A quantitative model of acoustic emissions in orthogonal cutting operations

Acoustic Emissions (AE) in cutting processes have shown a significant potential for the condition monitoring of tool wear. Attempts have been made to develop some relationship between acoustic emission and basic cutting parameters in turning operations. These models however, lack accuracy in the prediction of AE and hence are unsuitable for use in the adaptive control of machining operations. This paper presents a new model which incorporates a relationship between AE root mean square (RMS) voltage, cutting parameters, tool geometry and workpiece material in orthogonal cutting operations. A realistic seize ratio and computational statistical techniques have been employed for improving the accuracy of the developed theoretical model. A satisfactory agreement between the AE(RMS) values predicted by the mathematical model and those experimentally measured has been observed.