Tool Condition Monitoring Of Drill Bit Wear Using Camera For Composite Assembly In Aerospace Manufacturing System

The poor machinability of composite materials makes the tool condition monitoring (TCM) system is highly demanded for the drilling operation in aircraft manufacturing industry. It caused the drill bit to wear faster, reducing the tool life expectancy and increasing the manufacturing cost. It is impo...

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Main Author:	Ramzi, Ahmad Raiminor
Format:	Thesis
Language:	English
Published:	2019
Subjects:	T Technology
Online Access:	http://eprints.usm.my/48469/1/Tool%20Condition%20Monitoring%20Of%20Drill%20Bit%20Wear%20Using%20Camera%20For%20Composite%20Assembly%20In%20Aerospace%20Manufacturing%20System.pdf
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spelling	my-usm-ep.484692021-11-17T03:42:11Z Tool Condition Monitoring Of Drill Bit Wear Using Camera For Composite Assembly In Aerospace Manufacturing System 2019-07-01 Ramzi, Ahmad Raiminor T Technology The poor machinability of composite materials makes the tool condition monitoring (TCM) system is highly demanded for the drilling operation in aircraft manufacturing industry. It caused the drill bit to wear faster, reducing the tool life expectancy and increasing the manufacturing cost. It is important to replace the drill bit on time as the precautionary practice to avoid the expensive composite material from being damaged by the blunt drill bit. Therefore, TCM system provides a compact solution in monitoring, controlling and optimising the drill bit usage which will improve the machining quality indirectly. This research proposed a system to monitor the wear condition of drill bits used in composite machining which includes detection and measurement of wear. The detection concept is basically comparing the image of worn drill bit with the reference image of a brand new drill bit. The changes in the cutting edge region which indicating the amount of wear is measured in term of percentage by using image processing approach. Two samples of drill bits from real industry, FLE 190 and FLE 193 were used in the monitoring system testing. Based on the result, FLE 190 drill bit which is used to drill carbon fibre reinforced plastic - aluminium (CFRP/Al) stacks worn out at maximum flank wear percentage of 24.84 %. Meanwhile, FLE 193 drill bit is considered worn at 19.58 % when drilling glass fibre reinforced plastic - aluminium (GFRP/Al) stacks. The analysis shows that FLE 190 drill bit experienced a faster wear rate at average of 2.12 % per 100 holes while FLE 193 drill bit worn out at slower average rate of 0.46 % per 100 holes due to the different strength of the workpiece. The system is capable to monitor the drill bit flank wear and classify it into abrasive and adhesive wear mechanism. Besides, the illumination technique used enables the system to be used for various drill bit with different height and point angle. The output and contribution of this research proving that the direct optical monitoring system proposed is applicable for the industrial application. 2019-07 Thesis http://eprints.usm.my/48469/ http://eprints.usm.my/48469/1/Tool%20Condition%20Monitoring%20Of%20Drill%20Bit%20Wear%20Using%20Camera%20For%20Composite%20Assembly%20In%20Aerospace%20Manufacturing%20System.pdf application/pdf en public masters Universiti Sains Malaysia Pusat Pengajian Kejuruteraan Aeroangkasa
institution	Universiti Sains Malaysia
collection	USM Institutional Repository
language	English
topic	T Technology
spellingShingle	T Technology Ramzi, Ahmad Raiminor Tool Condition Monitoring Of Drill Bit Wear Using Camera For Composite Assembly In Aerospace Manufacturing System
description	The poor machinability of composite materials makes the tool condition monitoring (TCM) system is highly demanded for the drilling operation in aircraft manufacturing industry. It caused the drill bit to wear faster, reducing the tool life expectancy and increasing the manufacturing cost. It is important to replace the drill bit on time as the precautionary practice to avoid the expensive composite material from being damaged by the blunt drill bit. Therefore, TCM system provides a compact solution in monitoring, controlling and optimising the drill bit usage which will improve the machining quality indirectly. This research proposed a system to monitor the wear condition of drill bits used in composite machining which includes detection and measurement of wear. The detection concept is basically comparing the image of worn drill bit with the reference image of a brand new drill bit. The changes in the cutting edge region which indicating the amount of wear is measured in term of percentage by using image processing approach. Two samples of drill bits from real industry, FLE 190 and FLE 193 were used in the monitoring system testing. Based on the result, FLE 190 drill bit which is used to drill carbon fibre reinforced plastic - aluminium (CFRP/Al) stacks worn out at maximum flank wear percentage of 24.84 %. Meanwhile, FLE 193 drill bit is considered worn at 19.58 % when drilling glass fibre reinforced plastic - aluminium (GFRP/Al) stacks. The analysis shows that FLE 190 drill bit experienced a faster wear rate at average of 2.12 % per 100 holes while FLE 193 drill bit worn out at slower average rate of 0.46 % per 100 holes due to the different strength of the workpiece. The system is capable to monitor the drill bit flank wear and classify it into abrasive and adhesive wear mechanism. Besides, the illumination technique used enables the system to be used for various drill bit with different height and point angle. The output and contribution of this research proving that the direct optical monitoring system proposed is applicable for the industrial application.
format	Thesis
qualification_level	Master's degree
author	Ramzi, Ahmad Raiminor
author_facet	Ramzi, Ahmad Raiminor
author_sort	Ramzi, Ahmad Raiminor
title	Tool Condition Monitoring Of Drill Bit Wear Using Camera For Composite Assembly In Aerospace Manufacturing System
title_short	Tool Condition Monitoring Of Drill Bit Wear Using Camera For Composite Assembly In Aerospace Manufacturing System
title_full	Tool Condition Monitoring Of Drill Bit Wear Using Camera For Composite Assembly In Aerospace Manufacturing System
title_fullStr	Tool Condition Monitoring Of Drill Bit Wear Using Camera For Composite Assembly In Aerospace Manufacturing System
title_full_unstemmed	Tool Condition Monitoring Of Drill Bit Wear Using Camera For Composite Assembly In Aerospace Manufacturing System
title_sort	tool condition monitoring of drill bit wear using camera for composite assembly in aerospace manufacturing system
granting_institution	Universiti Sains Malaysia
granting_department	Pusat Pengajian Kejuruteraan Aeroangkasa
publishDate	2019
url	http://eprints.usm.my/48469/1/Tool%20Condition%20Monitoring%20Of%20Drill%20Bit%20Wear%20Using%20Camera%20For%20Composite%20Assembly%20In%20Aerospace%20Manufacturing%20System.pdf
_version_	1747821935981494272

Tool Condition Monitoring Of Drill Bit Wear Using Camera For Composite Assembly In Aerospace Manufacturing System

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