Tool Wear Detection Based on Duffing-Holmes Oscillator

The cutting sound in the audible range includes plenty of tool wear information. The sound is sampled by the acoustic emission AE sensor as a short-time sequence, then worn wear can be detected by the Duffing-Holmes oscillator. A novel engineering method is proposed for determining the chaotic threshold of the Duffing-Holmes oscillator. First, a rough threshold value is calculated by local Lyapunov exponents with a step size 0.1. Second, the exact threshold value is calculated by the Duffing-Holmes system in terms of the law of the golden section. The advantage of the method is low computation cost. The feasibility for tool condition detection is demonstrated by the 27 kinds of cutting conditions with sharp tool and worn tool in turning experiments. The 54 group data sampled as noisy are embedded into the Duffing-Holmes oscillator, respectively. Finally, one chaotic threshold is determined conveniently which can distinguish between worn tool or sharp tool.