An innovative approach to monitor the chip formation effect on tool state using acoustic emission in turning

Bhuiyan, M.S.H.; Choudhury, Imtiaz Ahmed; Nukman, Y.

doi:10.1016/j.ijmachtools.2012.02.001

Cited by 50 publications

(9 citation statements)

References 28 publications

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“…This may be due to the effectiveness of the lubricant and cooling in minimizing the frictional effects at the tool-workpiece interface, relative to the cutting forces seen for dry and MQL machining. The chip formation and breaking aspect play an important role in cutting process optimization, surface finish, workpiece accuracy, and tool life (Bhuiyan, Choudhury, and Nukman 2012). Furthermore, chip formation is generally dependent on the mechanical properties of the work materials, tool geometry (particularly rake angle), cutting parameters, nature of the chip-tool interaction, and the cutting environment.…”

Section: Experimental Apparatusmentioning

confidence: 99%

Development of a novel cooling system-assisted minimum quantity lubrication method for improvement of milling performance

Tsai

et al. 2014

Journal of the Chinese Institute of Engineers

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This paper presents a novel lubrication method for milling processes that employs cooling system-assisted minimum quantity lubrication (CSMQL) using a thermoelectric cooling system. The CSMQL method improves the cooling effect in the cutting area and enhances processing quality, in addition to reducing energy consumption. Four different coolant strategies including CSMQL, dry, minimum quantity lubrication (MQL), and wet methods were compared in processing mill die steel (SKD11), which is widely used in industry. Different aspects of the milling performance (e.g. surface roughness, morphology, milling temperature, and milling forces) were investigated using these coolant strategies. The experimental results show that not only is the surface roughness of steel milled using CSMQL better than that of steel milled using dry and MQL methods, but CSMQL also produces fewer tool marks on the workpiece surface. In addition, it was found from observations of chip color that using the CSMQL method reduced the cutting temperature by 27% and the cutting force by 22%, compared with dry machining. In summary, the use of CSMQL can not only improve the surface roughness and reduce the cutting force and cutting temperature, but also promote processing quality. This study will help researchers develop more efficient cooling strategies in the future.

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Section: Experimental Apparatusmentioning

confidence: 99%

Development of a novel cooling system-assisted minimum quantity lubrication method for improvement of milling performance

Tsai

et al. 2014

Journal of the Chinese Institute of Engineers

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“…The rubber insulation and the data-acquisition system (cut off frequencies below 50 kHz) collectively have made the passive tool signal independent. The effectiveness of the insulation was tested and found to be acceptable in the previous work [15]. The passive tool-setup was …”

Section: Methodsmentioning

confidence: 97%

“…Therefore, the statement, 'the resultant vibration represents the surface roughness of workpiece' can similarly be applied to the surface roughness at different flank wear for a particular cutting condition. This investigation could successfully identify the damaging factors for cutting tool condition based on the AE and vibration signals, whereas Segreto et al [15] captured AE, force and vibration signals together just to classify the fresh and worn tool. In this study, the tool state was determined by signal pattern recognition and with a marginal signal process; whereas the investigation carried out by Segreto et al [15] demanded an integration of data and a neural network system to analyze the captured signals to identify the tool condition.…”

Section: Signals At Different Stages Of Tool Lifementioning

confidence: 99%

“…This investigation could successfully identify the damaging factors for cutting tool condition based on the AE and vibration signals, whereas Segreto et al [15] captured AE, force and vibration signals together just to classify the fresh and worn tool. In this study, the tool state was determined by signal pattern recognition and with a marginal signal process; whereas the investigation carried out by Segreto et al [15] demanded an integration of data and a neural network system to analyze the captured signals to identify the tool condition. Therefore, the method proposed for sensor based monitoring was capable of investigating the different occurrences in turning and determining the tool condition in a simple manner with minimal signal processing.…”

Section: Signals At Different Stages Of Tool Lifementioning

confidence: 99%

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An Investigation into Turning of ASSAB-705 Steel Using Multiple Sensors

Bhuiyan¹,

Choudhury²,

Dahari³

et al. 2015

Materials and Manufacturing Processes

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The complex behavior of various occurrences in turning has made the tool condition and process monitoring with a conventional tool-sensor setup difficult. An additional passive tool arrangement has been adopted to circumvent the multifaceted mechanism of different occurrences and thus to investigate them by measuring the acoustic emission (AE), and vibration signals produced thereof. The investigation shows that both the AE and the radial vibration component, V y can independently assess the chip formation effect on cutting process and tool state. The tangential vibration component, V z can effectively evaluate the rate of flank wear progression whereas the resultant vibration components are efficient in measuring the surface roughness of workpiece in turning. The feed directional vibration, V x is always maximal regardless of cutting variables, tool wear, surface roughness and chip formation type. The application of vibration sensor can eliminate the necessity of the additional passive tool setup, and jointly with the AE sensor can investigate the process and cutting tool condition more promisingly.

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“…Импульсные сигналы АЭ связывают с разрушением режущего инструмента. Такие подходы используются при исследовании всех виды механической обработки материалов, в том числе и КМ [2,[4][5][6].…”

Section: анализ литературных данных и постановка проблемыunclassified

Infuencing processed composite material priperties on acoustic emission

Filonenko

2015

EEJET

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Проведено моделювання сигналів акустичної емісії при механічній обробці в залежності від властивостей поверхневого прошарку композиційного матеріалу, що руйнується, для механічної моделі акустичного випромінювання. Показано, що зростання значення параметру, який визначається властивостями матеріалу, приводить до падіння амплітудних характеристик акустичної емісії. Визначено, що найбільше падіння має дисперсія середнього рівня амплітуди сигналу акустичної емісії Ключові слова: акустична емісія, композиційний матеріал, сигнал, амплітуда, механічна обробка, площа руйнування Проведено моделирование сигналов акустической эмиссии при механической обработке в зависимости от свойств разрушаемого поверхностного слоя композиционного материала для механической модели акустического излучения. Показано, что возрастание значения параметра, определяемого свойствами материала, приводит к падению амплитудных характеристик акустической эмиссии. Определено, что наибольшее падение имеет дисперсия среднего уровня амплитуды сигнала акустической эмиссии Ключевые слова: акустическая эмиссия, композиционный материал, сигнал, амплитуда, механическая обработка, площадь разрушения

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An innovative approach to monitor the chip formation effect on tool state using acoustic emission in turning

Cited by 50 publications

References 28 publications

Development of a novel cooling system-assisted minimum quantity lubrication method for improvement of milling performance

Development of a novel cooling system-assisted minimum quantity lubrication method for improvement of milling performance

An Investigation into Turning of ASSAB-705 Steel Using Multiple Sensors

Infuencing processed composite material priperties on acoustic emission

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