Cutting temperature responses to flank wear

This paper discusses one feature of a continuing research program with the ultimate objective of tracking continuously the deterioration of the machining process, which must be overcome in order to achieve unmanned machining stations. Recent work using the non-contact infrared (IR) thermographic technique to investigate the cutting temperatures during chip formation has shown a clear relationship between the measured chip-back temperatures and the tool-chip interface temperatures. This result and the very fast response of the technique provide the potential means for tracking the progress of tool wear. The measured temperature increases rapidly corresponding to a sudden breakdown of the sharp cutting edge; this is followed by a slight increase in the temperature with increasing uniform wear, and then by acceleration after a critical wear value has been reached. Other early results indicate a definite correlation between the measured temperature and tool flank wear, suggesting that control over the process is feasible if the chip-back temperatures are monitored during cutting.