Integrated Computational Materials, Process and Product Engineering – IC-MPPE 2022

Condition monitoring of industrial milling tools is of vital importance in industrial production environments when trying to improve those processes that see ever-increasing demands in terms of productivity and process safety. Diagnosis of the damage state of end milling tools in real-time is crucial for the quality control of the produced workpieces. In the model-based condition monitoring approach presented here, the tool degradation state is monitored by tracking coefficients of a mechanistic model for the moments determined during the milling operation by an instrumented tool holder. The presented monitoring approach is based on two metrics derived from the goodness-of-fit provided by the milling mechanistic model for the observed sensor date. Cumulative sum control charts are constructed to monitor changes occurring to the tool condition during the milling tool’s operation. Compared to previously suggested methods based solely on the values of force model coefficients, our approach facilitates a preciser and less conservative identification of the point of transition from homogeneous wear to onset of breakout formation at the cutting edges. The proposed strategy is suitable for real-time monitoring of the milling tool’s damage condition based on a mechanistic model.