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Appl. Sci. 2016, 6(4), 107; doi:10.3390/app6040107

Methods of In-Process On-Machine Auto-Inspection of Dimensional Error and Auto-Compensation of Tool Wear for Precision Turning

1
Department of Mechanical Engineering, Chung Yuan Christian University, Taoyuan 32023, Taiwan
2
Mechanical and Systems Research Laboratories, Industrial Technology Research Institute, Hsinchu 31040, Taiwan
*
Author to whom correspondence should be addressed.
Academic Editor: Kuang-Cha Fan
Received: 1 February 2016 / Revised: 20 March 2016 / Accepted: 21 March 2016 / Published: 12 April 2016
(This article belongs to the Special Issue Design and Applications of Coordinate Measuring Machines)

Abstract

The purpose of this study is mainly to develop an information and communication technology (ICT)-based intelligent dimension inspection and tool wear compensation method for precision tuning. With the use of vibration signal processing/characteristics analysis technology combined with ICT, statistical analysis, and diagnosis algorithms, the method can be used to proceed with an on-line dimension inspection and on-machine tool wear auto-compensation for the turning process. Meanwhile, the method can also monitor critical tool life to identify the appropriate time for cutter replacement to reduce machining costs and improve the production efficiency of the turning process. Compared to the traditional ways, the method offers the advantages of requiring less manpower, and having better production efficiency, high tool life, fewer scrap parts, and low costs for inspection instruments. Algorithms and diagnosis threshold values for the detection, cutter wear compensation, and cutter life monitoring were developed. In addition, a bilateral communication module utilizing FANUC Open CNC (computer numerical control) Application Programming Interface (API) Spec was developed for the on-line extraction of instant NC (numerical control) codes for monitoring and transmit commands to CNC controllers for cutter wear compensation. With use of local area networks (LAN) to deliver the detection and correction information, the proposed method was able to remotely control the on-machine monitoring process and upload the machining and inspection data to a remote central platform for further production optimization. The verification experiments were conducted on a turning production line. The results showed that the system provided 93% correction for size inspection and 100% correction for cutter wear compensation. View Full-Text
Keywords: on-machine; turning; dimension error; auto-inspection; tool wear; auto-compensation on-machine; turning; dimension error; auto-inspection; tool wear; auto-compensation
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This is an open access article distributed under the Creative Commons Attribution License which permits unrestricted use, distribution, and reproduction in any medium, provided the original work is properly cited. (CC BY 4.0).

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MDPI and ACS Style

Wang, S.-M.; Chen, Y.-S.; Lee, C.-Y.; Yeh, C.-C.; Wang, C.-C. Methods of In-Process On-Machine Auto-Inspection of Dimensional Error and Auto-Compensation of Tool Wear for Precision Turning. Appl. Sci. 2016, 6, 107.

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