Characteristic of wear, force and their inter-relationship: In-process monitoring of tool within different phases of the tool life

摘要

This paper mainly concentrates on mapping and understanding of the inter-relationship between the tool wear and cutting force/s in view of in-process monitoring of the tool during turning within the different phases of the tool life. Inter-relationship between the tool wear and cutting forces was studied using two different industrial state-of-the-art tool coatings; PVD-applied (Ti,Al)N and CVD-applied TiCN/Al2O3/TiN during turning of AISI 4340 steel. The experimental results show that the feed component and radial component are more influenced by tool wear and increase sharply when rapid deterioration of the cutting edge takes place. Gradual growth of flank wear, rapid deterioration of the cutting edge and catastrophic failure due to increased crater wear rate was correctly sensed by the force signals and boost up the existence of a strong interrelationship between the cutting force-wear-time within the different phases of tool life. This paper also presents mathematical modeling of the force-wear characteristic for better understanding of the relationship.