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Sensor-integrated Tap Holder for Process Uncertainty Detection Based on Tool Vibration and Axial Length Compensation Sensors

Öztürk, Tuğrul ; Sarikaya, Erkut ; Weigold, Matthias (2021):
Sensor-integrated Tap Holder for Process Uncertainty Detection Based on Tool Vibration and Axial Length Compensation Sensors.
In: The International Journal of Advanced Manufacturing Technology, 116 (5-6), Springer, ISSN 0268-3768, e-ISSN 1433-3015,
DOI: 10.1007/s00170-021-07825-6,
[Article]

Abstract

The tapping process is one of the most widespread manufacturing processes for internal threads, usually carried out at the end of the value chain. Any non-compliance with required quality standards or even the destruction of the thread due to process uncertainty in the tapping process is therefore subjected to high rework costs. Possible process uncertainties in the tapping process can be triggered by synchronization errors between feed rate and spindle speed, axis offset, faulty core holes and wear of the tapping tool. In order to detect process uncertainties during tapping and thus provide a basis for initiating countermeasures, a sensor-integrated tap holder was developed. This paper presents the realized concept of a rotating telemetry unit for signal processing, data acquisition and wireless data transmitting via WiFi standard on basis of low-cost embedded systems. Furthermore, two unique sensor concepts for measuring close-to-tool vibrations and the axial length compensation of the tapping tool are shown. Based on the sensor data in combination with feature engineering methods, process uncertainty during tapping are detected.

Item Type: Article
Erschienen: 2021
Creators: Öztürk, Tuğrul ; Sarikaya, Erkut ; Weigold, Matthias
Title: Sensor-integrated Tap Holder for Process Uncertainty Detection Based on Tool Vibration and Axial Length Compensation Sensors
Language: English
Abstract:

The tapping process is one of the most widespread manufacturing processes for internal threads, usually carried out at the end of the value chain. Any non-compliance with required quality standards or even the destruction of the thread due to process uncertainty in the tapping process is therefore subjected to high rework costs. Possible process uncertainties in the tapping process can be triggered by synchronization errors between feed rate and spindle speed, axis offset, faulty core holes and wear of the tapping tool. In order to detect process uncertainties during tapping and thus provide a basis for initiating countermeasures, a sensor-integrated tap holder was developed. This paper presents the realized concept of a rotating telemetry unit for signal processing, data acquisition and wireless data transmitting via WiFi standard on basis of low-cost embedded systems. Furthermore, two unique sensor concepts for measuring close-to-tool vibrations and the axial length compensation of the tapping tool are shown. Based on the sensor data in combination with feature engineering methods, process uncertainty during tapping are detected.

Journal or Publication Title: The International Journal of Advanced Manufacturing Technology
Journal volume: 116
Number: 5-6
Publisher: Springer
Uncontrolled Keywords: Future engineering, Process uncertainty, Sensor-integrated tool holder, Tapping
Divisions: 16 Department of Mechanical Engineering
16 Department of Mechanical Engineering > Institute of Production Technology and Machine Tools (PTW)
16 Department of Mechanical Engineering > Institute of Production Technology and Machine Tools (PTW) > TEC Manufacturing Technology
Date Deposited: 16 Aug 2021 06:29
DOI: 10.1007/s00170-021-07825-6
Official URL: https://link.springer.com/article/10.1007%2Fs00170-021-07825...
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