Failure detection of cutting tools

Issue

Unable to determine when cutting tools are damaged

• During processing, the operator is almost always present to listen to the sound and monitor the process, but many defects occur.
• The timing of tool change differs depending on the worker being monitored.
• Tried AE sensor, but it is difficult to predict abnormalities or identify when they occur.

Solution

The bolt that holds the workpiece in place was replaced with a piezoelectric load sensor, PiezoBolt, to measure vibration behavior during cutting.

As a result, we were able to detect data changes and predictive signs of cutting tool breakage, abrasion, loosening, and other defects.
By setting the data before and after a cutting tool failure to a threshold value and sending a stop signal, the machine can be automatically stopped just before the failure occurs.

Result

Visualization of cutting tool defects to optimize tool replacement timing

• Machining could be performed until just before tool breakage, and the tool could be used until just before tool life.
• By comparing the measured data, it was possible to review the cutting conditions.
• AI enabled equipment monitoring, allowing the site to be managed with a minimum number of personnel.