Modeling and Experimental Analysis of Acoustic Emission from Metal Cutting

Abstract

Testing parameters characterizing acoustic emission (AE) detected during metal cutting may be theoretically correlated, in a simple manner, to work material properites, cutting conditions, and tool geometry. Experimental results, obtained during turning by different researchers using different AE techniques, are presented and critically assessed with reference to their reciprocal agreement as well as their agreement with theoretical predictions. A review of current methods for AE analysis is also presented and the correlations between different AE parameters and energy and jkiwer of the detected signals are reported.

Lathe stability charts via acoustic emission monitoring

“…The square of the RMS value is directly proportional to the energy released during an AE event (Table 1). Results [11,15] indicate that the AE energy is little affected by changes on feed rate and depth of cut (and hence volume of plastic deformation), contrary to the prediction of the theoretical models. The power spectrums of AE signals obtained in this research generally confirmed this observation.…”

“…The following relationship between the emission signal and its source was obtained. The AE total count, which is the number of times the signal overcomes a threshold voltage, has been correlated in a simple manner to the energy of the signals reaching the transducer [15] (and hence the energy of the signals generated by the AE source). Table 1 shows a summary of the findings.…”

“…Further, in normal machining there is always a finite flank wear and therefore AE generated in the tertiary zone should not be ignored. In [15], the model represented by Eqn. (5) has been improved by adding the terms τk,U, and l b (where l b is the average length of tool flank-workpiece interface) to account for flank wear -land generated AE.…”

A methodology for manufacturing process signature analysis

“…In manufacturing research, success has been achieved using acoustical signals from machining and forming operations (see [3], [13], and [16]). In work involving punch stretching and deep drawing of aluminum sheet metal, an acoustical sensor was placed in direct contact with the sheet metal during the forming process [7].…”

Acoustic emission and vibration for tool wear monitoring in single-point machining using belief network

“…These elastic waves can be detected by transducers attached to the surface of the specimen. Research into the use of acoustic emission for tool wear monitoring [15][16][17][18][19] has established that there exists a definite relation between AErms and tool wear.…”