A Critical Review of Options for Tool and Workpiece Sensing

The first interim report, A Critical Review of Options for Tool and Workplace Sensing, of a two-phase project identifies and analyzes existing and emerging state-of-the-art sensors for assessing and forecasting the condition of cutting tools and for measuring the dimensions and surface finish of workpieces. The goal of the project is to provide a versatile means to use the sensor data for reducing manufacturing costs and improving the quality of parts in production at the Rock Island Arsenal and other similar facilities. The study concludes that to minimize the number of sensors and the frequency of their use, an integrated system is needed in which the sensor outputs are fused by an algorithm and used in a mathematical model that automatically adapts to the changing process, tool, and workpiece conditions. The report defines integrated sensor systems for rotary and stationary cutters and recommends six sensor types for performance suitability verification by bench-top experimental tests. The next scheduled interim report will present the results of these tests, and the Phase I final report will provide conceptual designs and recommend a system configuration for evaluation in Phase II. Under Phase II, the selected sensor systems will be demonstrated as an integral part of an automated machining system. Keywords Detectors Sensor characterization Control equipment Process control Adaptive control Machining Tool life Tool wear In-process quality control Inspection.