What Sound Can Be Expected From a Worn Tool?

Abstract

This paper describes an electronic-mechanical system which utilizes sonic signals to detect the degree of cutting edge wear in metalworking tools and automatically trigger a cutting edge change. A packaged electronic unit reads out sonic vibrations from an instrumented machine-tool workpiece cutting-tool system to determine degree of cutting edge wear during a turning cut. At a predetermined comparative sonic ratio, the electronic unit commands stoppage of the machine tool feed, retraction of the tool and automatic index of the cemented carbide insert to the next good cutting edge. The latter function is performed by a prototype mechanical device. The paper describes the system and cites data generated during use of the sonic detection system with five grades of cemented carbide cutting AISI 1045 steel. Results under varying cutting conditions are reported. The authors speculate on the possibility of combining such a wear detection and cutting edge indexing arrangement with a computer to provide a complete system for optimum productivity and economy in a completely automatic operation.

Lathe stability charts via acoustic emission monitoring

“…Thus, as the crater wear progresses, the general tool geometry can vary considerably. In particular the effective rake angle increases [17]. As the rake angle increases the amount of AE generated in the cutting zone is expected to decrease, in agreement with the theoretical model (Eqn.…”

“…The decrease of AE due to an increase in rake angle has actually been observed by Teti and Dornfeld [15]. Weller et al [17] also observed a reduction in sound level due to cratering. Therefore during chatter, AE generated can be reduced considerably.…”

Feature-filtered fuzzy clustering for condition monitoring of tool wear

“…In the past few decades, several researchers have made significant contributions to reveal the relationship between tool wear and various features, such as forces (Krnig et al, 1972), power consumption of a spindle motor (Micheletti et al, 1976), vibration (Weller et al, 1969), and acoustic emission (Iwata and Moriwaki, 1977) for on-line tool wear monitoring. In general, there are two ways to describe the wear states of a cutting tool: one is quantitative and the other is qualitative.…”

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

“…1967). Weller et al (1969) used the sound emanating from the cutting operation as the indicator of tool wear. Machine operators have recognized for some time that the cutting tool emits different sounds as wear proceeds through its various stages toward tool failure.…”