Flank Wear Tool Condition Monitoring For Single Point Cutting Tool Using Acoustic Emission Techniques (AET)

摘要

In the recent years, the manufacturing environment has undergone dramatic changes. Because of the market pressure the trend is for saving cost of the production. i.e. to produce more items of good quality in less time. For achieving this goal great consideration is given to turning machining. Further it is a costly affair when product is not made to meet the quality specifications because of wear/tear or breakage of the tool. Unfortunately this happens without the machine operator suspecting anything until it suddenly does. In this paper theoretical and experimental study are carried out to investigate the intrinsic relationship between tool flank wear and operational conditions in metal cutting processes using carbide cutting inserts. A new flank wear rate model, which combines cutting mechanics simulation and an empirical model, is developed to predict tool flank wear land width. A set of tool wear cutting tests using hard metal coated carbide cutting inserts are performed under different operational conditions. The wear of the cutting inset is evaluated and recorded using FAC 500 model piezoelectric transducer AE sensor with 100 kHz to 2 MHz frequency range. The results of the experimental studies indicate that cutting speed has a more dramatic effect on tool life than feed rate. The wear constants in the proposed wear rate model are determined based on the machining data and simulation results. A good agreements between the predicted and measured tool flank wear land width show that the developed tool wear model can accurately predict tool flank wear to some extent. In this research work the results obtained from the analysis of Acoustic Emission sensor employs to predict flank wear in turning of C45 steel of 250 BHN hardness using coated carbide insert. The correlation between the tool wear and AE parameters is analyzed using the experimental study conducted in 5 H.P all geared lathe.