~ )P e r g a m o n

Int. J. Maeh. ToolsManufaet.Vol. 36, No. 6, pp. 687-711, 1996

Copyright~ 1996ElsevierScienceLtxl
Printed in Great Britain.All rightsreserved
0890--6955/96515.00 + .00

0890-6955(95)00058-5

TOOL CONDITION MONITORING IN DRILLING USING

VIBRATION SIGNATURE ANALYSIS
T. I. EL-WARDANY,t D. G A O t and M. A. ELBESTAWIt
(Received 25 January 1995; in final form 15 May 1995)

Abstract--This paper presents a study on monitoring tool wear and failure in drilling using vibration signature
analysis techniques. Discriminant features, which are sensitive to drill wear and breakage, were developed
in both time and frequency domains. These features were found to be relatively insensitive to cutting
conditions, and sensor location. In the time domain, a monitoring feature based on calculating the kurtosis
value of both tlae transverse and thrust vibrations, was found to be rather effective for on-line detection of
drill breakage. On the other hand, in the frequency domain, a cepstrum ratio, derived from the spectra of
the vibrations monitored in both directions, was also found effective in detecting breakage events. The effect
of different types of wear on the vibration power spectra, in both the transverse and the thrust directions,
was also investigated. A signature feature, namely the instantaneous ratio of the absolute mean value
(RAMVI), was developed in this study and used as a threshold for controlled capture of the vibration signal.
The ability of the monitoring features to detect drill wear and breakage was verified experimentally. The
drilling tests were performed using 3 and 6 mm diameter high speed steel twist drills, and cast iron workpieces.
The results confirmed the effectiveness and robustness of the proposed monitoring features. Copyright ©
1996 Elsevier Science Ltd

1. INTRODUCTION

Drilling is a widely used machining process; it represents approximately 40% of all

cutting operations performed in industry. Typically, twist drills are used in a diameter
range from 1 to 20 mm. In general, the failure of a twist drill occurs by one of two
modes; fracture or chipping and excessive wear. Experiments performed by Thangaraj
and Wright i[1] indicated that under normal cutting conditions, failure due to fracture
was observed with small size drills (--- 3 mm diameter), while excessive wear was the
dominant failure mode with large size drills ( > 3 mm diameter).
Drill wear and breakage have a direct influence on the dynamic characteristics of
the drilling process [2]. A worn drill generates vibration signals indicative of the drill
conditions [3]. The vibrations can cause the drill to "wander" from its true center or
they may result in a tapered or oversized hole. These defects are of particular importance
for high speed precision drilling. Such a process is common in the aircraft industry (e.g.
machining of aluminum alloy parts), and in the automobile industry (e.g. machining of
cast iron parts). Untended automation of drilling operations requires the development
of reliable methods for on-line sensing of cutter breakage and wear.
Several sensing techniques have been reported in the literature by various investi-
gators who dealt with the issues of detecting edge chipping, fracture, wear, and poor
hole quality. These techniques include touch sensors, power, acoustic emission,
vibration, torque and/or thrust force, and vision systems. Statistics related to the
application of various monitoring methods in machining are shown in Fig. 1 [4]. As
shown in the figure, touch probes are often used to detect drilling faults. Although
these types of probes are generally reliable, their range of application is rather limited
in several respects [5]. Power monitoring was reported to be approximately 80%
successful in detecting drill conditions [4]. This type of monitoring requires measure-
ment of the spindle motor armature current and voltage. Measurement of the spindle
speed is also required to calculate the corresponding torque. In this case, the monitoring

tlntelligent Machines and Manufacture Research Center, Mechanical Engineering Department, McMaster
University, 1280 Main street West, Hamilton, Ontario, Canada LSS 4L7.

687
688 T . I . El-Wardany et al.

15
14
13
12
o 11

Fap
"" 9
~ s
~ 7
,~ 6
= 5
Z 4

0
Load Image Proximity Work Touch Torque
amperage Processing Switch Sensor Sensing
Vibration Ring Tool Touch Acoustic Size
Sensor Sensor Sensor Emission Measuring

Fig. 1. Different monitoring methods for detecting edge chipping, tool fracture, tool wear and poor hole
quality [4].

system establishes a "tare" torque from the no load condition, and subtracts it from
the total torque calculated. The disadvantage of this monitoring technique is the
measurement bandwidth which is limited by the motor inertia. Also research performed
by Matsushima et al. [6] to detect tool failure in turning by measuring the power
reported a delay of 100-300 msec. An eddy current sensor installed on the drill shank
was used by Birnksmire [7] to measure the average torque, and to detect tool fracture
based on analyzing the dynamic component of the signal. This technique was applied
successfully on drills of 10 mm diameter.
Acoustic emission (AE) was reported to be approximately 33% successful when
used to monitor drill failure [4]. Saijo and Noh [8] monitored drill fracture using AE.
In their work, a large amplitude (spike) in the AE signal was found to be indicative
of drill fracture. The amplitude of the AE spike was strongly dependent on the fractured
area of the drill and its position [9]. The major difficulty in AE monitoring is the
development of appropriate filtering techniques and algorithms to separate useful signals
from background noise generated during the drilling process. In addition, problems
associated with transducer mounting and path dependency of the signal have also been
reported [4].
Monitoring thrust force-torque to predict drill failure has been widely used and
reported by several investigators [10-12]. The advantage of this technique is the
sensitivity of the thrust force-torque signals to changes in the drill conditions. Thangaraj
and Wright [12] used the rate of change of thrust force in predicting drill failure. This
rate of change was reported in their study to be independent of the cutting conditions
and the drill, geometry, which facilitate the use of a prespecified threshold to detect
drill failure.
Sensor fusion methods were used by Liu and Wu [13] for monitoring drill wear. In
this investigation both the thrust force and axial acceleration signals were used. A
fuzzy pattern recognition technique based on measuring the thrust force and torque
was used to monitor drill wear [14]. Subramanian and Cook [11] emphasized that drill
condition monitoring using the thrust force and/or torque was effective only when a
close tolerance on the workpiece hardness was maintained (about 5%). Neural networks
were proposed for the detection of tool failure in micro-drilling operations [15]. This
was done by encoding thrust force signals with wavelet transformations and classifying
 Vibration Signature Analysis 689

the estimated coefficients using adaptive resonance theory. This technique was rather
difficult to apply in situations involving small signal-noise ratios.
Vibration monitoring techniques applied to the detection of drill failure have been
reported by several investigators [2, 3, 16-18]. The advantages of these techniques
include ease of implementation and the fact that no modifications to the machine tool
or the workpiece fixture are required. However, the disadvantages reported in the
literature include dependency of the vibration signals on workpiece material, cutting
conditions, and machine structure. Clearly, additional research is required to develop
practical vibration monitoring techniques which are sensitive to tool conditions but
relatively insensitive to cutting conditions, sensor location, etc.
The present work deals with the development of vibration-based monitoring methods
for detecting breakage of small size drills (3 mm diameter) and wear of larger size
drills (6 mm diameter). The characteristics of the vibration signatures were examined
in both time and frequency domains. Signature features were developed and were
shown to be effective in detecting drill wear and breakage, while insensitive to variations
in cutting conditions. The effectiveness of the proposed monitoring features was verified
from drilling experiments using high speed steel twist drills and cast iron workpieces.
2. CHARACTERISTICS OF VIBRATION SIGNATURES IN DRILLING

Due to production variations, a drill is typically slightly asymmetric. Accordingly,

the two corners of the drill point wear gradually, while maximum wear alternates from
one cutting edge to the other. This alternating process continues until both lips have
zero clearance at the margin. The drill then adheres to the workpiece and breaks if
the cutting process is not stopped in time. A scanning electron microscope image of
a 3 mm diameter drill, which was used in the present investigation, is shown in Fig.
2. It can be seen that corner wear of the cutting lip is the predominant type of wear.
The effects of drill wear and breakage on the resulting vibration signatures are discussed
in the following sections. The vibrations were measured in both the transverse (Y)
and the axial (Z) directions. The vibration signals in both directions contain reliable
features for monitoring drill wear and breakage due to the following:
(a) The vibrating drill length in the transverse and axial modes does not change
during drilling, thus maintaining a rather constant mode frequency [3].
(b) The natural frequencies of the transverse and axial modes of the workpiece-drill
system are basically insensitive to drill cross-sectional size, thus simplifying monitoring
for a wide range of drill sizes.
(c) Vibrations in the directions Y and Z are influenced by the torque and thrust
force which are the major excitation sources in drilling.

2.1. Signature analysis in the time domain

Figures 3(a)-(c) and 4(a)-(c) show typical time domain signals monitored in both
the Z (vertical) and Y (transverse) directions, respectively, at different time intervals
until tool breakage occurred. Drilling was performed at a spindle speed (N) = 3000
rev/min, feed rate (f) = 750 mm/min, drill diameter (D) = 3 mm and for a length
(L) = 15 mm. As can be seen in these figures, the vibration signals can be characterized
as consisting of short oscillatory transients of high, narrow band frequency, occurring
randomly within the period required to drill one hole. With the progress of drill wear,
the amplitude of these transients starts to increase. Immediately before breakage, these
transients resemble those of a resonating system responding to some impulsive excitation
in the cutting process at a frequency which is independent of cutting conditions such
as feed and speed. By far the majority of the vibration signals consist of frequency
components related to the dynamics of the cutting system.
Drill breakage was invariably accompanied by a significant increase in the vibration
amplitude [see Figs 3(c) and 4(c)]. After breakage, the vibration signal was charac-
terized by spikes repeated twice per drill revolution (corresponding to two flutes on
the drill). This phenomenon can be related to the unbalanced forces caused by the
690 T.I. EI-Wardany et al.

Corner Wear

(a) Corner Wear On The Drill Lip

(b) Wear On The Drill Lips

Fig. 2. SEM imagesfor drill wear.

change in the drill geometry, and which subsequently causes the drill to "wander".
During this wandering phase, each broken cutting edge impacts the wall of the hole
and causes a spike in the vibration signature. The significant feature here is that the
vibration signal, after breakage, will manifest a frequency related to the spindle rotation.
This phenomenon occurs also during spindle retraction, and for any drill size.
2.2. Signature analysis in the frequency domain
Figures 5(a) and (b), show time spectral maps for the vibration signals in both Z
and Y directions. Cutting conditions were N---3000 rev/min, f = 750 mm/min,
D = 3 mm and L = 15 ram. As shown in the figures, the magnitude of the vibration
signal in the frequency range of 3-5 kHz increased sharply just before drill breakage.
Table 1 identifies the main natural frequencies of the workpiece-tool system obtained
by impact testing. It is clear that the high frequency components in the vibration signals
observed in Fig. 5(a) correspond to one or more of the natural frequencies of the
machine spindle, while those shown in Fig. 5(b) correspond to the frequencies of the
workpiece-fixture system.
 Vibration Signature Analysis 691
2
Hole#1
1,5
0

"0
= 0,5
o. 0
E
C
-0,5
O

~ -1.5
-2 i. i i
0 0 .9 ' 0:4 0:6 '
0.8
Drilling Time (sec)

a) Sharp Drill

~'1.5 Hole # 5
O

--I
0.5
~. ......... , , L _ tilL,.,
~. 0

, " -r-- ., . . . . lqlT1,-"~' ~'-~ - ,

E .4}.5 i

oq.d -1
¢=

.~ ..1.5
"2' J i I i
o o', 0'.4 o.0 o.0
Drilling Time (seo)

b)Severely Worn Drill

2
Hole # 6 Breakage
~ 1.5
Event
1
0.5
}o
-11.5

-1.5
-2
0 o'.2 ' 0'.4 ' o'.6 ' o'.e
Drilling Time (sec)

c)Drill Breakage
Fig, 3. Vibration measured in Z direction.

Experimental studies performed by several investigators, e.g. Li et al. [10], indicate

that different combinations of cutting conditions result in different patterns and amounts
of drill wear. The various drill wear patterns may change the resulting vibration
signatures in the frequency domain. Therefore, it is important to investigate the effect
of each type .of wear on the vibration power spectra generated during drilling. This
HIH 36-6-C
692 T.I. El-Wardany et al.

Hole#1

0.5
0
~C , 5
0

~ -1.5
-2 o ' o~ ' 0'.4 ' o'.e ' o'.8
Ddlllng Tlme (sec)

a) Sharp Drill

2 I
-~1.5 ¸. I

~ o.s!-
{ol I
~.o.5 ~- !
C :

~ "1i" !
~-1.5 -
"2"
0" 0.2 0.4 0.6 0.8
Orllllng Time (sec)

b)Severely Worn Drill

1.5-

.a,
~ 0,5

b-i
~1"5'
N" ~2
0 0.2 0.4 0.6 0.8
Dr.llng Time (sec)

c)Drill Breakage
Fig. 4. Vibration measured in Y direction.

was accomplished by performing "controlled" wear experiments. In these experiments,

various types of wear were artificially induced on the drill, and the resultinng vibration
spectra were evaluated.
Kanai and Kanda [19] classified the wear on large drills (of diameter - 6 mm) into
several types. These types of wear are: outer corner wear, flank wear, margin wear,
 Vibration Signature Analysis 693

o.3 ............ i'".... ii ill i .....i ......... :....

¢, 0.25- .........iiii ....i...........iiii ............i.......iii......! ii ........i iiili
"~ 0.2-

~ 0.15-

o,. !iiiiiiiii ....

0.05.

0>
6

5000

a) Z Direction

........-''"~"...
'...,. . . .
.....'""

i : ''""
4.
D

.......... i ! .......

1-

0:
6 "
5 .° "",,., . " "'.o .. """ ... "~'~ i
5000
"°~'0,,~_ 3 ~ ~....~"~.. ~ 3000
U~OO~~ 2 " l ' 1000 2000 "G~ t~z~'
e,S' 1 0 t:B¢---O~3Et~

b) Y Direction

Fig. 5. Time spectral maps.

Table 1. Frequency response for workpiece-tool system

Natural frequencies in Y direction Natural frequencies in Z direction

Workpiece and fixture 3504, 4600, 5300 Hz 3740, 4800 Hz

Tool Holder 530, 2627, 3868, 5500 Hz 4512, 5136 Hz
530, 960, 1730, 2120, 3100, 3840,
Spindle 5336 H_z 3872 Hz
694 T . I . El-Wardany et al.

crater wear, and chisel edge wear. These are illustrated in Fig. 6 together with chipping
of the lip. The dominant types of wear which result in drill failure and breakage are:
chisel wear, outer corner wear, flank wear and margin wear. The effect of each of
these four types of wear on the power spectra of the vibration signals will be described
and discussed below.
2.2.1. Vibration spectra in the transverse direction. Figures 7(a)-(h) show examples
of the power spectra of the vibration signals generated in the Y direction during drilling
with various levels of different types of induced wear. The tests were performed at a
cutting speed (V) = 12 m/min, f = 100 mm/min, D = 6 mm and L = 30 mm. Figures
7(a) and (b) show the effect of chisel wear on the vibration power spectra. It can be
seen that for a chisel wear of 0.225 mm [Fig. 7(a)], the power spectrum has two peaks
at frequencies of approximately 3.8 and 4.8 kHz, neglecting the peak existing at a
frequency of 720 Hz which was related to noise from the machine motor. The first
peak was related to one of the spindle modes in the Y direction, while the second one
was related to a workpiece mode in the Z direction. The first peak was damped out
with the increase in chisel wear up to 0.3 mm. However, increasing the amount of
chisel wear to 0.608 mm [Fig. 7(b)] shows an increase in the magnitude of the spectrum
in the frequency range of 4.5-5.8 kHz and a peak at approximately 5.3 kHz. The

'i
amplitude of this peak increased gradually with the progress of wear. As shown in

~u vr2 a) Outer Comer Wear

b Flank Wear

c) Margin Wear d) Crater Wear

Chisel edge

Lip

Outer corner
c) Chisel Edge Wear f) Chipping at Lip

Fig. 6. Types of drill wear [19].

 Vibration Signature Analysis 695

0.0016 I ~ o.oo16 ~............. ! .............................................................. 4 ..............................

•"" 0.0014 .I- ............. r .............. ,............... :............. t~ ............. i .............. ~........... ,,-~0.0014
~,. 0.0012 J,--.-..-.--l.-i .............. i.............. ~............ ti ........... ~............ ~......
,., o.oolf..~..~ ............ i...............i............i! ........... ~.......... 1 ............. ~, o.0o12 I ..............t..............................t...............i...............i : .........~...........
o.ool .............. ~............... i...............r ............. ~............ ~........ T .........
o.oo=f.+~ ............ i...............!...........~ .......... i ...... i ......... ,.o.0oo8 .........]~ .............. ~.............. ~............. i........... !.---r ....
~= o . o o o 6 +---li ............. i............... i .......... -I~ ........... ~ . . . . . . . . ~- . . . . . . . 0.0o06 + - . - - - + . - ............... ~............... ~ .............. ~ ........... ~ - . , . : . - - - b - .....

::::::::::::::::::::::::::::::: _:::: oooo, f

o0oo2 t ~ : , !
ti ................!...............i ............i ..........
............;r:--~~:~-i .....
0
0 1 2 3 4 5 6 0 1 2 3 4 5 6
Frequency(kHz) Frequency (kHz)
a) Chisel Wear = 0.225 m m b) Chisel Wear = 0.608 m m
i
,-,0.0025 i ,-, 0.0025 t ~ ', i i
o.~ ,---~, ..... ~> 0.002
i i i , I
'0.0015 ~" 0.0015 - - - - I
0.001 i
i t I
~. o ooo~ --~@ ! i I ......... i I i 1

0
i = ! ~ ! 0
0 1 2 3 4 5 6 0 1 2 3 4 5 6 7
Frequency (kHz) Frequency (kHz)
c) Corner Wear = 0.49 mm d) Corner Wear = 0.98 m m

~'~ 0.0015
0.002 ]- i

i i 1
i

[
]
~ " 0.0015
;>
°°L !1 1
0.001 t ............! ........... ~ .............r . . . . . . . ~-~---t----I "~" 0.001

0 0
2.! ~_
J I
0 1 2 3 4 5 6 7 0 1 2 3 4 5 6 7
Frequency(kHz) Freauency (kHz)
e) Margin Wear = 0.28 mm f) Margin Wear = 0.824 m m

0.005 0.005 ! ~ ~ i t
~, 0.004 ...........................-..............~............~.............~........... 4.......... ~ o.oo4 ..............~...............,...............t ............~........-r..... -~........
--o.oo~
.......... - ............ !.............. !~............ ! .............. -~ . . . . . . ! ...........
i
~ o 0 . 002 ............. : ............ ~ ............. '- ............ ~ ......... i i

I~ 0.001 " ' " ' - t ...........................................

0 0
0 1 3 4 5 6 7 0 1 2 3 4 5 6
Frequency(kHz) Frequency (kHz)
g) Average Flank Wear = 0. l mm h) Average Flank wear = 0.62 m m

F i g . 7. P o w e r spectra calculated in the Y direction for artificial wear tests.

T a b l e 1, this f r e q u e n c y 5.3 k H z is related to o n e of the w o r k p i e c e m o d e s in the Y

direction.
Figures 7(c) and (d) show the effect of different a m o u n t of corner w e a r on the
p o w e r spectra. A s can be seen, both overall and p e a k p o w e r amplitudes (within the
f r e q u e n c y r a n g e of 2 . 7 - 6 k H z ) increased with the progress of corner wear. Significant
changes in the vibration a m p l i t u d e s were o b s e r v e d only for a large a m o u n t of w e a r
on the tool.
Figures 7 ( e ) and (f) show the data collected w h e n artificial w e a r was induced on
the drill margin. In general, w h e n the m a r g i n w e a r was less than 0.36 m m t h e r e was
no significant change in the vibration signals. H o w e v e r , once the m a r g i n w e a r was
increased to 0.402 m m , a p e a k a p p e a r e d in the p o w e r s p e c t r u m , at a f r e q u e n c y of
a p p r o x i m a t e l y 4.6 k H z . This f r e q u e n c y was related to o n e of the w o r k p i e c e m o d e s in
the Y direction. T h e a m p l i t u d e of this p e a k was f o u n d to increase with the increase
in the level of the induced m a r g i n w e a r , see Fig. 7(f).
Figures 7(g) and (h) show the p o w e r spectra calculated for the vibration signals
696 T . I . El-Wardany et al.

generated during drilling with different values of artificial wear induced on the flank
of the tool. As can be seen in these figures, flank wear excites one mode only with a
peak at approximately 3.9 kHz, which corresponds to one of the natural frequencies
of the tool holder in the Y direction.
The above results show clearly that the vibration signature is rather sensitive to
flank, corner, and margin wear.
2.2.2. Vibration spectra in the thrust direction. Figures 8(a) and (b) represent the
power spectra in the Z direction obtained at different levels of chisel wear induced on
the drill. The cutting conditions were the same as those used for the tests in the Y
direction. The trends displayed are clearly similar to those found in the Y direction.
However, the vibration spectra resulting from corner wear in the Z direction are
different from those obtained in the Y direction. As shown in Fig. 8(c), two regions
with frequency ranges of 3-3.5 and 3.6-3.9 kHz were excited during drilling with a

0.0016 t-~][' ' ~ [ 0.0016 t , I •

o.oo14 ;.............
! ............ i............
i...........
i.........
i .-. 0,0014 t...... I ........ i ...........~"........-F-----
,'-- ..........
3, o.oo12 _--!---i .........-t~ ......
o.oo, =================================
0.0oo6
:::::
1 i-2-1111111111112 TT-_ ..... . ......
i 0.001
0.0008 ___r
0.00o6 __F___~ ...... !
,
I l
:
-r . . . . . -r--

......
,'~.~
I
.... ~_....~ ...... ,
I

0.0o04 -i~ T...... i .......... i................ ,r---t--- ~2 0.0004 . 1-1--4 ..... i _ ~

0.00020 i.-'i--["-[-i . ~ . .~ . . o.0002 Z . k L .. ~ ~ Y E / - ~
0
0 1 2 3 4 5 6 0 1 2 3 4 5 6 7
Frequency (kHz) Frequency (kHz)

a) Chisel W e a r = 0.225 m r n b) C h i s e l W e a r = 0.608 r a m

0.006 0.006 i I I
~ 0.005 L 0.005 t
3 " 0.004 ~o.~ ~ I;

'LI
I I
o.~
~ .0.002
0.11111 ='o.ool _~1 t ~k -~ I
0
1 2 3 4 5 6 0 1 2 3 4 5 6 7
0
Frequency (kHz) Frequency (ld-lz)

c) C o m e r W e a r = 0.49 m m d) Comer Wear = 0.98 mm

0.0o5 I ' i i i I
0.005 ! I
~".~^,
u.u~
, " _U_. U^U/~
l
t---l---'i
i

_.j~. . . . .
i

i
....... " - i - - - I
I

~
t ....

~
!__
- = -V--1
Jf - - - ~ - - - I I
! i

I "-" 0.003 J
!=
t-- t ........... 1. . . . . "1 .....
t. " ' ~ ~ | t J =
o 0 002 / I 1 I , ~ ~-----I
o ,l .... i . . . . L I i - - t .... r-i 0.001 - - 4 -
0 L~..-! _^
0 1 2 3 4 5 6 7 0 1 2 3 4 5 6
Frequency (kHz) Frequency (Id-lz)

e) M a r g i n W e a r = 0.28 m m f) M a r g i n W e a r = 0.824 m m

0.005 |' . ; i ~
,-., 0.005
"-" o.~, ..........~i....... ~~........ ~..... t-----~= ...... l I, ~, 0.004 1 1 1 i /
----~--- ,-----~.----I,-----1~
3"- o0o~t ........ ~............i ......... ! ...... i ....... ~ ...... "--.1 ' ~ 0.003

, ........i I i! 1 ~ o.~ | 1
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
0

~ 0.~1-
^t,,, , ~ I .ui i i
u - : . : -: ~ . i !
0
0 1 2 3 4 5 6 7 0 1 2 3 4 5 6
Frequency (kHz) Frequency (kHz)

g) A v e r a g e F l a n k W e a r = 0.1 m m h) A v e r a g e F l a n k w e a r = 0.62 m m

Fig. 8. Power spectra calculated in the Z direction for artificial wear tests.
 Vibration Signature Analysis 697

tool that had a comer wear of approximately 0.45 mm. Figure 8(d) indicates that the
power amplitude in these two regions increased with the progress of wear. The increase
in corner wear causes the amplitude of vibrations in the frequency range of 3.0-3.5 kHz
to increase gradually. An almost identical trend was seen in the signal produced in the
Z direction by the various values of margin wear [shown in Figs 8(e) and (f)].
The data collected to study the effect of the flank wear are shown in Figs 8(g) and
(h). As in the Y direction, the vibration amplitude increased for higher values of flank
wear. Howew:r several modes were excited in the Z direction. These modes occur in
frequency ranges between 3.5 and 4.4 kHz, 4.5 and 5.1 kHz, and 5.3 and 5.7 kHz.
In general the vibration signals measured in the Z direction were predominantly
affected by corner wear and margin wear. Flank wear and chisel wear have similar,
but lesser effects on the vibration spectra. The results show clearly that the vibration
spectra can be used to identify worn drills. Various types of information may be
extracted from the analysis of the vibration signals in both the time and the frequency
domain.

3. THE PROPOSED MONITORING METHOD

This section proposes monitoring features in both the time and frequency domains
which are based on the vibration signature characteristics as revealed above.

3.1. Development of time domain monitoring feature

The vibration signals measured during drilling were highly non-Gaussian and nonlin-
ear. In an attempt to quantify objectively these results, the vibration signals were
further evaluated by means of statistical analysis means. The kurtosis value is useful
in identifying transients and spontaneous events within vibration signals. The kurtosis
value of a time series is defined as the fourth central moment of a Gaussian distribution
and it is a measure of its peakedness. The calculated kurtosis value is typically nor-
malized by the square of the second moment, as follows:

1 '=." (x,
K = ~/xz~, (1)
i=1

where xi is the instantaneous amplitude of the vibration signal, :t is the average vibration
amplitude, 0-2 is the variance of the signal and N is the number of samples.
Computer simulation runs were performed to examine the sensitivity of the kurtosis
value to sudden impulses (or spikes). Figure 9 shows that the kurtosis value for a sine
wave is 1.5. "]?his value is constant irrespective of the signal amplitude or frequency.
The kurtosis value varies significantly when a single spike is introduced to the simulated
sine wave as ,~hown in Fig. 10. In this figure, the higher the ratio of A/B, the larger
the kurtosis wtlue. Increasing the number of spikes introduced in the simulation, while
keeping the ratio A/B constant, reduces the kurtosis value as shown in Fig. 11.
The above simulations show clearly that the kurtosis value is rather sensitive to the
occurrence of a single spike or an impulse in the vibration signal. However it is also
sensitive to the generation of a number of these spikes, which tends to reduce its
magnitude as compared to the situation for a single spike.

3.2. Development of frequency domain monitoring features

3.2.1. Monitoring drill breakage. Spectral analysis of the vibration signals can be
used for detecting drill breakage, as shown in Fig. 5. However, the risk of a false alarm
is rather high. This is because spikes generated during drill breakage are attenuated by
the averaging procedure used in the calculation of the power spectrum. As an alternative
approach, cepstrum analysis is used to identify a series of harmonics or side bands in
the power spectrum and to estimate their relative strength.
The cepstrum is defined as the inverse Fourier transform of the logarithm of the power
698 T . I . El-Wardany et al. r

40,
No. Sl~klm ~ None
- 1.499985
30-

20

~ o

~-10

-20

I I I I i I
0 1 2 3
Tlme (seconds)

a) No Spikes, kurtosis = 1.499

4O

3O

2O

~10
0
'13
= 0
n

~-10

-3O

0 1 2 3 4
Time (seconds)

b) No Spikes, kurtosis = 1.499

Fig. 9. Kurtosis for sine waves.

spectrum. Using the terminology ~{ } to indicate the forward Fourier transformation of

the bracketed quantity, the definition of the cepstrum is:

C (N) = $;-' {log F=(f)} (2)

where the power' spectrum of the time series fx(t) is given by: •

F=(f) = I~ U',,(t) }1~. ,(3)

N is the value of nAt, where At is the sampling interval, and n varies from 0 to 1023.
The variable f represents the frequency KAf (where Af is the line spacing in the
 Vibration Signature Analysis 699

4O
L~ -,-m I

20'
I A
10
O
"O 1
O.

~,-10

-20

-30

-40

a) Number of spikes = 1, kurtosis = 147.1

3O
i
I

I . l l , i , i l l | l u l i l l u ,liiJ *U n i l i l i i i l l l i i U i l i ~ l l U ilUiiilu liil lilliilllUilliiiilU UlililjU "I".

"0
0 m||||fl~ll|fl~lllll|lTfl~lHlllllWHWlflll~r IV| , U ~ l l l l l | l I l l H l l l ' ' l U | l l w v ' ' l ' l ' ' ' " ' v w ' H ' I

~,-10

, a i ,, & I I I

0 2 3 4
Time (seconds)

b) Number of spikes = 1, kurtosis = 38.25

Fig. 10. Effect of the ratio A/B on the kurtosis.

frequency spectrum) and in principle K also varies from 0 to 1023. The unit of the
cepstra abscissa (Quefrency) is 1/I-lz or second, and the position of the first peak
corresponds to the reciprocal of the spacing of the side bands or harmonics in the
power spectrum.
Figure 12 shows examples of power spectra and cepstra calculated from vibration
signals measured during a normal drilling process and during drill breakage. The
cutting conditions used in this set of tests were N = 3000 rev/min, f = 750 mm/min,
L = 15 mm and D = 3 mm. Spikes generated after drill breakage, as described earlier,
create a series of side bands in the power spectrum, as shown in Fig. 12(c). The
spacings between these side bands in the power spectrum will be represented by a
700 T. I. EI-Wardany et al.

40

3O

2O

+o

t.1: i" 0

.10

,2O

i i i i i ,
4O
o ; 2 ; 4
Time (.eoonds) Time (second.)

a) Number of spikes= 2, kurtosis = 74.27 b) Number of spikes = 20, kurtosis = 7.49

40

3O

2O

i
'_.j
-20

J i i i L J i i
o ' + ' +, s 4 - 0 1 2 3 4
TIrne (~onds) Time (seconds)
c) Number of spikes = 2, kurtosis = 33.95 d) Number of spikes = 20, kurtosis : 6.94

Fig. 11. Effect of number of spikes on the kurtosis.

series of peaks in the corresponding cepstrum, as shown in Fig. 12(d). The cepstra
calculated according to equation (2) vary considerably from one hole to another.
However, the cepstra calculated for the signal measured during drill breakage [see Fig.
12(d)] showed consistently a peak at a Quefrency related to the time of one spindle
revolution. This phenomenon was observed in all drilling tests performed for detecting
breakage in this investigation.
Monitoring the existence of a peak in the cepstra corresponding to the time of one
spindle revolution can be used as an index for detecting drill breakage. However, a
significant improvement to the sensitivity of this technique can be obtained by calculat-
ing the ratio of the cepstra generated in the Y and Z directions. This technique will
be discussed further in section 5.
3.2.2. Monitoring drill wear. The vibration signals measured during actual drilling
were examined and compared to those determined from the controlled wear signals.
The vibration power spectra measured in both the Y and Z directions, at different
states of drill wear, are shown in Figs 13(a) and (b), respectively. Drilling was performed
at cutting speed ( V ) = 12 m/rain, feed rate ( f ) = 100mm/min, drill diameter
(D) = 6 mm and for a length (L) = 30 mm.
When the drill used was sharp, none of the significant vibration modes were excited.
After six holes were drilled, the tool was examined under an optical microscope. Plastic
deformation on the drill flank as well as chisel wear were found to exist. The peaks
in the spectra occurred at 3.9 and 5.3 kHz. Recalling the artificial wear testing, it can
be seen that the peak frequency of 3.9 kHz, in the Y direction, corresponds to the
mode that is excited by flank wear. Similarly, the 5.3 kHz frequency is one of the
modes that is excited by chisel wear. Therefore, it can be concluded that these peaks
were a direct result of the amount of wear on the drill.
These types of wear continued until 21 holes were drilled. At this point, it was
observed that corner wear began to develop on the tool. This was accompanied by a
 Vibration SignatUre Analysis 701

o.oo,OO,o o
'

~0
.

!
.

1ooo
.

1~
.

2000
I
.

2so0
.

300o
.

|
.

-_

3500
.i _~1_i

4o00 ~ ~o
Frequency (Hz)

a) Power Spectrum for Vibration Signal Measured During Drilling Hole No. 1
().0~ | i

n,"
~ 0.04

~0.0~

l).0~

11.01
O

5 10 15 20 ?_5
Quefrency (msec)

b) Cepstrum for Vibration Signal Measured During Drilling Hole No. 1

~, 4 i i i

#.
0 1 1500 2000 2500 300O
Frequency (Hz)

c) Power Spectrum for Vibration Signal Measured During Drilling Hole No. 6
O.05 i i t i i

E"
0 0-04
After breakage
~.~-,0.03

O.02
I.-
03
0.01
O
o; 5 10 15 20 25
Quefrency (msec)

d)Cepstrum for Vibration Signal Measured During Drilling Hole No. 6

N=3000 r/min, f= 750 mm/min, L= 15 mm
Fig. 12. Frequency domain analysis for drill diameter 3 mm.

rather small peak, observed in the power spectrum calculated in the thrust direction,
at a frequency of approximately 3.2 kHz. This frequency was approximately the same
frequency excited by the artificial corner wear.
This pattern continued through the drilling process until hole number 32¢ when a
very large peak occurred at a frequency of 4.5 kHz. The tool was removed from the
machine and examined under the optical microscope, It was found that the margin
wear had increased on the tool: The frequency 4.5 kHz was within the region that was
excited with artificial margin wear.
•Starting from hole number 60, the vibration magnitude increased in the frequency
range of 2.4 kHz to 5.8 kHz. The next significant change in the vibration signals
occurred at hole number 128. As can be seen from the power spectrum corresponding
to this hole, several peaks existed in both the Y and Z spectra. These peaks were
702 T . I . El-Wardany et al.

.,." ...... !........:""i.................. - . .

0., ........ i..... ~ i ........~........~i.... ~l~i ...........~ ......' ......

o.o81 ........ ":.... i ~........i ........, ii.~... i..... ........ i .............. i

" " 5000 6000

t YO/"~',.9 0 o 1000 ~Fi,,~_.Our--

a) Y direction

0.1~

3"
L.

o
o
0.08 -

0.06 -

0.04,

0.02,

211
O:
i!!iiiii!!iii!i!!!iiii!ilii 0 0 f ~ 6 0 0 0

b) Z direction

Fig. 13. Power spectra calculated for vibration signals measured during actual drilling. V = 12 m min -1,
f = 100 mm min -1, D --- 6 mm, and L = 30 mm.

similar to those excited by the different types of artificial wear. Examination of the
tool showed an increase in all the wear types; flank, chisel, comer and margin wear.
The trend found at hole 128 continued, with only the amplitude increasing until hole
number 151. In this case, a peak occurred at a frequency of 4.8 kHz. Examining the
tool revealed a very large built up edge on the chisel edge. No significant changes in
the power spectra were noticed from those corresponding to hole number 128 until
hole number 211, when several peaks of large amplitude were found to exist.
In drilling holes numbered 211-217, it was observed that the fluctuation in the signal
amplitude was quite high. This indicated the onset of tool failure (breakage occurred
 Vibration Signature Analysis 703

at hole number 217). The vibration amplitude fluctuation and increase in the frequency
range was observed in all the tests performed to investigate the effect of drill wear.
Several drilling tests were performed under different cutting conditions and it was
observed that the changes in the frequency spectra were not affected by the variations
in the cutting speeds or feeds.
The power spectrum in the Y direction for hole number 217 has a peak at a frequency
of 5.2 kHz. This frequency exists between the modes excited by the chisel and margin
wear. Since this peak frequency does not correspond to any other natural frequencies
of the sub-systems involved (presented in Table 1), it must therefore correspond to a
natural frequency of the combined driU-workpiece system. On the other hand, several
peaks of small amplitudes existed in the power spectrum of vibration measured in the
Z direction. The frequencies of two of these peaks were similar to those excited by
chisel wear. The peak at the 3.3 kHz frequency corresponds to one excited by the
margin wear in the artificial wear test [see Fig. 8(c)].
Figure 14 shows average wear curves plotted for each of the four wear types measured
during the actual drilling tests. The cutting conditions used were the same as those in
Fig. 13. As ,:an be seen from these wear curves, accelerated wear occurred only on
the chisel edge and the margin of the drill.
The data presented in Figs 13 and 14 show that it may be, and indeed it was, possible
to correlate the drill wear to the resulting power spectrum. However, there are several
important difficulties which should be considered.
(1) Materials such as cast iron are not homogeneous and will affect the amplitude
of the vibration measured, and this may cause false alarms.
(2) As mentioned earlier, tool damage in drilling produces a high level of transient
vibrations (spikes) which are largely attenuated by the averaging procedure typically
used in spectrum calculation, and this makes it difficult to extract a discriminating
feature to distinguish the change in the tool conditions.
(3) Non-uniform hardness of the workpiece material, built up edges, and micro-
cracks can also cause false alarms by increasing the vibration amplitude.
In order to minimize the effects of these difficulties, monitoring the change in drill
condition was performed by averaging the power spectra of the vibration measured
during the drilling of M holes, over which wear development can be considered
negligible [20]. The average power spectrum can be calculated as follows:

1,4
,~ 1.2 0.8
1
o.6
o.8
0.6 ~=
.= 0.4
"~ 0.4
a 0.2
0.2
0 o
0 50 100 150 200 250 50 100 150 200 250
Number of Holes Number of Holes

b)

0.3 0.35 j
o.3 .................... . .................... i ............... ............

.........~..........i : ~ - ! i - ~ o.25 t ....................~ ~ " t ............!.....................

0.2 I
~ 0.25 i 0.2 ' ...............................i......................
-.....................
i......................
0.15
0.1 o.1 t Y ~ ' i .....................~,......................~......................
0.05
~ o
0 50 100 150 200 250 0 50 100 150 200 250
Number of Holes Number of Holes
c) d)

Fig. 14. Types of wear measured during actual drilling test. V = 12 m m i n - l , f = 100 mm min -1, D = 6 mm,
and L = 3 0 m m .
704 T.I. El-Wardany et al.

1
Fav= ~ , F x x ( f ) (4)

where M represents the number of holes produced with negligible wear development.
In this group of tests it was chosen to be 6 at the start of drilling up to hole number
42, then it increased to 10 for holes numbered 42-151. The value of M was then
reduced to 6 until the end of the tool life.
To avoid the effects of random variations in peak amplitudes, the area under the
vibration spectrum was considered as a monitoring feature for drill wear (rather than
using the variation of the peak at any one frequency). The area under each power
spectrum between two different frequencies, namely, fl and f~, was calculated using
the trapezoid method [20];

A = ~-~(Power (fl) + 2 Power (f2) + ... + 2 Power (J~-l) + Power ~l)) (5)

where Af = f/+l = fi"

3.3. Threshold estimation for controlled capture of vibration signal
The insensitivity of the kurtosis value to adjoining spikes may introduce false alarms
during monitoring for drill breakage. In addition, false alarms may occur in detecting
drill wear or fracture using power spectrum or cepstrum analysis. These false alarms
can be related to the generation of spikes, e.g. in the case of new drills wandering at
the start of cut. However, the amplitude of these spikes will always be smaller than
those generated from drill breakage. To eliminate or minimize these false alarms, a
second feature was therefore required in conjunction with either the kurtosis value or
the cepstrum analysis. This feature can be used to trigger the calculation of the kurtosis
value, cepstrum ratio, and average power spectrum. It was called the instantaneous
Ratio of the Absolute Mean Value (RAMV0, and it was calculated for each spindle
revolution, as follows:

AMVi
R A M V i - AMVb (6)

where AMVb represents a base line instantaneous Absolute Mean Value calculated at
the start of the drilling process, and AMVi is the current Absolute Mean Value
calculated at the ith revolution of the spindle.

1 i=N
AMViVb = ~ ~ Ixil (7)
i=1

where x i is the instantaneous amplitude of the vibration signal, and the subscript i V b
means i or b. The ratio RAMVi can be used as a setting index for starting the calculation
of the kurtosis or the cepstra ratio. This index or threshold value can be obtained from
a set of calibration tests, or it can be user-defined based on experience.
4. EXPERIMENTALSET UP
Figure 15 shows the experimental set up used in this study. The drilling tests were
performed using a YAM, 2½-axis, CNC machining center. The tools used were 3 and
6 mm diameter high speed steel twist drills and the workpieces were "as-cast" ferritic
nodular cast iron blocks of 290 x 130 x 41 ram, A series of holes were drilled at feeds
in the range of 0.12-0.37 mm/rev, cutting speeds at 12 and 31 m/min, and depths in
the range of 15 to 30 mm. All experiments were performed under dry cutting conditions.
Cast iron was chosen as the workpiece material in order to study the effect of any
 Vibration Signature Analysis 705

Eric

YAM CNC 5-A Machine spindle

3 mm HSS Twist Drill

/
IMPc I
H I
c m:@li Filter

Fig. 15. Schematic diagram of the experimental set up.

2000................................................... o 2000....................................................
Iii i i il
iiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiii

HoleNumber HoleNumber

a) V=30 nVmin, f=375 mm/min, L = I 5 mm b) V =30 m/min, f =1 I00 mm/min, L =15 mm

"~~Iiiii2000
1000.....................................................
.....................................................
ii! i i i i !! !i!ii~ iq
HoleNumber HoleNumber
c) V=20 m/min, f=375 mm/min, L =20 mm d) V=30 m/mio, f--400 ram/rain, L =20 mm

Fig. 16. Calculated kurtosis values (K) for different drilling conditions using 3 m m d i a m e t e r drill.

variation in hardness on the sensitivity and robustness of the proposed monitoring

techniques, l:',ach workpiece used in the tests was mounted on a special fixture, in
which two accelerometers (type PCB model 308B) were installed in the transverse Y
and axial Z directions. The outputs from the accelerometers were connected to charge
amplifiers (type PCB model 464A), filters, an A / D board, and a PC computer. Sampling
was synchronized with spindle rotation, using an optical shaft encoder mounted on the
machine spindle, which supplied 1024 pulses per revolution.
706 T . I . EI-Wardany et al.

5. RESULTS AND DISCUSSION

The proposed monitoring features were evaluated experimentally under various
cutting conditions.

5.1. Failure prediction based on the kurtosis calculations

The R A M V i values were calculated in each test. A threshold value of RAMVi = 5
was used to initiate the calculation of the kurtosis Ky and Kz for each of the vibration
signals measured in both Y and Z directions, respectively. In each direction, the number
of sampling points per revolution was 200. In all tests performed the vibration signal
in the Y direction was band-pass filtered in the frequency range of 3.5-5.0 kHz, while
the signal in the Z direction was filtered in the range of 2.5-5.0 kHz. Figure 16 shows
sample results obtained under several cutting conditions. For each case, the kurtosis
value (K) which is the product of Ky and Kz was plotted for each hole until breakage
occurred. The kurtosis value (K) im:reased rapidly when the drill was broken. The
same trend was found in all drilling tests. The threshold value of K was set to 100,
for alarm purposes. False alarms due to chip accumulation during drilling were elimin-

...... aAu..il:_ ......

t'
"' .... i

....... r -~r" -1
.!

F I- "
-2
1,1oo I~oo

'nmI~

i) Y Direction ii) Z ~-~ction

............i.......... a) Vibration Signals

i..........!...... ~........i........ o~...Y i ..........i .............

.. ~i....................
.......... i iT"'""~
i...... ! ....~......
..... ' ....

,,, 0.$ .-. .-L ~ ~ ....... i

. . . . . . . . . "" " >, i .......~.

).~ ......... ~ ........... i "~ ,. i......... ~... ~" .i,I ! ; ':..........i........... i ...... ~ i"-..i ..... ~""i
~... .....~.....-:": • i ~ " - : , . !""i.. i o .,
-I' "~,"~J~ i::"~".'""i":"~'~[:" '"[[?:g'"'"-L :;i ........ .'=:L,,[i, "

~ ~ ' - - . . . . ~ ~..:..: . , ......................

o "~" ............ ::::.".:::~II....Y:..,.*~.::II"I.II:::~:. " ~.=.L.. i
_

' ]i!!i; ~?II)::<:!>Y { - ...... ::.-,. ......... , .......... , .... -

) Y Direction ii) Z Direction

b) Corresponding Power Spectra

:LII:II:i.... !

Fig. 17. Vibration amplitude, power spectra, and cepstra ratio for normal drillin~ process, hole no. 3, drill
diameter was 3 m m (results are shown for R A M V t value > 5 only).
 Vibration Signature Analysis 707

ated when setting the RAMVi to 5 for both Z and Y direction. The results represented
in Fig. 16 show that the kurtosis value (K) is insensitive to cutting conditions, or
changes in the: workpiece hardness.

5.2. Failureprediction using cepstrurn analysis

The RAMVi values were calculated for each of the vibration signals measured in Y
and Z directions. RAMVi values -> 5 triggered the start of the cepstrum analysis.
Cepstra were calculated for each of the vibration signals measured in both Y and Z
directions, namely Py and Pz, respectively. The ratio between the cepstra in the Y and
Z directions was then determined. In each direction, the number of sampling points
per revolution, was 200. The number of points (time window) used for calculating the
power spectrum and the cepstra was 1024. Figures 17-19 show the vibration signals in
the time domain as well as the corresponding power spectra, and cepstra ratio (Py/P~).
The drilling conditions used in this case were V = 30 m/min, f = 750 mm/min,
D = 3 mm and L = 15 mm. Figure 17 shows the vibrations measured during normal
drilling for hole number 3. Although the total number of points sampled during the
drilling of an)' hole (in this set of tests) was about 30,000, the cepstra ratio was only
calculated for 2048 sampling points (two time windows), which had RAMVi values

-1
.1 I r',,m~ I r'u,..e

.~ ~i~ wqlvandow:Zlwlndow31window4|
600 900 1~ "26oo m,

i) Y Direction ii) Z d i r e c t i o n
a) VibrationSignals
..... ii •- "., , ....... • -i ¸ ....~
..... i

......... ~......... ~ ::~ 1 ~ ".-. ~ l i~;. |~'--.

...... i::..
.
............ ,~

i) Y Direction ii) Z Direedon

b) CorrespondingPowerSpectra

2 ...... ":'" "

'~y . ° ' s l " ~ [ I . A ~ ...... " . .

T ~ ©w ~ o , ~ I 0 OOe~-'

Fig. 18. Vibration amplitude, power spectra, and cepstra ratio generated by a worn drill (corner wear
0.1 ram), hole no. 4 D = 3 mm (results are shown for RAMVi value -> 5 only).
HTH 36-6-D
708 T . I . El-Wardany et al.

-1
-I

°~
35O S~ 75O

i) Y Direction ii) Z direction

a) Vibration Signals .......~.......................i.......................
.........., i ......~.... :: "~..
2, ...........i i......... ' i ' '-i.. :: ; ......

~.~,~,~. -...............::: : ........ ~.. .....

• "" ~ ~ 2oo0 _.a

i) Y Direction ii) Z Direction

b) Corresponding Power Spectra

• 10 ....... !. :: i • i .: ....

" " '" .... " ., " • i ""~:

~,,~,,~°" 3 ~ ' . . ~

c) Cepstra Ratio ( Py ! P~ ) Calculated From Both Cepstmm Py and Cepstmm P~

Fig. 19. Vibration amplitude, power spectra, and ccpstra ratio generated dm'ing dnll failure, hole no. 6,
drill diameter was 3 mm (results are shown for RAMVi value -> 5 only).

higher than 5. Figure 17(a) shows the vibration signals (in both Y and Z directions)
used in calculating the cepstra ratio. Figure 17(b) represents the corresponding power
spectra calculated from the vibration signals shown in Fig. 17(a). Figure 17(c) shows
the cepstrum ratio calculated from the vibration signals in both Y and Z directions.
The same procedure was repeated when measuring the vibration signals during the
drilling of hole number 4 with a worn tool (average corner wear was 0.1 mm), which
is illustrated in Fig. 18. In this case, the R A M V i allowed calculation of the cepstra
ratio to be performed for four time windows only, as can be seen in Fig. 18(a).
Although the time needed to drill one hole was 1.2 sec, the calculation of the cepstra
ratio was started after drilling for 0.72 sec as shown in Fig. 18(a). Figure 18(c) shows
that a small peak at a Quefrency of 20 msec (corresponding to one spindle revolution)
appears only once in the cepstra ratio calculated from the vibration signal captured in
time window number 2. Figure 19 represents the case when the tool was broken during
drilling hole number 6. Again, the RAMVi allowed the calculation of the cepstra ratio
to be performed during the drilling time of 0.31-0.715 seconds only. As can be seen
 Vibration Signature Analysis 709

0 4000 . . . . . . . .

m breakage

tu %t._ , , I . , l._ .l , . . . . . t
0 5 10 15 20 25 30 35 40 45 50
Quefreney (msee)

(Hole No. 3, V=20 m/min, Time of one revolution=30 msec, f= 375 mm/min, L --20 mm, D =3 mm)

0 2 x 105

t'" d'"
After
"~- breakage
< 1
n" event
t-
oO
n
I
"u°;
0 '
5 'o
1 ;
1 20 ' '
25 3 'o 3'5 40 ;5 fi0
Quefreney (msec)

(Hole No. 5, V=30 m/min, Time of one revolution=20 msec, f= 1100 mm/min, L =15 mm, D =3 mm)

Fig. 20. Cepstra ratio at the breakage event for different cutting conditions.

in Fig. 19(a), three time windows of the vibration signals were processed instead of
the expected 29 time windows. The number 29 was determined from dividing the total
number of points sampled during the drilling of one hole (30,000) by the number of
points (time window) used for calculating the power spectrum and the cepstra, which
is 1024. A peak of large magnitude, at the Quefrency related to the time of one spindle
revolution, appears clearly as a result of drill breakage [see Fig. 19(c)]. Figure 20
shows sample results for the cepstra ratio obtained at different cutting conditions. It
can be seen that the proposed technique is effective for various cutting conditions.
Monitoring of drill breakage using the cepstra ratio is based on the sudden increase
in its value at 1thetime corresponding to one spindle revolution. Therefore, a rectangular
window whose width is about five times the duration of one spindle revolution was
monitored. This proved appropriate for detecting tool breakage. The signals monitored
during drill breakage were affected mainly by the workpiece-spindle resonance, hence,
analyzing the vibration signals up to 5 kHz gave satisfactory results.

5.3. Monitoring of drill wear using the area under the average power spectrum
An R A M V i value of 5 was used to capture the vibration signals in both Y and Z
directions. The number of points used for calculating the power spectrum was 1024,
and 10 data segments were used to perform the averaging process. The power spectrum
was then calculated for each hole. Depending on the number of holes drilled (i.e.
amount of drill wear), the value M was set, and the average power spectrum was then
calculated.
Figure 21 slhows variation of the area under the averaged power spectrum in the Y
direction as a function of the number of drilled holes. As can be seen, these results
showed a trend similar to those observed in Fig. 14.
6. CONCLUSIONS

The development of practical and reliable methods for detecting tool wear and failure
in machining is essential for the realization of intelligent and flexible manufacturing
systems, In this study, the problem of on-line detection of tool failure in drilling
has been studied. Vibration monitoring methods have been developed and verified
710 T . I . El-Wardany et al.

20

15

10

-X--
.l(..
¢1
* -X--
<
- -)(- *

* -1(-

I I I I
50 100 150 200

Number of drilled holes

(V=12 m/min, f=100 mm/min, L =30 mm, D=6 mm)

Fig. 21. Effect of tool wear on the area under the power spectrum curves.

experimentally. The focus of the work was on drills of 6 and 3 mm diameters, used
in conjunction with cast iron workpieces. The main conclusions of this paper are as
follows:
(1) Monitoring vibrations during drilling operation proved useful in predicting drill
wear and failure.
(2) The development of the instantaneous Ratio of the Absolute Mean Value
(RAMVi) was useful in eliminating false alarms, and speeding up the calculations.
(3) Two parameters were selected to detect changes in the pattern of the vibration
signals in the time domain during drill breakage, namely the instantaneous Ratio of
the Absolute Mean Value (RAMVi) and the kurtosis (K).
(4) In the frequency domain, the ratio of the calculated cepstra in the transverse
and thrust directions was used as a monitoring index for detecting drill breakage. The
instantaneous Ratio of the Absolute Mean Value ( R A M V i ) w a s again used to start
the cepstrum calculations.
(5) Monitoring experiments using the small diameter twist drills (3 mm diameter)
verified the effectiveness of both the time and frequency domain methods. Using the
proposed approach for monitoring breakage, it was possible to eliminate false alarms
due to the effect of a sharp drill wandering at the start of the cut. In addition,
experimental evidence showed that changes in the hardness of the workpiece material
had no effect on the proposed monitoring techniques.
(6) The area under the power spectrum curve was used to monitor the wear of large
size drills (6 mm diameter). The RAMVi was used to trigger the calculation of the
 Vibration Signature Analysis 711

vibration powe:r spectrum generated during the drilling of a specified number of holes,
where the change in the wear state was minimum. A good correlation was found
between the power spectra calculated and the tool wear.
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