I-Corps: Cutting Tool Wear Monitoring Sensor

I-Corps项目的更广泛/商业影响包括探索切削刀具磨损监测传感器的商业潜力。刀具制造商、机床制造商和数控机床运营公司可以通过改进刀具生产工艺和节省生产所需的刀具时间而潜在地受益。有一个潜在的不断增长的工业客户需要准确、精确、廉价地检测和诊断刀具磨损、损坏和/或刃口质量。然而，市场上很少有可靠的仪器可以满足所需的精度、分辨率、成本和机器上的使用。提出的传感器允许高分辨率的监测和边缘质量诊断，通过提供定量的形态学信息，包括刀具边缘质量和磨损相关的磨损，磨损和切屑。这个I-Corps项目弥合了最先进的仪器技术和切削刀具检测方法之间存在的知识差距。现有的方法通常不能提供一种定量的措施，以方便和及时/经济有效的方式监测精密切削刀具的健康状况。该项目开发的刀口干涉仪通过提供包括磨损、磨损和切屑在内的形态特性的定量信息，可以对刀具的磨损进行精确测量和监测。该项目实现了一种新的切削刀具磨损监测范式，在仪器和表征方面产生了新的知识。该研究将为精密刀具提供一种新的变革性磨损诊断原理，以提高制造可靠性和自动化程度。该奖项反映了美国国家科学基金会的法定使命，并通过使用基金会的知识价值和更广泛的影响审查标准进行评估，被认为值得支持。

The broader/commercial impact of this I-Corps project involves exploring the commercial potential of cutting tool wear monitoring sensors. Cutting tool manufacturers, machine tool manufacturers, and CNC machine operating companies can potentially benefit through improved cutting tool production processes and saving tooling time needed for production. There is a potential growing industrial customer need to accurately, precisely, and inexpensively sense and diagnose cutting tool wear, damage, and/or cutting edge quality. However, there are few reliable instruments available in the market with the required accuracy, resolution, cost, and on-machine usage. The proposed sensor allows for high-resolution monitoring and diagnosis of edge quality by providing quantitative information on morphological properties, including tool edge quality and wear related to abrasion, attrition, and chipping.This I-Corps project bridges a knowledge gap existing between the state-of-the-art instrumentation technologies and cutting tool inspection methods. Existing methods do not typically provide a quantitative measure to monitor the health of precision cutting tools in a convenient and time/cost-effective manner. The knife-edge interferometer developed in this project allows for precision cutting tool wear measurement and monitoring by providing quantitative information on morphological properties including abrasion, attrition, and chipping. This project enables a new cutting tool wear monitoring paradigm, producing new knowledge in instrumentation and characterization. This research will create a new transformative wear diagnosis principle for precision cutting tools to improve manufacturing reliability and the automation process.This award reflects NSF's statutory mission and has been deemed worthy of support through evaluation using the Foundation's intellectual merit and broader impacts review criteria.