TY - JOUR
T1 - A robust embedded load cell sensor for tool life prognosis and smart sawing of medium carbon steel
AU - Tsai, Ping Chi
AU - Jeng, Yeau Ren
AU - Tseng, Chien Wei
N1 - Funding Information:
This work was financially supported by the Ministry of Science and Technology of Taiwan (MOST 108–2221-E-006–228-MY3, 109–2923-E-006–005-MY3 and 110–2124-M-006–005) and Air Force Office of Science Research (AFOSR) under contract no. FA4869- 06–1-0056 AOARD 064053.
Funding Information:
Professor Yeau-Ren Jeng would like to acknowledge the Medical Device Innovation Center (MDIC) and Intelligent Manufacturing Research Center (iMRC) from The Featured Areas Research Center Program within the framework of the Higher Education Sprout Project by the Ministry of Education (MOE) in Taiwan and AC2T research GmbH (AC2T) in Austria (COMET InTribology, FFG-No.872176).
Publisher Copyright:
© 2022, The Author(s).
PY - 2022/7
Y1 - 2022/7
N2 - An embedded load cell sensor is proposed for the tool life prognosis and thrust force control of a band saw machine. The sensor enables the tool life and surface quality of the machined workpiece to be effectively improved through the use of a single sensing device strategically located in the cutting machine. The feasibility of the proposed sensor is demonstrated experimentally using a double-column horizontal sawing machine with medium carbon steel bars as the workpiece material. An investigation is performed into the effects of the cutting force, feed rate, and machining time on the machined workpiece’s tool wear and surface roughness. It is shown that the machined workpiece’s thrust force, tool wear, and surface roughness are strongly correlated and increase over time. Based on the experimental results, a feedback control system is proposed for maintaining a constant thrust force on the band saw during cutting under even the most challenging conditions. Overall, the results confirm that a single embedded load cell sensor located in a key position can provide effective force monitoring. Such force monitoring enables a control methodology to maintain the optimal cutting conditions in the sawing of medium carbon steel and improve the tool life and machined part quality.
AB - An embedded load cell sensor is proposed for the tool life prognosis and thrust force control of a band saw machine. The sensor enables the tool life and surface quality of the machined workpiece to be effectively improved through the use of a single sensing device strategically located in the cutting machine. The feasibility of the proposed sensor is demonstrated experimentally using a double-column horizontal sawing machine with medium carbon steel bars as the workpiece material. An investigation is performed into the effects of the cutting force, feed rate, and machining time on the machined workpiece’s tool wear and surface roughness. It is shown that the machined workpiece’s thrust force, tool wear, and surface roughness are strongly correlated and increase over time. Based on the experimental results, a feedback control system is proposed for maintaining a constant thrust force on the band saw during cutting under even the most challenging conditions. Overall, the results confirm that a single embedded load cell sensor located in a key position can provide effective force monitoring. Such force monitoring enables a control methodology to maintain the optimal cutting conditions in the sawing of medium carbon steel and improve the tool life and machined part quality.
UR - http://www.scopus.com/inward/record.url?scp=85131054326&partnerID=8YFLogxK
UR - http://www.scopus.com/inward/citedby.url?scp=85131054326&partnerID=8YFLogxK
U2 - 10.1007/s00170-022-09377-9
DO - 10.1007/s00170-022-09377-9
M3 - Article
AN - SCOPUS:85131054326
VL - 121
SP - 1353
EP - 1364
JO - International Journal of Advanced Manufacturing Technology
JF - International Journal of Advanced Manufacturing Technology
SN - 0268-3768
IS - 1-2
ER -