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Procedia CIRP 58 (2017) 601 – 606

16th CIRP Conference on Modelling of Machining Operations

Model-Based Online Tool Monitoring for Hobbing Processes

F. Klockea, B. Döbbelera , S. Goetza*, T. Deeke Vieka
a
WZL der RWTH Aachen, Steinbachstr. 19, 52072 Aachen, Germany

* Corresponding author. Tel.: +49-241-8027466;. E-mail address: S.Goetz@wzl.rwth-aachen.de

Abstract

Continuous increase in flight passengers alongside with a high demand for fuel efficiency has led to the development of Geared Turbo Fans
(GTF). Being a safety-critical part, the gearbox faces strong safety requirements that also account for sophisticated manufacturing processes and
monitoring systems. One major issue is tool wear and the threat of tool breakage during the hobbing process. Due to the high costs of both the
raw material and the tool, wear induced tool breakage is a major cost driver. Common practice today is to use each tool for a designated time, but
in-situ online wear assessment would result in a reduction of costs as tools can be used to their individual potential. Tool wear of hobs is not
spread equally across all cutting edges; hence the assignment of tool wear to each tooth would enable a monitoring system to analyze the individual
tool life and predict its operational capability. This research paper presents a method of using effective power signals in combination with a
predictive model to determine the actual wear status of each tooth. The model uses the chip geometry and a force model in order to predict the
expected torques of the spindle and compares them in real-time with measurement data. An algorithm then estimates the wear status of each
tooth. These findings enable further research on an online, model based and position-oriented tool wear monitoring system.

©
© 2017
2017The TheAuthors.
Authors.Published
Publishedby Elsevier B.V. This
by Elsevier B.V.is an open access article under the CC BY-NC-ND license
(http://creativecommons.org/licenses/by-nc-nd/4.0/).
Peer-review under responsibility of the scientific committee of The 16th CIRP Conference on Modelling of Machining Operations, in the
Peer-review
person of the under responsibility
Conference of theProf.
Chairs scientifi
J.C.c committee of The
Outeiro and 16thG.CIRP
Prof. Conference on Modelling of Machining Operations
Poulachon.

Keywords: Wear, Modelling, Monitoring

1. Introduction prediction of tool wear an arduous work. Especially during the

1.1. Problem description
The drive for economic aero engines has eventually led to
the development of Geared Turbo Fans (GTF), where a gearbox
separates the turbo fan from the low-pressure shaft. These gears
are subject to very high loads and also very strict safety
requirements. Due to that, hard to machine materials and
special alloys are used that allow only for low process
parameters. Still, parameters such as tool wear and force
magnitude are substantially high, so that the risk of a tool
failure during a machining process is paramount. [1]
As it owns the highest efficiency with outstanding accuracy
and quality, gear hobbing is one of the principal gear
manufacturing methods. Nonetheless, its kinematics and wear
evolution mechanisms are rather challenging, what makes the
production of large gears, it is often difficult to decide whether
the present tool is capable or not of machining more gears
without striking a critical level of wear. [2]
Thereby, an online surveillance of the hobbing tool can
minimize this problem by giving the possibility of deciding
upon the tool status on a more reliable and solid basis, and to
prevent sudden tool breakage during the machining process.
1.2. State of the art
The progress of tool wear is dependent on factors involving
the hobbing tool, the work piece and the process itself, such as
the cutting speed and gear design. Furthermore, parameters like
the presence of coolant, the materials of the hobbing tool and
the work piece lead to distinct contact conditions, cutting time
and chip thickness [3]. The chip formation affects the
progression of tool wear, so that a light chip formation drives

2212-8271 © 2017 The Authors. Published by Elsevier B.V. This is an open access article under the CC BY-NC-ND license
(http://creativecommons.org/licenses/by-nc-nd/4.0/).
Peer-review under responsibility of the scientific committee of The 16th CIRP Conference on Modelling of Machining Operations
doi:10.1016/j.procir.2017.03.271
602 F. Klocke et al. / Procedia CIRP 58 (2017) 601 – 606
to a shorter wear evolution rate. Thus, as the process conditions
are uneven between the teeth, there will be different loads and
chip geometries for every generation position, which leads to a
different wear behavior among the teeth of the hobbing tool [4].
Additionally, there is a high influence of the axis lubrication
state, transverse rate and axis conditions [6].
Moreover, ZAHNG (2012) [7] performed experiments to
estimate the correlation among the wear rate and the cutting
force deployed by tool during a milling process. From his
results, it can be concluded that the tool wear propagation is
believed to be responsible for the gradual increase of the cutting
forces. Hence, the more wear rate the cutting tool develops, the
more the process power increases. As the evolution of the wear
leads to higher cutting forces, this variable is directly related to
the tool conditions [8], making it a great alternative to
indirectly measure wear.
“Tool Condition Monitoring Systems” (TCMS) are required
to verify the conditions of the tool, in order to ensure a smooth
operation and the final quality requested of the production [5].
TCMS’s can be divided into either online or offline
surveillance. This paper will focus on the online systems, since
it enables a real time assessment of the tool condition. TCMS
can be divided into direct and indirect methods. While direct
methods measure the wear on the tool directly, indirect systems
use signals that are affected by a progressing tool wear (e.g.
force or vibrations). The indirect methods are usually applied
to online systems, allowing the continuous monitoring of the
process [6]. This method was used by PRADES-MARTELL et al.
(2013) [9] to monitor the conditions of a grinding line with
sixteen pairs of wheels. Each wheel has its power consumption
monitored and compared with a reference signal. The changes
in the wheel positions or conditions caused an increase or
decrease of the consumption, enabling the decision-taking to
properly repair the machine.
Although a cutting force signal can be measured directly by
a tool force dynamometer, its use is limited by high cost, sensor
reliability in the harsh cutting environment, layout constraints
(space, weight, etc.) and interference with cutting performance
(stiffness reduction). A monitoring method that has potential to
eliminate many of the above limitations is the model-based
monitoring [10]. This method requires sensors to measure
remotely and to easily access signals, models that represent the
physics of the process between the remote sensors and the
cutting forces signal, as well as estimation algorithms to
estimate the force from indirect measurement output. For
example, SPIEWAK (1995) [11] developed an indirect force
sensor based on the measurement of three-axis spindle
acceleration and spindle deflections. Furthermore, SHIRAISH
and AOSHIMA (1997) [12] estimated the cutting force through
a state observer and the displacement transducer.
Many commercial systems are capable of creating a
signature of the process using multi-sensors signals (torque,
spindle vibration, power consumption, Acoustic Emission
(AE) signals, etc.) and then use it to verify the actual process
state. One example would be the ARTIS monitoring system
[15]. However, the hobbing process requires a high batch size
for teaching and is not able to detect sudden process changes or
a minor tool breakage that only affects one tooth. Hence, the
development of a model-based monitoring system that is
capable of detecting local wear on a hobbing tool or local tool
edge breakage would enable a safer and more economical
production of highly-loaded gears for GTF.
1.3. Research aim and approach
As mentioned above, a reliable and accurate measurement
of the tool wear and prediction of remaining tool life time
online has a large advantage for high-performance gears. At the
same time, current systems are not capable of monitoring the
exact tool status with the resolution of a single tooth in a
satisfying way.
The aim of the research is therefore to develop a model that
can be used for a system to estimate the tool wear of single
cutting teeth of a hobbing tool by combining simulation data
with measurement data from an effective power measurement
system. This is done by creating a model-based link between
the measurement data and the simulation data of the hobbing
process with the aim to create a wear estimator for each single
cutting tooth. This model uses the simulated torque and
compares it with the measurement data in order to create
information about the tool wear status from the discrepancy.
2. Experimental setup and results
2.1. Description of experimental setup
The experiments were performed with a Liebherr LC 100
machine using a fly cutter hobbing process. They were already
carried out in the scope of prior research and shown in KLOCKE
et al. [16]. Fly cutter hobbing is a widespread method to
evaluate tool wear and other tool influences in a hobbing
process, since it outlines the entire process on one single tooth.
The process as well as the parameters used are shown in Figure
1. The fly cutter passes the work piece once for each generating
position, then shifts back and cuts the next gap.
K
Fly cutter
Tool
PM-HSS
vw material
LF Crater RF Coating (Al, Cr)N
wear
Tool
80 mm
diameter
Process data
vc Cutting speed
240
m/min
Workpiece 18CrNi
material Mo7-6
No. of teeth 1
LF Left flank
LFT Left flank transition RFT Right flank transition
K Head zone RF Right flank
Figure 1: Experimental setup [16]
By using three different types of specimen, geometrically
uniformed gears were produced until striking the tool life end.
The material used was 18CrNiMo7-6 in different heat
treatments (1x forged, 2x quenched and tempered). These were
named I, II and III respectively. Each material specification
was used for as many parts as it took to reach the wear criterion
of either 100 µm crater wear or flank wear. The entire tooth
flank of the cutter was segmented into five zones to get more
 F. Klocke et al. / Procedia CIRP 58 (2017) 601 – 606 603

precise information on where the wear arose. The tool wear was 1,4
1.4
measured and assigned to the according area of the tooth, as
shown in Figure 1 (left). The process itself was monitored by 1,3
1.3
measuring the effective power of the main spindle with a

R(X) /-
frequency of 20 kHz. 1,2
1.2

2.2. Experimental results 1,1

1.1

The effective power signal was measured and analyzed. In

11
order to create one gear, 37 repetitions were done, where a 0 50 100 150 200 250 300 350
repetition means a set of cuts within the same generating Crater wear /µm
position. Figure 2 (left) shows the effective power signal of all
of these repetitions for one gear. It can be seen that each Figure 3: Correlation between crater wear and the power ratio [16]
repetition is represented by one peak of the signal and consists
of a minor peak for each cut, as shown in blue on the left hand R(X) is the power ratio according to the definition above.
side. The right hand side of Figure 2 shows one such peak for The coefficient of correlation between these two is 0.979. This
a new tool (blue) and for a worn tool (orange) of the same peak means a very strong correlation between crater wear and the
and material. The green line shows the ratio of these two power ratio, which means the power ratio is a very good
curves, i.e. the pairwise division of worn signal value uworn by estimator for crater wear. It is yet to be researched how this
the new signal value unew as R(x) = uworn/unew. relates for other types of wear.

No. of peak: 3. Model description

Effective power signal U/V

5 10 15 20 25 30 35 New and worn tool

3.5 3.5 New
3.1. Force model “SPARTA pro”
Extreme value U/V

3.0 3.0
Worn
2.5 2.5
Ratio
2.0 2.0
1.5 1.5 SPARTApro is a simulation software developed at the WZL
1.0 1.0
0.5 0.5
of the RWTH Aachen University. As input characteristics are
0
0
given, the program evaluates the hobbing process parameters.
1k 2k 3k 4k 5k 20 40 60 80
Time t/s Time t/s These inputs are geometrical information of the work piece,
such as module, number of teeth, and outside diameter, as well
Figure 2: Effective power signal [16] as the tool data and its profile geometry [13].

It can be seen that the ratio is very constant over the entire Tool geometry Workpiece geometry
Flankentopografie Process
„ Tool profile
Input

time. This leads to the conclusion that tool wear leads to a „ da / n i / z o

fa
vc
proportional increase of the effective power, so that the power „ …

ratio could be a suitable estimator for the tool wear and it was
Fc/b
thus analyzed how the correlation between tool wear and the
power ratio is.
SPARTApro vc hcu

Table 1: Wear measurement of all three experiments [16] Setup time

Idle time
Main time
Output

Flank wear [µm] Crater wear

LF LFT K RFT RF (RFT) [µm] Chip geometry Force calculation Economy
I.11 58 56 63 70 69 102
II.4 45 43 39 37 56 172 Figure 4: SPARTApro inputs and outputs [13]
III.3 70 55 60 51 77 310
Table 1 shows the flank wear (left) and crater wear) of all The computations are executed by penetration calculations,
three experiment sets (I, II and III). The number after the I’s performed as the axial feed of the process is given [14].
shows the number of gears that were produced in that particular Afterwards, these geometries are analyzed and, by means of
set. The wear data refers to the tool after the last gear in that GUTMANN’s cutting force model for gear hobbing,
series. This data was correlated to all power ratio signal of the characteristics values, such as the maximum and average chip
respective experiments, c.f. Figure 3. thickness, the specific chip volume, the maximum and average
cutting length, cutting forces and the economic feasibility are
determined [13].

3.2. Determination of the tooth contribution to torque

The input signal available in the acquisition module is the

total effective power signal. However, the aim of the module is
to be capable of monitoring the evolution of wear over each
604 F. Klocke et al. / Procedia CIRP 58 (2017) 601 – 606
particular tooth. Therefore, since the effective power signal is
composed by the power deployed in different generating
positions in a particular instant, it can be assumed that for the
instant ‫ݐ‬௜ the total measured power ܲெ் is the sum of the power
developed by each tooth ܲெ௝ , from 1 to N, being N the number
of teeth cutting the work piece. It can be written as:
ே Therefore, if a possibility is found to cancel the disturbances in
ܲெ் ሺ‫ݐ‬௜ ሻ ൌ ෍ ܲெ௝ ሺ‫ݐ‬௜ ሻ (1)
ଵ the tool wear estimator. This cleansing of σj(ti) will be
Furthermore, the power deployed by each tooth can be
described as the arrangement of two terms, as shown in
Equation (2). The first term (ܲௌ௝ ) represents the ideal signal,
obtained from either analytical calculations or numerical
simulations, i.e. SPARTApro data, and the second term is the
deviation ߪ௝ of the real signal, i.e. errors in the simulated data,
comprising stochastic effects and the presence of tool wear.
ܲெ௝ ൌ ܲௌ௝ ሺ‫ݐ‬௜ ሻ ൅ ߪ௝ ሺ‫ݐ‬௜ ሻ (2)
As shown in chapter 2.2, Xj can be seen as an estimator for
the tool wear. Since the fly cutter is similar to a single tooth on
the hobbing tool, the ratio Xj can be described as seen in
Equation (3). Here, the assumption is made that the simulated
power PSj equals the power of a new tooth.
ܲெ௝ ሺ‫ݐ‬௜ ሻ
ܺ௝ ൌ (3)
ܲௌ௝ ሺ‫ݐ‬௜ ሻ
ே assumed that averaging the estimators will reduce much of the
ܲெ் ሺ‫ݐ‬௜ ሻ ൌ ෍ ܺ௝ ‫ܲ ڄ‬ௌ௝ ሺ‫ݐ‬௜ ሻ (4)
ଵ
Rationalizing (1) with inserting (2) and (3), Equation (4) is
formulated. Thereby, the set is written as a linear system of
equations in the form of ‫ ݔ כ ܣ‬ൌ ‫ ݕ‬for each time ‫ݐ‬௜ and will be
readily solved by the monitoring system calculation module,
c.f. Equation 5. Each row of the matrix represents the simulated
power developed by the individual theeth of the hobbing tool
tool according to its respective process time:
ܲௌ௝ ሺ‫ݐ‬௜ ሻ ‫ڮ‬ ܲௌ௝ା௡ ሺ‫ݐ‬௜ ሻ ܺ௝ ܲெ் ሺ‫ݐ‬௜ ሻ
቎ ‫ڭ‬ ‫ڰ‬ ‫ڭ‬ ቏቎ ‫ ڭ‬቏ ൌ ൥ ‫ڭ‬ ൩ (5)
ܲௌ௝ ሺ‫ݐ‬௜ା௠ ሻ ‫ܲ ڮ‬ௌ௝ା௡ ሺ‫ݐ‬௜ା௠ ሻ ܺ௝ାேିଵ ܲெ் ሺ‫ݐ‬௜ା௠ ሻ
The key assumption in order to solve the set of equations is
to consider that the wear increases stably along short time
intervals, so that for a small enough ο‫ ݐ‬interval of time the
values of ܺ௝ can be considered constant and the system becomes
possible to solve. Furthermore, to avoid over and
underdetermined systems situations, the quantity of equations
is limited by the maximum number of contacts (ܿ୫ୟ୶ ) among
the hobbing tool and the work piece, since the maximum
amount of teeth performing a torque different from zero is
ܿ୫ୟ୶ .
3.3. Wear model
As seen in chapter 2.2, the power ratio between the new tool
and a worn tool is an estimator for the tool wear. The Xj that
was deducted in chapter 3.2 describes the ratio between the
simulated power and the real power, regardless of the time and
hence the tool wear. However, the simulated power assumes a
new tool. For any given point, the difference between the
simulated power and the real power is described by σj(ti). For a
new tool, the part of σj(ti) that describes the tool wear is zero.
σj(ti) that derive from uncertainties and noise, Xj can be used as
described later.
Averaging
Process deviation the
estimators
Simulation Calibration
Xj with
uncertainties teaching cut
Wear Target value
Figure 5: Disturbances in the process and their effect on Xj
Figure 5 shows how Xj decomposes into different aspects.
One part of the disturbance is the process deviation. Due to
small changes in the material, limited stiffness in the machine
tool and other stochastic effects, the process force will fluctuate
around an average value. At the same time, tool wear is
increasing the process force constantly (c.f. 2.2). This was
proven in the conducted experiments. It can therefore be
effect of process deviation while keeping the effects of wear.
The second part of the disturbances are simulation
uncertainties. These are due to the limited level of the
underlying material model of the simulation, to variations of
the material lot and to fluctuations of the cutting conditions.
However, the first two of these aspects can be eliminated when
using the first cut of the process to calibrate. Here, the
simulation should be equal to the measurement signal. A
calibration factor can reduce the offset.
With the effects of the first two aspects, if not annihilated,
then strongly reduced, the new Xj’ mainly consists of the tool
wear, which is the target value.
4. Monitoring system
4.1. General architecture
The monitoring system uses both simulation and
measurement data and combines them with information about
the machine tool in order to create an estimated tool wear status
for each cutting tooth (c.f. Figure 6). In a first step, it draws the
contribution to the total torque of each tooth from the
SpartaPRO data. These torques have a high time resolution and
can be obtained separately for each tooth over its entire cutting
path through the work piece. In a second step, the simulation
data is matched with the measurement data of the same discrete
time. Afterwards, for each discrete time the set of wear
estimators is calculated as described in chapter 3.2.
 F. Klocke et al. / Procedia CIRP 58 (2017) 601 – 606
Analysis system:
¾ Data processing
¾ Comparision with sim. data Estimation of position
¾ Calculation of estimator oriented wear status
Force simulation
based on engagement
situation
Sensor data
(effective power, AE)
Machine
data
Figure 6: General architecture of the monitoring system
Since the simulation data and the measurement data are
taken from different sources, they need to be synchronized. For
typical hobbing processes, the tooth engagement rate is in an
order of several hundred Hertz and thus the required time
resolution only a few milliseconds. This requires a very
accurate synchronizing process to ensure the right set of data is
matched. A rotary encoder in the machine tool can give the
information about the rotary position, while an incision
detection can match the set position of the machine tool with
the real position. All this information is processed in the
analysis tool, with a wear estimator as the output of the system
that estimates the tool wear situation for each cutting tooth. The
following chapter describes the first part of the analysis system
where the estimator is calculated from the simulation and
measurement data.
4.2. Model use in the monitoring system
In order to reach the solution from the set of equations
starting from the input data, i.e. simulated data and measured
signal, and to be able to monitor the hobbing process along
time, an algorithm has been developed and realized in a
program. It is based on the mathematical relations as shown in
chapter 3.2, especially Equation 5. Its aim is to automatically
solve Equation 5 within the tact time of the monitoring system.
This is determined by the angular resolution of the simulation
tool, which is set to be 3°. That means, the torque and forces
are simulated for each 3° of angular position of the hobbing
tool, thus alongside with the angular speed determining the
time resolution by ∆t = ∆φ*ω with ∆φ being the angular
resolution. The structure of the algorithm is shown in Figure 7.
The program itself was done using MATLAB. It comprises
three specific partitions: an input interface, a pre-processing
script, and a solver script.
The first step of the algorithm is the acquisition of the data.
The simulation data is loaded in advance of the process and
determines the structure of the second step. There is one value
Psj(ti) for each generating position and one set of generating
positions for each φ(ti). The power signal is acquired with the
sampling rate of 20 kHz and the average for each ∆t is
calculated and saved as PMT(ti), then matched to the according
angular position φ(ti). The simulation of the process power is
performed using SPARTApro.
605
SPARTApro
Simulation Data Power Measurement
Algorithm
STEP 1: Input Interface
Simulation Data, Effective Power, User Interface.
STEP 2: Pre-Processing Script
Effective Power Matrix, Simulation Power Matrix.
STEP 3: Solving Script
Least Square Method.
Tool Wear Estimation Xj
Figure 7: Block diagram representing the data flow along the monitoring
module
In the second step, the data that has been acquired is
prepared to be used for solving Equation 5. Given n as the
number of generating positions, in order to be able to solve
Equation 5, ‫(ܣ‬ti) needs to be in the form of n x n. Therefore,
the last n values for PMT(ti) give the right hand side of Equation
5. Similarly, the last n sets of Psj(ti) give the matrix ‫( ܣ‬ti).
According to the assumption made in chapter 3.2, tool wear
increase is negligible for small ∆t. Therefore, we can assume a
constant vector ܺ(ti), making it possible to solve the resulting
equation.
In the third step, the Equation 5 is solved. This is done
numerically, using the Least Square Method. With common
angular speeds in hobbing being 1000/min and the angular
resolution of 3°, ∆t is of the magnitude of less than 1 ms.
Therefore, the calculation speed of the system is vital. Due to
the nature of the hobbing process, ‫(ܣ‬ti) tends to be a sparse
matrix. The pre-processing step will therefore eliminate zero
entries. This reduces the size of the matrix to n’ x n’ with n’ <
n. n’ is determined by the maximum number of generating
position within the original matrix ‫(ܣ‬ti). This resolves into the
new ‫(’ ܣ‬ti). In further research, new ways of reducing the
calculation times further will be investigated.
Being a numerical method, the Least Square Method relies
on the maximum number of iterations as well as the tolerance
for the Least Square Method, and finally the limit of variance
between the results of the calculations along time.
The result of this algorithm is a vector ܺ(ti) for each ti, which
can be used to describe the tool wear status as shown in chapter
3.3. Given the high time resolution as compared to the slow
propagation of tool wear, the averaging method shown in
chapter 3.3 is viable, but has yet to be proven in cutting
experiments.
5. Conclusion
Experiments have proven that the ratio between the effective
power signals of a new and a worn tool are a strong indicator
606 F. Klocke et al. / Procedia CIRP 58 (2017) 601 – 606
for tool wear. This concept is widely used by commercial wear
monitoring systems, such as the ARTIS system [15]. However,
these systems are unable to monitor the different tool wear state
that occurs in hobbing, or the breaking of single cutting teeth.
Furthermore, they require a large number of teaching cuts. In
order to overcome these problems and be able to assess single
teeth even without teaching cuts, a model-based approach was
presented.
This model uses simulation of the expected power in a
process with a new tool and compares the measurement data
with that simulation data. An algorithm was developed that
automatically combines simulation and measurement data and
calculates the tool wear estimators from this information.
However, the simulation that is used for the monitoring system
is flawed by uncertainties and signal noise as well as stochastic
process deviation. Therefore, future research needs to focus on
a way to eliminate these disturbances.
6. Outlook and further investigation
The model was developed based on the preliminary research
about tool wear in a hobbing process. However, although the
basic algorithms are implemented using MATLAB, there is at
present no coherent monitoring system available that is based
on the models presented in this paper. The major challenges are
the timely synchronization of the tool position, the effective
power signal and the simulation data. Therefore, future
research needs to focus on the implementation of the model into
an online monitoring system.
The real-time knowledge about the actual wear status can
also be used to increase the efficiency of tool usage. Common
practice is to determine a tool life expectancy by either
experience or simulation, and then using the tools for the time
determined. However, the real lifetime of a tool varies by large
extend.
Tool wear VB/µm
Max. VB
Original
estimation
Uncertainty
corridor
New
Measurement estimation
point
Numer of cuts n/-
Figure 8: Model-based premonitoring og the remaining tool life
With real time information, this variance can be used to full
potential by adjusting the tool time to the actual wear status. By
combining the real-time data with a tool life time simulation
(e.g. as proposed by [2]), the uncertainty of the remaining tool
life time can be reduced, thus increasing efficiency and
eliminating waste. As shown in Figure 8, the further the process
advances, the smaller is the uncertainty corridor, until it
becomes a singular point when the tool life was reached.
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