Selected aspects of diagnosing material removal machining processes state

Abstract

The article presents the results of works on the analysis of the possibility of using force measurements to determine the state of the machining process, both in relation to the phenomena occurring during machining and the workpiece itself compared to acoustic emission signal (AE). The research and analyzes were carried out for the commonly used material removal processes of objects; turning, milling, grinding and drilling. Various materials were processed - metal alloy Hardox 400 as well as fiber composite materials (GFRP - Glass Fiber Reinforced Polymer) and polymer construction material RenShape® BM5035 with various structures. As a result of the conducted analyzes, it was determined that the forces generated in the machine tool-holder-workpiece-tool layout can constitute a good diagnostic signal, on the basis of which it is possible to conclude about the state of the process.

Diagnosing of the Glass Fiber Reinforced Polymer Material High Performance Drilling Process State

“…cutting forces and torque, which were diagnostic signals of the state of the process. As in the previous study [13], the determined changes in the value of cutting forces were a good diagnostic signal of the process status. During the experiment, it was found that a large amount of heat was generated (measurements of temperature changes were not the subject of the study), which was manifested by the formation of smoke in the place where the hole was made and glowing of the machined surface.…”

“…in the field of determining trust forcee and torque [1,2,20], modeling temperature or forces occurring in the process [3,7,9,11,15,18] as well as testing the material itself, in particular its abrasive properties or abrasion resistance [10]. Based on the review of the literature in the field of the study, it was found possible to diagnose and monitor the state of the removal process of fiber-reinforced polymer composites on the basis of forces and acoustic emission (AE) [4,13,17].…”

AISI 304 stainless steel milling process state diagnosing

“…cutting forces and torque, which were diagnostic signals of the state of the process. It was shown, similarly to previous works [15,16], that measurements of changes in the values of forces or torque can be a good diagnostic signal of the state of the cutting process. The experiment was stopped when increased force values were obtained in order to avoid catastrophic wear of the tool.…”

“…1 shows force Fx, Fy, Fz and Fig. 2 -torque Mz values changes during whole milling process [15,16]. The values of the total cutting force were determined from the relationship:…”

“…Due to the significant machining costs, also resulting from tool costs, it seems reasonable to diagnose [15,16] or monitor the cutting edge condition, enabling tool optimal use and preventing tool damage and/or the workpiece surface [2,3,6,10 ,19] Many works describe the use of force measurement or acoustic emission to determine the state of the process, mainly due to the cutting edges condition [4,9,13,22].…”