Intelligent machining technology for online monitoring and control of tool condition: A review

Abstract

The core objectives of intelligent manufacturing are to enhance product quality, reduce production costs, and improve manufacturing efficiency. One of the key technologies to achieve this goal is the monitoring and control of the machining process. Traditional offline tool condition monitoring (TCM) methods are prone to human error and require additional downtime. By contrast, tool condition online monitoring technology enables real-time monitoring throughout the machining process. This study reviews the progress of research on online monitoring of tool conditions and process parameter control based on tool status. It provides a detailed analysis from three perspectives: tool condition perception, algorithms for monitoring and control, and applications of monitoring and control. In terms of tool condition perception, the advantages and drawbacks of various sensing methods are explored. In terms of monitoring and control algorithms, developments from traditional monitoring algorithms to intelligent monitoring and parameter control algorithms are progressively reviewed. With regard to applications, the review focuses on how to adjust process parameters online on the basis of TCM by building on abnormal detection, tool wear monitoring, and life prediction to protect tools and improve machining efficiency. Then, the main development trends in tool condition online monitoring and control are introduced. Unlike previous reviews, this work extends the discussion beyond TCM to include recent progress in process parameter control on the basis of tool condition. The integration of tool online monitoring and process parameter control is recognized as one of the essential technologies for realizing intelligent manufacturing.

Graphical abstract

Keywords

intelligent manufacturing / online tool wear monitoring / tool remaining life prediction / process parameter control / sensor technology / intelligent monitoring algorithm

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