In recent years, the investigation of the acoustic signals (AS) produced from different machining processes have primarily focused on the ultrasonic frequency range. The objective of this work is to propose a novel technique for predicting the flank wear condition of a tool and ultimately tool failure (insert chipping) during the process of conventional face milling. Preliminary experiments suggest that the spectral content of audible acoustic emission (AAE) signals could be used to predict the cumulative flank wear in real time for an indexable carbide insert during the milling process. The experiments conducted for this study suggest a strong correlation between the magnitudes of the AAE in the selected frequency range, and the amount of wear on the insert.
Friction stir welding (FSW) is a solid-state metal fusion process that is characterized by several benefits over comparable processes such as a reduction in energy input and low part distortion. This process has been shown to hold great potential in the fusion of dissimilar metals, a technology highly sought after in the aerospace and automotive industries for its promising weight-reduction capabilities. Furthermore, electrically-assisted FSW (EAFSW) is the supplementation of the FSW process with an electrical current. This modification has been shown to improve many parameters; however, the current literature related to this subject is scarce. Herein, the fusion of Al 6061-T651 to mild steel is performed using EAFSW methods. A novel tool constructed a proprietary ceramic, XSYTIN-1, is also tested in this application. It was found that EAFSW improved material flow between the constituent materials; however, was unable to increase the joint strength of the weld. Additionally, it was found that the XSYTIN-1 tool did not exhibit any significant differences when compared to a conventional steel tool.
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