Condition monitoring of turning process using infrared thermography technique – An experimental approach

In metal cutting machining, major factors that affect the cutting tool life are machine tool vibrations, tool tip/chip temperature and surface roughness along with machining parameters like cutting speed, feed rate, depth of cut, tool geometry, etc., so it becomes important for the manufacturing industry to find the suitable levels of process parameters for obtaining maintaining tool life. Heat generation in cutting was always a main topic to be studied in machining. Recent advancement in signal processing and information technology has resulted in the use of multiple sensors for development of the effective monitoring of tool condition monitoring systems with improved accuracy. From a process improvement point of view, it is definitely more advantageous to proactively monitor quality directly in the process instead of the product, so that the consequences of a defective part can be minimized or even eliminated.In the present work, a real time process monitoring method is explored using multiple sensors. It focuses on the development of a test bed for monitoring the tool condition in turning of AISI 316L steel by using both coated and uncoated carbide inserts. Proposed tool condition monitoring (TCM) is evaluated in the high speed turning using multiple sensors such as Laser Doppler vibrometer and infrared thermography technique. The results indicate the feasibility of using the dominant frequency of the vibration signals for the monitoring of high speed turning operations along with temperatures gradient. A possible correlation is identified in both regular and irregular cutting tool wear. While cutting speed and feed rate proved to be influential parameter on the depicted temperatures and depth of cut to be less influential. Generally, it is observed that lower heat and temperatures are generated when coated inserts are employed. It is found that cutting temperatures are gradually increased as edge wear and deformation developed.     

Theoretical and experimental investigations on rotary ultrasonic surface micro-machining of brittle materials

Many brittle materials, such as single-crystal materials, amorphous materials, and ceramics, are widely used in many industries such as the energy industry, aerospace industry, and biomedical industry. In recent years, there is an increasing demand for high-precision micro-machining of these brittle materials to produce precision functional parts. Traditional ultra-precision micro-machining can lead to workpiece cracking, low machined surface quality, and reduced tool life. To reduce and further solve these problems, a new micro-machining process is needed. As one of the nontraditional machining processes, rotary ultrasonic machining is an effective method to reduce the issues generated by traditional machining processes of brittle materials. Therefore, rotary ultrasonic micro-machining (RUμM) is investigated to conduct the surface micro-machining of brittle materials. Due to the small diameter cutting tool (<500 μm) and high accuracy requirements, the impact of input parameters in the rotary ultrasonic surface micro-machining (RUSμM) process on tool deformation and cutting quality is extremely different from that in rotary ultrasonic surface machining (RUSM) with relatively large diameter cutting tool (∼10 mm). Up till now, there is still no investigation on the effects of ultrasonic vibration (UV) and input variables (such as tool rotation speed and depth of cut) on cutting force and machined surface quality in RUSμM of brittle materials. To fill this knowledge gap, rotary ultrasonic surface micro-machining of the silicon wafer (one of the most versatile brittle materials) was conducted in this study. The effects of ultrasonic vibration, tool rotation speed, and depth of cut on tool trajectory, material removal rate (MRR), cutting force, cutting surface quality, and residual stress were investigated. Results show that the ultrasonic vibration could reduce the cutting force, improve the cutting surface quality, and suppress the residual compressive stress, especially under conditions with high tool rotation speed.     

DYNAMICS OF CUTTING TOOL TEMPERATURES DURING CUTTING PROCESS

An experimental study is performed to measure temperature variation of a carbide insert during metal cutting by means of fine thermocouples connected to a data acquisition system. A semiempiriad equation is developed based on transient conduction solutions combined with experimental data to predict temperature-time history in the cutting tool during operation. The governing parameters in the equation are derived, using AISI 1045 steel as the workpiece, to be the cutting speed, feed rate, and depth of cut at fixed rake and lead angles. Emphasis is placed on analyzing effects of the important factors on the cutting process, such as frictional heat generated at the tool-workpiece interface and wear of the tool. Dynamic behavior of the metal cutting process as predicted by the direct thermocouple measurement agreed with phenomenological observations reported in the existing literature.     

单点金刚石车削加工切削距离的计算

讨论了大型金属反射镜在金刚石车削中,金刚石刀具的磨损对加工精度的影响;详细介绍了超精密加工中几种典型零件形状单点金刚石车削加工的切削距离计算方法,经计算在加工直径为1000mm的圆盘工件时,当刀具的进给量为2μm/r,切削距离达到近400km。通过计算为加工大型光学元件刀具磨损规律的研究提供分析基础。     

Application of Machine Learning for Tool Condition Monitoring in Turning

The machining process is primarily used to remove material using cutting tools. Any variation in tool state affects the quality of a finished job and causes disturbances. So, a tool monitoring scheme (TMS) for categorization and supervision of failures has become the utmost priority. To respond, traditional TMS followed by the machine learning (ML) analysis is advocated in this paper. Classification in ML is supervised based learning method wherein the ML algorithm learn from the training data input fed to it and then employ this model to categorize the new datasets for precise prediction of a class and observation. In the current study, investigation on the single point cutting tool is carried out while turning a stainless steel (SS) workpeice on the manual lathe trainer. The vibrations developed during this activity are examined for failure-free and various failure states of a tool. The statistical modeling is then incorporated to trace vital signs from vibration signals. The multiple-binary-rule-based model for categorization is designed using the decision tree. Lastly, various tree-based algorithms are used for the categorization of tool conditions. The Random Forest offered the highest classification accuracy, i.e., 92.6%.

     

切削参数对新型光学铝级金刚石车削刀具磨损的影响

光学器件和光学测量系统的关键部件主要通过超精密加工制造。铝合金具有很多优势,通常用于光子产业。光学领域对铝合金使用和需求的不断增加,促进了在铸造过程中采用快速凝固技术对铝合金等级重新改良的发展。优异的微观结构和改进的机械和物理性能是新型铝合金等级的特点。目前主要问题在于采用金刚石车削时,由于在切削性方面缺乏对铝合金性能的充分研究,导致机械加工数据库非常有限。本文通过改变金刚石的切削参数,测量切齿安装距超过4km时金刚石刀具的磨损,研究了快速凝固铝合金RSA 905的切削性能。改变的机械加工参数为切削速度、进给速度和切削深度。结果表明切削速度对金刚石刀具的磨损影响最大。主轴转速为500rpm、进给速度为25mm/min、切削深度为15μm时,刀具磨损达到最大值12.2μm;主轴转速为1750rpm、进给速度为5mm/min、切削深度为5μm时,刀具磨损达到最小值2.45μm。通常,较高的切削速度、较低的进给速度和较短的切削深度的组合可以减少金刚石刀具磨损。建立了模型统计以分析金刚石刀具磨损。通过该模型可以生成磨损图,从而确定切削参数产生最小磨损的区域。结果证明,快速凝固铝是更好的选择,为机械工程师使用这种材料提供了参考。     

Ultrasonic excitation affects friction interactions between food materials and cutting tools

In the food industry, ultrasonic cutting is used to improve separation by a reduction of the cutting force. This reduction can be attributed to the modification of tool–workpiece interactions at the cutting edge and along the tool flanks because of the superposition of the cutting movement with ultrasonic vibration of the cutting tool. In this study, model experiments were used to analyze friction between the flanks of a cutting tool and the material to be cut. Friction force at a commercial cutting sonotrode was quantified using combined cutting–friction experiments, and sliding friction tests were carried out by adapting a standard draw-off assembly and using an ultrasonic welding sonotrode as sliding surface. The impact of material parameters, ultrasonic amplitude, and the texture of the contacting food surface on friction force was investigated. The results show that ultrasonic vibration significantly reduces the sliding friction force. While the amplitude showed no influence within the tested range, the texture of the contact surface of the food affects the intensity of ultrasonic transportation effects. These effects are a result of mechanical interactions and of changes in material properties of the contact layer, which are induced by the deformation of contact points, friction heating and absorption heating because of the dissipation of mechanical vibration energy.     

Study of AFM-based nanometric cutting process using molecular dynamics

Three-dimensional molecular dynamics (MD) simulations are conducted to investigate the atomic force microscope (AFM)-based nanometric cutting process of copper using diamond tool. The effects of tool geometry, cutting depth, cutting velocity and bulk temperature are studied. It is found that the tool geometry has a significant effect on the cutting resistance. The friction coefficient (cutting resistance) on the nanoscale decreases with the increase of tool angle as predicted by the macroscale theory. However, the friction coefficients on the nanoscale are bigger than those on the macroscale. The simulation results show that a bigger cutting depth results in more material deformation and larger chip volume, thus leading to bigger cutting force and bigger normal force. It is also observed that a higher cutting velocity results in a larger chip volume in front of the tool and bigger cutting force and normal force. The chip volume in front of the tool increases while the cutting force and normal force decrease with the increase of bulk temperature.     

单晶金刚石刀具后刀面沟槽磨损的石墨化生成过程分析

单晶金刚石刀具切削单晶硅时后刀面会发生剧烈沟槽磨损,严重影响零件加工质量和刀具寿命。为了从金刚石石墨化转变角度揭示沟槽磨损生长扩展机制,建立了金刚石刀具后刀面具有初始沟槽的分子动力学模型,模拟了切削单晶硅时初始沟槽处的工件材料流动行为与金刚石刀具晶体结构变化情况。结果表明,初始沟槽的存在改变了工件材料的流动状态;并且这种材料流动引起了刀具初始沟槽附近温度和能量的变化,温度升高了8%,势能提高了1.4%;通过分析金刚石刀具晶体结构发现,初始沟槽处的刀具材料发生了石墨化转变,并通过计算采样点处原子间键角,得到了石墨化转化率随着切削的进行不断升高,并最终趋于恒定的规律,当切削进入到稳定切削阶段时,石墨化转化率约为6%。     

Force measurement in cutting metals at 100–700 m/sec

Kuznetsov [1] in 1947 proposed a new method of obtaining very high cutting speeds by firing past the tool. This method has been used in an apparatus for measuring the tangential component of the cutting force and for extracting swarf in undamaged form [2]. Recently there have been several papers [3–5] describing high-speed cutting tests by this method. Research on cutting is of interest also in relation to the behavior of materials at high speeds. Here we describe a method of measuring cutting forces, and results are given on the forces acting on the tool in free cutting of aluminum at 100–700 m/sec with various tool angles.     

Applications for ion implantation as a surface treatment process in production engineering

The special advantages offered by ion implantation for the treatment of metal components without inducing distortion or softening due to temperature rise are being examined in a number of industrial trials. Some examples of current evaluations are discussed covering manufacturing tools, dies and similar items. The types of potential application are broadly grouped into categories defined by cutting and drilling, corrosion and extrusion operations. The mechanisms for improved wear performance as a result of high dose gaseous ion implantation into tool steels and cemented tungsten carbide are briefly discussed.     

An approach based on tool mode control for surface roughness reduction in high-frequency vibration cutting

The presented research work, aimed at deeper understanding of vibrational process during high-frequency vibration cutting, is accomplished by treating cutting tool as an elastic structure which is characterized by several modes of natural vibrations. An approach for surface quality improvement is proposed in this paper by taking into account that quality of machined surface is related to the intensity of tool-tip (cutting edge) vibrations. It is based on the excitation of a particular higher vibration mode of a turning tool, which leads to the reduction of deleterious vibrations in the machine-tool-workpiece system through intensification of internal energy dissipation in the tool material. The combined application of numerical analysis with accurate finite element model as well as different experimental methods during investigation of the vibration turning process allowed to determine that the most favorable is the second flexural vibration mode of the tool in the direction of vertical cutting force component. This mode is excited by means of piezoelectric transducer vibrating in axial tool direction at the corresponding natural frequency, thereby enabling minimization of surface roughness and tool wear.     

一种曲线路径剪裁中刀具形变及其误差分析

动态移动切削阻力载荷对高速数控裁床加工过程中刀具形变及其剪裁误差具有的重要影响,提出了一种适用多层布料/皮革曲线剪裁路径的刀具形变及其误差计算方法;建立了动态负载条件下可伸缩刀具的挠度与转角方程,进而推导出高频振动裁刀剪裁误差及其随切削深度变化规律;计算结果表明,数控布料/皮革剪裁刀的动态载荷、高频振动参数、切削深度对剪裁误差具有重要影响,深入剖析高层数控裁床的加工机理,动态参数数据分析,对于提高机床加工效率,降低加工误差,提高刀具使用寿命具有一定的工程应用价值。     

Visualization of thermal cutting fluid flows

Outside of the fields where flow visualization is traditionally applied, there exist many processes where fluid phenomena are critical. Here, we survey flow visualization work with a focus on two thermal metal cutting processes. These two processes – plasma-arc cutting and gas assisted laser cutting – account for a large fraction of the means by which steel is cut in our world. Plasma-arc cutting utilizes an electric arc transferred between a cathode and the steel being cut to produce a high temperature gas jet that melts and removes metal. In gas assisted laser cutting, the assist jet is often high-pressure supersonic nitrogen for stainless steel, or near-atmospheric pressure, low-speed oxygen for carbon steel. Visualization of these millimeter-range diameter jets helps to understand the different roles that the assist gas has in these cutting processes, particularly with how the jets interact with the metal being cut. We describe experimental techniques for visualization of the arc jet and gas assist jet, as well as the liquid metal flows being removed from the cut and the gas flow in the torch itself. These visualizations overcome the small physical scales of the process, the bright illumination from the arc itself, and harsh high-temperature environment. The results lend perspective and understanding of the physical phenomena important to process control.     

EXPERIMENTAL AND NUMERICAL METHOD FOR DETERMINING TEMPERATURE DISTRIBUTION IN A WOOD CUTTING TOOL

A 2-D boundary-element model was used to solve the steady-state heat conduction problem in a wood cutting tool. Cutting experiments were conducted in order to measure temperatures at remote locations on the tool rake face and at the tool/holder interface. The tool/holder interface temperatures were used as inputs into the boundary-element model. Heat input into the tool was adjusted until predicted temperatures on the rake face agreed with experimental results. The proportion of the machining power conducted into the tool as heat was determined as a function of the cutting geometry, specific cutting energy, and cutting speed.     

单晶硅纳米切削中C–C键断裂对金刚石刀具磨损的影响

本文基于分子动力学方法模拟金刚石刀具纳米切削单晶硅, 从刀具的弹塑性变形、C–C键断裂对碳原子结构的影响以及金刚石刀具的石墨化磨损等方面对金刚石刀具的磨损进行分析, 采用配位数法和6元环法表征刀具上的磨损碳原子. 模拟结果表明: 在纳米切削过程中, 金刚石刀具表层C–C键的断裂使其两端碳原子由sp³杂化转变为sp²杂化, 同时, 表面上的杂化结构发生变化的碳原子与其第一近邻的sp²杂化碳原子所构成的区域发生平整, 由金刚石的立体网状结构转变为石墨的平面结构, 导致金刚石刀具发生磨损; 刀具表面低配位数碳原子的重构使其近邻区域产生扭曲变形, C–C键键能随之减弱, 在高温和高剪切应力的作用下, 极易发生断裂; 在切削刃的棱边上, 由于表面碳原子的配位严重不足, 断开较少的C–C键就可以使表面6 元环中碳原子的配位数都小于4, 导致金刚石刀具发生石墨化磨损.     

Longitudinal ultrasonic vibration assisted guillotining of stacked paper

Ultrasonic vibration assisted cutting is a complex process with high dynamics. The interaction between cutting tool and workpiece is of key interest to understand the entire process. Experimental investigations are limited by the dynamics of the measurement system, and thus appropriately modeling of the ultrasonic vibration assisted cutting process is essential. In this investigation, a dynamic model regarding the ultrasonic vibration assisted guillotining of stacked paper sheets is developed. A Kelvin–Voigt material model, representing the individual sheets, is chosen, with its stiffness and damping parameters being empirically determined. A novel measurement strategy for studying the contact time and interaction between cutting tool and workpiece is introduced. It allows the verification of the highly dynamic behavior of the developed model. With the dynamic model, the experimentally observed cutting forces can be calculated. It is found that the dynamic forces cause a quicker failure of the material, which leads to a lower compression of the stack prior to reaching the critical cutting force.     

Macrosonics in industry: 5. Ultrasonic machining

Ultrasonics has been used in cutting processes for many years. Slurry drilling is one area, for example, that has attained an accepted, though limited, status in manufacturing technology. Ultrasonic twist drilling is a more recent process aimed at achieving faster cutting speeds. Numerous other metal cutting configurations have been studied with varying success. Certain non-manufacturing applications, such as rock cutting and surgical and dental cutting tasks have emerged. This paper reviews these various areas, including the degree of commercial usage.     

Numerical–experimental identification of the most effective dynamic operation mode of a vibration drilling tool for improved cutting performance

This study is concerned with application of numerical–experimental approach for characterizing dynamic behavior of the developed piezoelectrically excited vibration drilling tool with the aim to identify the most effective conditions of tool vibration mode control for improved cutting efficiency. 3D finite element model of the tool was created on the basis of an elastically fixed pre-twisted cantilever (standard twist drill). The model was experimentally verified and used together with tool vibration measurements in order to reveal rich dynamic behavior of the pre-twisted structure, representing a case of parametric vibrations with axial, torsional and transverse natural vibrations accompanied by the additional dynamic effects arising due to the coupling of axial and torsional deflections ((un)twisting). Numerical results combined with extensive data from interferometric, accelerometric, dynamometric and surface roughness measurements allowed to determine critical excitation frequencies and the corresponding vibration modes, which have the largest influence on the performance metrics of the vibration drilling process. The most favorable tool excitation conditions were established: inducing the axial mode of the vibration tool itself through tailoring of driving frequency enables to minimize magnitudes of surface roughness, cutting force and torque. Research results confirm the importance of the tool mode control in enhancing the effectiveness of vibration cutting tools from the viewpoint of structural dynamics.     

A METHOD TO ESTIMATE THE AVERAGE TEMPERATURE ON THE CUTTING EDGE OF TOOLS: APPLICATION ON THE MILLING PROCESS

In this work we present an experimental technique for the estimation of the average temperature on the cutting edge of each insert in a milling tool. The experimental device used thermistors, one per insert, and a rotational collector in order to ensure the transmission of the signals between the rotating tool and the acquisition device. Each thermistor is located at a point in the tool close to the tip of each insert. The average temperature on the cutting edge of each insert is estimated from the temperature at the nearest sensor and a model expressing these two temperatures. This model is achieved from the noninteger system identification method.