A tool wear sensor for circular saws using wavelet transform signal processing

Universality and usefulness of the tool wear index developed by the wavelet transform of a circular saw is discussed in this paper. Cutting tests were carried out on an NC-router under various cutting conditions with three types of circular saws and particleboards that are commercially available. A Daubechies wavelet was used for the discrete wavelet transform of the cutting signals. The higher frequency components were investigated with reference to our previous work (Suetsugu et al. 2003). The tool wear index was developed by the resultant wavelet coefficients. The effect of the cutting condition on the tool wear index was then examined to evaluate the usefulness of the wear index. The results are summarized as follows: 1) the tool wear index developed by the wavelet coefficients in the frequency range of 10 to 20 kHz has a strong correlation with flank wear; 2) the signals processed by the high-pass filter and sound pressure levels depend on other parameters such as spindle rotation and number of teeth, except for flank wear; 3) the tool wear index developed by the wavelet coefficients is very useful for developing a health monitoring system for the tool wear of circular saws because it has good linearity and is independent parameters such as spindle rotation and number of teeth, except for flank wear.

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