TOOL-WEAR MONITORING IN MACHINE TURNING

Metal-cutting quality is normally affected by the contact conditions at the tool and workpiece interface. The wear on the tool is an important consideration for an effective unmanned machine-turning system. This paper presents the changes that can be detected in the vibration signatures during the machine turning operation. It is found that at various cutting speeds, the vibration amplitudes consistently produce two peaks throughout the life of the tool. A strong correlation between the tool flank wear and the acceleration amplitude of vibration is shown. This signal can be incorporated in a software program for an on-line monitoring system to indicate the onset of tool failure. The tool life as a function of the vibration amplitude is also established. The tool wear is therefore a major factor in assessing the life of the cutting tool and improving cutting performance.