On-line tool breakage monitoring of vibration tapping using spindle motor current

Input current of driving motor has been employed successfully as monitoring the cutting state in manufacturing processes for more than a decade. In vibration tapping, however, the method of on-line monitoring motor electric current has not been reported. In this paper, a tap failure prediction method is proposed to monitor the vibration tapping process using the electrical current signal of the spindle motor. The process of vibration tapping is firstly described. Then the relationship between the torque of vibration tapping and the electric current of motor is investigated by theoretic deducing and experimental measurement. According to those results, a monitoring method of tool's breakage is proposed through monitoring the ratio of the current amplitudes during adjacent vibration tapping periods. Finally, a low frequency vibration tapping system with motor current monitoring is built up using a servo motor B-106B and its driver CR06. The proposed method has been demonstrated with experiment data of vibration tapping in titanic alloys. The result of experiments shows that the method, which can avoid the tool breakage and giving a few error alarms when the threshold of amplitude ratio is 1.2 and there is at least 2 times overrun among 50 adjacent periods, is feasible for tool breakage monitoring in the process of vibration tapping small thread holes.