A study of the relationship between remote thermocouple temperatures and tool wear in machining

Abstract

Experimental data. are presented which demonstrate a strong correlation between tool wear and the signal of a thermocouple located at a position on the cutting tool remote from the cutting edge. A mathematical model is proposed for explaining this relationship between tool wear and. temperature. The model is supported by good statistica.! agreement between the data and the form of the proposed equation. For Q total of nine different machining conditions with replications for several of the conditions, the correlation coefficient ranged in vsJue between 1),837 and 1),978. IntroductionSince about 1962, there have been a number of attempts to develop relationships between tool wear and other process variables in metal cutting. The motivation behind these efforts has been to determine a scheme for estimating tool wear while the cut was in progress. Work sponsored by the United States Air Force at the Bendix Research Laboratories (1964) led to a proposed tool wear rate expression based on measured values of metal removal rate, cutting temperature and torque rate of change. Another study was based on the use

A cutting damping index for real-time monitoring of tool wear in turning

“…Neither method is suitable for on-line tool wear measurement due to long processing times and potential hazards. Other direct methods use tool/work junction electrical resistance (Groover et al 1977), workpiece size changing (Koren et al 1991) and tool/work distance (Gamaye I and Bregger 1986) as the parameters to estimate tool wear in a turning process. However, Revision received December 1993.…”

An adaptive observer for on-line tool wear estimation in turning, Part I: Theory

“…The discrete-time form of the linear model is defined by equations (11) and (12). The transfer function of this model is defined by equation (13).…”

Multimilling-Insert Wear Assessment Using Non-Linear Virtual Sensor, Time-Frequency Distribution and Neural Networks

“…Direct methods include optical [2], wear particle [3], radioactivity [4], tool/work-piece junction electrical resistance [5], pneumatic [6] and tool/work-piece distance measurements [7,8]. Indirect methods include those measuring cutting force [9], acoustic emission [10,11] motor power/current [12], vibration [13], cutting temperature [14], roughness [15], damping index [16], friction coe$cient [17], either alone or in combination [18]. These studies deal exclusively with turning operations which use non-rotating single point tools.…”