THE 11

th
INTERNATIONAL SYMPOSIUM OF MEASUREMENT TECHNOLOGY AND INTELLIGENT INSTRUMENTS July 1
st
-5
th
201 !1


NOMENCLATURE

LSM: Laser Scan Microscope
MIDEMMA = Minimizing Defects in Micro-manufacturing
Applications
a
r
: Radial depth of cut

a
e
: Axial depth of cut

1. Introduction

Focus on the ualit! of medical "or# pieces "ithin the micro
milling process$ a tool "ear monitoring and life time prediction is
needed %&$ '$ ($ and )*+ ,orrelations -et"een the signals pro.ided -!
the micro milling process$ /process parameters0 and the tool "ear
ha.e -een in.estigated+ 1nce the selection of the .ital parameters are
found$ a pattern has to -e created for different "ear of the tool and
stored in an historical data -an#+ A "a.elet discrete anal!sis is used to
extract further patterns+ 2hen the actual monitoring data "ill -e
compared "ith the patterns stored in the historical data and a
statistical anal!sis "ill -e used to detect the tool "ear according to the
highest le.el of pro-a-ilit! of the different patterns+ 2he patterns "ill
-e classified in three scales good$ a.erage and -ad tool+ After"ards
predictions of the tool lifetime "ill -e possi-le+


2. Experimental set up

2he experiments ha.e -een performed using a 3 axis milling
machine tool "ith an! cooling s!stem+ For the experiments t"o tools
ha.e -een used$ MS'4LD5&556575 /c!lindrical end mill0 and
MS'4L8R5596&'5 /end -all milling0+

2.1 Methodolo!
In order to simplif! the detection of tool "ear during complex 3
axes micro milling process of the dental pieces$ a methodolog! -ased
on milling or drilling on a reference "or# piece has -een introduced+
Simple lines are milled on a reference "or# piece for -etter
estimation of the tool "ear in terms of ta#ing compara-le signal
patterns+ Alternati.el!$ drilling of simple holes has -een also used+














Fig+ & :or#piece /2i0-/&0 and reference "or#piece /2i0-/'0

Tool wear monitoring and life time prediction
in micro milling process


Antoni B. Barcel
*
, Thomas Wagner, Romrio A. Guimares and Anthimos Georgiadis

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Abstract: Common monitoring systems detect the presence or the breakage of the tool and they compare actual
values with thresholds or actual curves with learned curves but they dont detect the wear of the tool in terms of
predicting their life time. The objective of this work is the implementation of tool wear prediction in micro milling
of Titanium parts. A new approach has been introduced based on reference drilling or milling interrupting shortly
the main process in regular time intervals. This helps to obtain reference process parameters for the
characterization of the tool wear. Those parameters are: Acoustic emission, true electric power of the spindle,
vibrations of the spindle axis, cutting forces and torque. The tool wear has been measured after drawing off one or
two layers of the main work piece. Process parameters have been analysed using wavelets and their correlation to
the tool wear has been established in order to estimate the tool lifetime. First results using the acoustic emission
are presented. In the future an adaptive feed back to the controller of the machine would be possible in order to
modify the angle, position or speed of the tool according to the tool wear. The final goal could be to reduce defects
in the micro milling process caused of the tool wear.


&
'
THE 11
th
INTERNATIONAL SYMPOSIUM OF MEASUREMENT TECHNOLOGY AND INTELLIGENT INSTRUMENTS July 1
st
-5
th
201 !2


Figure & sho"s the arrangement of the main "or# piece and the
reference "or# piece into the machine tool+
2"o series of experiments /3&'$) min milling time each0 ha.e
-een performed using reference drilling in Al and one /more than &5 h
milling time0 using reference milling in 2i+ For the first t"o series the
follo"ing cutting parameters$ applied to the reference$ are: speed
''+555 rpm$ a
r
=&$;mm$ a
e
=955<m and feed rate (5mm=min
-&+
For the
last series: speed ''+555 rpm$ a
r
=355<m$ a
e
=&3<m and tool feed
)35mm=min
-&

2herefore after one or t"o la!ers milled on the "or# piece a
reference line has -een milled in the reference "or# piece+ 2hen the
same procedure has -een repeated ten times or more and an e.olution
of the tool "ear has -een monitored+

2.2 "rocess parameters and tool #ear
Man! process parameters could -e extracted during milling$ li#e
cutting forces$ acoustic emission$ .i-rations and accelerations$ torue
and po"er of the spindle+ 2hose parameters ha.e -een measured and
stored during the trials+ 2he sample rate "as &55 >z+
2he tool "ear and the surface topograph! ha.e -een measured "ith
the follo"ing microscopes: an LSM ?55 from @EISS /used
resolution: &$(<m0$ the .ision engineering macro d!nanoscope
microscope 3D /used &55 magnification0 or the 1l!mpus S@7&+
Additionall! a porta-le digital microscope /digitus0 /max+ '55
magnification "ith a resolution of 7)5x?;5 pixels0 has -een used
inside the machine tool+



















Fig+ ' 2ool "ears on the flan# of the MS'4LD5&556575 measured
-! LSM and the MS'4L8R5596&'5 measured -! the 1l!mpus
S@7& microscope

2he correlations -et"een the tool "ear$ the surface profile and the
process parameters ha.e -een esta-lished+

2.$. %ata treatment and decision ma&in
2en series of milling ha.e -een used to define three patterns
-ased on the coefficients of discrete "a.elets+ 2he patterns
correspond to good$ a.erage and -ad status of the tool /figure (0+ 2he
"a.elet famil! Dau-echies (-le.el ( /MatLa- "a.elet tool-ox0 has
-een used in this case+ 2hen the correlation matrix -et"een the actual
monitored signals and the esta-lished patterns has -een calculated+
















Fig+ ( ,oefficients "a.elet patterns of the acoustic emission
signal /top0 and the actual signal /do"n0+

According to the highest .alue of correlation$ the s!stem could
estimate the life time of the tool and pro.ide predictions a-out the
tool "ear+

'. Conclusions and (uture #or&

2his method succeeded to detect the tool "ear inside the classes
good$ a.erage and -ad$ in ;5A of the cases+ In the future "or#
different families of "a.elets "ill -e tested$ as "ell as se.eral
statistics methods "ill -e tried+ A higher sampling rate of the
acuisition s!stem could -e necessar! in order to impro.e the results+

AC)NO*LE%+EMENT

I "ould li#e to than#s the colla-oration of ,+ Fuhrhop and Brof+
Mercorelli from Leuphana Cni.ersit!$ F+ Diao from the Cni.ersit! of
8runel$ E+ ,ole from the compan! 2agueri and all the partners "hich
ha.e -een in.ol.ed in the micro milling group of the MIDEMMA
proFect$ such as Ide#o$ ,reatech and Sensofar+
2he research reported in this paper is supported -! the European
,ommission "ithin the proFect GMinimizing Defects in Micro-
Manufacturing Applications /MIDEMMA0H /FB?-'5&&-6MB-I,2-
FoF-';37&)0+

RE,ERENCE-

1. Eunpeng @+$ Soon >+ I+$ and San :+ J+$ GMultiscale Singularit!
Anal!sis of ,utting Forces for Micromilling 2ool-:ear
MonitoringG$ '5&5
2. Male#ian M+$ Bar# S+ S+$ Dun M+8+I+$ G2ool "ear monitoring of
micro-milling operationsH$ Else.i.er$ '559
3. Jao J+$ Li 4+$ Juan+ @$ G2ool "ear detection "ith fuzz!
classification and "a.elet fuzz! neuronal net"or#H$ Machine
toolsKManufacture$ Danuar! &999
4. @hou D->+$ Bang ,+E+$ Le"is F+L+$ @hong @-:+$ GIntelligent
Diagnosis and Brognosis Csing Dominant Feature
Identification$HIEEE transactions on industrial informatics$ Lol+ 3$
6M)$ 6o.em-er '559+