ON-LINE MONITORING OF FLANK WEAR IN SINGLE POINT CUTTING TOOL USING ULTRASONIC TECHNIQUE
Keywords:
Tool wear, condition monitoring, ultrasonic sensing, ultrasonic attenuation, ultrasonic reflection coefficient, peak to peak amplitude, time of flight, pulse widthAbstract
The condition of tool and the cutting process are the essential inputs to any productivity improvements in unmanned machining. Generally tool replacement and tool wear compensation strategies are based on previous experiences or tool history. On-line monitoring of tool increases the cutting tool utilization by 20% and also gives better surface quality; however, few reliable and robust indirect methods have yet been established for industrial use. This is mainly due to the complexity of the machining process and uncertainty in the correlation between the process parameters and tool wear. So promising methods are yet to be developed for detecting the tool wear. Ultrasonic technique is proposed for detecting the tool wear in machining process by on-line monitoring. Ultrasonic testing uses A- scan to evaluate the depth, position and area of tool wear. An integrated ultrasonic transducer operating at a frequency of 1-20 MHz is placed in contact with the tool. The change in amount of reflected energy from the nose and the flank of the tool, amplitude level, TOF and pulse width can be related to the wear of the tool.
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References
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