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A novel method for online monitoring of surface quality and predicting tool wear conditions in machining of materials

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Abstract

Roughness on the surface of the machined workpiece is one of the most important machining outcomes in terms of determining the quality of the product. This publication presents a new, original methodology for online monitoring machined materials’ quality. The methodology was designed to ensure the surface finish quality was maintained throughout the production process and under the selected cutting conditions. The remaining useful life of the cutting tool was predicted using online time mode with simultaneous surface quality checks. An indirect method was used to monitor the vibration levels generated during the machining process of the part. The vibrations were measured continuously throughout the longitudinal turning process. The sensor was installed on the revolving turret of the machine. Measurements were taken in the direction of the horizontal (lateral) axis perpendicular to the longitudinal axis of the machine. The experiment was carried out for technical operations of roughing and finishing turning. This methodology is based on an analytical model describing the relationship between the mean value of the surface roughness, the feed rate, and the radius of the tooltip. It has been developed with the primary objective of predicting sudden failure of tools, possible destruction of components, and premature tool replacement. As a result, the applied tools exceed the average statistical value of their actual operational potential for a given cutting mode.

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Data availability

The datasets generated during and/or analysed during the current study are available from the corresponding author on reasonable request.

Abbreviations

Ind Ra :

Roughness indicator

Ind Q :

Damage indicator

Ind T :

Time indicator (min)

T :

Tool life (min)

Ra :

Average value of micro roughness height at base length (µm)

T res :

Remaining tool life (min)

f :

Feed speed (mm/rev)

(r)t :

Time-varying tool nose radius (mm)

Vb :

Amount of wear on the main flank of the tool (mm)

L :

Path travelled by the tool during machining (mm)

T L :

Normal tool wear time (min)

V :

Cutting speed (m/min)

Vb i :

Current wear value (mm)

Vb 0 :

Initial wear (mm)

Vb max :

Maximum linear wear (mm)

t i :

Current machining time (min)

t 0 :

Running time (min)

Vr max :

Maximum allowable radial wear (mm)

r 0 :

Radius at the tip of a sharpened tool (mm)

r max :

Tool nose radius at the end of the linear wear (mm)

γ :

Linear wear factor

η :

Catastrophic wear factor

Vr :

Linear radial wear in tool nose radius (mm)

Vrc :

Catastrophic radial wear of the tool nose radius (mm)

r min :

Minimum tool nose radius (mm)

α, β :

Exponents

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Funding

This research was funded by Scientific Grant Agency of the Ministry of Education, Science, Research and Sport of the Slovak Republic, grant number VEGA 1/0226/21 and grant number VEGA 1/0236/21.

Author information

Authors and Affiliations

  1. Department of Automobile and Manufacture Technologies, Faculty of Manufacturing Technology With Seat in Prešov, Technical University of Košice, Štúrova 31, 08001, Prešov, Slovakia

    Anton Panda & Patrik Soročin

  2. Department of Computer Science, Faculty of Electronics and Information Technologies, Sumy State University, Rimsky Korsakov, 2, Sumy, 44007, Ukraine

    Volodymyr Nahornyi

  3. Institute of Electrical Engineering, Automation, Informatics and Physics, Faculty of Engineering, Slovak University of Agriculture in Nitra, Tr. A. Hlinku 2, 949 76, Nitra, Slovakia

    Jan Valíček & Marta Harničárová

  4. Department of Mechanical Engineering, Faculty of Technology, Institute of Technology and Business in České Budějovice, Okružní 10, 370 01, České Budějovice, Czech Republic

    Jan Valíček, Marta Harničárová & Milena Kušnerová

  5. Department of Computer Aided Manufacturing Technologies, Faculty of Manufacturing Technology With Seat in Prešov, Technical University of Košice, Štúrova 31, 08001, Prešov, Slovakia

    Petr Baron

  6. Department of Natural Sciences and Humanities, Faculty of Manufacturing Technologies of the Technical University of Košice With the Seat in Prešov, Bayerova 1, 080 01, Prešov, Slovakia

    Iveta Pandová

Authors
  1. Anton Panda
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  2. Volodymyr Nahornyi
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  4. Marta Harničárová
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  5. Milena Kušnerová
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  6. Petr Baron
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  7. Iveta Pandová
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  8. Patrik Soročin
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Contributions

Conceptualization: Volodymyr Nahornyi. Methodology: Volodymyr Nahornyi. Validation: Jan Valíček, Milena Kušnerová, and Marta Harničárová. Formal analysis: Marta Harničárová and Jan Valíček. Investigation: Anton Panda and Iveta Pandová. Data curation: Patrik Soročin and Petr Baron. Writing—original draft preparation: Volodymyr Nahornyi. Writing—review and editing: Jan Valíček, Milena Kušnerová, and Marta Harničárová. Project administration: Anton Panda. All authors read and approved the final manuscript.

Corresponding author

Correspondence to Marta Harničárová.

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Panda, A., Nahornyi, V., Valíček, J. et al. A novel method for online monitoring of surface quality and predicting tool wear conditions in machining of materials. Int J Adv Manuf Technol 123, 3599–3612 (2022). https://doi.org/10.1007/s00170-022-10391-0

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