Tool Wear Condition Monitoring System for Turning Operation Using Neuro Fuzzy Technique

Abstract

In Modern manufacturing industry, automation and flexible manufacturing system (FMS) is main stream to create products rapidly and economically. Failures in the machining process and machine tool components may also have negative effects on the final produced product. For this, it is very important to predict work piece and tool condition while it’s in running condition. Tool life is mainly affected by cutting conditions including the cutting speed, feed, depth of cut, generated temperature cutting forces and vibration. Implementation of computer based unattended machining has attached great attention in manufacturing industry for automation and also a constant, high quality of the products can be guaranteed, which is not possible with human supervision alone. Therefore, tool wear monitoring is important to achieve an efficient manufacturing process. This necessitates the development of sensor and intelligent decision making system for tool wear monitoring system. In CNC turning operation many concepts have been developed to achieve a reliable tool condition monitoring of the cutting process. In Most of them are based on force measurement, acoustic emission and vibration measurement. The concept behind monitoring these parameters is based on the fact that these dynamic parameters generally increase as the tool gradually wears due to the increasing friction between tool and work piece. The main objective of this work is to develop sensor based process condition monitoring that is able to predict the wear propagation in the cutting tool using information obtained from the analysis of cutting vibration generated during turning of cast iron. To predict tool wear Neuro Fuzzy technique is develop using Matlab and alarm system is develop using LabVIEW during machine in running condition. Predicting wear of the partially degraded tool give information about remaining tool condition which save natural resources to a great extent. This will also contribute considerably in achieving our goal of attaining in unattended machining and FMS.