Tool wear compensation scheme for DTM

Abstract

This paper is aimed to monitor tool wear in diamond turn machining (DTM), assess effects of tool wear on accuracies of the machined component, and develop compensation methodology to enhance size and shape accuracies of a hemispherical cup. In order to find change in the centre and radius of tool with increasing wear of tool, a MATLAB program is used. In practice, x-offsets are readjusted by DTM operator for desired accuracy in the cup and the results of theoretical model show that change in radius and z-offset are insignificant however x-offset is proportional to the tool wear and this is what assumed while resetting tool offset. Since we could not measure the profile of tool; therefore we modeled our program for cup profile data. If we assume no error due to slide and spindle of DTM then any wear in the tool will be reflected in the cup profile. As the cup data contains surface roughness, therefore random noise similar to surface waviness is added. It is observed that surface roughness affects the centre and radius but pattern of shifting of centre with increase in wear of tool remains similar to the ideal condition, i.e. without surface roughness. © Published under licence by IOP Publishing Ltd.