[논문]PLC 기반 주축 모터의 토크에 의한 드릴링 절삭상태 감시에 관한 연구

윤상환; 문성민; 류성기

doi:10.14775/ksmpe.2018.17.3.007

Abstract ▼ AI-Helper

Drilling processes require a cutting monitoring function that can be analyzed and gives feedback about strange conditions, tool collision and tool wear in real time. In this study, we proposed a drill monitor using the torque from the main spindle in CNC machine tools and a PROFIBUS network as a PLC...

Drilling processes require a cutting monitoring function that can be analyzed and gives feedback about strange conditions, tool collision and tool wear in real time. In this study, we proposed a drill monitor using the torque from the main spindle in CNC machine tools and a PROFIBUS network as a PLC-based interface. This paper studied drilling torque changes depending on drill size, the repetition cutting of the drilling and the drill's wear in the same cutting conditions. The material of the drills was high speed steel (HSS) and uncoated. The drills chosen were 2.7 mm, 6.7 mm, and 10.0 mm in diameter. These drills were selected because they had basic holes for their taps.

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문제 정의

This study aimed to investigate change in cutting torque by drill size with regard to the same materials using PROFIBUS communication based on the PLC, and in particular, analyze how torque changes when a drill size is small. In addition, this study also investigated variability of cutting torque by drill size according to repeated processing.

가설 설정

1. Difference in torque value was within a range of 2-3 Nm according to a material of workpiece for the case of small-diameter (2.7 mm) drill, which showed no significant effect of materials. Thus, it was difficult to distinguish normal and abnormal states, and change in torque was minimal when a diameter was small.

제안 방법

In addition, this study also investigated variability of cutting torque by drill diameter according to drill wear. Tool wear influences torque differently, and this problem can be prevented in the production phase if this change is detected and predicted in advance for tool replacement^[5].
This study aimed to investigate change in cutting torque by drill size with regard to the same materials using PROFIBUS communication based on the PLC, and in particular, analyze how torque changes when a drill size is small. In addition, this study also investigated variability of cutting torque by drill size according to repeated processing. This is because reliability can be achieved when torque size appearing at the same condition should be within a certain level of deviation.
Currently, various signals such as cutting force, motor current, acoustic emission (AE), vibration, and the number of rotations are used for process monitoring. In this study, a motor torque detected using PROFIBUS (Process Field Bus) communications from the spindle motor drive unit was used as a monitoring signal.
This study performed data input/output (I/O) via PROFIBUS communication, which can collect all information contained in CNC machine tools using a PLC-based interface method, which was then combined with drilling monitoring technology.
As described in the above, methods that calculate a drilling torque are known, but torque must be calculated every time drill processing conditions change, such as material characteristics of workpieces, and cutting conditions including transfer rate, tool materials, and machine's performance and specifications, and a calculated value is often different from an actual measured value. To address the above problem, this study selected a method that converts and displays a current value extracted from the spindle motor power in a processing machine into a torque value.

대상 데이터

The cutting condition was set to a dry mode, which did not use cutting oil. The cutting depth was 15 mm, and materials of the workpiece used for testing were SM45C, Al, SCM415, and GC25.
The material type of the drill for testing used in this study was high-speed steel (HSS) whose surface was not coated and with a point angle of 118°. The drill diameters used were 2.7 mm, 5.0 mm, 6.7mm, 8.5 mm, and 10.0 mm. These were chosen because they are widely used sizes and basic drills particularly for tapping.
The machine's specification used in the test was a horizontal machining center whose main spindle size was BT40.
These were chosen because they are widely used sizes and basic drills particularly for tapping. The most widely used material, SM45C, was selected as a material for the workpiece for processing.

성능/효과

2. SM45C and SCM415 materials exhibited a similar torque value regardless of drill diameter, and their torque sizes were larger than those of aluminum and cast iron materials. That is, aluminum and cast iron were materials with a good cutting property so that they showed a small cutting resistance.
3. The repeatability test by drill diameter showed that a variation was revealed within around 8% when a drill's diameter was 2.7 mm, and within 5% when a drill's diameter was 10.0 mm.
4. The wear test showed that a smaller-diameter drill had no significant change in torque according to wear amount, and torque size varied significantly according to a wear amount if diameter was larger. Thus, since a change in torque according to a wear amount can be a good factor for determining replacement time of tools, it can be helpful to derive test data that can determine replacement time considering materials of workpieces, cutting condition, and other devices and jig effects.
0 mm. This result indicated that repeatability is more stable as diameter is larger, but that a smaller-diameter drill had a larger change in torque compared to a mean torque size at the same condition than that of a larger-diameter drill.

후속연구

Thus, this result indicated that the difference may be smaller than the above result depending on material characteristics of the workpiece or machine's conditions, which was needed to be studied further.

참고문헌 (6)

Kuk, Y. H., Choi, H. J., "Analysis of Fluid-Structure Interaction of Cleaning System of Micro Drill Bits", Journal of the Korean Society of Manufacturing Process Engineers, Vol. 15, No. 1, pp. 8-13, 2016.
Hong, S. M., Park, D. H., Han, S. G., Song, C. K., "A Study on the Drilling Performance of the Assembly Machine for the an Aircraft's Main Wings", Journal of the Korean Society of Manufacturing Process Engineers, Vol. 17, No. 1, pp. 8-15, 2018.
Park, D. S., Jeong, Y. H., "Study on Tool Wear and Cutting Forces by Tool Properties in CFRP Drilling", Journal of the Korean Society of Manufacturing Process Engineers, Vol. 16, No. 4, pp. 83-88, 2017.
Yoon, S. H., Cho, S. P., Lyu, S. G., "A Study on Real Time Cutting Monitoring using Profibus," Journal of the Korean Society of Manufacturing Process Engineers, Vol. 15, No. 3, pp. 1-7, 2016.
Kim, H. Y., Ahn, J. H., Chip Disposal State Monitoring in Drilling Using Neural Network, Journal of the Korean Society of Precision Engineering, Vol. 16, No. 6, pp. 67-75, 1999.
Sa, S. Y., Kim, K. L., "A Study on the System Identification for Detection of Tool Breakage, Journal of the Korean Society of Machine Tool Engineers, Vol. 9, No. 5, pp. 35-41, 2000.

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PLC 기반 주축 모터의 토크에 의한 드릴링 절삭상태 감시에 관한 연구
A Study on Monitoring Drilling using Torque from Main Spindle Based on PLC in CNC Machine Tools 원문보기

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PLC 기반 주축 모터의 토크에 의한 드릴링 절삭상태 감시에 관한 연구 A Study on Monitoring Drilling using Torque from Main Spindle Based on PLC in CNC Machine Tools 원문보기

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PLC 기반 주축 모터의 토크에 의한 드릴링 절삭상태 감시에 관한 연구
A Study on Monitoring Drilling using Torque from Main Spindle Based on PLC in CNC Machine Tools 원문보기

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