Detection of Cutting Edge Breakage in Turning

Advanced monitoring of machining operations

“…They applied digital filters to separate two frequency ranges of cutting force signals: the low frequency range was an indication of static cutting forces and the high-frequency range of the natural frequencies of the toolholder which resulted from the excitation of the cutting operation. Jemielniak [74] used low-pass filtering of cutting force signals for catastrophic tool failure detection in turning based on the detection of sudden force value changes. The filtering allowed a much lower tolerance band on the limit set on force value.…”

Detecting tool breakage in turning aisi 1050 steel using coated and uncoated cutting tools

“…If the limit of cutting force changes before two revolutions of workpiece is completed, no tool breakage warning is generated. In the other work, it has been stated that after catastrophic tool failure occurs the average level of the cutting forces stays stable during at least one workpiece revolution [1]. Hence this helps to distinguish catastrophic tool failure from other disturbances.…”

“…Hence industry needs a system that can detect the tool fracture in real-time and stop the feed motion soon enough to avoid considerable deterioration of the production. One of the most commonly used techniques in detecting the tool failure is based on measuring of cutting force components [1].…”

“…In the event of catastrophic tool failure the cutting force rapidly increases and after about 2 or 3 ms the force drops due to the gap between the tool and the workpiece. The increase of force above the preset threshold and a sudden drop is considered to be a tool failure [1]. Tool breakage is time critical because it may induce fatal damages to machine, workpiece and operator.…”

Methods and Research for Multi-Component Cutting Force Sensing Devices and Approaches in Machining

“…Multi-component cutting force sensing systems have gradually become known as the most reliable indicators of important cutting action information, and have been widely used to predict and evaluate cutting tool conditions such as wear and breakage of the cutting tool [70,71,72,73,74]. …”