Cutting tool wear is found to be the major cause affecting the finished product in term of surface finish quality, dimensional precision and the cost of the defect. This paper proposes the development of a reliable machine condition monitoring system by using a low-cost piezoelectric sensor to monitor the flank wear progression on the cutting tool. The wear of the cutting insert was measured an...

A model of the flank wear of cutting tools is developed by using linear control theory. The flank wear is assumed to consist of a mechanically activated and a thermally activated component. The wear process is mathematically treated as a feedback process, whereby the progressive wear raises the cutting forces and temperature thereby increasing the thermally activated wear-rate, and contributes ...

In this research work a series of tests were conducted in order to determine flank wear and cutting force FY on hard AISI 440 C martensitic stainless steel and SCM 440 alloy steels. The operating parameters are cutting speed, feed rate and a constant depth of cut to investigate the flank wear and cutting force. No cutting fluid was used during the turning process. The cutting tool used was CBN ...

Reliable tool wear monitoring system is one of the important aspects for achieving a self-adjusting manufacturing system. The original contribution of the research is the developed monitoring system that can detect tool breakage in real time by using a combination of neural decision system and ANFIS tool wear estimator. The principal presumption was that force signals contain the most useful in...

In this paper, predictive modeling of cutting and ploughing forces, stress distributions on tool faces, and temperature distributions in the presence of tool flank wear are presented. The analytical and thermal modeling of orthogonal cutting that is introduced in Part I of the paper is extended for worn tool case in order to study the effect of flank wear on the predictions. Work material const...

In this study, 3-D finite element modeling of precision hard turning has been used to investigate the effects of cutting edge microgeometry on tool forces, temperatures and stresses in machining of AISI H13 steel using polycrystalline cubic boron nitrite (PCBN) inserts with two distinct edge preparations. Hard turning experiments were conducted to investigate the effects of cutting edge geometr...

Original scientific paper In this paper, the orthogonal cutting force model is proposed comprising forces due to flank wear in addition to the forces for chip formation during the hard turning of round bar made of steel 60WCrV7 hardened at 55+2HRc. Cutting force model includes two tool conditions: perfectly sharp tool with VBB = 0 and tool with maximum permissible flank wear VBBmax. Based on cu...

ABSTRACT Inconel 718 is a difficult-to-cut nickel-based superalloy commonly used in aerospace industry. This paper presents an experimental study of the tool wear propagation and cutting force variations in the end milling of Inconel 718 with coated carbide inserts. The experimental results showed that significant flank wear was the predominant failure mode affecting the tool life. The tool fla...

abstract: the lifetime of a cutting tool is an important and determinant parameter for evaluating its performance. the amount of tool abrasion affects seriously dimensions and surface quality of the working piece so that one of the main factors to determine the lifetime of a tool is the level of its wearing. for this purpose, an abrasion standard is defined for each particular tool above which ...

Bimetallic parts are used in many industries for weight and cost reduction of workpieces working under high loads and wear. One application for this type of composite material is in automotive industry. In this work the tool wear and cutting forces in the face milling of bimetallic parts made of aluminum and cast iron were investigated. A356 and GG25 alloys that are common materials for bimetal...