Abstract
In precision hard turning, tool flank wear is one of the major factors contributing to the geometric error and thermal damage in a machined workpiece. Tool wear not only directly reduces the part geometry accuracy but also increases the cutting forces drastically. The change in cutting forces causes instability in the tool motion, and in turn, more inaccuracy. There are demands for reliably monitoring the progress of tool wear during a machining process to provide information for both correction of geometric errors and to guarantee the surface integrity of the workpiece. A new method for tool wear monitoring in precision hard turning is presented in this paper. The flank wear of a CBN tool is monitored by feature parameters extracted from the measured passive force, by the use of a force dynamometer. The feature parameters include the passive force level, the frequency energy and the accumulated cutting time. An ANN model was used to integrate these feature parameters in order to obtain more reliable and robust flank wear monitoring. Finally, the results from validation tests indicate that the developed monitoring system is robust and consistent for tool wear monitoring in precision hard turning.
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Acknowledgements
The authors wish to express sincere gratitude to Mr. J. Hogberg from Ovako Steel AB for his great help during the machining test. The authors would also like to thank the European Community for their support of this project.
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Zhou, J.M., Andersson, M. & Stahl, J.E. The monitoring of flank wear on the CBN tool in the hard turning process. Int J Adv Manuf Technol 22, 697–702 (2003). https://doi.org/10.1007/s00170-003-1569-2
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DOI: https://doi.org/10.1007/s00170-003-1569-2