Tool Life Determination using MATLAB

Published on 03 Jul 2021. Written by Koustubh Prem

In this project we will be determining the tool life of a drilling tool based on MATLAB and using tools of DAQ( Data Acquisition) like accelerometer an impact hammer for detection of force applied on the tool and workpiece from which we use the basic knowledge of MATLAB and LabVIEW for determination of the life cycle of the drilling bit.

The project is focused on to investigate a model for tool life estimation during any kind of operation like drilling based on the relation between the wear progress i.e. speed and time. The equation is valid in the range of optimum operation speed for drilling and even with the depth of cut and will be having two extreme values. The test for this system will be based on factors like speed and acceleration which will give a certain set of results, those results are needed to be compared and at the end will be used to form a common FRF for a certain tool which can be used to find out the force for the real tool operation which will at the end guide us to the tool life. It is also shown that different feed rate and depth of cut values change the location of the two extreme values of the tool life curve. A Matlab model will be developed at the end to determine the tool life equation. at the end of the test, we will compare the theoretical value to the experimental value of the test.

Project Requirements:

DAQ Tool:Data acquisition is a process of measuring any electrical or physical action/signal such as current, acceleration, pressure, or force with a computer. A DAQ system generally consists of sensors, hardware’s for DAQ, and a computer which has programmable software for any kind of requirements. Compared to traditional measurement systems, PC-based DAQ systems make use of the processing power, productivity, display, and connectivity capabilities of industry-standard computers providing a more powerful, flexible, and cost-effective measurement solution.
Impact Hammer:It is a tool which measures the stimulus force. it works in wide varieties of tests generally in structural but is capable to work in wide range of force and frequency operations.
Accelerometer:a piezoelectric accelerometer is used in this system which can easily detect the change in dynamic pulses in any mechanical variables like acceleration vibration and impact like that of impact hammer.

Project Implementation:

The mathematical model of the Tool life problem can be divided into many sections.
First make the proper arrangements and place the accelerometer sensor on the body of the tool.
Hit the tool with an impact hammer and note down the readings.
Once the data is generated u will get a data sheet of it in LabVIEW.
Attach that file in the algorithm written in MATLAB and run the file.
At the end you will get a FRF of the above result use that value to simulate the forces acting on tool in working conditions and determine the impact forces.
Based on these formulations use the Taylor equation for tool life and find the life cycles of the tool on certain loads.

Software Requirments:

MATLAB: Matlab will be required to convert the data of impact hammer and accelerometer that we will be getting in 30000 times which will be within 3 seconds to form a graph plot out the necessary data. it will also be used to write the background code for these operations and codes to apply filters to improve the accuracy of the result.
LabVIEW: LabVIEW will be used to generate the flow of energy from DAQ tool to the data format which will be used by Matlab.

Kit required to develop Tool Life Determination using MATLAB:

Technologies you will learn by working on Tool Life Determination using MATLAB:

Tool Life Determination using MATLAB

Project Requirements:

Project Implementation:

Software Requirments:

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