International Conference on Recent Advances in Mechanical Engineering and Interdisciplinary Developments [ICRAMID - 2014]

Influence of Sensor Positioning in Tool

Condition Monitoring of Drilling Process
through Vibration analysis
Nakandhrakumar. R.S*

Dinakaran. D*

Dept. of Mechanical Engineering,

Hindustan University,
Chennai, India.
rsn_kumar@rediffmail.com

Dept. of Mechanical Engineering,

Hindustan University,
Chennai, India.
dinakaran@hindustanuniv.ac.in

Satishkumar. S

Gopal. M

Dept. of Production Engineering,

Velammal Engineering College,
Chennai, India.
satish_shan@yahoo.com

Dept. of Mechanical Engineering,

SRM University, Chennai, India.
gopal.m@ktr.srmuniv.ac.in

Abstract In this study, the relationship between vibration and

tool wear and also influence of sensor positioning in tool
condition monitoring were investigated during drilling. For this
purpose, a series of experiment were conducted in a CNC
vertical milling machine using drilling cycle. A 6 mm diameter
HSS drill and EN24 as workpiece material were used in these
experiments. The vibration was measured in the transverse
direction of sensor which is positioned on the workpiece with
constant distance from the holes to be drilled for monitoring tool
wear as in previous studies. But, positioning of sensor in a
constant place with equal distance from all holes to be drilled is
not possible for all the workpiece profiles in actual practice.
Experiments show that the distance of sensor from the holes in
drilling affects the vibration signals for the same state of wear. It
shows that the tool wear models presented in previous studies
using acceleration signals are sensor location dependent. This
work presents a Variance amplitude of the vibration signals
received for tool condition monitoring which is the most sensitive
statistical parameter than other statistical parameters such as
Root Mean S quare (RMS ), Exponential, Peak, max-min, mean
and standard deviation. Results showed that there was no
considerable increase in the vibration amplitude of variance until
flank wear value of 0.30 mm was reached, above which the
vibration amplitude increased significantly.
Keywords Tool condition monitoring, Drilling, Vibration
Analysis

I. INT RODUCTION
Machining operations such as turning, milling, drilling and
grinding are extensively used metal removal processes in
industry. The drilling is generally used and also contributing
over 40% of cutting operations performed in industries [1].
However, in practice, tool life is estimated by Taylor equation
and decisions relative to drill tool change time are now greatly
depends on the history of tool wear. As the manufacturing
industries are moved to the automation over th e years,
monitoring of tool wear condition has gained important role in
order to prevent abrupt tool failures. Here the Informat ion on
drill wear state is required to increase the predictive capability
to permit the machine operator to program for tool changing
or regrinding to avoid shutdown of machines and to minimize
scrap or rework. Otherwise drill wear in fluence in the
performance characteristics which results the damage to the

workp iece and somet ime machine may get damaged which
leads to disrupt the automated machin ing operation [2].
Universal TCM system should not only be capable of detecting
the existence of drill wear but should also be able to predict the
status of wear and also should give informat ion on tool failure.
Primarily there are two monitoring methods available; they
are direct and indirect. Direct methods measure the worn area
of the tool directly using optical and co mputer vision systems
etc., provides high measuring accuracy but are very difficult to
use for on-line application and not feasible method in the case
of drilling because the drill is engaged in the workp iece during
drilling, workpiece and chips obstruct the view [3]. In indirect
method, measurement is carried out by parameter correlated to
tool wear during machining process using different sensors
such as the cutting forces, vibration analysis, acoustic emission
and cutting temperature without interrupting the machining
process. Still the development is needed towards reliable and
robust sensor for industrial use. This is mainly due to co mplex
nature of drilling process and lack of tool wear models.
II. LITERATURE SURVEY
In the past three decades, many tool wear condition
monitoring techniques have been investigated in the
manufacturing process using a various sensors for monitoring
the cutting process indirectly including dynamometer for force
and torque, accelerometers for mechanical v ibration, A E
sensor for acoustic emission and current probes for current /
power measurement of spindle [7], feed motors and ultrasonics
[8].
Slavko Dolinsek et al., [2] used the acoustic emission
signals for identifying tool wear and tool breakage in the
turning operation. Their experiments showed that energy
distribution is more with h igher frequencies when the tool gets
breakage. They suggested that these signals are difficult to use
because suitable filtering techniques and algorithms must be
developed to separate significant signals fro m the background
noise generated during mach ining and added that an AE signal
is very sensitive to placement of AE sensor.
El-Wardany et al., [4] used vibration signature analysis
technique for mon itoring tool wear and failure in drilling. They
presented a study using the kurtosis of the time domain and the
area under the power spectrum curve to mon itor variou s types

ISBN 978-93-80609-17-1
653

International Conference on Recent Advances in Mechanical Engineering and Interdisciplinary Developments [ICRAMID - 2014]

of drill wear and breakage but insensitive to cutting condition

and sensor location.
Abbu-Mahfouz [3] carried experimental procedure for
detecting and classification of twist drill wear using FFT of
vibration signature as an input to a mult iple lay er neural
network. He concluded that trained neural network become a
powerful and reliable tool in solving classificat ion and pattern
recognition problem in drilling p rocess monitoring. Further he
suggested that vibration signals are promising tool for
condition monitoring and manufacturing process diagnostics.
Panda et al., [6] used back propagation neural network and
radial basis function network for p redicting HSS d rill flank
wear in a cast iron workpiece using drill d iameter, spindle
speed, feed, thrust force, torque and vibration signals as input
parameters and flank wear as output parameter fo r both neural
network. They concluded that inclusive of vibrat ion signal as
an input parameter to network leads to predict the wear with
more accuracy.
Nakandhraku mar et al.,[5] carried drilling experiments
using constant cutting conditions (speed, feed, drill diameter)
and by varying distances in radius by keeping sensor at centre
of the plate and concluded that amplitude variat ion in
vibration signals due to d istance variation fro m sensor
position.
Nevertheless, no research studies have been reported on
influence of sensor location with respect to drill hole in tool
condition monitoring of drilling process. Therefore, the
research presented to study the effect of location of sensor in
tool condition monitoring of drilling.

positioned at center of the plate to receive the response of

acceleration in Y-direction. The analog output signals from the
accelero meter sensor were converted to the digital signals by a
data acquisition card (NI 9133) interfaced with a personal
computer and further processing was carried out using
Lab VIEW 8.5 (Sound and Vibration assistant) software.

III. EXPERIM ENTA L DETAILS

Figure 1 shows a schematic d iagram of the experimental set
up in this research study. Drilling experiments were
conducted on a HAAS 3 axis CNC mach ining centre. The
tool used was a 6 mm d iameter high speed steel twist drill and
the geometrical specificat ions are shown in Table I. The
geometry of the workpiece was composed of 120 mm and 9
mm thickness EN24 steel / 1040 carbon steel and the chemical
composition is given in Table II. In order to study the drilling
process related to sensor location and sensitiveness of various
statistical parameter a series of drilling was performed at
spindle speed 800 r.p.m., feed 71.2 mm/ min wh ich are ASM
standards for making through holes in dry cutting. Each
workp iece used in the experiment was properly secured on a
three jaw chuck.

TABLE I
HSS DRILL GEOMET RY

Drill Geometry
Tool diameter (mm)
Flute length (mm)
Overall length (mm)
Point angle (degree)
Helix angle (degree)
Flutes/Flute type
Shank type

S pecifications
6
57
93
118
25
2/Parabolic
Straight cylindrical

TABLE II
EN24 ST EEL CHEMICAL COMPOSITION

Chemical composition
Carbon
Nickel
Chromium
M olybdenum
Sulphur
M anganese
Silicon
Phosphorus

Weight %
0.380
1.300
1.020
0.200
0.047
0.200
0.250
0.034

IV. RESULTS AND DISCUSSIONS

Drilling operations have been conducted using spindle
speed of 800 r.p.m., feed of 71.2 mm/ min and 6 mm h igh
speed steel drill. The flank wear value g reater than 0.45 mm is
considered as worn out tool as per ASM standards. It is
performed fro m fresh tool to worn out stage of drill for the
pitch circle d iameter (PCD) of 100 mm and 80 mm by placing
the sensor at center of the plate.

Fig. 2 PCD maintained for drilling holes on plate from constant sensor
position

Fig. 1 Schematic diagram of the experimental set -up

The machine was stopped for each 20 holes during

workab le state of wear and for each 10 holes during severe
state to measure the flank wear using tool makers microscope
(RMech Equip ments, Chennai Model 176-811E).
An
accelero meter sensor (Kistler Model 8636C50) was

ISBN 978-93-80609-17-1
654

Figure 2 shows that PCD maintained fo r d rilling holes on

workp iece fro m constant sensor position. While drilling each
hole, the vibration signal is measured using accelerometer
sensor and the data are stored in the computer through the
Lab VIEW software. Totally 10 plates are used for making 280
holes in PCD 100 and PCD 80. The flank wear was measured
for each 40 holes up to 200 holes. Then the flank wear was
measured for each 20 holes fro m 201 to 260 holes. In severe
condition of wear, its measured for each 10 holes fro m 261 to
280 holes. The results of the experiments conducted are
tabulated in the Table III (a) and (b) & IV (a) and (b) for PCD
100 and PCD 80 respectively. It shows the magnitude of all

International Conference on Recent Advances in Mechanical Engineering and Interdisciplinary Developments [ICRAMID - 2014]

statistical parameters of PCD 100 and PCD 80 and average

flank wear corresponding to the cutting conditions followed.
Figure 3 shows that the relationships between the flank
wear and magnitude of statistical parameters as RM S,
Exponential, Peak, and Maximu m Min imu m (max-min ),
mean, standard deviation and variance amplitude. It is
observed that amplitude variations are not sensitive to all the
statistical parameters. The amplitude for PCD 80 is larger
than PCD 100 for the same state of wear. Because the sensor
and drill holes distance is lesser for PCD 80 and larger
TABLE III (a)
EXPERIMENTAL DATA FOR DRILLING HOLES FOR PCD 100 IN EN24
WORKPIECE

No. of
holes

0-40
41-80
81-120
121-160
161-200
201-220
221-240
241-260
261-270
271-280

Average
Flank
Wear
[mm]
0.09
0.15
0.18
0.21
0.24
0.28
0.31
0.35
0.41
0.48

Magnitude of S tatistical
parameters [m/s 2]
RMS
Exponen
Peak
-tial
1.00
8.1X10-6
16.35
1.32
2.7X10-5
23.3
1.58
4.4X10-5
31.26
1.95
8.5X10-5
42.74
2.76
1.3X10-4
52.35
4.20
3.1X10-4
62.96
6.44
9.9X10-4
70.20
8.77
4.0X10-2
78.16
11.22
2.0X10-2
88.3
13.56
5.6X10-2
107.2

TABLE IV (b)
EXPERIMENTAL DATA FOR DRILLING HOLES FOR PCD 80 IN EN24
WORKPIECE

No. of
holes

Magnitude of S tatistical parameters [m/s 2]

MaxMean
S tandard
Variance
min
deviation
[Unit less]

0-40
41-80
81-120
121-160
161-200
201-220
221-240
241-260
261-270
271-280

31.2
48.3
58.4
72.45
91.03
110.73
135.6
156.94
183.16
205.25

0.03
0.003
0.0128
0.0275
0.181
0.913
1.949
2.364
2.736
3.82

1.33
2.13
2.89
3.57
4.42
6.70
9.49
11.70
13.65
17.16

1.88
4.56
8.36
12.8
18.66
42.76
90.16
137.15
187.76
297.37

TABLE III (b)

EXPERIMENTAL DATA FOR DRILLING HOLES FOR PCD 100 IN EN24
WORKPIECE

No. of
holes

0-40
41-80
81-120
121-160
161-200
201-220
221-240
241-260
261-270
271-280

Magnitude of S tatistical parameters [m/s 2]

MaxMean
S tandard
Varia
min
deviation
nce
30.84
46.71
57.4
70.96
83.5
99.1
112.15
128.2
147.3
176.66

0.09
0.02
0.023
0.014
0.112
0.484
0.884
1.437
1.870
3.447

[Unit less]
0.79
0.765
1.28
1.645
1.56
2.425
1.95
3.828
2.76
7.88
4.06
17.13
6.09
39.47
8.36
73.07
10.88
122.56
13.06
199.96

TABLE IV (a)
EXPERIMENTAL DATA FOR DRILLING HOLES FOR PCD 80 IN EN24
WORKPIECE

No. of
holes

0-40
41-80
81-120
121-160
161-200
201-220
221-240
241-260
261-270
271-280

Average
Flank
Wear
[mm]
0.09
0.15
0.18
0.21
0.24
0.28
0.31
0.35
0.41
0.48

Magnitude of S tatistical
parameters [m/s 2]
RMS
ExponenPeak
tial
1.38
9.27X10-5
17.8
2.09
2.15X10-4
27.7
2.86
3.5X10-4
35.62
3.59
6.4X10-4
44.65
4.32
2.2X10-3
55.06
5.99
6.7X10-3
68.4
9.28
1.2X10-2
80.57
11.58
3.1X10-2
90.76
14.52
4.6X10-2
101.8
17.50
8.4X10-2
114.4

Fig. 3 Relationship between the amplitude and the drill flank wear (a) RMS
(b) Exponential (c) Peak (d) Max-Min (e) Mean (f) Standard deviation (g)
Variance

ISBN 978-93-80609-17-1
655

International Conference on Recent Advances in Mechanical Engineering and Interdisciplinary Developments [ICRAMID - 2014]

distance for PCD 100 leads to loss of vibration signals. This

shows that the location of sensor with respect to hole affects
the vibration amp litude. So all the models presented in
previous studies are location dependent. Figure 3 shows that
the relationship between flank wear and magnitude of
statistical parameters is linear and the trend followed by all
the parameters are same except variance amplitude. Figure
3 (g ) shows that the flank wear up to 0.3, the variance
amp litude for both the PCDs are belo w 50. It can be noted
that the variance amplitude status increases exponentially
fro m 0.3 to 0.45. Because, wear state up to 0.3 mm is
considered as workab le state in wh ich smooth cutting is
taking place. When the tool reaches the worn out stage it
affects the cutting dynamics and offers uneven force on the
workp iece. This fluctuation of cutting force leads to uneven
excitation of various frequency components of vibration
signals. Since, the variance parameter is reflecting the
unevenness of the distribution of data with respect to mean
line. So, the variance parameter is reflect ing the uneven
fluctuations of vibrat ion signals than other statistical
measures. It is inferred that the difference of amplitude of
variance for workable and worn out stage of tool is very h igh
compared with other parameters. So, the variance amplitude
can be an indicator of the tool replacement.

[6]
[7]
[8]

IV. CONCLUSIONS
In this study, amplitude variat ion in the vibration signals
due to distance of sensor position and its relat ionship to tool
wear was investigated during drilling. It was found that the
vibration amplitude increases in the progression o f tool wear.
This paper represents linear relat ion between flank wear and
magnitude of all the statistical parameters is in linear, but the
magnitude of the variance amplitude is sensitive to flank wear
than the other statistical parameters. Variance amp litude up to
0.3 mm of flank wear for both PCDs is 10 times larger the
amp litude of worn out stage. For specific cutting conditions
and wear state, change in amp litude was observed which is
due to distance of sensor with drill hole. It can be concluded
that the tool wear models developed in the previous studies
are limited to constant sensor location. In future, nullifying
procedure for tool wear model may be developed for
compensating the amp litude variation due to d istance
variation fro m location of sensor.
A CKNOWLEDGMENT
This work was conducted under the support given by DST
FIST for Vibration and Mechatronics Lab at Hindustan
University wh ich the authors greatly appreciate.

[1]

[2]
[3]
[4]
[5]

REFERENCES
H. M. Ertunc and K. A. Loparo, A decision fusion algorithm for tool
wear condition monitoring in drilling, International Journal of Machine
Tools & Manufacture, vol. 41, pp. 1347 1362, 1998.
Slavko Dolinsek and Janez Kopac, Acoustic emission signals for tool
wear identification, Wear, pp. 295 -303, 1999.
Issam Abu-Mahfouz, Drilling wear detection and classification using
vibration signals and artificial neural network, International Journal
of Machine Tools & Manufacture, vol. 43, pp. 707720, 2003.
T.I. El Wardany, D. Gao and M. A. Elbestawi, Tool condition
monitoring in drilling using vibration signature analysis, International
Journal Machine Tools and Manufacture, vol. 36, pp. 687-711, 1996.
R.S. Nakandhrakumar, D. Dinakaran, S. Satishkumar, and J.
Pattabiraman, Normalization of distance variation in sensor

ISBN 978-93-80609-17-1
656

positioning for tool condition monitoring through vibration analysis,

in Proc. ICCAE13, 2013, pp. 929-935.
S. S. Panda, D. Chakraborty, and S. K. Pal, Flank wear prediction in
drilling using back propagation neural network and radial basis
function network, Applied Soft Computing, vol.8, pp. 858-871, 2008.
K. Patra, K. Pal, and K. Bhattacharya, ANN based prediction of drill
flank wear form motor current signals, Applied soft computing, vol. 7,
pp. 929 -935, 2007.
D
D. Dinakaran, S. Sampthkumar, and N.Sivashanmugam, An
experimental investigation on monitoring of crater wear in turning
using ultrasonic technique, International Journal of Machine Tools and
Manufacture, vol. 49, pp. 1234 1237, 2009.