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Evaluating tool wear by measuring the real-time contact resistance

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Abstract

A method is proposed to diagnose wear and to determine the replacement schedule for a working end-mill cutter. Changes in the contact area between a working end-mill cutter and the workpiece during a milling process lead to a real-time variation in the contact resistance. Measuring the real-time contact resistance using a micro-ohm meter and a GPIB (general-purpose interface bus) interface control card allows the wear in a working end-mill cutter to be determined. Real-time contact resistance values for a working end-mill cutter are measured and recorded every second. The experimental results demonstrate that when the milling cutter operates continuously for about 20,000 s, the contact resistance decreases to about 25% of the original value for the brand new state. This method can be used for the future design of milling machines. If the value of the contact resistance for a working end-mill of the same type approaches this value, the cutter should be replaced in order to maintain efficient machining.

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Authors and Affiliations

  1. Department of Mold and Die Engineering, National Kaohsiung University of Science and Technology, 415, Jiangong Rd., Sanmin Dist., Kaohsiung City, 80778, Taiwan

    Chuang-Wen Yao & T. W. Hong

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  1. Chuang-Wen Yao
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  2. T. W. Hong
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Correspondence to Chuang-Wen Yao.

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Yao, CW., Hong, T.W. Evaluating tool wear by measuring the real-time contact resistance. Int J Adv Manuf Technol 100, 2349–2355 (2019). https://doi.org/10.1007/s00170-018-2815-y

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  • DOI: https://doi.org/10.1007/s00170-018-2815-y

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