A Comparative Study of I-kaz Based Signal Analysis Techniques: Application to Detect Tool Wear during Turning Process

2013 ◽  
Vol 66 (3) ◽  
Author(s):  
Muhammad Rizal ◽  
Jaharah A. Ghani ◽  
Mohd Zaki Nuawi ◽  
Mohamad Amir Shafiq r Mohd Tahir ◽  
Che Hassan Che Haron
Keyword(s):  
Tool Wear ◽  
Cutting Force ◽  
Flank Wear ◽  
Multilevel Methods ◽  
Machining Process ◽  
Turning Process ◽  
Feed Force ◽  
Machined Parts ◽  
Force Signal ◽  
Analysis Of Results

Detection of tool wear during in-progress machining process is a significant requirement to assure the quality of machined parts that helps to improve the productivity. The cutting force is one of the signals in machining process that has been widely used for tool wear monitoring. In the present paper three derived I-kazTM based methods explained and compared for monitoring tool wear changes during turning process. The aim of this work is to study the performance of I-kazTM, I-kaz 2D and I-kaz Multilevel techniques to detect flank wear width using the cutting force signal. The experiments were carried out by turning hardened carbon steel, and cutting force signals were measured by two channels of strain gauges that were mounted on the surface of tool holder. The analysis of results using I-kaz 2D, I-kazTM and also I-kaz Multilevel methods, revealed that all methods can applied to determine tool wear progression during turning process and feed force signal change is very significant due to flank wear.

I-KazTM-Based Analysis of Cutting Force Signals for Tool Condition Monitoring in Turning Process

2013 ◽  
Vol 471 ◽  
pp. 203-207
Author(s):  
Muhammad Rizal ◽  
Jaharah A. Ghani ◽  
Mohd Zaki Nuawi ◽  
Che Hassan Che Haron
Keyword(s):  
Tool Wear ◽  
Cutting Force ◽  
Condition Monitoring ◽  
Tool Condition Monitoring ◽  
Machining Process ◽  
Machined Surface ◽  
Tool Condition ◽  
Feed Force ◽  
The Status ◽  
Force Signal

Cutting force is an important signal in machining process and has been widely used for tool condition monitoring. Monitoring the condition of the cutting tool in the machining process is very important to maintain the machined surface quality and consequently reduce inspection costs and increase productivity. This paper utilizes I-kaz-based analysis of cutting force signal to monitor the status of tool wear. The cutting force signals are measured by two channels of strain gauge that were mounted on the surface of tool holder. Experiments were carried out by turning hardened carbon steel and cutting force signals were analyzed using I-kazTM technique by integrating two component of signals (I-kaz 2D, Z2), I-kaz of cutting force (Z of Fy), and I-kaz of feed force (Z of Fx). The results show that I-kaz of feed force can be effectively used to monitor tool wear progression during turning operation.

Predictive Modeling of Flank Wear in Turning Under Flood Cooling

2006 ◽  
Vol 129 (3) ◽  
pp. 513-519 ◽  
Author(s):  
Kuan-Ming Li ◽  
Steven Y. Liang
Keyword(s):  
Tool Wear ◽  
Cutting Force ◽  
Metal Cutting ◽  
Flank Wear ◽  
Cutting Temperature ◽  
Machining Process ◽  
Analytical Models ◽  
Dynamic Strain ◽  
Process Conditions ◽  
Force Analysis

The objective of this paper is to present physical and quantitative models for the rate of tool flank wear in turning under flood cooling conditions. The resulting models can serve as a basis to predict tool life and to plan for optimal machining process parameters. Analytical models including cutting force analysis, cutting temperature prediction, and tool wear mechanics are presented in order to achieve a thermo-mechanical understanding of the tool wear process. The cutting force analysis leverages upon Oxley’s model with modifications for lubricating and cooling effect of overhead fluid application. The cutting temperature was obtained by considering workpiece shear deformation, friction, and heat loss along with a moving or stationary heat source in the tool. The tool wear mechanics incorporate the considerations of abrasive, adhesion, and diffusion mechanisms as governed by contact stresses and temperatures. A model of built-up edge formation due to dynamic strain aging has been included to quantify its effects on the wear mechanisms. A set of cutting experiments using carbide tools on AISI 1045 steels were performed to calibrate the material-dependent coefficients in the models. Experimental cutting data were also used to validate the predictive models by comparing cutting forces, cutting temperatures, and tool lives under various process conditions. The results showed that the predicted tool lives were close to the experimental data when the built-up edge formation model appropriately captured this phenomenon in metal cutting.

FRACTAL-BASED ANALYSIS OF THE VARIATIONS OF CUTTING FORCES ALONG DIFFERENT AXES IN END MILLING OPERATION

Fractals ◽  
2018 ◽  
Vol 26 (06) ◽  
pp. 1850089 ◽  
Author(s):  
HAMIDREZA NAMAZI ◽  
ALI AKHAVAN FARID ◽  
TECK SENG CHANG
Keyword(s):  
Fractal Dimension ◽  
Cutting Force ◽  
Cutting Forces ◽  
End Milling ◽  
Fractal Theory ◽  
Radial Force ◽  
Machining Conditions ◽  
Feed Force ◽  
Milling Operation ◽  
Force Signal

Analysis of cutting forces in machining operation is an important issue. The cutting force changes randomly in milling operation where it makes a signal by plotting over time span. An important type of analysis belongs to the study of how cutting forces change along different axes. Since cutting force has fractal characteristics, in this paper for the first time we analyze the variations of complexity of cutting force signal along different axes using fractal theory. For this purpose, we consider two cutting depths and do milling operation in dry and wet machining conditions. The obtained cutting force time series was analyzed by computing the fractal dimension. The result showed that in both wet and dry machining conditions, the feed force (along [Formula: see text]-axis) has greater fractal dimension than radial force (along [Formula: see text]-axis). In addition, the radial force (along [Formula: see text]-axis) has greater fractal dimension than thrust force (along [Formula: see text]-axis). The method of analysis that was used in this research can be applied to other machining operations to study the variations of fractal structure of cutting force signal along different axes.

Study on the cutting performance in machining assembled hardened steel workpiece with torus cutter

2019 ◽  
Vol 234 (4) ◽  
pp. 701-709
Author(s):  
Tao Chen ◽  
Weijie Gao ◽  
Guangyue Wang ◽  
Xianli Liu
Keyword(s):  
Tool Wear ◽  
Cutting Force ◽  
Surface Quality ◽  
Wear Mechanism ◽  
Hardened Steel ◽  
Cutting Performance ◽  
Machining Process ◽  
Machined Surface ◽  
Machined Surface Quality ◽  
Two Sides

Torus cutters are increasingly used in machining high-hardness materials because of high processing efficiency. However, due to the large hardness variation in assembled hardened steel workpiece, the tool wear occurs easily in machining process. This severely affects the machined surface quality. Here, we conduct a research on the tool wear and the machined surface quality in milling assembled hardened steel mold with a torus cutter. The experimental results show the abrasive wear mechanism dominates the initial tool wear stage of the torus cutter. As the tool wear intensifies, the adhesive wear gradually occurs due to the effect of alternating stress and impact load. Thus, the mixing effect of the abrasive and adhesive wears further accelerates tool wear, resulting in occurrence of obvious crater wear band on the rake face and coating tearing area on the flank face. Finally, the cutter is damaged by the fatigue wear mechanism, reducing seriously the cutting performance. With increase of flank wear, moreover, there are increasingly obvious differences in both the surface morphology and the cutting force at the two sides of the joint seam of the assembled hardened steel parts, including larger height difference at the two sides of the joint seam and sudden change of cutting force, as a result, leading to decreasing cutting stability and deteriorating seriously machined surface quality.

Control Method for Elimination of Self–Excited Oscillations during Turning

2010 ◽  
Vol 164 ◽  
pp. 171-176 ◽  
Author(s):  
Tomáš Březina ◽  
Jan Vetiška ◽  
Petr Blecha ◽  
Pavel Houška
Keyword(s):  
Tool Wear ◽  
Computer Model ◽  
Pid Controller ◽  
Control Method ◽  
The Self ◽  
Machining Process ◽  
Geometric Accuracy ◽  
Turning Process ◽  
Machined Surface ◽  
Excited Oscillation

The oscillations occurring between the tool and the machined area during the turning process lead to degradation of the machined surface, cause poor geometric accuracy, accelerate tool wear and generate noise. This paper deals with the possibility of elimination of these self-excited oscillations by changing the parameters of the turning process. On the basis of the regenerative principle of self-excited oscillation generation, a computer model of the machining process was developed. Furthermore, a PID controller was proposed to control the compensation of the vibrations and its suitability for elimination of the self-excited oscillations was verified experimentally.

Predictive Models for Flank Wear in Near Dry Machining

2005 ◽  
Author(s):  
Kuan-Ming Li ◽  
Steven Y. Liang
Keyword(s):  
Tool Wear ◽  
Cutting Force ◽  
Flank Wear ◽  
Cutting Temperature ◽  
Dominant Factor ◽  
Force Model ◽  
Temperature Model ◽  
Dry Machining ◽  
Cutting Force Model ◽  
Wear Model

The objective of this paper is to present a methodology to analytically model the tool flank wear rate in near-dry turning. The resulting models can serve as a basis to minimize time-consuming machining tests in predicting tool life. Analytical models, including cutting force model, cutting temperature model, and tool wear model, are presented. The cutting force model was established based on Oxley’s model with modifications for lubricating and cooling effect due to the air-oil mixture in near-dry machining. The cutting temperature was obtained by considering a moving or stationary heat source in the tool. The tool wear model contained abrasive mechanism, adhesion mechanism, and diffusion mechanism. The important factors related to this model were contact stresses and temperatures that were obtained from the cutting force model and the cutting temperature model. To develop these models, a set of cutting experiments using carbide tools on AISI 1045 steels were performed to calibrate the coefficients in the models and to verify the proposed flank wear mechanisms. The comparisons between the model-predictive flank wear and experimental results showed that the flank wear in near dry machining can be estimated well by the proposed models. It was also found that the cutting velocity was a dominant factor among the cutting conditions.

Identification, Analysis and Evolution of the Mechanisms of Wear for Secondary Adhesion for Dry Turning Processes of Al-Cu Alloys

2010 ◽  
Vol 107 ◽  
pp. 141-146 ◽  
Author(s):  
Moisés Batista ◽  
J. Salguero ◽  
Alvaro Gómez ◽  
M.S. Carrilero ◽  
Miguel Álvarez ◽  
...  
Keyword(s):  
Tool Wear ◽  
Critical Size ◽  
Main Tool ◽  
Machining Process ◽  
Rake Face ◽  
Turning Process ◽  
Dry Turning ◽  
Cu Alloys ◽  
Tool Wear Mechanism ◽  
Identification Analysis

In this work, Stereoscopic Optical Microscopy (SOM), Scanning Electron Microscopy (SEM) and Energy Dispersive Spectroscopy (EDS) have been applied for analyzing the evolution of tool wear during the dry turning process of aerospace Al-Cu alloys. The results derived from this analysis have revealed that secondary adhesion is the main tool wear mechanism that takes place in such process. So, in the first instants of the machining process, a Built-Up Layer (BUL) is developed onto the tool rake face by thermomechanical causes, promoting the conditions for developing a Built-Up Edge (BUE) which grows to a critical size. Starting from it, BUE is extruded giving rise to secondary BUL-BUE effects. When these are removed, tool particles are dragged out provoking the tool wear.

scholarly journals PENGARUH GAYA POTONG PEMBUBUTAN TERHADAP KEAUSAN PAHAT KARBIDA COATED PADA BENDA KERJA BAJA AISI 4340

POROS ◽  
2018 ◽  
Vol 16 (1) ◽  
Author(s):  
Rosehan Rosehan Rosehan
Keyword(s):  
Tool Wear ◽  
Cutting Force ◽  
Alloy Steel ◽  
Tool Life ◽  
Cutting Tools ◽  
Machining Process ◽  
Maximum Value ◽  
Trial Analysis ◽  
Steel Aisi ◽  
Aisi 4340

Cutting force and tool life is the important data in planning a machining process. The research is in order to describe about the influence of the cutting force to the tool wear on carbide coated cutting tools used the turning process of an alloy steel of AISI 4340. The research was conducted by observing the growth of tool wear on minutes 4.5, 9, 13.5, 18, 22.5 with the maximum value VB 0.3 mm, at the same time, the condition of other cutting such as the motion while the cutting, the depth and speed of the cutting movement was constant. The purpose of this experiment is to examine scientifically the influence cutting force to the growth of tool wear on carbide coated while the cutting process of alloy steel AISI 4340. The graphical method was used for the trial analysis, to see the cutting force comparison with the decrease of tool life of the carbide coated, and the correlation of the cutting movement with the cutting force. The mechanism decrease showed the adhesion decrease.

scholarly journals Experimental Investigation on Dry Routing of CFRP Composite: Temperature, Forces, Tool Wear, and Fine Dust Emission

Materials ◽  
2021 ◽  
Vol 14 (19) ◽  
pp. 5697
Author(s):  
Tarek Elgnemi ◽  
Victor Songmene ◽  
Jules Kouam ◽  
Martin B.G. Jun ◽  
Agnes Marie Samuel
Keyword(s):  
Tool Wear ◽  
Cutting Force ◽  
Dust Emission ◽  
Cutting Temperature ◽  
Cutting Speed ◽  
Machining Process ◽  
Specific Cutting Energy ◽  
Fine Dust ◽  
Cutting Energy ◽  
Cutting Speeds

This article presents the influence of machining conditions on typical process performance indicators, namely cutting force, specific cutting energy, cutting temperature, tool wear, and fine dust emission during dry milling of CFRPs. The main goal is to determine the machining process window for obtaining quality parts with acceptable tool performance and limited dust emission. For achieving this, the cutting temperature was examined using analytical and empirical models, and systematic cutting experiments were conducted to assess the reliability of the theoretical predictions. A full factorial design was used for the experimental design. The experiments were conducted on a CNC milling machine with cutting speeds of 10,000, 15,000, and 20,000 rpm and feed rates of 2, 4, and 6 µm/tooth. Based on the results, it was ascertained that spindle speed significantly affects the cutting temperature and fine particle emission while cutting force, specific cutting energy, and tool wear are influenced by the feed rate. The optimal conditions for cutting force and tool wear were observed at a cutting speed of 10,000 rpm. The cutting temperature did not exceed the glass transition temperature for the cutting speeds tested and feed rates used. The fine particles emitted ranged from 0.5 to 10 µm aerodynamic diameters with a maximum concentration of 2776.6 particles for those of 0.5 µm diameters. Finally, results of the experimental optimization are presented, and the model is validated. The results obtained may be used to better understand specific phenomena associated with the milling of CFRPs and provide the means to select effective milling parameters to improve the technology and economics of the process.

scholarly journals The effect of changes in depth of cut and cutting speed of CNC toolpaths on turning process performance

2018 ◽  
Vol 38 (1) ◽  
pp. 40-44
Author(s):  
Krzysztof Jarosz ◽  
Piotr Niesłony ◽  
Piotr Löschner
Keyword(s):  
Cutting Force ◽  
Tool Life ◽  
Cutting Speed ◽  
Machining Process ◽  
Depth Of Cut ◽  
Process Performance ◽  
Turning Process ◽  
Machining Time ◽  
Toolpath Optimization ◽  
The Impact

Abstract In this article, a novel approach to computer optimization of CNC toolpaths by adjustment of cutting speed vcand depth of cut apis presented. Available software works by the principle of adjusting feed rate on the basis of calculations and numerical simulation of the machining process. The authors wish to expand upon this approach by proposing toolpath optimization by altering two other basic process parameters. Intricacies and problems related totheadjustment of apand vcwere explained in the introductory part. Simulation of different variant of the same turning process with different parameter values were conducted to evaluate the effect of changes in depth of cut and cutting speed on process performance. Obtained results were investigated on the account of cutting force and tool life. The authors have found that depth of cut substantially affects cutting force, while the effect of cutting speed on it is minimal. An increase in both depth of cut and cutting speed affects tool life negatively, although the impact of cutting speed is much more severe. An increase in depth of cut allows for a more significant reduction of machining time, while affecting tool life less negatively. On the other hand, the adjustment of cutting speed helpsto reduce machining time without increasing cutting force component values and spindle load.

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