A model-based monitoring and fault diagnosis methodology for free-form surface machining process

Rixin Zhu, Richard E. DeVor, Shiv Gopal Kapoor

Research output: Contribution to journalArticle


In this paper, a process model-based approach has been proposed for monitoring and fault diagnosis in the multi-axis ball end milling process. Besides its ability to deal with complex cutting geometry in free-form surface machining, the method has the capability of not only detecting the presence but also estimating the magnitudes of faults, which include flute chipping, breakage and spindle/cutter axes runout. A threshold-based fault detection method is developed based on the analysis of harmonic power distribution in the cutting force signal. A genetic algorithm approach is used to search and determine the fault pattern and magnitudes. The new approach is validated through both constant cross-section cut and free-form surface machining tests on 1018 steel.

Original languageEnglish (US)
Pages (from-to)397-404
Number of pages8
JournalJournal of Manufacturing Science and Engineering, Transactions of the ASME
Issue number3
StatePublished - Aug 1 2003


ASJC Scopus subject areas

  • Industrial and Manufacturing Engineering
  • Mechanical Engineering

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