Title: Cutting tool condition monitoring system for high-speed turning operations

Authors: H. Chelladurai, V.K. Jain, N.S. Vyas

Addresses: Department of Mechanical Engineering, Indian Institute of Technology Kanpur, Kanpur 208016, UP, India. ' Department of Mechanical Engineering, Indian Institute of Technology Kanpur, Kanpur 208016, UP, India. ' Department of Mechanical Engineering, Indian Institute of Technology Kanpur, Kanpur 208016, UP, India

Abstract: In this paper, an attempt has been made to create artificial flank wear using Electrical Discharge Machining (EDM) process. Experiments have been conducted to evaluate vibration and strain responses of cutting tool for various cutting speeds, depths of cut and feed rates. To increase the confidence limit, experimental work has been carried out for full factorial design (135 experiments). Vibration and strain data from the cutting process are recorded using two accelerometers and a strain gauge bridge. Power spectral analysis is carried out and a statistical model is developed for empirical prediction of the condition of the cutting tool. The amplitude of vibration and strain were measured at the tool|s natural frequency. Experimental results are analysed with respect to depth of cut, feed rate and cutting speed.

Keywords: cutting tool wear; multiple sensors; vibration; strain signals; flank wear; electrical discharge machining; electro-discharge machining; EDM; high speed machining; turning; condition monitoring; tool monitoring; cutting speed; depth of cut; feed rate; wear monitoring.

DOI: 10.1504/IJMTM.2010.034289

International Journal of Manufacturing Technology and Management, 2010 Vol.21 No.1/2, pp.99 - 111

Published online: 31 Jul 2010 *

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