Monitoring tool wear and tool load

Application

With Adaptive Feed Control (AFC), you can monitor the tool for wear or breakage. To do this, use columns AFC-OVLD1 or AFC-OVLD2 in the tool management.

Related topics

Description of function

If the AFC.TAB columns FMIN and FMAX each have a value of 100%, Adaptive Feed Control is deactivated, but cut-related tool wear monitoring and tool load monitoring remain active.

Basic AFC settings in AFC.tab

Tool wear and tool breakage cannot be monitored at the same time. If the AFC_OVLD2 column contains a value, the control will ignore the AFC_OVLD1 column.

Tool wear monitoring

Activate cut-related tool wear monitoring by entering a value not equal to 0 in the AFC-OVLD1 column in the tool table.

The overload response depends on the AFC.TAB column OVLD.

In conjunction with cut-related tool wear monitoring, the control only evaluates the options M, E, and L in the OVLD column. The following responses are possible:

  • Pop-up window
  • Lock current tool
  • Insert replacement tool

Tool load monitoring

Activate cut-related tool load monitoring (tool breakage control) by entering a value not equal to 0 in the AFC-OVLD2 column in the tool table.

As overload response, the control always executes a machining stop and locks the momentary tool.

Example

The entries in columns AFC-OVLD1 and AFC-OVLD2 are added to the feedback-control reference power AFC-LOAD.

AFC teach-in cut

Example input for tool wear and tool load monitoring:

Column

Input

AFC-LOAD

30%

AFC-OVLD1

5%

AFC-OVLD2

10%

In this example, the control adds the 5% and 10% to the 30% in each case.

As soon as a value is defined in column AFC-OVLD1, the tool will monitor tool wear. When the control used in the example reaches a spindle power of 35% in total, it executes the defined reaction.