Turning Tool Wear Estimation Based on the Calculated Parameter Values of the Thermodynamic Subsystem of the Cutting System

Abstract

Today, modern metalworking centers are not yet able to reliably assess the degree of wear of the tool used in metal cutting. Despite the fact that a large number of methods for monitoring the service life of the tool have been developed, this issue still remains a difficult task that needs to be solved. Idea: The article proposes a new, previously unused method for estimating the power of a cutting wedge in metalworking. The aim of the study is to develop a method for indirectly estimating the tool wear rate based on a consistent model of intersystem communication that describes the force, thermal and vibration reactions of the cutting process to the shaping movements of the tool. Research methods: The study consists of experiments on a measuring stand and a homemade measuring complex. It also uses the Matlab mathematical software package for processing and graphical interpretation of data obtained during experiments. The results show that the proposed method of estimating the current tool wear is applicable for the interpretation of experimental data. Statistically, the modified Voltaire operator of the second kind models the temperature more accurately; at the peak, this method is three times more accurate than the other.

Modeling of the influence of the wear of the cutting wedge of the tool on the stability of the metal turning process

“…( 6)). The experimental data confirm this position, and this effect is described in more detail in the previous work [29]. The change in the response time of the thermodynamic subsystem of the cutting system causes the following: at some stage of the evolution of the cutting system, the response of this system is so delayed concerning the power subsystem reaction that the temperature no longer compensates for the growth in cutting force.…”

“…A feature of the application of the method of thermal potentials in the case under consideration is that the temperature value at a given time and in a given tool-workpiece contact zone during cutting is determined not only by the current value of the heat released here (cutting power converted into heat), but also by the effect of power allocated on the entire previous path of the product processing time. The very methodology for converting cutting power into heat can be viewed in more detail in the following papers [28][29]. Based on the reasoning given in these works, the current temperature in the tool-workpiece contact zone can be presented as:…”

“…[28][29]. The experiments did show that in the second section of the wear curve there is a slight drop in the amplitude of the vibration activity of the tool, compared to the first section, and in the third section of the wear curve, a sharp increase in the amplitude of vibrations, significantly exceeding the amplitude of vibrations in the first and second sections.The results of modeling the total cutting force and temperature in the tool-workpiece contact zone are shown in Fig.15.As the tool flank wear area increases, the temperature in the tool-workpiece contact area also grows (see Fig.15).…”

Theoretical Roughness Modeling of Hard Turned Surfaces Considering Tool Wear

“…Modern metalworking centers cannot yet reliably estimate the wear status of a tool used in metal cutting. The aim of Lapshin's article [64] was to estimate the wear rate of a tool indirectly, based on a consistent model between systems designed for the force, heat and vibration conditions of the cutting process. In an article by Airao et al [65], they investigated how ultrasonic vibration affects tool wear when a coated carbide insert is used for machining Nimonic-90 nickel-based superalloy in dry and wet conditions.…”

Research on Influence of Tool Deformation in the Direction of Cutting and Feeding on the Stabilization of Vibration Activity during Metal Processing Using Metal-Cutting Machines

“…As a result, the effects of synchronization and asynchronous interactions, as well as the effects of complex formation, attracting sets of feeds, and corresponding cutting forces, are observed, which can lead to the formation of chaotic attractors of deformations [22][23][24][25]. In addition to the regeneration of vibrations during cutting, the dynamics of deformation movements of the tool tip are also significantly affected by the process of temperature formation in the contact zone of the tool and the workpiece, which includes the conversion of irreversible transformation power into heat generated during cutting [26].…”