An Investigation of the Cutting Process for Chip Breaking Monitoring in Turning of Steels

Abstract

This paper presents some results of an experimental study on chip breaking monitoring when turning steels with chip forming inserts. In the first part of this study the recognition of chip forms by means of cutting force analysis in the frequency domain is described. Generally, the present work is concerned with the use of the interface control factor for determining the transition from unacceptable chip forms to the chip breaking. For this purpose experiments under approximately orthogonal machining conditions including measuring the shear strain, the cutting energy and the average interface temperature are carried out. The obtained results confirmed that the initiation of acceptable chip breaking for a wide range of cutting conditions and the three steels used could be predicted in terms of an appropriate energy consumption rate. An architecture for on-line cutting state monitoring system based on signal processing procedure in the frequency domain is developed and the performance of the system is experimentally evaluated.

Advanced monitoring of machining operations

“…The use of single Fourier coefficients X[m] is not practical due to leakage effects. Thus, further SFs are usually considered: (i) amplitude of dominant spectral peaks [69,78,87,90,92,104]; (ii) signal power in specific frequency ranges [69,71,85,87,105,106]; (iii) energy in frequency bands [72,78,84]; (iv) statistic features of band power spectrum such as mean frequency, variance, skewness, kurtosis of the power spectrum distribution [87]; and (v) frequency of the spectrum highest peak [69,89,107].…”

“…WT coefficients are usually treated as separate signals, each characterized by features used for time domain signals: average value [111,112,118], RMS [118], standard deviation or variance [104,112,118,119], crest factor [84,112], peak-to-valley or peakto-peak value [112,118], kurtosis [84,112,118,119].…”

Intelligent identification of turning process based on pattern recognition of cutting states

“…Hence, it is desired to make chips broken into small pieces to realize safe and reliable machining. [1][2][3][4][5]. Normally, the continuous chips become broken at lower cutting speed.…”

In-process monitoring and detection of chip formation and chatter for CNC turning

“…They are also difficult to remove from the machine, and cause the thermal deformation of machine tool. Hence, it is desired to make chips broken into small pieces to realize safe and reliable machining (Moriwaki et al, 2004;Andreasen and Chiffre, 1993;Grzesik and Bernat, 1998). Normally, the continuous chips become broken at * Tel.…”