Cutting tool wear progression index via signal element variance

Abstract

This paper presents a new statistical-based method of cutting tool wear progression in a milling process called Z-rotation method in association with tool wear progression. The method is a kurtosis-based that calculates the signal element variance from its mean as a measurement index. The measurement index can be implicated to determine the severity of wear. The study was conducted to strengthen the shortage in past studies notably considering signal feature extraction for the disintegration of non-deterministic signals. The Cutting force and vibration signals were measured as a tool of sensing element to study wear on the cutting tool edge at the discrete machining conditions. The monitored flank wear progression by the value of the RZ index, which then outlined in the model data pattern concerning wear and number of samples. Throughout the experimental studies, the index shows a significant degree of nonlinearity that appears in the measured impact. For that reason, the accretion of force components by Z-rotation method has successfully determined the abnormality existed in the signal data for both force and vibration. It corresponds to the number of cutting specifies a strong correlation over wear evolution with the highest correlation coefficient of R2 = 0.8702 and the average value of R2 = 0.8147. The index is more sensitive towards the end of the wear stage compared to the previous methods. Thus, it can be utilised to be the alternative experimental findings for monitoring tool wear progression by using threshold values on certain cutting condition.

Analysis of tool vibration and surface roughness with tool wear progression in hard turning: An experimental and statistical approach

“…From the Table 7, it can be concluded that feed has the highest statistical significance followed by 'V' while parameter'd' was discover less effect on Ra. This shows acceptable concurrence with Auici et al [3], D'Mello et al [21] and Boy et al [25]. The interactions V×f has statistical and physical significance on Ra.…”

“…The conventional processes for turning hardened steel are electricdischarge and grinding; and are in limited is use due to high tooling cost, low surface finish and material removal rate, faster wear. To overcome these drawbacks, these materials are turned with the super-hard cutting tools and process is referred as hard turning [3][4]. It is reported that this process is performed with no cooling media.…”

“…The much of the time utilized coatings incorporate TiN, TiAlN, TiCN, TiAlCN Al2O3 [9][10][11][12][13]. The performance of cutting tool with and without coatings in terms of cutting force [3][4], surface roughness [9][10][11][12][13], chip morphology [15] and acoustic emission [16] with various grades of the cutting tools is studied by different researchers and in-depth review related process parameter is reported by Ambhore et al [17].…”

Process monitoring in end milling using polar figures

“…Similar methods are being developed over the past 10 years at the Universiti Kebangsaan Malaysia from various researchers. They use the standard deviation of a force signal and its higher-order statistical measures (skewness and kurtosis) to calculate a tool wear indicator [10][11][12][13]. Fussel et al also use the force signal to calculate the coefficients of a force model.…”

Substantiation of the parameters of the process of plasma-mechanical milling of titanium alloys and alloyed steels

“…Productive processing of billets of alloy steels, which are used in large volumes in all industries, is also an urgent task. Reduction deadlines manufacturing products engineering in a lot associated with a raise performance milling planes, edges, chamfers for welding and other parts that are in parts durable titanium ship hull [2]. A significant part of the total volume of milling occurs in extreme conditions -on the scale, with large cross section of cut.…”