Skip to main content

Advertisement

SpringerLink
Log in

Development of universal wireless sensor node for tool condition monitoring in milling

  • ORIGINAL ARTICLE
  • Published:
The International Journal of Advanced Manufacturing Technology Aims and scope Submit manuscript

Abstract

Advanced material processing technologies require non-traditional monitoring system devices to provide real-time information on the ongoing technological processes. The article proposes a sensor node composed from cone-shaped tool holder for shank-type rotating tools with embedded self-powering wireless data processing and transmission system. Design of the tool holder with helical slots on its surface is prepared and presented. These helical slots introduced on the surface of the cone-shaped tool holder transforms the cutting tool torsional (T) vibrations present during operation into the longitudinal (L) vibrations that propagate through the tool holder in the axial direction and excite the piezoelectric transducer. The purpose of the developed sensor node inside the tool holder is to monitor the heavy lubricated milling process which is expressed by the capacitor load rate of harvested electric charge, which depends on the conditions of the cutting tool. The electric charge generated by exciting of piezoelectric transducer from the cutting tool vibrations exponentially rises until the capacitor is fully charged and the capacitor charging time interval is recorded while the harvested energy is used to power auxiliary electronics with wireless data transmission capability. As the intensity of energy accumulation depends on the state of the cutting tool wear, the capacitor charging time is used to detect changes in the tool condition. Such proposed real-time cutting process monitoring allows controlling the quality of the workpiece being machined and preventing damage to the equipment. This paper is dedicated to the research and development into one of the key stages of “Industry 4.0,” using cybernetic-physical components, numerical models, and self-powering wireless monitoring systems for the application in context of the “Internet of Things” (IoT).

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Fig. 6
Fig. 7
Fig. 8
Fig. 9
Fig. 10
Fig. 11

Similar content being viewed by others

References

  1. Ray YZ, Xu X, Eberhard K, Stephen TN (2017) Intelligent manufacturing in the context of Industry 4.0: a review. Engineering 3(5):616–630. https://doi.org/10.1016/J.ENG.2017.05.015

    Article  Google Scholar 

  2. Ostasevicius V, Markevicius V, Jurenas V, Zilys M, Cepenas M, Kizauskiene L, Gyliene L (2015) Cutting tool vibration energy harvesting for wireless sensors applications. Sensors Actuat A-Phys 223:310–318. https://doi.org/10.1016/j.sna.2015.07.014

    Article  Google Scholar 

  3. Park HS, Tran NH (2015) Development of a cloud based smart manufacturing system. J Adv Mech Des Syst Manuf 9(3). https://doi.org/10.1299/jamdsm.2015jamdsm0030

  4. Sarker MR, Julai S, Sabri MFM, Said SM, Islam M, Tahir M (2019) Review of piezoelectric energy harvesting system and application of optimization techniques to enhance the performance of the harvesting system. Sensors Actuat A-Phys. https://doi.org/10.1016/j.sna.2019.111634

  5. Chen T, Liu S, Liu W, Wu C (2017) Study on a longitudinal – torsional ultrasonic vibration system with diagonal slits. Adv Mech Eng 9(7):1–10. https://doi.org/10.1177/1687814017706341

    Article  Google Scholar 

  6. Wu C, Chen S, Cheng K, Ding H, Xiao C (2019) Innovative design and analysis of a longitudinal-torsional transducer with the shared node plane applied for ultrasonic assisted milling. J Mech Eng Sci 223 (12):4128–4139. https://doi.org/10.1177/0954406218797962

    Article  Google Scholar 

  7. Pang Y, Feng P, Zhang J, Ma Y, Zhang Q (2020) Frequency coupling design of ultrasonic horn with spiral slots and performance analysis of longitudinal-torsional machining characteristics. Int J Adv Manuf Tech 106:4093–4103. https://doi.org/10.1007/s00170-019-04898-2

    Article  Google Scholar 

  8. Al-Budairi H, Lucas M, Harkness P (2013) A design approach for longitudinal–torsional ultrasonic transducers. Sensors Actuat A-Phys 198:99–106. https://doi.org/10.1016/j.sna.2013.04.024

    Article  Google Scholar 

  9. Zhao B, Bie W, Wang X, Chen F, Chang B (2019) Design and experimental investigation on longitudinal-torsional composite horn considering the incident angle of ultrasonic wave. Int J Adv Manuf Tech 105:325–341. https://doi.org/10.1007/s00170-019-04220-0

    Article  Google Scholar 

  10. Liu S, Shan X, Cao W, Yang Y, Xie T (2017) A longitudinal-torsional composite ultrasonic vibrator with thread grooves. Ceram Int 43:S214–S220. https://doi.org/10.1016/j.ceramint.2017.05.305

    Article  Google Scholar 

  11. Liu S, Shan X, Guo K, Xie T (2016) Design and fabrication of a skew-typed longitudinal-torsional composite ultrasonic vibrator for titanium wire drawing. IEEE Access 4:6749–6755. https://doi.org/10.1109/ACCESS.2016.2614516

    Article  Google Scholar 

  12. Mohanraj T, Shankar S, Rajasekar R, Sakthivel N.R., Pramanik A (2020) Tool condition monitoring techniques in milling process - a review. J Mater Res Technol 9(1):1032–1042. https://doi.org/10.1016/j.jmrt.2019.10.031

    Article  Google Scholar 

  13. Zhou Y, Xue W (2018) Review of tool condition monitoring methods in milling processes. Int J Adv Manuf Tech 96:2509–2523. https://doi.org/10.1007/s00170-018-1768-5

    Article  Google Scholar 

  14. Rizal M, Ghani JA, Nuawi MZ, Haron CHC (2014) A review of sensor system and application in milling process for tool condition monitoring. Res J Appl Sci Eng Technol 7(10):2083–2097. https://doi.org/10.19026/rjaset.7.502

    Article  Google Scholar 

  15. Zhu K, Zhang Y (2018) A cyber-physical production system framework of smart CNC machining monitoring system. IEEE ASME Trans Mechatron 23(6):2579–2586. https://doi.org/10.1109/TMECH.2018.2834622

    Article  Google Scholar 

  16. Chung TK, Yeh PC, Lee H, Lin CM, Tseng CY, Lo WT, Wang CM, Wang WC, Tu CJ, Tasi PY, Chang JW (2016) An attachable electromagnetic energy harvester driven wireless sensing system demonstrating milling-processes and cutter-wear/breakage-condition monitoring. Sensors 16 (3):269:1–20. https://doi.org/10.3390/s16030269

    Article  Google Scholar 

  17. Ostasevicius V, Jurenas V, Augutis V, Gaidys R, Cesnavicius R, Kizauskiene L, Dundulis R (2017) Monitoring the condition of the cutting tool using self-powering wireless sensor technologies. Int J Adv Manuf Tech 88(9-12):2803–2817. https://doi.org/10.1007/s00170-016-8939-z

    Article  Google Scholar 

  18. Ostasevicius V, Jurenas V, Markevicius V, Gaidys R, Zilys M, Cepenas M, Kizauskiene L (2016) Self-powering wireless devices for cloud manufacturing applications. Int J Adv Manuf Tech 83:1937–1950. https://doi.org/10.1007/s00170-015-7617-x

    Article  Google Scholar 

  19. Wang C, Cheng K, Chen X, Minton T, Rakowski R (2014) Design of an instrumented smart cutting tool and its implementation and application perspectives. Smart Mater Struct 23(3). https://doi.org/10.1115/1.1381399

  20. Cus F, Zuperl U (2011) Real-time cutting tool condition monitoring in milling. Stroj vestn-J Mech Eng 57(2):142–150. https://doi.org/10.5545/sv-jme.2010.079

    Article  Google Scholar 

  21. Qin Y, Wang D, Yang Y (2020) Integrated cutting force measurement system based on MEMS sensor for monitoring milling process. Microsyst Technol 26:2095–2104. https://doi.org/10.1007/s00542-020-04768-y

    Article  Google Scholar 

  22. Mohantya S, Guptaa KK, Raju KS (2015) Vibration feature extraction and analysis of industrial ball mill using MEMS accelerometer sensor and synchronized data analysis technique. Procedia Comput Sci 58:217–224. https://doi.org/10.1016/j.procs.2015.08.058

    Article  Google Scholar 

  23. Zhang XY, Lu X, Wang S, Wang W, Li WD (2018) A multi-sensor based online tool condition monitoring system for milling process. Procedia CIRP 72:1136–1141. https://doi.org/10.1016/j.procir.2018.03.092

    Article  Google Scholar 

  24. Qin J, Liu Y, Grosvenor R (2016) A categorical framework of manufacturing for industry 4.0 and beyond. Procedia CIRP 52:173–178. https://doi.org/10.1016/j.procir.2016.08.005

    Article  Google Scholar 

  25. Lin B, Wang L, Guo Y, Yao J (2016) Modeling of cutting forces in end milling based on oblique cutting analysis. Int J Adv Manuf Tech 84:727–736. https://doi.org/10.1007/s00170-015-7724-8

    Article  Google Scholar 

  26. Erturk A, Inman DJ (2011) Piezoelectric energy harvesting (374)

  27. Niu J, Ding Y, Geng Z, Zhu L, Ding H (2018) Patterns of regenerative milling chatter under joint influences of cutting parameters, tool geometries and runout. J Manuf Sci Eng 140(12):121004. https://doi.org/10.1115/1.4041250

    Article  Google Scholar 

  28. Bayly P, Metzler S, Schaut A, Young K (2001) Theory of torsional chatter in twist drills: model, stability analysis and composition to test. J Manuf Sci Eng 123(4):552–561. https://doi.org/10.1115/1.1381399

    Article  Google Scholar 

  29. Ostasevicius V, Jurenas V, Karpavicius P, Bubulis A, Eidukynas D, Cesnavicius R, Cepenas M (2019) Wireless sensor to assess the quality of rotating tools. Patent Application LT2019: 535

Download references

Funding

This research was funded by the European Regional Development Fund according to the supported activity No. 01.2.2- LMT-K-718 under the project No. DOTSUT-234.

Author information

Authors and Affiliations

  1. Institute of Mechatronics, Kaunas University of Technology, Studentu 56-123, Kaunas, LT-51368, Lithuania

    Vytautas Ostasevicius, Paulius Karpavicius, Vytautas Jurenas & Darius Eidukynas

  2. Faculty of Electrical and Electronics Engineering, Kaunas University of Technology, Studentu 48, Kaunas, LT-51367, Lithuania

    Mindaugas Cepenas

  3. Faculty of Mechanical Engineering and Design, Kaunas University of Technology, Studentu 56, Kaunas, LT-51369, Lithuania

    Ramunas Cesnavicius

  4. Institute of Mechatronics, Kaunas University of Technology, Studentu 56, Kaunas, LT-51368, Lithuania

    Darius Eidukynas

Authors
  1. Vytautas Ostasevicius
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Paulius Karpavicius
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Vytautas Jurenas
    View author publications

    You can also search for this author in PubMed Google Scholar

  4. Mindaugas Cepenas
    View author publications

    You can also search for this author in PubMed Google Scholar

  5. Ramunas Cesnavicius
    View author publications

    You can also search for this author in PubMed Google Scholar

  6. Darius Eidukynas
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to Paulius Karpavicius.

Ethics declarations

Conflict of interest

The authors declare that they have no conflict of interest.

Additional information

Author contributions

All authors, including Vytautas Ostasevicius, Paulius Karpavicius, Vytautas Jurenas, Mindaugas Cepenas, Ramunas Cesnavicius, and Darius Eidukynas, conducted this research. This paper was written by Paulius Karpavicius.

Publisher’s note

Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Ostasevicius, V., Karpavicius, P., Jurenas, V. et al. Development of universal wireless sensor node for tool condition monitoring in milling. Int J Adv Manuf Technol 110, 1015–1025 (2020). https://doi.org/10.1007/s00170-020-05812-x

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s00170-020-05812-x

Keywords

Search

Navigation