Chẩn đoán tuổi thọ dao phay ngón dựa trên phân tích đặc trưng tín hiệu rung động trong miền tần số
Abstract
This study presents a method for diagnosing the condition of an AlCrN-coated solid carbide end mill while machining SKD11 steel on a HAAS UMC-1000SS 5-axis CNC milling center. A vibration monitoring device for cutting tools that incorporates wireless signal transmission technology has been developed. This system employs an ESP32-C3 Super Mini microcontroller alongside an H3LIS331DL 3-axis accelerometer for signal acquisition and transmission. The proposed method involves extracting seven characteristic frequency-domain parameters from the vibration signal to assess the condition of the cutting tool. Experimental results indicate a significant correlation between tool wear progression and essential characteristic parameters. The characteristic parameter “Sum” was determined to be the most appropriate for monitoring the tool’s wear state, effectively indicating the initiation and conclusion of the cutting process. The characteristic parameter “Variance” demonstrated significant utility in identifying tool chipping, acting as an indicator for the initiation of the catastrophic failure phase. This proposed method will augment techniques for predicting cutting tool life and improve the efficiency of CNC milling operations.
Tóm tắt
Nội dung nghiên cứu đề xuất một phương pháp chẩn đoán tình trạng dao phay ngón liền khối phủ AlCrN khi gia công thép SKD11 trên máy phay CNC 5 trục HAAS UMC 1000SS. Một thiết bị giám sát rung động dụng cụ cắt tích hợp công nghệ truyền tín hiệu không dây đã được phát triển, mạch vi điều khiển ESP 32 C3 super mini kết hợp cảm biến gia tốc 3 trục H3LIS331DL để thu và truyền tín hiệu. Phương pháp được đề xuất dựa trên trích xuất 7 tham số đặc trưng miền tần số của tín hiệu rung động để đánh giá tình trạng dụng cụ cắt. Kết quả thực nghiệm cho thấy mối tương quan mạnh mẽ giữa quy luật mòn dao và các tham số đặc trưng tiềm năng. Tham số đặc trưng Tổng biên độ phổ tần số phù hợp nhất với trạng thái mòn của dao, phản ánh rõ rệt điểm bắt đầu và kết thúc của quá trình cắt. Tham số đặc trưng Phương sai phổ tần số rất hữu ích cho việc phát hiện các vết nứt mẻ dao, là dấu hiệu nhận biết sự bắt đầu của giai đoạn phá hủy. Phương pháp đề xuất sẽ bổ sung cho kỹ thuật dự báo tuổi thọ dụng cụ cắt và giúp nâng cao hiệu quả gia công phay CNC.
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