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A new approach to investigate tool condition using dummy tool holder and sensor setup

The industrial demand for automated machining systems to enhance process productivity and quality in machining aerospace components requires investigation of tool condition monitoring. The formation of chip and its removal have a remarkable effect on the state of the cutting tool during turning. Thi...

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Main Authors:	Choudhury, I.A., Bhuiyan, M.S.H., Nukman, Y.
Format:	Article
Language:	English
Published:	Springer Verlag (Germany) 2012
Subjects:	TJ Mechanical engineering and machinery
Online Access:	http://eprints.um.edu.my/10485/1/A_new_approach_to_investigate_tool_condition_using_dummy.pdf http://eprints.um.edu.my/10485/ http://link.springer.com/article/10.1007%2Fs00170-011-3722-7
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spelling	my.um.eprints.104852014-10-27T02:46:44Z http://eprints.um.edu.my/10485/ A new approach to investigate tool condition using dummy tool holder and sensor setup Choudhury, I.A. Bhuiyan, M.S.H. Nukman, Y. TJ Mechanical engineering and machinery The industrial demand for automated machining systems to enhance process productivity and quality in machining aerospace components requires investigation of tool condition monitoring. The formation of chip and its removal have a remarkable effect on the state of the cutting tool during turning. This work presents a new technique using acoustic emission (AE) to monitor the tool condition by separating the chip formation frequencies from the rest of the signal which comes mostly from tool wear and plastic deformation of the work material. A dummy tool holder and sensor setup have been designed and integrated with the conventional tool holder system to capture the time-domain chip formation signals independently during turning. Several dry turning tests have been conducted at the speed ranging from 120 to 180 m/min, feed rate from 0.20 to 0.50 mm/rev, and depth of cut from 1 to 1.5 mm. The tool insert used was TiN-coated carbide while the work material was high-carbon steel. The signals from the dummy setup clearly differ from the AE signals of the conventional setup. It has been observed that time-domain signal and corresponding frequency response can predict the tool conditions. The rate of tool wear was found to decrease with chip breakage even at higher feed rate. The tool wear and plastic deformation were viewed to decrease with the increased radius of chip curvature and thinner chip thickness even at the highest cutting speed, and these have been verified by measuring tool wear. The chip formation frequency has been found to be within 97.7 to 640 kHz. Springer Verlag (Germany) 2012-07 Article PeerReviewed application/pdf en http://eprints.um.edu.my/10485/1/A_new_approach_to_investigate_tool_condition_using_dummy.pdf Choudhury, I.A. and Bhuiyan, M.S.H. and Nukman, Y. (2012) A new approach to investigate tool condition using dummy tool holder and sensor setup. The International Journal of Advanced Manufacturing Technology, 61 (5-8). pp. 465-479. ISSN 0268-3768 http://link.springer.com/article/10.1007%2Fs00170-011-3722-7 DOI: 10.1007/s00170-011-3722-7
institution	Universiti Malaya
building	UM Library
collection	Institutional Repository
continent	Asia
country	Malaysia
content_provider	Universiti Malaya
content_source	UM Research Repository
url_provider	http://eprints.um.edu.my/
language	English
topic	TJ Mechanical engineering and machinery
spellingShingle	TJ Mechanical engineering and machinery Choudhury, I.A. Bhuiyan, M.S.H. Nukman, Y. A new approach to investigate tool condition using dummy tool holder and sensor setup
description	The industrial demand for automated machining systems to enhance process productivity and quality in machining aerospace components requires investigation of tool condition monitoring. The formation of chip and its removal have a remarkable effect on the state of the cutting tool during turning. This work presents a new technique using acoustic emission (AE) to monitor the tool condition by separating the chip formation frequencies from the rest of the signal which comes mostly from tool wear and plastic deformation of the work material. A dummy tool holder and sensor setup have been designed and integrated with the conventional tool holder system to capture the time-domain chip formation signals independently during turning. Several dry turning tests have been conducted at the speed ranging from 120 to 180 m/min, feed rate from 0.20 to 0.50 mm/rev, and depth of cut from 1 to 1.5 mm. The tool insert used was TiN-coated carbide while the work material was high-carbon steel. The signals from the dummy setup clearly differ from the AE signals of the conventional setup. It has been observed that time-domain signal and corresponding frequency response can predict the tool conditions. The rate of tool wear was found to decrease with chip breakage even at higher feed rate. The tool wear and plastic deformation were viewed to decrease with the increased radius of chip curvature and thinner chip thickness even at the highest cutting speed, and these have been verified by measuring tool wear. The chip formation frequency has been found to be within 97.7 to 640 kHz.
format	Article
author	Choudhury, I.A. Bhuiyan, M.S.H. Nukman, Y.
author_facet	Choudhury, I.A. Bhuiyan, M.S.H. Nukman, Y.
author_sort	Choudhury, I.A.
title	A new approach to investigate tool condition using dummy tool holder and sensor setup
title_short	A new approach to investigate tool condition using dummy tool holder and sensor setup
title_full	A new approach to investigate tool condition using dummy tool holder and sensor setup
title_fullStr	A new approach to investigate tool condition using dummy tool holder and sensor setup
title_full_unstemmed	A new approach to investigate tool condition using dummy tool holder and sensor setup
title_sort	new approach to investigate tool condition using dummy tool holder and sensor setup
publisher	Springer Verlag (Germany)
publishDate	2012
url	http://eprints.um.edu.my/10485/1/A_new_approach_to_investigate_tool_condition_using_dummy.pdf http://eprints.um.edu.my/10485/ http://link.springer.com/article/10.1007%2Fs00170-011-3722-7
_version_	1643688810928668672
score	13.211869

A new approach to investigate tool condition using dummy tool holder and sensor setup

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