MODEL BASED MONITORING AND FAILURE PREDICTION METHODOLOGY FOR HIGH SPEED MACHINING

摘要

This paper presents a model-based monitoring and failure prediction approach in high speed machining process. A mechanistic force model was established for high speed milling on hardened stavax steel (HRc 52) (0.38%C, 0.5%Mn, 13.6%Cr and 0.3%V) with 6mm micro-grain tungsten carbide 2 flute ball-nose end mill. The threshold curve can be obtained off-line based on the process model as the cutting engagement conditions along the tool path are determined at simulation stage. The measured cutting forces are monitored on-line to detect the faults by comparing them with the threshold curve at machining stage. If a fault is detected at certain position along the tool path, an intelligent predictive method is developed to predict whether this fault will cause catastrophic failure. Experimental results have been provided in this paper to prove the feasibility of this presented monitoring approach.