Acoustic emission monitoring of tool wear during the face milling of steels and aluminium alloys using a fibre optic sensor. Part 2: Frequency analysis

This paper describes the application of acoustic emission (AE) frequency analysis to cutting tool wear monitoring in finish milling operations. AE detection was achieved using a fibre optic interferometer which, unlike conventional piezoelectric transducers, allows absolute measurements of the frequency content of the signals, generated during face milling of various steels and aluminium alloys, to be made. A model detailing the expected variations in AE mean frequency with various forms of tool wear in the different processes is presented and is validated by the practical set of tool wear tests using the fibre optic interferometer.

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Acoustic emission monitoring of tool wear during the face milling of steels and aluminium alloys using a fibre optic sensor. Part 1: Energy analysis

Proceedings of the Institution of Mechanical Engineers Part B Journal of Engineering Manufacture ◽

10.1243/0954405971516275 ◽

1997 ◽

Vol 211 (4) ◽

pp. 299-309 ◽

Cited By ~ 22

Author(s):

T A Carolan ◽

S R Kidd ◽

D P Hand ◽

S J Wilcox ◽

P Wilkinson ◽

...

Keyword(s):

Acoustic Emission ◽

Tool Wear ◽

Face Milling ◽

Tool Geometry ◽

Fibre Optic ◽

Ae Energy ◽

The Face ◽

Tool Types ◽

The Relationship ◽

Wear Tests

An investigation of the relationship between tool wear and the energy of acoustic emission (AE) produced during various face milling finishing operations is presented. A model detailing how the AE energy, quantified by the r.m.s. value, varies depending on the material and the detailed tool geometry formed by flank and crater wear is described. Validation of the model was achieved in a series of practical machining tests covering a range of materials and tool types which resulted in various different wear forms. In all these wear tests a non-contact fibre optic interferometer was employed for AE detection directly from the workpiece. This sensor makes absolute, calibrated measurements of AE, unlike conventional contacting piezoelectric AE transducers, which may suffer uncertainties due to their frequency response and variations in transmission path. The fibre optic instrument is thus advantageous for studying variations of AE energy with tool wear.

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An effective sensor for tool wear monitoring in face milling: Acoustic emission

Sadhana ◽

10.1007/s12046-008-0016-3 ◽

2008 ◽

Vol 33 (3) ◽

pp. 227-233 ◽

Cited By ~ 19

Author(s):

M. T. Mathew ◽

P. Srinivasa Pai ◽

L. A. Rocha

Keyword(s):

Acoustic Emission ◽

Tool Wear ◽

Face Milling ◽

Tool Wear Monitoring ◽

Wear Monitoring

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The Image Similarity Analysis Technique Applied to the Tool Wear Monitoring in Face Milling

Key Engineering Materials ◽

10.4028/www.scientific.net/kem.315-316.628 ◽

2006 ◽

Vol 315-316 ◽

pp. 628-631

Author(s):

Yu Teng Liang ◽

C.J. Lo ◽

W.C. Chen

Keyword(s):

Tool Wear ◽

Vision System ◽

Image Data ◽

Face Milling ◽

Image Similarity ◽

Similarity Analysis ◽

Analysis Technique ◽

Milling Operation ◽

The Face ◽

Wear Monitoring

The purpose of this paper is to monitor the tool wear based on the image data of cutting tool in the face milling operation. The surface images of the different coated inserted blade cutters are captured using a machine vision system incorporating with the mutual information and image similarity analysis technique for processing the images. The milling test is designed by using Taguchi’s method. The experimental results indicate that the coating layer factor is recognized to make the most significant contribution to the over all performance. The TiAlN-surface multilayer coated inserted blade cutter has the least wear rate amongst these coated milling cutters and has the longest tool life in this experiment.

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Acoustic emission analysis for tool wear monitoring in face milling

International Journal of Production Research ◽

10.1080/00207540110107534 ◽

2002 ◽

Vol 40 (5) ◽

pp. 1081-1093 ◽

Cited By ~ 42

Author(s):

P. Srinivasa Pai ◽

P. K. Ramakrishna Rao

Keyword(s):

Acoustic Emission ◽

Tool Wear ◽

Face Milling ◽

Tool Wear Monitoring ◽

Emission Analysis ◽

Wear Monitoring ◽

Acoustic Emission Analysis

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The effects of progressive wear on the frequency characteristic of acoustic emission acquired during face milling

Proceedings of the Institution of Mechanical Engineers Part B Journal of Engineering Manufacture ◽

10.1243/095440505x69355 ◽

2005 ◽

Vol 219 (11) ◽

pp. 803-810 ◽

Cited By ~ 6

Author(s):

M L Jakobsen ◽

P Wilkinson ◽

J S Barton ◽

R L Reuben ◽

D Harvey ◽

...

Keyword(s):

Acoustic Emission ◽

Tool Wear ◽

Flank Wear ◽

Cutting Speed ◽

Face Milling ◽

Cutting Process ◽

Optical Interferometer ◽

Wear Monitoring ◽

Carbide Inserts ◽

Wear Tests

Acoustic emission (AE) provides a non-intrusive means of monitoring insert flank wear in face milling. Progressive wear tests of carbide inserts in eight-point milling of annealed En24 steel were instrumented with piezoelectric AE transducers and a non-contact optical interferometer, from which AE frequency information could be extracted. Mean AE frequency was found generally to decrease with wear in agreement with other published studies. Tool indexed measurements enabled the time evolution of the frequency content to be studied on the timescale of a single pass of the insert. The results may be explained by a simple analytical model for AE frequency associated with plastic deformation. The observed AE decay time constants following insert entry decreased with cutting speed, consistent with thermal models of the cutting process. Whereas the results of this study alone would not constitute an independent means of tool wear monitoring, they could provide a diagnosis of tool wear when supplemented with other AE measures and with knowledge of the specific cutting process.

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