institute for Machine Tools and Forming Technology, Nöthnitzer Str. 44, 01187 Dresden, Germany

6. Thomas Bergs Aachen Manufacturing Technology Institute (MTI)

   RWTH Aachen University

   Affiliation as printed

   Manufacturing Technology Institute (MTI) of RWTH Aachen University, Campus-Boulevard 30, 52074 Aachen, Germany