A hybrid approach for robust diagnostics of cutting tools

A new multisensor based hybrid technique has been developed for robust diagnosis of cutting tools. The technique combines the concepts of pattern classification and real-time knowledge based systems (RTKBS) and draws upon their strengths; learning facility in the case of pattern classification and a higher level of reasoning in the case of RTKBS. It eliminates some of their major drawbacks: false alarms or delayed/lack of diagnosis in case of pattern classification and tedious knowledge base generation in case of RTKBS. It utilizes a dynamic distance classifier, developed upon a new separability criterion and a new definition of robust diagnosis for achieving these benefits. The promise of this technique has been proven concretely through an on-line diagnosis of drill wear. Its suitability for practical implementation is substantiated by the use of practical, inexpensive, machine-mounted sensors and low-cost delivery systems