Article: Online diagnosis and monitoring of roundness defects in CNC machining processes Journal: International Journal of Mechatronics and Manufacturing Systems (IJMMS) 2010 Vol.3 No.5/6 pp.357 - 367 Abstract: The main aim of this study was to design and develop an online diagnostic system for the real-time prediction of roundness error (ER) in automated CNC turning processes. Initially, during the first phase, cutting force signals (Fx, Fy, Fz) were registered during the machining process. Thereafter, the signals were characterised using a series of parameters, i.e., time domain and previously selected frequency. The parameters that were found to significantly influence roundness error, which constituted the basis of the predictive models using regression techniques, were analysed. This global monitoring system has been developed with Dasylab 9.0, which enables the register and characterisation of signals as well as the real-time prediction of the roundness error (ER). The system predicted the parameter ER with a mean relative error percentage of ∼10%, a degree of precision similar to that obtained by post-process quality control of roundness using form measuring. Inderscience Publishers - linking academia, business and industry through research

Title: Online diagnosis and monitoring of roundness defects in CNC machining processes

Authors: Eustaquio Garcia-Plaza, Pedro J. Nunez, Angel R. Martin, Elena Beamud, Carlos De la Cruz

Addresses: Departamento de Mecanica Aplicada e Ingenieria de Proyectos, E.T.S. de Ingenieros Industriales, Universidad de Castilla-La Mancha, Avda. Camilo Jose Cela, 3, 13071 Ciudad Real, Spain. ' Departamento de Mecanica Aplicada e Ingenieria de Proyectos, E.T.S. de Ingenieros Industriales, Universidad de Castilla-La Mancha, Avda. Camilo Jose Cela, 3, 13071 Ciudad Real, Spain. ' Departamento de Mecanica Aplicada e Ingenieria de Proyectos, E.T.S. de Ingenieros Industriales, Universidad de Castilla-La Mancha, Avda. Camilo Jose Cela, 3, 13071 Ciudad Real, Spain. ' Departamento de Mecanica Aplicada e Ingenieria de Proyectos, E.T.S. de Ingenieros Industriales, Universidad de Castilla-La Mancha, Avda. Camilo Jose Cela, 3, 13071 Ciudad Real, Spain. ' Departamento de Mecanica Aplicada e Ingenieria de Proyectos, E.T.S. de Ingenieros Industriales, Universidad de Castilla-La Mancha, Avda. Camilo Jose Cela, 3, 13071 Ciudad Real, Spain

Abstract: The main aim of this study was to design and develop an online diagnostic system for the real-time prediction of roundness error (E_R) in automated CNC turning processes. Initially, during the first phase, cutting force signals (F_x, F_y, F_z) were registered during the machining process. Thereafter, the signals were characterised using a series of parameters, i.e., time domain and previously selected frequency. The parameters that were found to significantly influence roundness error, which constituted the basis of the predictive models using regression techniques, were analysed. This global monitoring system has been developed with Dasylab 9.0, which enables the register and characterisation of signals as well as the real-time prediction of the roundness error (E_R). The system predicted the parameter E_R with a mean relative error percentage of ∼10%, a degree of precision similar to that obtained by post-process quality control of roundness using form measuring.

Keywords: online monitoring; regression; cutting forces; roundness errors; online diagnosis; CNC turning; roundness defects; CNC machining; predictive modelling; quality control; fault diagnosis.

DOI: 10.1504/IJMMS.2010.036062

International Journal of Mechatronics and Manufacturing Systems, 2010 Vol.3 No.5/6, pp.357 - 367

Published online: 17 Oct 2010 *

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Title: Online diagnosis and monitoring of roundness defects in CNC machining processes

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