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Relation between tool wear and workpiece modal vibration in ultra-precision raster fly cutting

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Abstract

Tool wear is a key factor affecting machined surface quality; numerous methods have been adopted to reflect tool wear features online. In the present research, workpiece modal frequencies were employed to present tool wear level in ultra-precision raster fly cutting (UPRFC) process. In time domain, cutting force composition and the relation between cutting force amplitude and tool wear level were explored. In frequency domain, the relation between workpiece modal frequencies as a response of cutting force stimulus and tool wear level was investigated. Theoretical and experimental results reveal that the peak power spectrum density (PSD) values of the workpiece modal vibration (especially the first order workpiece modal vibration) grow with the progress of tool wear, the width of flank wear land and the first order workpiece modal vibration has a linear relationship, which could be used to predict tool wear in UPRFC and even other intermittent cutting process.

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Authors and Affiliations

  1. Guangdong Provincial Key Laboratory of Micro/Nano Optomechatronics Engineering, College of Mechatronics and Control Engineering, Shenzhen University, Nan-hai Ave 3688, Shenzhen, 518060, Guangdong, People’s Republic of China

    Guoqing Zhang

  2. State Key Laboratory of Ultra-precision Machining Technology, Department of Industrial and Systems Engineering, The Hong Kong Polytechnic University, Kowloon, Hong Kong, People’s Republic of China

    Suet To

Authors
  1. Guoqing Zhang
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  2. Suet To
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Correspondence to Guoqing Zhang.

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Zhang, G., To, S. Relation between tool wear and workpiece modal vibration in ultra-precision raster fly cutting. Int J Adv Manuf Technol 93, 3505–3515 (2017). https://doi.org/10.1007/s00170-017-0777-0

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  • DOI: https://doi.org/10.1007/s00170-017-0777-0

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