Title: Real-time tool condition monitoring of face milling using acousto-optic emission – an experimental approach

Authors: B. Srinivasa Prasad; M.M.M. Sarcar; B. Satish Ben

Addresses: Department of Mechanical Engineering, GIT, GIATM University, Vizag, India. ' Department of Mechanical Engineering, AUCE, Andhra University, Visakhapatnam, India. ' Department of Mechanical Engineering, GIT, GIATM University, Vizag, India

Abstract: In metal cutting, as a result of the cutting motion, the surface of work piece will be influenced by cutting parameters, cutting force, vibrations, etc. The effects of vibrations have been paid little attention. Accurate detection of the tool conditions under given cutting conditions is very important so that worn tools can be identified and replaced in time. Objective of the present work is to predict the effects of displacements due to vibration during face milling and to examine the correlation of surface roughness along with progression of tool wear at different machining combinations so as to develop a base for online tool condition monitoring system. A laser doppler vibrometer and FFT analyser are used for online data acquisition and subsequent processing of signals. The encouraging results of the work pave the way for the development of a real-time and reliable tool-condition-monitoring system.

Keywords: tool monitoring; condition monitoring; acousto-optic emission; laser doppler vibrometry; FFT analysis; signal processing; fast Fourier transform; metal cutting; face milling; vibration; tool wear; wear monitoring; surface roughness; surface quality.

DOI: 10.1504/IJCAT.2011.042709

International Journal of Computer Applications in Technology, 2011 Vol.41 No.3/4, pp.317 - 325

Available online: 25 Sep 2011 *

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