基于切削电流系数的铣刀磨损状态监测

基于切削力系数的铣刀磨损状态监测方法提出了与切削参数独立的刀具磨损指标。由于存在干扰机床正常加工、实时性不佳、传感器安装不便和成本过高等问题,限制了其在实际工业环境中的应用。针对上述问题,结合切削力与主轴电流的关系,提出一种基于主轴切削电流系数的铣刀磨损状态监测方法。首先,融合切削力系数和主轴电流的优点,建立铣削电流模型;其次,根据切削电流模型进行切削电流系数辨识,记录新刀状态下切削系数;然后,使用切削系数实时估计相同加工工况下新刀切削电流,监测实际切削电流偏离估计值的程度,判断铣刀磨损状态;最后,通过实验与力信号对比验证该方法的正确性。实验结果表明,该方法可以替代基于切削力系数的磨损状态监测方法,能有效、实时、无干扰、便利和低成本地识别新刀、正常和严重3种磨损状态。

Monitoring Milling Cutter Wear Condition Based on Cutting Current Coefficients

The cutting condition independent method based on force model coefficients is applied to monitor tool wear status. However, its application in an actual industrial environment is restricted due to multiple reasons, such as the interference in normal processing, lagging in real-time tracking, difficulties in sensor installation and high cost. In light of these problems, spindle cutting current coefficients are introduced. First, the cutting current model of a sharp tool is built with cutting force coefficients and spindle current. Then, the coefficients are identified, and the cutting current of a sharp real tool with the same parameters as the simulated model is estimated in real-time. The difference between the actual cutting current from that of the estimated value is tracked and the wear status is judged; Finally, the correctness and validity of the method are verified by experiments and comparison with force signals. The experimental results show that this method can replace the method based on cutting force coefficients. The proposed method recognizes the wear status without interference and narrowly lags behind in real-time tracking.