Diagnostics and predictive analysis of the wear of a cutting tool when processing on CNC machines

Abstract

This article addresses a significant issue in material processing, specifically the forecasting
of cutting blade tool resources and the development of a novel method to diagnose the criticality of
its technical condition. The concept of resource refers to the period of the tool wear before
resharpening, since the duration of the tool operation, which does not require resharpening, is the
easiest to control automatically.
This article presents the outcomes of research aimed at developing a method for forecasting
the resource of a cutting tool by continuously monitoring the sound pressure level during the cutting
process.
The investigation employed system analysis, cutting theory, oscillation theory, and
identification methods through random search. The study focused on analyzing the dynamic
behavior of the metalworking technological system as the cutting tool undergoes wear.
The research resulted in the development of a forecasting method for the cutting tool resource.
This method involves identifying parameters of a forecast model based on continuous monitoring of
the sound pressure level during the cutting process. Moreover, the model is compiled in such a way
that the sought-after resource is included in its mathematical structure, eliminating the need for
statistically unreliable criteria parameters when making forecasts about the limit state of the tool.
This article presents a novel model for forecasting the technical state of technological
systems, enabling estimation of the resource of both the tool and the technological system as a
whole. Knowledge of the system resource facilitates the implementation of adaptive management,
preventing unforeseen interruptions for tool replacement or machine repair, and minimizing the risk
of workpiece omissions. The developed automated predictive and diagnostic complex facilitates the
practical application of the proposed forecasting model across a wide range of material processing
scenarios. This advancement addresses a crucial scientific and practical objective of enhancing
cutting process efficiency.