Design of tool life estimation system in the turning process

Abstract

The cutting tools have a critical wear limit. Its life is essential for machining data for usage and tool replacement planning. One of the challenges in planning is the difficulty of real-time tool life estimation before and after usage. Real-time estimation of tool life before and after use is expected to assist the Production Planning and Control (PPC) department in selecting tools based on their remaining life, estimating the number of machined products, and planning timely tool replacements. A system has been designed to estimate tool life before and after usage to address this issue. The outcome of this research is the conceptual design of the tool life estimation system and the interface design illustrating the results. The tool life estimation system consists of five pages with several essential features. Firstly, the login page for user authentication and authority control. Secondly, the main page presents two menu options, namely insert registration, and insert list. Thirdly, the insert registration page is used to register the usage of a new tool based on the tool's identity, machining process, and machining parameters. Fourthly, the insert list page displays a list of registered tools, the estimation of new tool life based on the Taylor equation, and the estimation of remaining tool life. Lastly, the new project and insert history page is used to estimate the number of workpieces that can be processed by the selected tool, estimate the remaining tool life after usage, and display the tool usage history.