A Review of Indirect Tool Condition Monitoring Systems and Decision-Making Methods in Turning: Critical Analysis and Trends

Abstract

The complex structure of turning aggravates obtaining the desired results in terms of tool wear and surface roughness. The existence of high temperature and pressure make difficult to reach and observe the cutting area. In-direct tool condition, monitoring systems provide tracking the condition of cutting tool via several released or converted energy types, namely, heat, acoustic emission, vibration, cutting forces and motor current. Tool wear inevitably progresses during metal cutting and has a relationship with these energy types. Indirect tool condition monitoring systems use sensors situated around the cutting area to state the wear condition of the cutting tool without intervention to cutting zone. In this study, sensors mostly used in indirect tool condition monitoring systems and their correlations between tool wear are reviewed to summarize the literature survey in this field for the last two decades. The reviews about tool condition monitoring systems in turning are very limited, and relationship between measured variables such as tool wear and vibration require a detailed analysis. In this work, the main aim is to discuss the effect of sensorial data on tool wear by considering previous published papers. As a computer aided electronic and mechanical support system, tool condition monitoring paves the way for machining industry and the future and development of Industry 4.0.

Parametric Optimization for Improving the Machining Process of Cu/Mo-SiCP Composites Produced by Powder Metallurgy

“…Among tool wear types, flank wear is the primary one providing wear development information from the main cutting edge and clearance face of the tool. It is also generally accepted and standardized wear indicator in order to determine the remaining useful life of cutting tool [53]. Thus, flank wear becomes the prominent factor in machinability investigations.…”

Tornalamada Akustik Emisyon ve Motor Akımı Optimizasyonu ve Analizi

“…Devir sayısının artması, kesme sıcaklıklarını artıracağından malzeme deformasyonunu kolaylaştırır (Aslan, 2020; Kuntoğlu ve ark., 2021). Klasik bir tornalama işleminde talaş kaldırmayı sağlayan esas hareket olan iş parçası devri, bu vesileyle hareketi ileten motor üzerinde en yüksek akımın oluşmasına sebep olmaktadır (Kuntoğlu ve Aslan, 2021). Devir sayısını takiben ilerleme hızı ve yaklaşma açılarının etkili olduğu görülmektedir.…”

Measurement of Micro Burr and Slot Widths through Image Processing: Comparison of Manual and Automated Measurements in Micro-Milling

“…Despite the high performance of the micro-machining process, the quality of micro-sized parts is related to the burr formation [ 5 , 6 , 9 , 10 ]. Especially in studies on micro-machining processes and working piece analyses, the precision measurement on slot and burr widths is necessary for better investigation of the micro-machining process and optimization of the machining conditions [ 11 , 12 , 13 , 14 ]. In the micro-machining process, cutting conditions and cutting parameters significantly affect the burr formation [ 15 , 16 , 17 , 18 ].…”