Innovative Optical Monitoring System for Performance Assessment of Cutting Tools

ABSTRACT: To address the Air Force need for in-process monitoring of machine tool wear, Physical Optics Corporation (POC) proposes to develop an Innovative optical Monitoring system for Performance Assessment of Cutting Tools (IMPACT). This proposed system is based on a new design that uses POC-developed mature components and commercial off-the-shelf components. The innovative strategy for isolating vibrations of interest will enable the system to determine the condition of cutting tools during the course of routine production. As a result, this system enables the end user to replace or refurbish worn cutting tools before performance falls below the required work piece quality requirements. This directly addresses the Air Force Research Laboratory"s (AFRL"s) requirements of periodic production tool inspection. In Phase I, POC will demonstrate the feasibility of IMPACT by correlating machine part quality with the measurable outputs of our sensor system. In Phase II, POC plans to develop a prototype system to show how the approach solves the problem in a production-relevant environment. BENEFIT: In addition to the fabrication of military aircraft, the IMPACT system will find application in parts machining for commercial aircraft, shipbuilding, the automotive industry, and other industries in which automated quality control of the machining process will deliver the benefits of cost reduction and performance improvement. This system will enhance production quality and yield by maintaining the optimal machining conditions and helping ensure the timely replacement of cutting tools. The proposed system will also reduce manufacturing costs by reducing material waste on failed parts as well as reducing manpower and resources required for cutting tool maintenance.