×

Time-variant reliability assessment and its sensitivity analysis of cutting tool under invariant machining condition based on Gamma process. (English) Zbl 1264.62099

Summary: The time-variant reliability and its sensitivity of cutting tools under both wear deterioration and an invariant machining condition are analyzed. The wear process is modeled by a gamma process which is a continuous-state and continuous-time stochastic process with independent and nonnegative increments. The time-variant reliability and its sensitivity of cutting tools under six cases are considered. For the first two cases the compensation for the cutting tool wear is not carried out. For the last four cases the off-line or real-time compensation method is adopted. While the off-line compensation method is used, the machining error of the cutting tool is supposed to be stochastic. Whether the detection of the real-time wear is accurate or not is discussed when the real-time compensation method is adopted. The numerical examples are analyzed to demonstrate the idea of how the reliability of cutting tools under the invariant machining condition could be improved according to the methods described in this paper.

MSC:

62N05 Reliability and life testing
62P30 Applications of statistics in engineering and industry; control charts
PDF BibTeX XML Cite
Full Text: DOI

References:

[1] K. Subramanian and N. H. Cook, “Sensing of drill wear and prediction of drill life,” Journal of Engineering for Industry, vol. 99, no. 2, pp. 295-301, 1977.
[2] H. Liu and V. Makis, “Cutting-tool reliability assessment in variable machining conditions,” IEEE Transactions on Reliability, vol. 45, no. 4, pp. 573-581, 1996. · Zbl 04536903
[3] B. M. Hsu and M. H. Shu, “Reliability assessment and replacement for machine tools under wear deterioration,” International Journal of Advanced Manufacturing Technology, vol. 48, no. 1-4, pp. 355-365, 2010.
[4] Z. Klim, E. Ennajimi, M. Balazinski, and C. Fortin, “Cutting tool reliability analysis for variable feed milling of 17-4PH stainless steel,” Wear, vol. 195, no. 1-2, pp. 206-213, 1996.
[5] K. Nagasaka and F. Hashimoto, “Tool wear prediction and economics in machining stepped parts,” International Journal of Machine Tool Design and Research, vol. 28, no. 4, pp. 569-576, 1988.
[6] C. Zhou and R. A. Wysk, “Tool status recording and its use in probabilistic optimization,” Journal of Engineering for Industry, vol. 114, no. 4, pp. 494-499, 1992.
[7] A. Hoyland and M. Rausand, System Reliability Theory: Models and Statistical Methods, John Wiley & Sons, New York, NY, USA, 1994. · Zbl 0846.93001
[8] D. H. Kim, B. M. Kim, and C. G. Kang, “Estimation of die service life for a die cooling method in a hot forging process,” International Journal of Advanced Manufacturing Technology, vol. 27, no. 1-2, pp. 33-39, 2005.
[9] K. Tahera, R. N. Ibrahim, and P. B. Lochert, “Determination of the optimal production run and the optimal initial means of a process with dependent multiple quality characteristics subject to a random deterioration,” International Journal of Advanced Manufacturing Technology, vol. 39, no. 5-6, pp. 623-632, 2008. · Zbl 1154.90379
[10] M. K. Tsai, B. Y. Lee, and S. F. Yu, “A predicted modelling of tool life of high-speed milling for SKD61 tool steel,” International Journal of Advanced Manufacturing Technology, vol. 26, no. 7-8, pp. 711-717, 2005.
[11] R. K. Fish, M. Ostendorf, G. D. Bernard, and D. A. Castanon, “Multilevel classification of milling tool wear with confidence estimation,” IEEE Transactions on Pattern Analysis and Machine Intelligence, vol. 25, no. 1, pp. 75-85, 2003. · Zbl 05110374
[12] X. Li and Z. Yuan, “Tool wear monitoring with wavelet packet transform-fuzzy clustering method,” Wear, vol. 219, no. 2, pp. 145-154, 1998.
[13] T. Moriwaki and M. Tobito, “A new approach to automatic detection of life of coated tool based on acoustic emission measurement,” Journal of Engineering for Industry, vol. 112, no. 3, pp. 212-218, 1990.
[14] J. Sun, M. Rahman, Y. S. Wong, and G. S. Hong, “Multiclassification of tool wear with support vector machine by manufacturing loss consideration,” International Journal of Machine Tools and Manufacture, vol. 44, no. 11, pp. 1179-1187, 2004.
[15] J. M. van Noortwijk, M. Kok, and R. M. Cooke, “Optimal maintenance decisions for the sea-bed protection of the Eastern-Scheldt barrier,” in Engineering Probabilistic Design and Maintenance For Flood Protection, R. Cooke, M. Mendel, and H. Vrijling, Eds., pp. 25-56, Kluwer Academic, Dordrecht, The Netherlands, 1997. · Zbl 0896.76078
[16] J. M. van Noortwijk, R. M. Cooke, and M. Kok, “A Bayesian failure model based on isotropic deterioration,” European Journal of Operational Research, vol. 82, no. 2, pp. 270-282, 1995. · Zbl 0905.90092
[17] J. M. van Noortwijk, “A survey of the application of gamma processes in maintenance,” Reliability Engineering and System Safety, vol. 94, no. 1, pp. 2-21, 2009.
[18] C. Y. Li, M. Q. Xu, S. Guo, R. X. Wang, and J. B. Gao, “Real-time reliability assessment based on gamma process and bayesian estimation,” Journal of Astronautics, vol. 30, no. 4, pp. 1722-1726, 2009 (Chinese).
[19] A. M. Deng, X. Chen, C. H. Zhang, and Y. S. Wang, “Reliability assessment based on performance degradation data,” Journal of Astronautics, vol. 27, no. 3, pp. 546-552, 2006 (Chinese).
[20] J. M. van Noortwijk, J. A. M. van der Weide, M. J. Kallen, and M. D. Pandey, “Gamma processes and peaks-over-threshold distributions for time-dependent reliability,” Reliability Engineering and System Safety, vol. 92, no. 12, pp. 1651-1658, 2007.
[21] Z. Y. Yu, T. Masuzawa, and M. Fujino, “Micro-EDM for three-dimensional cavities-development of uniform wear method,” CIRP Annals, vol. 47, no. 1, pp. 169-172, 1998.
[22] J. P. Kruth and P. Bleys, “Machining curvilinear surfaces by NC electro-discharge machining,” in Proceedings of the 2nd International Conference on MMSS, pp. 271-294, Krakow, Poland, 2000.
[23] W. Meeusen, D. Reynaerts, and H. Van Brussel, “A CAD tool for the design and manufacturing of freeform micro-EDM electrodes,” in Proceedings of the Society of Photo-Optical Instrumentation Engineers, vol. 4755, pp. 105-113, 2002.
[24] T. Nakagawa and Y. Imai, “Feedforward control for EDM milling,” in Proceedings of the 2nd International Conference on MMSS, pp. 305-312, Krakow, Poland, 2000.
[25] Y. H. Jeong and B. K. Min, “Geometry prediction of EDM-drilled holes and tool electrode shapes of micro-EDM process using simulation,” International Journal of Machine Tools and Manufacture, vol. 47, no. 12-13, pp. 1817-1826, 2007.
[26] P. Bleys, J. P. Kruth, and B. Lauwers, “Sensing and compensation of tool wear in milling EDM,” Journal of Materials Processing Technology, vol. 149, no. 1-3, pp. 139-146, 2004.
[27] M. T. Yan, K. Y. Huang, and C. Y. Lo, “A study on electrode wear sensing and compensation in Micro-EDM using machine vision system,” International Journal of Advanced Manufacturing Technology, vol. 42, no. 11-12, pp. 1065-1073, 2009.
[28] D. Shouszhi, D. Yanting, and S. Weixiang, “The detection and compensation of tool wear in process,” Journal of Materials Processing Technology, vol. 48, no. 1-4, pp. 283-290, 1995.
[29] S. K. Choudhury and S. Ramesh, “On-line tool wear sensing and compensation in turning,” Journal of Materials Processing Technology, vol. 49, no. 3-4, pp. 247-254, 1995.
[30] T. Kaneko, M. Tsuchiya, and A. Kazama, “Improvement of 3D NC contouring EDM using cylindrical electrodes-optical measurement of electrode deformation and machining of free-curves,” in Proceedings of the International Symposium for Electromachining (ISEM ’92), vol. 10, pp. 364-367, Magdeburg, German, 1992.
[31] Y. Mizugaki, “Contouring electrical discharge machining with on-machine measuring and dressing of a cylindrical graphite electrode,” in Proceedings of the IEEE 22nd International Conference on Industrial Electronics, Control, and Instrumentation (IECON ’96), pp. 1514-1517, Taipei, China, August 1996.
[32] C. Tricarico, B. Forel, and E. Orhant, “Measuring device and method for determining the length of an electrode,” US Patent 6072143, Charmilles Technologies S.A., 2000.
[33] R. Delpretti and C. Tricarico, Dispositif et procédé d’électroérosion selon les trois dimensions avec une électrode-outil rotative de forme simple, Demande de brevet européen EP0639420, Charmilles Technologies S.A., 1995.
This reference list is based on information provided by the publisher or from digital mathematics libraries. Its items are heuristically matched to zbMATH identifiers and may contain data conversion errors. It attempts to reflect the references listed in the original paper as accurately as possible without claiming the completeness or perfect precision of the matching.