- Milling of sleeves
- Turning (cast and rough parts)
- Turning (Aluminum)
- HPC milling cutters
- Rotary transfer machine
- Spiral bevel gears
These are only a few selected examples ... do you want to know more?
at milling of sleeves
(back to overview)
Getrag Ford Transmissions GmbH,
Monitoring taskIn manufacturing of transmissions the sliding sleeves run through a lot of procedures until final completion. For example the gear cutting of the sleeve is subject to a slight milling (groove) done by means of a two-edged milling tool.
In the past it happened that one cutting edge of the tool broke off resulting in an incorrect performance of the milling process and consequently in production of scrap.
was confirmed that the applied measuring
technique is perfectly suited for a continuous monitoring of milling on the manufacture of sleeves.
The measuring signals are representing the process clearly and interpretably and have a very good accuracy of repeats.
While plunging the grooves, which is done by using the same multi-purpose
tool, an increased wear of the cutting
edge arose that was detected and monitored
reliably by means of vibration measuring technique.
Tool breakage detection in turning of cast and forged parts (initial cut)
PROMETEC's Dynamic Limits are the best solution for tool breakage detection in turning of cast and forged parts.
The part to be machined - e.g. a brake disk, a flywheel, a sprocket blank or a train wheel - is out-of-roundness, has an undulating material surface with pronounced hardness fluctuations in its outer surface and can only be clamped off-center. So the force signal detected by the sensor shows strong fluctuations:
1. Pronounced signal fluctuations
The animation displays pronounced fluctuations in the force signal:
Where should the feed stop limit be placed? (see the following segment)
2. Static Limit: faulty breakage detection
If a Static Limit for breakage detection is placed at for e.g. 160%, this could cause false alarms and unwanted switch-off of the workpiece feed due to the natural signal fluctuations:
Where should the limit be placed now? Higher? This would render the breakage detection unusable. Lower? This would create even more false alarms. The perfect solution in this case are:
3. Dynamic Limits
The Dynamic Limits (in combination with fast force sensors) are continuously adjusting to the measured signal and therefore tolerate dynamic signal changes. Adjustment of the Dynamic Limits takes place within cycles of milliseconds and thus several times within a single workpiece rotation.
The unexpected extreme signal peak (for example a harder area in the material or an extreme material allowance, see arrow) is tolerated and no false alarms are generated. The machining process is not interrupted!
4. Dynamic Limit in case of breakage
What will happen when an actual breakage occurs? A sudden signal change, typical for breakage, changes the behavior of the
Dynamic Limits - they are are violated and „freeze“ immediately - right where they were:
A fast analysis for atypical breakage signal profile occurs: only if an actual tool breakage happened, the workpiece feed of the machine is stopped, a different analysis(like hard spots, cut interruption etc.)will not stop the machining!
Dynamic Limits need
minor operating expense only, more than 95% of the breakage events in turning of cast or forged parts are detected. Extremely few false alarms (typical: 1 per shift/week) are generated.
Turning of pistons
Breakage Monitoring in Lathes,
Piston manufacturing (Aluminum)
Machining Car and truck pistons
Machining - Monitoring Task Especially turning the bottom hole may cause a chipping jam, leading to tool breakage. The pure software solution PROSIN is used for tool breakage monitoring and as a protection against static overload.
Monitoring Function The monitored drive current signal exceeds an overload limit in case of the jam mentioned before – PROSIN switches off the machine in time and activates a warning light via NC digital output. The user is able to react immediately and thus reducing the idle times to a minimum. Furthermore machine and tool holder are damage-protected by PROSIN.
Amortization Because of the replaceable cutting insert’s low cost a detroyed tool is not much of a problem here. But the chances are that any tool breakage not detected in time will lead to a secondary damage of tool holder and turret head. The resulting repair costs and the loss of production make for an Amortization of PROSIN at the first tool breakage!
Bedienerakzeptanz According to the users at Kolbenschmidt PROSIN permits an effective value, because the software solution can be used to full extend due to its plausible concept and its simple operation. Especially today’s multi machine operation makes a powerful and easy-to-use (almost self-explaining) tool monitoring solution a must-have, to ensure a secure and economic production.
Source: KS Kolbenschmidt GmbH, Neckarsulm
Profilating, Polygon turning unit for castle teeth machining
Breakage detection at Profilating
User data Wera Profilator, Wuppertal
Process/Problem Manufacturing of the annulus gears of automatic gearboxes.
Tool Polygon turning unit for castle teeth machining. One cutter head with five cutting edges and five internal broaching tools is used for this manufacturing process.
Specialities of installation Here a vibration sensor and the algorithm Peak Analyser I² are used, allowing for a safe and complete monitoring of breakages on the cutting inserts of the cutter head.
Conclusion Commissioning of the PROMOS-2-System on Profilator machines lead to process safety as desired and enabled a 100% in-process detection of tool breakage.
HPC Milling Cutters
of HPC milling cutters, valve manufacturing
Monitoring solutionIn collaboration with Bürkert company (in charge of the project: Mr Hlawatschke)
The final cut triggered the overload limit of spindle 2 at the start of the cut and stopped the machine instantly, resulting in a low work value of both spindles.
Conclusion Wear monitoring was possible on this tool. The development of the monitored values corresponds with the tools’ condition. A large variation of the values, because of the work piece fluctuations or material variations is unlikely, as the
cutting conditions are very stable.
Rotary Transfer Machine (oil pan/tooth belt tensioner)
Breakage Monitoring in Rotary Transfer Machine
Machining of the oil pan
The pure software solution PROSIN is used for drill breakage monitoring for protection of the successional tool as well as for monitoring the milling processes as an overload protection.
Machining of the tooth belt tensioner Regarding drill breakage monitoring and overload protection the same applies as for the oil pan.
Advantage user acceptance According to the users at Stoeferle PROSIN permits an effective value, because the software solution can be used to full extent due to its plausible concept and its simple operation.
ConclusionIn today’s multi machine operation PROSIN makes for a powerful and easy-to-use (almost self-explaining) tool monitoring solution to ensure a secure and economic
Machining of spiral bevel gears
Tool wear detection at
machining of spiral bevel gears
Machine Gear hobbing mill for spiral bevel gears
Workpiece spiral bevel gears, steel
MachiningThis application should prove the applicability of the PROMETEC Real Time Compact Monitor (RTCM) with vibration sensor VBS 50 for monitoring of hobbing processes.
Results The following image displays the I2 Mean values of 381 machinings.
Conclusion The PROMETEC PROMOS 2(RTCM) System provides the ideal possibility to safely detect the end of
life of gear hobbing mills. Thus, several interesting
and quantifiable economical advantages arise.