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Prediction of Tool Wear in the Turning Process Using the Spectral Center of Gravity

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Abstract

The recent increase in machining productivity is closely related to longer tool life and good surface quality. In the present study, an experimental technique is proposed to evaluate the performance of a cemented carbide inset during the machining of AISI D3 steel. The aim of this technique is to find a relationship between the vibratory state of the cutting tool and the corresponding wear during machining in order to detect the beginning of the transition period to excessive wear. A spectral indicator named spectral center of gravity, SCG, is proposed to highlight the three phases of tool wear using the spectra of the accelerations measured. Very promising results are obtained which can be used to underpin an industrial monitoring system capable of detecting the onset of transition to excessive wear and alerting the user of the end of the tool’s life. The purpose of this study is to review the vibration analysis techniques and to explore their contributions, advantages and drawbacks in monitoring of tool wear.

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Abbreviations

V c :

Cutting speed (m/min)

f :

Feed rate (mm/rev)

ap:

Depth of cut (mm)

RMS:

Root mean square

VB:

Flank wear (mm)

R a :

Arithmetic average of absolute roughness (µm)

R t :

Maximum height of the profile (µm)

R z :

Average maximum height of the profile (µm)

SCG:

Spectral center of gravity

OL:

Overall level

WMRA:

Wavelet multi-resolution analysis

\(fs\) :

Sampling frequency

L i :

Value of the autospectrum at the sampling frequency

γ :

Rake angle (°)

λ :

Inclination angle (°)

χ r :

Major cutting edge angle (°)

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Acknowledgements

This work was completed in the Laboratory of Mechanics and Structures, University 8 May 1945, Guelma, Algeria. The authors would like to thank the Algerian Ministry of Higher Education and Scientific Research for granting financial support of the CNEPRU Research Project—LMS No.: J0301520130034 (University of 8 May 1945 Guelma).

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Authors and Affiliations

  1. Department of Mechanical Engineering and Productics (CMP), FGM & GP, University of Sciences and Technology Houari Boumediene, P.O. Box 32, El-Alia, Bab-Ezzouar, 16111, Algiers, Algeria

    Mohamed Khemissi Babouri

  2. Mechanics and Structures Laboratory (LMS), May 8th 1945 University, P.O. Box 401, 24000, Guelma, Algeria

    Mohamed Khemissi Babouri, Nouredine Ouelaa, Mohamed Cherif Djamaa & Abderrazek Djebala

  3. Laboratory of Vibration-Acoustics, INSA of Lyon, Bâtiment A. St. Exupéry, 25 bis Avenue Jean Capelle, 69621, Villeurbanne Cedex, France

    Nacer Hamzaoui

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  1. Mohamed Khemissi Babouri
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  2. Nouredine Ouelaa
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  3. Mohamed Cherif Djamaa
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  4. Abderrazek Djebala
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  5. Nacer Hamzaoui
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Correspondence to Mohamed Khemissi Babouri.

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Babouri, M.K., Ouelaa, N., Djamaa, M.C. et al. Prediction of Tool Wear in the Turning Process Using the Spectral Center of Gravity. J Fail. Anal. and Preven. 17, 905–913 (2017). https://doi.org/10.1007/s11668-017-0319-y

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  • DOI: https://doi.org/10.1007/s11668-017-0319-y

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