Monitoring microdrill wear and breakage

Machining tiny holes with solid-carbide microdrills presents a host of challenges, one of which is monitoring tool wear and breakage.

Tracking microdrilling applications in real time can be problematic because a drill that’s 0.1 mm (0.0039″) in diameter, for example, has a power consumption of 0.2 W when cutting steel, according to Digital Way Inc. If the resolution of a system for monitoring tool wear and breakage is no better than 1 or 2 W, detecting anything about a microdrill is impossible.

To overcome that obstacle, Digital Way offers the WattPilote monitoring system, said John Cosic, North American sales and service manager. He’s based in Simi Valley, California, and the company also has an office in Troy, Michigan. He said the system provides “true” power monitoring in which current consumption is combined with voltage to provide an accurate representation of what’s actually happening at the cutting edge.

An example is shown of a 0.47 mm-dia. (0.0185″) drill on a 5-kW spindle. Machining power is about 5.5 W. The red curve represents a new drill, and the blue lines are the upper and lower power limits. Note the increases in power due to drill wear. Image courtesy of Digital Way

He said the use of a resistive shunt sensor differentiates the system from other power monitors for machining applications.

“From the perspective of the machine tool builder,” Cosic said, “it looks like three short pieces of copper wire, but what is really in there are three precision low-ohm resistors. They provide power measurements that are more repeatable, more sensitive, more accurate and faster so you can detect tripping events that you normally can’t see with a power sensor.”

He said that capability enables reliable measurement of small amounts of power consumption when drilling with large motors. A motor can be sized appropriately on a dedicated microdrilling machine that applies only one tool or a limited number of different tools, which makes detecting the condition of microdrills easier. But if a variety of tools are needed on a machining center, ranging from a microdrill to a large-diameter endmill, the motor must be sized for the endmill.

“That’s how we developed the technology in the first place,” Cosic said, “because we often find ourselves monitoring big and small tools on the same machine. Automotive is my typical application.”