Development of In-Process Chip Breaking Detection by Using Cutting Force and Temperature Signals

2011 ◽  
Vol 337 ◽  
pp. 489-493 ◽  
Author(s):  
Kitikun Klungphon ◽  
Somkiat Tangjitsitcharoen
Keyword(s):  
Cutting Force ◽  
Chip Formation ◽  
Cutting Temperature ◽  
Low Frequency ◽  
Cutting Conditions ◽  
Frequency Range ◽  
Chip Breaking ◽  
Dynamic Cutting Force ◽  
Spectrum Density ◽  
Continuous Chip

In order to realize the intelligent machines, an in-process monitoring system is developed to detect the continuous chip and the broken chip regardless of the cutting conditions on CNC turning by utilizing the power spectrum density, PSD of dynamic cutting force and the variance of the dynamic cutting temperature, which are measured during the cutting by employing the dynamometer and the infrared pyrometer. The broken chip formation is required for the reliable turning operation. The preliminary experiments suggested that there are basically two patterns of PSDs of chip forms. One is the case of relatively high PSD of the dynamic cutting force at low frequency range, which corresponds to the continuous chip formation. The other is the case of relatively large PSD of the dynamic cutting force observed in a frequency range corresponding to the chip breaking frequency when the broken chip are formed. The variances of the cutting temperature are also significantly different between the broken chip and the continuous chip. Hence, the method has been developed by using the PSD of dynamic cutting force and the variance of cutting temperature to determine the proper threshold values for classification of the broken chip and the continuous chip during the cutting. The new algorithm is proposed to obtain the broken chip by changing the cutting conditions during the cutting process. It has been proved by series of cutting experiments that the broken chip can be well identified by the proposed method even though the cutting conditions are changed.

Integrated Monitoring of Surface Roughness and Chip Formation by Utilizing Cutting Force and Cutting Temperature

2012 ◽  
Vol 538-541 ◽  
pp. 1338-1350
Author(s):  
Somkiat Tangjitsitcharoen ◽  
Suthas Ratanakuakangwan
Keyword(s):  
Surface Roughness ◽  
Cutting Force ◽  
Chip Formation ◽  
Cutting Temperature ◽  
Cutting Parameters ◽  
Cutting Conditions ◽  
Integrated Monitoring ◽  
Roughness Model ◽  
Spectrum Density ◽  
Roughness Prediction

This research presents the integration of the surface roughness and chip formation monitoring by using the cutting force and the cutting temperature during the in-process turning. The surface roughness prediction model is proposed by utilizing the response surface analysis with the Box-Behnken design. The effects of cutting parameters on the cutting force and the cutting temperature are investigated. The cutting force and the cutting temperature are measured to help analyze the relation between the surface roughness and the cutting conditions. The models of the cutting force ratio and the cutting temperature are also proposed based on the experimental data. The in-process monitoring of chip formation is developed to detect the continuous chip and the broken chip by utilizing the power spectrum density of dynamic cutting force and the variance of the dynamic cutting temperature.The broken chip formation is required for the reliable turning operation. The algorithm is proposed to obtain the broken chip by changing the cutting conditions during the cutting process based on the cutting force and the cutting temperature. It has been proved by series of cutting experiments that the proposed surface roughness model can be effectively used to predict the surface roughness, and the broken chip is well identified by the proposed method.

Advance in Chip Breaking Detection System by Monitoring of Cutting Temperature

2012 ◽  
Vol 217-219 ◽  
pp. 1676-1681
Author(s):  
Somkiat Tangjitsitcharoen
Keyword(s):  
Process Monitoring ◽  
Chip Formation ◽  
Detection System ◽  
Cutting Temperature ◽  
Cutting Parameters ◽  
Chip Breaking ◽  
Maximum Variance ◽  
Average Variance ◽  
Cutting Experiments ◽  
Continuous Chip

This research presents the chip breaking detection system by monitoring the cutting temperature during the in-process turning. The effects of cutting parameters on the cutting temperature and the chip formation are investigated. The in-process monitoring of chip formation is developed to detect the continuous chip, the mixed chip and the broken chip by utilizing the ratio of the maximum variance of the dynamic cutting temperature to the average variance of the dynamic cutting temperature. The broken chip formation is required for the reliable turning operation. The new algorithm is proposed to obtain the broken chip by changing the cutting conditions during the cutting process referring to the cutting temperature. It has been proved by series of cutting experiments that the broken chip can be well identified by the proposed method.

Experiment Research on Dynamic Cutting Force and its Power Spectrum

2010 ◽  
Vol 37-38 ◽  
pp. 412-416
Author(s):  
Hong Jiao Liu ◽  
Min Min
Keyword(s):  
Power Spectrum ◽  
Cutting Force ◽  
Close Relation ◽  
Frequency Domain Analysis ◽  
Radial Force ◽  
Testing System ◽  
Turning Process ◽  
Frequency Range ◽  
Dynamic Cutting Force ◽  
Cutting Experiments

To improve turning process, a testing system for dynamic cutting force was established. The paper studied the dynamic cutting force theoretically and experimentally with the frequency domain analysis. Cutting experiments were conducted for new tools, worn tools, and broken tools respectively. And a comparison among three forces’ power spectrum was made. The results show that the power spectrum value of radial force in the frequency range of 2450~3100 Hz has a close relation to the state of tool wear and tool breakage, which can be used to monitor the cutting process in real time.

L16 Orthogonal Array-Based Three-Dimensional Finite Element Modeling for Cutting Force and Chip Formation Analysis During Dry Machining of Ti–6Al–4V

2020 ◽  
pp. 1-12
Author(s):  
Raviraj Shetty ◽  
Sanjeev Kumar ◽  
Ravindra Mallagi ◽  
Laxmikanth Keni
Keyword(s):  
Finite Element ◽  
Finite Element Modeling ◽  
Cutting Force ◽  
Chip Formation ◽  
Orthogonal Array ◽  
Three Dimensional ◽  
Cutting Conditions ◽  
Element Modeling ◽  
Dimensional Finite Element ◽  
Three Dimensional Finite Element

The outstanding characteristics of titanium alloy (Ti–6Al–4V) have made this material applicable in aerospace and medical components. However, due to its poor machinability characteristics, researchers are forced to understand the machinability behavior of Ti–6Al–4V. In this paper, [Formula: see text] orthogonal array-based three-dimensional finite element modeling for the cutting force and chip formation analysis during the machining of Ti–6Al–4V using cubic boron nitride tool in dry turning environment has been investigated. The finite element simulation was performed using ANSYS Workbench, version 19.0. Cutting force and chip formation were investigated using the results obtained from [Formula: see text] orthogonal array-based three-dimensional finite element modeling. This research would help to identify the optimum cutting conditions and minimize the cutting force followed by analyzing the types of chips formed during machining under the selected set of cutting conditions.

Monitoring of chip breaking and surface roughness in computer numerical control turning by utilizing wavelet transform of dynamic cutting forces

2015 ◽  
Vol 231 (14) ◽  
pp. 2479-2494 ◽  
Author(s):  
Somkiat Tangjitsitcharoen ◽  
Kanyakarn Samanmit
Keyword(s):  
Surface Roughness ◽  
Wavelet Transform ◽  
Chip Formation ◽  
Cutting Forces ◽  
Computer Numerical Control ◽  
Numerical Control ◽  
Cutting Conditions ◽  
Chip Breaking ◽  
Frequency Domains ◽  
Meyer Wavelet

The aim of this research is to monitor and classify the broken chip signals from the dynamic cutting forces, in order to predict the surface roughness during the computer numerical control turning process utilizing the Meyer wavelet transform to decompose the dynamic cutting forces. The dynamic cutting forces of the broken chips and the surface roughness can be decomposed into the different levels. The levels of decomposed cutting forces can aid to explain the broken chip formation and the surface roughness profile in both time and frequency domains. The experimentally obtained results showed that the surface roughness frequency occurs at the higher level of decomposed cutting forces, especially at the fifth level, although the cutting conditions are changed. However, the chip breaking frequency appears at the lower level, which depends on the cutting conditions and the chip length. The ratio of the fifth level of decomposed feed forces to that of main forces is proposed to predict the surface roughness during the in-process cutting. It is understood that the broken chip formation can be separated clearly and the surface roughness can be predicted well during the cutting, regardless of the cutting conditions.

The Measurement of Dynamic Cutting Force Data and its Application to the Prediction of Chatter

1982 ◽  
Vol 24 (3) ◽  
pp. 139-145
Author(s):  
M. Burdekin ◽  
S. E. Kilic
Keyword(s):  
Machine Tool ◽  
Cutting Force ◽  
Orthogonal Cutting ◽  
Cutting Conditions ◽  
Cutting Force Coefficients ◽  
Regenerative Chatter ◽  
Dynamic Cutting Force ◽  
Force Data ◽  
Cut Surface ◽  
Tangential Directions

A method and the related equipment to obtain dynamic cutting force coefficients under simulated regenerative chatter conditions are described. The coefficients in both thrust (normal to the cut surface) and the main cutting (tangential) directions for orthogonal cutting are presented for various cutting conditions. An algorithm which is developed to predict chatter instability by combining the receptance of a machine tool with the dynamic cutting data is also presented. Comparison of experimentally-determined stability charts of a centre lathe with the predicted ones is made to evaluate the reliability of the method.

Chip Formation of Highly Efficient Cutting Titanium Alloy Membrane Disk

2010 ◽  
Vol 33 ◽  
pp. 549-554
Author(s):  
Shu Cai Yang ◽  
Min Li Zheng ◽  
Yi Hang Fan
Keyword(s):  
Titanium Alloy ◽  
Cutting Force ◽  
Chip Formation ◽  
Fem Analysis ◽  
Cutting Conditions ◽  
Machining Process ◽  
Thin Wall ◽  
Variable Cross ◽  
Serrated Chip ◽  
Membrane Disk

Titanium alloy membrane disk is a typical part in aerial engine and it belongs to variable cross-section thin-wall part, which is apt to change its nature and difficult to machine. Serrated chip is prone to create in the machining process. A periodic serrated chip will cause high frequency undulation of the cutting force, and further leads to the cutting tool wear and affect the surface’s integrity. Based on the turning of titanium membrane disk, this paper used metallographic microscope and SEM to observe the morphology and micro shape of the chip, and analyzed the influence of cutting conditions on chip formation and the reason for serrated chip. Finally, a FEM analysis on the chip formation process is completed. Analysis results show that under all the set cutting conditions the serrated chip was formed in the machining process. The shearing slippage and fracture caused by dislocation movement can better explain the formation mechanism of serrated chip. The feed rate has great effect on the chip formation and the forming frequency of serrated chip. The FEM analysis results primly consistent with the experiment results, which can accurately forecast the cutting force, the distribution of temperature and the surface quality.

Analytical Prediction of Three Dimensional Cutting Process—Part 2: Chip Formation and Cutting Force with Conventional Single-Point Tool

1978 ◽  
Vol 100 (2) ◽  
pp. 229-235 ◽  
Author(s):  
E. Usui ◽  
A. Hirota
Keyword(s):  
Cutting Force ◽  
Chip Formation ◽  
Single Point ◽  
Orthogonal Cutting ◽  
Cutting Conditions ◽  
Tool Geometry ◽  
Depth Of Cut ◽  
Analytical Prediction ◽  
Nose Radius ◽  
Cutting Model

The cutting model and the energy method to predict chip formation and cutting force, which were proposed in the previous part of this study, are extended to machining with conventional single-point tool. The prediction is always possible in the practical range of cutting conditions regardless of size of cutting and tool geometry, if only orthogonal cutting data under equivalent cutting conditions are in hand. The predicted results are verified to be in good agreement with the experimental results in a wide variety of depth of cut, side and back rake angles, side cutting edge angle, and nose radius.

Research on the Machinability of Hydrogenated Cylindrical Shell Materials (2.25 Cr-1Mo-0.25V Steel)

2010 ◽  
Vol 142 ◽  
pp. 253-257 ◽  
Author(s):  
Hui Ping Zhang ◽  
Fu Gang Yan ◽  
Yan Xin Wang ◽  
Yuan Sheng Zhai ◽  
Xian Li Liu
Keyword(s):  
Stainless Steel ◽  
Cylindrical Shell ◽  
Cutting Force ◽  
Cutting Temperature ◽  
Depth Of Cut ◽  
Chip Breaking

Firstly, with studying three typical aspects as cutting force, cutting temperature and chip breaking behavior, contrast experiments of machinability were made on hydrogenated cylindrical shell materials (2.25Cr-1Mo-0.25V), 45 steel, and stainless steel (1Cr18Ni9Ti). The experiment results show that the depth of cut ap have a larger effect on the main cutting force FZ and the cutting temperature θ than the affection of the feedrate f, for that reason, in order to reduce the main cutting force FZ and the cutting temperature θ, large feedrate situation will be better for machining work of hydrogenated cylindrical shell materials. When cutting hydrogenated cylindrical shell materials , many difficult points appearance, such as large cutting force, high cutting temperature, serious chips winding, chips difficult to break etc, which has worse machinability even than stainless steel(1Cr18Ni9Ti).

scholarly journals Optimizing Multi-Response Parameters in Turning of AISI1040 Steel Using Desirability Approach

2019 ◽  
Vol 4 (4) ◽  
pp. 905-921
Author(s):  
Srinu Gugulothu ◽  
Vamsi Krishna Pasam
Keyword(s):  
Surface Roughness ◽  
Cutting Force ◽  
Flank Wear ◽  
Cutting Temperature ◽  
Cutting Speed ◽  
Cutting Conditions ◽  
Depth Of Cut ◽  
Tool Flank Wear ◽  
Multi Objective ◽  
Single Objective

In this study, an attempt is made to examine the machining response parameters in turning of AISI 1040 steel under different lubrication environment. Subsequently, design of experiment technique Response surface methodology (RSM) is used for analyzing machining performance by varying cutting conditions with the use of 2wt% of CNT/MoS2(1:2) HNCF. Regression models are developed for multiple machining responses. Optimization is performed for these models by using desirability function, which converts multi-objective into single objective. Then the optimal setting parameters for single objective is found. Significant reduction in main cutting force (Fz), cutting temperature (T), surface roughness(Ra) and tool flank wear (Vb) are found with the use of 2wt% of CNT/MoS2(1:2) HNCF compared to other lubrication environment. Significant factors that affect the main cutting force (Fz), the temperature in the cutting zone are cutting speed, feed rate and depth of cut. Parameter depth of cut has an insignificant effect on tool flank wear and surface roughness (Ra). The optimal cutting conditions for four multi-objective optimization of main cutting force (Fz), cutting temperature, surface roughness (Ra) and tool flank wear are found to be cutting speed 70.25 m/min, feed 0.13 mm/rev and doc 0.5mm at desirability value of 0.907.

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