Search results for: tool condition monitoring

Authors: Hatim Laalej, Salvador Sumohano-Verdeja, Thomas McLeay

Abstract:

Monitoring of tool wear in milling operations is essential for achieving the desired dimensional accuracy and surface finish of a machined workpiece. Although there are numerous statistical models and artificial intelligence techniques available for monitoring the wear of cutting tools, these techniques cannot pin point which cutting edge of the tool, or which insert in the case of indexable tooling, is worn or broken. Currently, the task of monitoring the wear on the tool cutting edges is carried out by the operator who performs a manual inspection, causing undesirable stoppages of machine tools and consequently resulting in costs incurred from lost productivity. The present study is concerned with the development of a flute tracking system to segment signals related to each physical flute of a cutter with three flutes used in an end milling operation. The purpose of the system is to monitor the cutting condition for individual flutes separately in order to determine their progressive wear rates and to predict imminent tool failure. The results of this study clearly show that signals associated with each flute can be effectively segmented using the proposed flute tracking system. Furthermore, the results illustrate that by segmenting the sensor signal by flutes it is possible to investigate the wear in each physical cutting edge of the cutting tool. These findings are significant in that they facilitate the online condition monitoring of a cutting tool for each specific flute without the need for operators/engineers to perform manual inspections of the tool.

Keywords: Tool condition monitoring, tool wear prediction, milling operation, flute tracking.

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Authors: Cem Karacal, Sohyung Cho, William Yu

Abstract:

In metal cutting industries, mathematical/statistical models are typically used to predict tool replacement time. These off-line methods usually result in less than optimum replacement time thereby either wasting resources or causing quality problems. The few online real-time methods proposed use indirect measurement techniques and are prone to similar errors. Our idea is based on identifying the optimal replacement time using an electronic nose to detect the airborne compounds released when the tool wear reaches to a chemical substrate doped into tool material during the fabrication. The study investigates the feasibility of the idea, possible doping materials and methods along with data stream mining techniques for detection and monitoring different phases of tool wear.

Keywords: Tool condition monitoring, cutting tool replacement, data stream mining, e-Nose.

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Authors: Sheng Fu, Yinbo Gao, Hao Lin

Abstract:

In the current mine air compressors monitoring system, there are some difficulties in the installation and maintenance because of the wired connection. To solve the problem, this paper introduces a new air compressors monitoring system based on ZigBee in which the monitoring parameters are transmitted wirelessly. The collecting devices are designed to form a cluster network to collect vibration, temperature, and pressure of air cylinders and other parameters. All these devices are battery-powered. Besides, the monitoring software in PC is developed using MFC. Experiments show that the designed wireless sensor network works well in the site environmental condition and the system is very convenient to be installed since the wireless connection. This monitoring system will have a wide application prospect in the upgrade of the old monitoring system of the air compressors.

Keywords: Condition monitoring, wireless sensor network, air compressor, ZigBee, data collecting

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Authors: Jaharah A. Ghani, Muhammad Rizal, Ahmad Sayuti, Mohd Zaki Nuawi, Mohd Nizam Ab. Rahman, Che Hassan Che Haron

Abstract:

This study presents a new method for detecting the cutting tool wear based on the measured cutting force signals using the regression model and I-kaz method. The detection of tool wear was done automatically using the in-house developed regression model and 3D graphic presentation of I-kaz 3D coefficient during machining process. The machining tests were carried out on a CNC turning machine Colchester Master Tornado T4 in dry cutting condition, and Kistler 9255B dynamometer was used to measure the cutting force signals, which then stored and displayed in the DasyLab software. The progression of the cutting tool flank wear land (VB) was indicated by the amount of the cutting force generated. Later, the I-kaz was used to analyze all the cutting force signals from beginning of the cut until the rejection stage of the cutting tool. Results of the IKaz analysis were represented by various characteristic of I-kaz 3D coefficient and 3D graphic presentation. The I-kaz 3D coefficient number decreases when the tool wear increases. This method can be used for real time tool wear monitoring.

Keywords: mathematical model, I-kaz method, tool wear

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Authors: Joon-Young Park, Beom-Joo Kim, Jae-Kyung Lee

Abstract:

As an effort to promote wind power industry in Korea, Korea South-East Power Corporation has been developing 22MW YeungHeung wind farm consisting of nine 2 to 3MW wind turbines supplied by three manufacturers. To maximize its availability and reliability and to solve the difficulty of operating three kinds of SCADA systems, Korea Electric Power Corporation has been developing a condition monitoring system integrated with control functions. This paper presents the developed condition monitoring system and its application to YeungHeung wind test bed, and the design of its control functions.

Keywords: condition monitoring, control function, reliability, wind turbine

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Authors: N. Ahmed, A.J. Day, J.L. Victory L. Zeall, B. Young

Abstract:

The manufacture of large-scale precision aerospace components using CNC requires a highly effective maintenance strategy to ensure that the required accuracy can be achieved over many hours of production. This paper reviews a strategy for a maintenance management system based on Failure Mode Avoidance, which uses advanced techniques and technologies to underpin a predictive maintenance strategy. It is shown how condition monitoring (CM) is important to predict potential failures in high precision machining facilities and achieve intelligent and integrated maintenance management. There are two distinct ways in which CM can be applied. One is to monitor key process parameters and observe trends which may indicate a gradual deterioration of accuracy in the product. The other is the use of CM techniques to monitor high status machine parameters enables trends to be observed which can be corrected before machine failure and downtime occurs. It is concluded that the key to developing a flexible and intelligent maintenance framework in any precision manufacturing operation is the ability to evaluate reliably and routinely machine tool condition using condition monitoring techniques within a framework of Failure Mode Avoidance.

Keywords: Maintenance, Condition Monitoring, CNC, Machining, Accuracy, Capability, Key Process Parameters, Critical Parameters

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Authors: Javier A. Dominguez Caballero, Graeme A. Manson, Matthew B. Marshall

Abstract:

Cutting tools with ceramic inserts are often used in the process of machining many types of superalloy, mainly due to their high strength and thermal resistance. Nevertheless, during the cutting process, the plastic flow wear generated in these inserts enhances and propagates cracks due to high temperature and high mechanical stress. This leads to a very variable failure of the cutting tool. This article explores the relationship between the continuous wear that ceramic SiAlON (solid solutions based on the Si3N4 structure) inserts experience during a high-speed machining process and the evolution of sparks created during the same process. These sparks were analysed through pictures of the cutting process recorded using an SLR camera. Features relating to the intensity and area of the cutting sparks were extracted from the individual pictures using image processing techniques. These features were then related to the ceramic insert’s crater wear area.

Keywords: Ceramic cutting tools, high speed machining, image processing, tool condition monitoring, tool wear.

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Authors: M. Amir Abas, M. Dahlui

Abstract:

This paper presents the development of analysis tools for Home Agriculture project. The tools are required for monitoring the condition of greenhouse which involves two components: measurement hardware and data analysis engine. Measurement hardware is functioned to measure environment parameters such as temperature, humidity, air quality, dust and etc while analysis tool is used to analyse and interpret the integrated data against the condition of weather, quality of health, irradiance, quality of soil and etc. The current development of the tools is completed for off-line data recorded technique. The data is saved in MMC and transferred via ZigBee to Environment Data Manager (EDM) for data analysis. EDM converts the raw data and plot three combination graphs. It has been applied in monitoring three months data measurement for irradiance, temperature and humidity of the greenhouse..

Keywords: Monitoring, Environment, Greenhouse, Analysis tools

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Authors: Ayman M. Mansour

Abstract:

In this paper, we propose a multi-agent intelligent system that is used for monitoring the health conditions of elderly people. Monitoring the health condition of elderly people is a complex problem that involves different medical units and requires continuous monitoring. Such expert system is highly needed in rural areas because of inadequate number of available specialized physicians or nurses. Such monitoring must have autonomous interactions between these medical units in order to be effective. A multi-agent system is formed by a community of agents that exchange information and proactively help one another to achieve the goal of elderly monitoring. The agents in the developed system are equipped with intelligent decision maker that arms them with the rule-based reasoning capability that can assist the physicians in making decisions regarding the medical condition of elderly people.

Keywords: Fuzzy Logic, Inference system, Monitoring system, Multi-agent system.

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Authors: M. Elhaj, M. Almrabet, M. Rgeai, I. Ehtiwesh

Abstract:

A Comparison and evaluation of the different condition monitoring (CM) techniques was applied experimentally on RC e.g. Dynamic cylinder pressure and crankshaft Instantaneous Angular Speed (IAS), for the detection and diagnosis of valve faults in a two - stage reciprocating compressor for a programme of condition monitoring which can successfully detect and diagnose a fault in machine. Leakage in the valve plate was introduced experimentally into a two-stage reciprocating compressor. The effect of the faults on compressor performance was monitored and the differences with the normal, healthy performance noted as a fault signature been used for the detection and diagnosis of faults. The paper concludes with what is considered to be a unique approach to condition monitoring. First, each of the two most useful techniques is used to produce a Truth Table which details the circumstances in which each method can be used to detect and diagnose a fault. The two Truth Tables are then combined into a single Decision Table to provide a unique and reliable method of detection and diagnosis of each of the individual faults introduced into the compressor. This gives accurate diagnosis of compressor faults.

Keywords: Condition Monitoring, Dynamic Pressure, Instantaneous Angular Speed, Reciprocating Compressor.

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Authors: Aswir Premadi, Mohammad Syuhaimi Ab. Rahman, Mohamad Najib Moh. Saupe, KasmiranJumari

Abstract:

An optical fault monitoring in FTTH-PON using ACS is demonstrated. This device can achieve real-time fault monitoring for protection feeder fiber. In addition, the ACS can distinguish optical fiber fault from the transmission services to other customers in the FTTH-PON. It is essential to use a wavelength different from the triple-play services operating wavelengths for failure detection. ACS is using the operating wavelength 1625 nm for monitoring and failure detection control. Our solution works on a standard local area network (LAN) using a specially designed hardware interfaced with a microcontroller integrated Ethernet.

Keywords: ACS, monitoring tool, FTTH-PON.

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Authors: N. A. Muhamad, S.A.M. Ali

Abstract:

Condition monitoring of electrical power equipment has attracted considerable attention for many years. The aim of this paper is to use Labview with Fuzzy Logic controller to build a simulation system to diagnose transformer faults and monitor its condition. The front panel of the system was designed using LabVIEW to enable computer to act as customer-designed instrument. The dissolved gas-in-oil analysis (DGA) method was used as technique for oil type transformer diagnosis; meanwhile terminal voltages and currents analysis method was used for dry type transformer. Fuzzy Logic was used as expert system that assesses all information keyed in at the front panel to diagnose and predict the condition of the transformer. The outcome of the Fuzzy Logic interpretation will be displayed at front panel of LabVIEW to show the user the conditions of the transformer at any time.

Keywords: LabVIEW, Fuzzy Logic, condition monitoring, oiltransformer, dry transformer, DGA, terminal values.

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Authors: Faisal AlShammari, Abdulmajid Addali

Abstract:

Monitoring the conditions of rotating machinery, such as bearings, is important in order to improve the stability of work. Acoustic Emission (AE) and vibration analysis are some of the most accomplished techniques used for this purpose. Acoustic emission has the ability to detect the initial phase of component degradation. Moreover, it has been observed that vibration analysis is not as successful at low rotational speeds (below 100 rpm). This because the energy generated within this speed region is not detectable using conventional vibration. From this perspective, this paper has presented a brief review of using acoustic emission techniques for monitoring bearing conditions.

Keywords: Condition monitoring, stress wave analysis, low-speed bearings, bearing defect diagnosis.

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Authors: S. Sendhilkumar, N. Mohanasundaram, M. Senthilkumar, S. N. Sivanandam

Abstract:

The operational life of rotating machines has to be extended using a predictive condition maintenance tool. Among various condition monitoring techniques, vibration analysis is most widely used technique in industry. Signals are extracted for evaluating the condition of machine; further diagnostics is carried out with detected signals to extend the life of machine. With help of detected signals, further interpretations are done to predict the occurrence of defects. To study the problem of defects, a test rig with various possibilities of defects is constructed and experiments are performed considering the unbalanced condition. Further, this paper presents an approach for fault diagnosis of unbalance condition using Elman neural network and frequency-domain vibration analysis. Amplitudes with variation in acceleration are fed to Elman neural network to classify fault or no-fault condition. The Elman network is trained, validated and tested with experimental readings. Results illustrate the effectiveness of Elman network in rotor-bearing system.

Keywords: Elman neural network, fault detection, rotating machines, unbalance, vibration analysis.

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Authors: A. P. Anvar, T. Dowling, T. Putland, A. M. Anvar, S.Grainger

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This paper presents the application of Intelligent Techniques to the various duties of Intelligent Condition Monitoring Systems (ICMS) for Unmanned Aerial Vehicle (UAV) Robots. These Systems are intended to support these Intelligent Robots in the event of a Fault occurrence. Neural Networks are used for Diagnosis, whilst Fuzzy Logic is intended for Prognosis and Remedy. The ultimate goals of ICMS are to save large losses in financial cost, time and data.

Keywords: Intelligent Techniques, Condition Monitoring Systems, ICMS, Robots, Fault, Unmanned Aerial Vehicle, UAV, Neural Networks, Diagnosis, Fuzzy Logic, Prognosis, Remedy.

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Authors: Omid A. Zargar

Abstract:

In this paper, some common gearboxes vibration analysis methods and condition monitoring systems are explained. In addition, an experimental gearbox vibration analysis is discussed through a critical case history for a mixer gearbox related to Iran oil industry. The case history also consists of gear manufacturing (machining) recommendations, lubrication condition of gearbox and machinery maintenance activities that caused reduction in noise and vibration of the gearbox. Besides some of the recent patents and innovations in gearboxes, lubrication and vibration monitoring systems explained. Finally micro pitting and surface fatigue in pinion and bevel of mentioned horizontal to vertical gearbox discussed in details.

Keywords: Gear box, condition monitoring, time wave form (TWF), fast Fourier transform (FFT), gear mesh frequency (GMF), Shock Pulse measurement (SPM), bearing condition unit (BCU), pinion, bevel gear, micro pitting, surface fatigue.

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Authors: Il Dong Kim, Jin Rak Lee, Young Jun Ko, Young Taek Jin

Abstract:

An on-line condition monitoring method for transmission line is proposed using electrical circuit theory and IT technology in this paper. It is reasonable that the circuit parameters such as resistance (R), inductance (L), conductance (g) and capacitance (C) of a transmission line expose the electrical conditions and physical state of the line. Those parameters can be calculated from the linear equation composed of voltages and currents measured by synchro-phasor measurement technique at both end of the line. A set of linear voltage drop equations containing four terminal constants (A, B ,C ,D ) are mathematical models of the transmission line circuits. At least two sets of those linear equations are established from different operation condition of the line, they may mathematically yield those circuit parameters of the line. The conditions of line connectivity including state of connecting parts or contacting parts of the switching device may be monitored by resistance variations during operation. The insulation conditions of the line can be monitored by conductance (g) and capacitance(C) measurements. Together with other condition monitoring devices such as partial discharge, sensors and visual sensing device etc.,they may give useful information to monitor out any incipient symptoms of faults. The prototype of hardware system has been developed and tested through laboratory level simulated transmission lines. The test has shown enough evident to put the proposed method to practical uses.

Keywords: Transmission Line, Condition Monitoring, Circuit Parameters, Synchro- phasor Measurement.

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Authors: Radek Fisera, Petr Stluka

Abstract:

This paper describes a methodology for remote performance monitoring of retail refrigeration systems. The proposed framework starts with monitoring of the whole refrigeration circuit which allows detecting deviations from expected behavior caused by various faults and degradations. The subsequent diagnostics methods drill down deeper in the equipment hierarchy to more specifically determine root causes. An important feature of the proposed concept is that it does not require any additional sensors, and thus, the performance monitoring solution can be deployed at a low installation cost. Moreover only a minimum of contextual information is required, which also substantially reduces time and cost of the deployment process.

Keywords: Condition monitoring, energy baselining, fault detection and diagnostics, commercial refrigeration.

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Authors: Kious Mecheri, Hadjadj Abdechafik, Ameur Aissa

Abstract:

The wear of cutting tool degrades the quality of the product in the manufacturing processes. The on line monitoring of the cutting tool wear level is very necessary to prevent the deterioration of the quality of machining. Unfortunately there is not a direct manner to measure the cutting tool wear on line. Consequently we must adopt an indirect method where wear will be estimated from the measurement of one or more physical parameters appearing during the machining process such as the cutting force, the vibrations, or the acoustic emission etc…. In this work, a neural network system is elaborated in order to estimate the flank wear from the cutting force measurement and the cutting conditions.

Keywords: Flank wear, cutting forces, high speed milling, signal processing, neural network.

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Authors: C. Lanzerstorfer

Abstract:

Liquid sprays of water are frequently used in air pollution control for gas cooling purposes and for gas cleaning. Twin-fluid nozzles with internal mixing are often used for these purposes because of the small size of the drops produced. In these nozzles the liquid is dispersed by compressed air or another pressurized gas. In high efficiency scrubbers for particle separation, several nozzles are operated in parallel because of the size of the cross section. In such scrubbers, the scrubbing water has to be re-circulated. Precipitation of some solid material can occur in the liquid circuit, caused by chemical reactions. When such precipitations are detached from the place of formation, they can partly or totally block the liquid flow to a nozzle. Due to the resulting unbalanced supply of the nozzles with water and gas, the efficiency of separation decreases. Thus, the nozzles have to be cleaned if a certain fraction of blockages is reached. The aim of this study was to provide a tool for continuously monitoring the status of the nozzles of a scrubber based on the available operation data (water flow, air flow, water pressure and air pressure). The difference between the air pressure and the water pressure is not well suited for this purpose, because the difference is quite small and therefore very exact calibration of the pressure measurement would be required. Therefore, an equation for the reference air flow of a nozzle at the actual water flow and operation pressure was derived. This flow can be compared with the actual air flow for assessment of the status of the nozzles.

Keywords: Twin-fluid nozzles, operation data, condition monitoring, flow equation.

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Authors: A. Samraj, S. Sayeed, J. E. Raja., J. Hossen, A. Rahman

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Monitoring the tool flank wear without affecting the throughput is considered as the prudent method in production technology. The examination has to be done without affecting the machining process. In this paper we proposed a novel work that is used to determine tool flank wear by observing the sound signals emitted during the turning process. The work-piece material we used here is steel and aluminum and the cutting insert was carbide material. Two different cutting speeds were used in this work. The feed rate and the cutting depth were constant whereas the flank wear was a variable. The emitted sound signal of a fresh tool (0 mm flank wear) a slightly worn tool (0.2 -0.25 mm flank wear) and a severely worn tool (0.4mm and above flank wear) during turning process were recorded separately using a high sensitive microphone. Analysis using Singular Value Decomposition was done on these sound signals to extract the feature sound components. Observation of the results showed that an increase in tool flank wear correlates with an increase in the values of SVD features produced out of the sound signals for both the materials. Hence it can be concluded that wear monitoring of tool flank during turning process using SVD features with the Fuzzy C means classification on the emitted sound signal is a potential and relatively simple method.

Keywords: Fuzzy c means, Microphone, Singular ValueDecomposition, Tool Flank Wear.

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Authors: Ayman M. Mansour

Abstract:

In this paper, we propose an intelligent system that is used for monitoring the health conditions of patients. Monitoring the health condition of patients is a complex problem that involves different medical units and requires continuous monitoring especially in rural areas because of inadequate number of available specialized physicians. The proposed system will improve patient care and drive costs down comparing to the existing system in Jordan. The proposed system will be the start point to faster and improve the communication between different units in the health system in Jordan. Connecting patients and their physicians beyond hospital doors regarding their geographical area is an important issue in developing the health system in Jordan. The ability of making medical decisions, the quality of medical is expected to be improved.

Keywords: GSM, SMS, Patient, Monitoring system, Fuzzy Logic, Multi-agent system.

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Authors: Breda M. Kiernan, Cormac Fay, Stephen Beirne, Dermot Diamond

Abstract:

This paper describes the designs of a first and second generation autonomous gas monitoring system and the successful field trial of the final system (2nd generation). Infrared sensing technology is used to detect and measure the greenhouse gases methane (CH4) and carbon dioxide (CO2) at point sources. The ability to monitor real-time events is further enhanced through the implementation of both GSM and Bluetooth technologies to communicate these data in real-time. These systems are robust, reliable and a necessary tool where the monitoring of gas events in real-time are needed.

Keywords: Environmental monitoring, infrared sensing, autonomous system.

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Authors: Onkar Bhat Kodical, Sridhar Srinivasan, N.K. Srinath

Abstract:

Tool Tracker is a client-server based application. It is essentially a catalogue of various network monitoring and management tools that are available online. There is a database maintained on the server side that contains the information about various tools. Several clients can access this information simultaneously and utilize this information. The various categories of tools considered are packet sniffers, port mappers, port scanners, encryption tools, and vulnerability scanners etc for the development of this application. This application provides a front end through which the user can invoke any tool from a central repository for the purpose of packet sniffing, port scanning, network analysis etc. Apart from the tool, its description and the help files associated with it would also be stored in the central repository. This facility will enable the user to view the documentation pertaining to the tool without having to download and install the tool. The application would update the central repository with the latest versions of the tools. The application would inform the user about the availability of a newer version of the tool currently being used and give the choice of installing the newer version to the user. Thus ToolTracker provides any network administrator that much needed abstraction and ease-ofuse with respect to the tools that he can use to efficiently monitor a network.

Keywords: Network monitoring, single platform, client/server application, version management.

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Authors: M. El-Alej, D. Mba, T. Yan, M. Elforgani

Abstract:

This paper presents an experimental investigation using Acoustic Emission (AE) technology to monitor sand transportation in multiphase flow. The investigations were undertaken on three-phase (air-water-sand) flow in a horizontal pipe where the superficial gas velocity (VSG) had a range of between 0.2msˉ¹ to 2.0msˉ¹ and superficial liquid velocity (VSL) had a range of between 0.2msˉ¹ to 1.0msˉ¹. The experimental findings clearly show a correlation exists between AE energy levels, sand concentration, superficial gas velocity (VSG), and superficial liquid velocity (VSL).

Keywords: Acoustic Emission (AE), multiphase flow, sand monitoring, sand minimum transport condition (MTC), condition monitoring.

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Authors: P. Mottaghizadeh, M. Bagheri

Abstract:

In the present paper, the three-dimensional temperature field of tool is determined during the machining and compared with experimental work on C45 workpiece using carbide cutting tool inserts. During the metal cutting operations, high temperature is generated in the tool cutting edge which influence on the rate of tool wear. Temperature is most important characteristic of machining processes; since many parameters such as cutting speed, surface quality and cutting forces depend on the temperature and high temperatures can cause high mechanical stresses which lead to early tool wear and reduce tool life. Therefore, considerable attention is paid to determine tool temperatures. The experiments are carried out for dry and orthogonal machining condition. The results show that the increase of tool temperature depends on depth of cut and especially cutting speed in high range of cutting conditions.

Keywords: Finite element method, Machining, Temperature measurement, Thermal fields

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Authors: Somkiat Tangjitsitcharoen, Siripong Damrongthaveesak

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This paper presents an advance in monitoring and process control of surface roughness in CNC machine for the turning and milling processes. An integration of the in-process monitoring and process control of the surface roughness is proposed and developed during the machining process by using the cutting force ratio. The previously developed surface roughness models for turning and milling processes of the author are adopted to predict the inprocess surface roughness, which consist of the cutting speed, the feed rate, the tool nose radius, the depth of cut, the rake angle, and the cutting force ratio. The cutting force ratios obtained from the turning and the milling are utilized to estimate the in-process surface roughness. The dynamometers are installed on the tool turret of CNC turning machine and the table of 5-axis machining center to monitor the cutting forces. The in-process control of the surface roughness has been developed and proposed to control the predicted surface roughness. It has been proved by the cutting tests that the proposed integration system of the in-process monitoring and the process control can be used to check the surface roughness during the cutting by utilizing the cutting force ratio.

Keywords: Turning, milling, monitoring, surface roughness, cutting force ratio.

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Authors: G. Santamato, M. Solazzi, A. Frisoli

Abstract:

Systems for detection of damages in railway pantographs effectively reduce the cost of maintenance and improve time scheduling. In this paper, we present an approach to design a monitoring tool fitting strong customer requirements such as portability and ease of use. Pantograph has been modeled to estimate its dynamical properties, since no data are available. With the aim to focus on suspensions health, a two Degrees of Freedom (DOF) scheme has been adopted. Parameters have been calculated by means of analytical dynamics. A Finite Element Method (FEM) modal analysis verified the former model with an acceptable error. The detection strategy seeks phase-plots topology alteration, induced by defects. In order to test the suitability of the method, leakage in the dashpot was simulated on the lumped model. Results are interesting because changes in phase plots are more appreciable than frequency-shift. Further calculations as well as experimental tests will support future developments of this smart strategy.

Keywords: Pantograph models, phase-plots, structural health monitoring, vibration-based condition monitoring.

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Authors: Nasrin Farajiparvar

Abstract:

In the present article, a new method has been developed to enhance the application of equipment monitoring, which in turn results in improving condition-based maintenance economic impact in an automobile parts manufacturing factory. This study also describes how an effective software with a simple database can be utilized to achieve cost-effective improvements in maintenance performance. The most important results of this project are indicated here: 1. 63% reduction in direct and indirect maintenance costs. 2. Creating a proper database to analyse failures. 3. Creating a method to control system performance and develop it to similar systems. 4. Designing a software to analyse database and consequently create technical knowledge to face unusual condition of the system. Moreover, the results of this study have shown that the concept and philosophy of maintenance has not been understood in most Iranian industries. Thus, more investment is strongly required to improve maintenance conditions.

Keywords: Condition-based maintenance, Economic savings, Iran industries, Machine life prediction software.

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Authors: M. Ibrahim Sadik, Toril Myrtveit

Abstract:

The aim of this investigation is to study the performance of the new generation of the PVD coated grade and to map the influence of cutting conditions on the tool life in milling of ADI (Austempered Ductile Iron). The results show that chipping is the main wear mechanism which determines the tool life in dry condition and notch wear in wet condition for this application. This due to the different stress mechanisms and preexisting cracks in the coating. The wear development shows clearly that the new PVD coating (C20) has the best ability to delay the chipping growth. It was also found that a high content of Al in the new coating (C20) was especially favorable compared to a TiAlN multilayer with lower Al content (C30) or CVD coating. This is due to fine grains and low compressive stress level in the coating which increase the coating ability to withstand the mechanical and thermal impact. It was also found that the use of coolant decreases the tool life with 70-80% compare to dry milling.

Keywords: Austempered Ductile Iron (ADI), coating, chipping, milling, tool performance.

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